Home

Adjustable Frequency AC Drive for Fan & Pump Applications

1. Typical Typical aN Loss 1 4 SRC Wiring SNK Wiring z 1 of 7 Digital Input Circuits 01 7 Q NEN 02 Start Run FWD e yod Enable 9 m Direction Run REV e e Jumper Digital C SNK SRC igital Common 04 Digital Input 1 ENBL gt o ee oo o od 06 Digital Input 2 a rH 07 Digital Input 3 o 08 Digital Input 4 oo 09 Digital Common 10 Opto Common 1 Relay N O IET 1 Relay Common T iu m 24V DC Source 1 Relay B3 iEarth Referenced 10V 10V DC Source Frames D amp 12 f EOV m Analog Input 1 A 1 T1 2 Relay R4 i 20 5 Analog Common 1 Li e 2 Common ap ET 1 SU My Analog Output 1 A01 2 Relay 3 2 Watt Min emea TY gg Ei a Analog Output 2 AO2 0 20mA 16 lsolated 0 10V A Input 2 Al2 108 ed 20 10 17 nalog Input 2 12 0 20 6 18 Analog Common 2 PS L Opto Output Common 24V 30V DC w c 19 50mA Non inductive 20 01 AO AH 2 0 10V 20MA 10V 20MA 10 20MA 10 20 Silla ia ss 036
2. 1 Analog In 1 Sleep enabled from Analog Input 1 2 Analog In 2 Sleep enabled from Analog Input 2 3 Command Freq Sleep enabled based on drive commanded frequency T078 Sleep Level Related Parameter s 1077 T079 T080 T081 Sets the analog input level the drive must reach to enter sleep mode Values Default 10 0 0 0 100 0 Display 0 196 T079 Sleep Time Related Parameter s T077 T078 T080 T08 Sets the analog input time the drive must stay below to enter sleep mode Values Default 0 0 Secs Min Max 0 0 600 0 Secs Display 0 1 Secs T080 Wake Level Related Parameter s T077 T078 T079 T081 Sets the analog input level the drive must reach to wake from sleep mode Values Default 15 0 Min Max 0 0 100 0 Display 0 1 T081 Wake Time Related Parameter s T077 T078 T079 T080 Sets the analog input time the drive must stay above to wake from sleep mode Values Default 0 0 Secs Min Max 0 0 600 0 Secs Display 0 1 Secs 3 24 Programming and Parameters Terminal Block Group continued T082 Analog Out1 Sel Related Parameter s P035 T083 T084 Sets the analog output signal mode 0 20 mA 4 20 mA or 0 10V The output is used to provide a signal that is proportional to several drive conditions This parameter must match DIP Switch AO1 setting DIP Switch Outpu
3. 1 29 Prepare For Drive Start Up 2 1 Integral 2 3 Viewing and Editing Parameters 2 5 Keypad Hand Off Auto Functions 2 6 About Parameters 3 1 Parameter Organization 3 2 Basic Display 3 4 Basic Program 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 Drive Status iix breton ad wae 4 1 Faults Rr eign ee 4 1 Fault 4 3 Common Symptoms and Corrective 4 5 2 Table of Contents Appendix A Appendix B Appendix C Appendix D Appendix E Appendix F Appendix G Index Supplemental Drive Information Drive Fuse amp Circuit Breaker Ratings 1 2 Input Power 7 Accessories and Dimensions Product Selection B 1 Product Dimensions B 7 RJ45 DSI Splitter Cable Application Notes Damper Control D 1 PID Setup ss ls Ss qen emere tse D 2 Auxiliary Motor Control Setup D 11 Modbus RTU Protocol Network
4. 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 sse soe reves tees E 5 Additional Information E 5 Metasys N2 Understanding Metasys 2 F 1 Network Points F 3 Using Percent 26 for the Reference F 5 Using Metasys Configurable Objects to Access Parameters 3 0 RE s F 6 P1 Floor Level Network FLN Understanding PI FLN G 1 Network Points G 2 Using Percent 26 for the Reference G 6 Using P1 Configurable Points to Access Parameters ss v xo Sa qa usthuy a G 7 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 For information on See page Who Should Use this Manual 1 Reference Materials 1 Manual Conventions P 2 Drive Frame Sizes 2 General Precautions P 3 Catalog Number Explanation P 4 Who Should Use this Manual This manual is intended for qualified personnel You must be able to program and operate Adjustable Frequency AC Drive devices
5. 45 100 45 22C B049A103 11 15 49 49 180 265 213 51 70 140 CMN 6300 100 C60 22C B065A103 15 20 65 65 180 265 28 8 68 90 140 CMN 9000 100 85 22C B075A103 18 5 25 75 75 180 265 32 5 78 100 140 CMN 9000 100 095 22C B090A103 22 30 90 81 180 265 38 3 92 125 100 0110 22C B120A103 30 40 120 120 180 265 516 124 175 100 0180 22C B145A103 37 50 145 130 180 265 624 150 200 100 0180 380 480V AC 3 Phase Input 0 460V 3 Phase Output 22C D6PON103 2 2 3 0 6 6 340 528 6 3 7 5 10 140M D8E C10 100 09 22C D010N103 4 0 5 0 10 5 10 5 1340 528 109 13 20 140M D8E C16 100 16 22C D012N103 5 5 7 5 12 12 340 528 11 9 142 20 140M D8E C16 100 23 22C D017N103 7 5 10 17 17 340 528 153 184 25 140M D8E C20 100 C23 22C D022N103 11 15 22 22 340 528 192 23 30 140M F8E C32 100 C30 22C D030N103 15 20 30 27 340 528 258 31 40 140M F8E C32 100 C37 22C D038A103 18 5 25 38 38 340 528 33 8 40 50 140M F8E C45 100 60 22C D045A103 22 30 45 5 45 5 340 528 391 47 60 140 CMN 6300 100 C60 22C D060A103 30 40 60 54 340 528 53 3 64 80 140 CMN 9000 100 C85 22C D072A103 37 50 72 72 340 528 60 7 73 100 140 9000 100 85 22C D088A103 45 60 88 88 340 528 74 9 90 125 100 D110 22C D105A103 55 75 105 105 340 528 89 107 150 100 0140 22C D142A103 75 100 142 128 340 5
6. Parameter 9 Device Type set to Master and connected to Master port M on RJ45 Splitter Cable Parameter 1 Adapter Cfg set to Auto default or Slave and connected to Slave port S on RJ45 Splitter Cable Serial Converter 4 RJ45 DSI Splitter Cable Connecting Two Permanent Peripherals NEMA 1 Bezel with DSI Hand Held NEMA 4 Panel Mount Unit DSI Drive Parameter 9 Device Type set to Master and connected to Master port M on RJ45 Splitter Cable Parameter 9 Device Type set to Slave and connected to Slave port S on RJ45 Splitter Cable Connecting an RS 485 Network DSI Drives AK U0 RJ45 TB2 F Two position Terminal Block AK U0 RJ45 TR1 Terminating Resistor end of network i or j L or Customer supplied RJ45 male to RJ45 male cables with wires connected at pins 4 and 5 only naonon Both the Master M and Slave S ports on the RJ45 Splitter Cable operate as standard RS 485 ports in this configuration Appendix D Application Notes Damper Control Setup The PowerFlex 400 allows damper control logic to be imbedded within the drive reducing cost associated with external control hardware and software system Run command can be wired directly into one of the drive inputs Relay outputs can be used to energize the damper to either open or close A damper limit switch can be wired back to the drive providing in
7. if 1 F OTOH g G Catalog Number A B D E F G 22 RFD036 74 2 91 272 10 71 161 6 34 60 2 36 258 10 16 7 5 0 30 7 0 22 RFD050 93 3 66 312 12 28 190 7 48 79 3 11 298 11 73 13 5 0 53 7 0 22 RFD070 93 3 66 312 12 28 190 7 48 79 3 11 298 11 73 13 5 0 53 7 0 22 RFD100 93 3 66 312 12 28 190 7 48 79 3 11 298 11 73 13 5 0 53 7 0 6 12 28 224 8 82 11 73 0 77 7 6 12 28 224 8 82 11 73 7 22 RFD180 126 4 96 312 12 28 224 8 82 112 4 41 298 11 73 27 1 06 Catalog Numbers 22 RFD330 Z 400 15 0 68 0 _ 157 059 7064 WE fl B 9 550 Y 250 48 8 B fe 120 0 4 72 210 285 Accessories and Dimensions B 17 Figure B 9 Remote Panel Mount Small HIM Dimensions are in millimeters and inches Catalog Number 22 25 25 93 098 3 66 gt C FB 180 7 09 lt 2m gt X _ FB SS EM Y 154 6 06 T 2 19 1 3 03 0 75 f l Y 248 l 18 Accessories and Dimensions Figure B 10 NEMA Type 1 Bezel Dimensions
8. Values Default 0 096 Min Max 0 0 100 0 Display 0 196 P035 Maximum Freq P034 Minimum Freq 0 T070 Analog In 1 Lo 071 Analog In 1 Hi T071 Analog In 1 Hi Related Parameter s P035 P038 T069 T070 T072 A152 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 T070 Analog In 1 Lo Values Default 100 0 Min Max 0 0 100 0 Display 0 1 Programming and Parameters 3 21 Terminal Block Group continued T072 Analog In 1 Loss Related Parameter s T055 T060 T065 069 070 T071 A152 Stop drive before changing this parameter Selects drive action when an input signal loss is detected Signal loss is defined as an analog signal less than 1V or 2mA The signal loss event ends and normal operation resumes when the input signal level is greater than or equal to 1 5V or 3mA If using a 0 10V analog input set T070 Analog In 1 Lo to a minimum of 20 i e 2 volts The drive will fault on an F29 Analog Input Loss when the analog signal is lost if this parameter and A152 PID Ref Sel are both set to an option other than 0 Disabled Options 0 Disabled Default 1 Fault F29 F29 Analog Input Loss 2 Stop Uses P037 Stop Mode 3 Zero Ref Drive runs at zero speed reference 4 Min Freq Ref Drive runs a
9. Input Protection T Input Protection Ti T D 5 S H m 1 R m I TI 1 5 Three Phase Input m T Single Phase Input 7 Figure A 2 Frame F Connections PER sua i EEE E ae i Input Protection T Input Protection T f mo T 1 5 i S mm m om RI R m 1 ty 1 1 1 I 7 Three Phase Input Single Phase Input Note UL Approval pending for Single Phase operation 8 Supplemental Drive Information Notes Appendix B Accessories and Dimensions Product Selection Table B 1 Catalog Number Description 22C B 024 N 1 0 3 Drive Voltage Rating Rating Enclosure Emission Class Comm Slot Table 2 PowerFlex 400 Drives Drive Ratings Output Current Amps Frame Input Voltage kW HP 45 506 Catalog Number Size 240V 50 60 Hz 2 2 3 0 12 12 22C B012N103 3 Phase 37 5 0 175 75 22 017 103 C 5 5 7 5 24 24 22C B024N103 7 5 10 33 33 22C B033N103 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 2 2 3 0 6 6 22C D6PON103 3 Phase 40 50 105 105 22C DO10N103 C 5 5 7 5 12 12 22C D012N103 C 7 5 10 17 17 22C D017N103 11 15 22 22 22C D022N103 C 15 20 30 27 22C D030N103 C 18 5 25 38 38 22C D038A103 D 22 30 45 5 45 5 22C D045A103 D 30 40 60 54 22
10. Press Enter or Sel to enter a group The right digit of the last viewed parameter in that group will flash Press the Up Arrow or Down Arrow to scroll through the parameters that are in the group 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 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 10 If desired press Sel to move from digit to digit or bit to bit The digit or bit that you can change will flash 11 Press the Up Arrow or Down Arrow to change the parameter value 12 Press Esc to cancel a change The digit will stop flashing the previous value is restored and the Program LED will turn off Or Press Enter to save a change The digit will stop flashing and the Program LED will turn off 13 Press Esc to return to the parameter list Continue to press Esc to back out of the programming menu If pressing Esc does not change the display then 2001 Output Freq is displayed Press Enter or Sel to enter the last group menu viewed Key s co co Start Up 2 5 Example Displays eo ceo DO DO eco The Basic Program Group page 3 7 contains the most commonly changed parame
11. 1 Stop input also clears active fault 3 10 Programming and Parameters Basic Program Group continued P038 Speed Reference Related Parameter s 5001 b002 P038 P040 P042 051 054 1070 071 073 074 T075 C102 A141 A142 A143 A146 152 0301 Sets the source of the speed reference to the drive The drive speed command can be obtained from a number of different sources The source is normally determined by P038 Speed Reference However when 1051 T054 Digital Inx Sel is set to option 1 2 3 4 5 8 14 15 16 17 and the digital input is active or if A152 PID Ref Sel is not set to option 0 the speed reference commanded by P038 Speed Reference will be overridden Refer to the flowchart on page 1 24 for more information on speed reference control priority Options 0 Drive Keypad Internal frequency command from the digital speed keys on the integral keypad 1 InternalFreq Internal frequency command from 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 1069 Analog In 1 Sel and DIP Switch on the control board Default Dip Switch setting is 10V 3 Analog In 2 External frequency command from an analog source as determined by 1073 Analog In 2 Sel and DIP Switch AI2 on the control board Default Dip Switch setting is 10V 4 Preset Freq External frequency comm
12. Values Default 0 0 Hz Min Max 0 0 320 0 Hz Display 0 1 Hz 3 34 Programming and Parameters Advanced Program Group continued A152 PID Ref Sel Related Parameter s P038 T070 T071 T072 T074 T075 Stop drive before changing this parameter Enables disables PID mode and selects the source of the PID reference Refer to Appendix D for details Options 0 Disabled Default 1 PID Setpoint 2 Analog In 1 3 Analog In 2 4 Comm Port 5 Setpnt Trim Use PID output as Trim on Frequency Select 6 A In 1 Trim Use PID output as Trim on Frequency Select 7 A In 2 Tim Use PID output as Trim on Frequency Select 8 Comm Trim Use PID output as Trim on Frequency Select 0 The PID will not function with bipolar input It will ignore any negative voltages and treat them like Note PID analog reference is scaled through the Analog In x Hi Lo parameters The invert operation is obtained through 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 1074 T075 Select the source of the PID feedback Refer to Appendix D for details Options 0 Analog In 1 Default PID will not function with a bipolar input Negative voltages are treated as 0 volts 1 Analog In 27 2 Comm
13. 1 30 Installation Wiring Essential Requirements for FCC Compliance Conditions 1 4 listed below must be satisfied for PowerFlex 400 drives to meet the requirements of FCC Part 15 Subpart B 1 Grounding as described in Figure 1 11 Refer to page 1 9 for additional grounding recommendations 2 Output power control I O and signal wiring must be braided shielded cable with a coverage of 75 or better metal conduit or equivalent attenuation 3 All shielded cables should terminate with the proper shield connector 4 Conditions in Table 1 Table 1 K PowerFlex 400 FCC Part 15 Subpart Compliance PowerFlex 400 Drive Required Filter Restrict Motor Install Drive and kW HP Cat Cable to Meters Filter in Enclosure 200 240 Volts 2 2 3 0 22C B012N103 22 034 5 10 No 3 7 5 0 22 017 103 22 RF034 CS 10 No 5 5 7 5 22 024 103 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 RFD100 150 Required 18 5 25 22 075 10 3 22 RFD100 150 Required 22 30 22C B090A103 22 RFD150 150 Required 30 40 22C B120A103 22 RFD150 150 No 37 50 22C B145A103 22 RFD180 150 No 380 480 Volts 2 2 3 0 22 6 0 103 22 018 5 10 No 4 0 5 0 22 010 103 22 RF018 CS 10 No 5 5 7 5 22
14. CED CODOO00 0000000 as B Li Accessories and Dimensions Figure 4 PowerFlex 400 Frame F Drive Dimensions are in millimeters and inches I 498 0 16 73 381 0 15 00 13 0 0 51 i 264 0 10 39 165 8 6 53 fa S 381 0 15 00 370 0 14 57 gt I 287 5 11 32 9 137 5 5 41 gt 55 0 2 17 r bO OS o O o d 0 EEEEEEEEEEEESEEEREESEEESERE GEEEEEEEESEEERESEEERESEEEEE k 280 0 11 02 B 11 12 Accessories and Dimensions Figure 5 PowerFlex 400 Frame C Flange Mount Drive Dimensions are in millimeters and inches lt 130 3 300
15. Frame Screw Size Screw Torque C 5 10 24 2 45 2 94 22 26 Ib in D 8 5 16 in 6 0 7 4 N m 53 2 65 0 Ib in E M8 5 16 in 8 8 10 8 N m 78 0 95 3 Ib in F M10 3 8 in 19 6 23 5 N m 173 6 208 3 Ib in e 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 Frame Enclosure Rating Temperature Minimum Mounting Range Clearances C IP 20 UL Open Type 10 to 45 C See Figure 1 1 14 to 113 F Mounting Option A 30 NEMA 1 UL Type 10 10 to 45 C See Figure 1 1 14 to 113 F Mounting Option B IP 20 UL Open Type 10 to 50 C See Figure 1 1 14 to 122 F Mounting Option B D 30 NEMA 1 UL Type 1 10 to 45 See Figure 1 2 E 14 to 113 F F 0 Frame C drives require installation of the PowerFlex 400 IP 30 NEMA 1 UL Type 1 option kit to achieve this rating Minimum Mounting Clearances Refer to Appendix B for mounting dimensions Figure 1 1 Frame C Mounting Clearances 120 mm 4t 4 7 in a 120 mm t 4 7 in lt gt between drives Mounting Option B gt Mounting Option No clearance required 4 25 mm 1 0 47 in ag Le 120 mm 4i 4 7 in a fr Installation Wiring 1 5 Figure 1 2 Frames D E and F
16. Min Max 0 0 20 0 Secs Display 0 1 Secs Programming and Parameters 3 27 Communications Group C101 Language Selects the language displayed by the integral LCD display and remote communications option Options English Default Francais Espa ol 1 2 3 4 Italiano 5 Deutsch 6 7 8 9 Reserved Portugu s Reserved Reserved 10 Nederlands C102 Comm Format Related Parameter s 1303 0306 Selects the protocol data bits 8 data bits only parity None Even Odd and stop bits 1 or 2 used by the RS485 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 Options 0 RTU 8 N 1 Default RTU 8 E 1 RTU 8 0 1 RTU 8 N 2 RTU 8 E 2 RTU 8 0 2 MetaSys P1 8 N 1 Floor Level Network FLN P1 8 E 1 Floor Level Network FLN P1 8 0 1 Floor Level Network FLN 0 A N C103 Comm Data Rate Related Parameter s 4303 Sets the serial port rate for the RS485 051 port Important Power to drive must be cycled before any changes will affect drive operation Options 0 1200 2400 4800 9600 Default 19 2K 38 4K 3 28 Programming and Parameters
17. 23 Aux Motor Auxiliary Motor is commanded to run Refer to Appendix C 3 48 Programming and Parameters Aux Relay Card Group continued R222 Relay Out3 Level R225 Relay Out4 Level R228 Relay Out5 Level R231 Relay Out6 Level R234 Relay Out 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 Relay OutX Select Setting Relay OutX Level Min Max 6 0 320 Hz 7 0 180 8 0 815 Volts 9 0 100 10 1 180 degs 12 0 1 Values Default 0 0 Min Max 0 0 9999 Display 0 1 Refer to Appendix C for details on the application of parameters R239 through R254 R239 Aux Motor Mode Enables operation of the auxiliary motor control modes when in PID mode Options 0 Disabled Default 1 Enabled Programming and Parameters 3 49 Aux Relay Card Group continued R240 Aux Motor Qty Sets the number of auxiliary motors used while in Auxiliary Motor Control mode Options 1 1 Aux Default 1 Auxiliary Motor 2 2 Aux Mtr 2 Auxiliary Motors 3 3 Aux 3 Auxiliary Motors 4 4 Mtr Swap 1 1 Auxiliary Motor and AutoSwap Active 5 2 Mtr Swap 7 2 Auxiliary Motors and AutoSwap Active 6 3 Mtr Swap 7 3 Auxiliary Motors and AutoSwap Active R240 Drive Relays Auxiliary Relay Card Relays Option 1 Rel
18. Adjustable Frequency AC Drive for Fan amp Pump Applications FRN 4 xx User Manual Automation 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 conten
19. setting DIP Switch Output Min Output Max Output Value A02 Related Setting Range Value Analog Output Hi Filter Setting Parameter 0 OutFreq0 10 0 10V OV 0Hz Maximum Frequency None 10V b001 1 0 10 0 10V OV 20 Amps 200 Drive Rated FLA Filter A 10 b003 2 OutTorq0 10 0 10V OV 0 Amps 200 Drive Rated FLA Filter A 10V b013 3 OutVolt0 10 0 10V OV 0 Volts 120 Drive Rated Output V None 10V b004 4 OutPowr 0 10 0 10V OV 0kW 200 Drive Rated Power Filter A 10V b010 5 Setpnt0 10 0 10V 0 0 0 100 0 Setting None 10V 1084 6 TstData0 10 0 10V 0 0000 65535 Hex FFFF None 10V A196 7 OutFreq 0 20 0 20mA 0 0 Hz Maximum Frequency None 20 b001 8 0 20 0 20mA 0 0 200 Drive Rated FLA Filter A 20 mA b003 9 OutTorg 0 20 0 20 OmA 0Amps 200 Drive Rated FLA Filter A 20 b013 10 OutVolt 0 20 0 20 0mA 0 Volts 120 Drive Rated Output V None 20 b004 11 OutPowr0 20 0 20mA OmA 0kW 200 Drive Rated Power FilterA 20 b010 12 Setpnt0 20 0 20 0 0 100 0 Setting None 20 T084 13 TstData 0 20 0 20mA 0 0000 65535 Hex FFFF None 20 196 14 OutFreq 4 20 4 20 4 0 Hz Maximum Frequency None 20 b001 15 OutCurr4 20 4 20mA 4mA 0Amps 200 Drive Rated FLA Filter A 20 b003 16 OutTorq 4 20 4 20mA 4mA 0Amps 200 Drive Rated FLA Filter A 20 b013 17 OutVolt 4 20 4 20 4mA 0 Volts 120 Drive Rated Output V None 20 b004 18 OutPowr 4 20 4 20
20. 0 1 Hz A160 Process Factor Related Parameter s b008 Scales the output frequency value displayed by b008 Process Display Output Process _ Process Freq Factor Display Values Default 30 0 Min Max 0 1 999 9 Display 0 1 3 36 Programming and Parameters Advanced Program Group continued A163 Auto Rstrt Tries Related Parameter s T055 T060 T065 T066 A164 Sets the maximum number of times the drive attempts to reset a fault and restart Clear a Type 1 fault and restart the drive 1 Set A163 Auto Rstrt Tries to a value other than 0 2 Set A164 Auto Rstrt Delay to a value other than 0 Clear an OverVoltage UnderVoltage or Heatsink OvrTmp fault without restarting the drive 1 Set A163 Auto Rstrt Tries to a value other than 0 2 Set A164 Auto Rstrt Delay to 0 Note If the parameter is not set to zero and Auto Rstrt Time is set to zero auto fault clear is enabled This feature automatically clears faults but does not restart the drive ATTENTION Equipment damage and or personal injury may result if this parameter is used in an inappropriate application Do not use this function without considering applicable local national and international codes standards regulations or industry guidelines Values Default 0 Min Max 0 9 Display 1 A164 Auto Rstrt Delay Related Parameter s 163 Sets the time between restart attempts when A163 Auto Rstrt Tries is set to a valu
21. 4mA 0kW 200 Drive Rated Power FilterA 20 b010 19 Setpnt4 20 4 20 4mA 0 0 100 0 Setting None 20 1084 20 TstData 4 20 4 20 4 0000 65535 Hex FFFF None 20 196 7 For settings with the filter enabled if a 0 100 step change occurs the output will reach 95 in 500 milliseconds 99 in 810 milliseconds and 100 in 910 milliseconds Values Default 1 Min Max 0 20 Display 1 3 26 Programming and Parameters Terminal Block Group continued T086 Analog Out2 High Related Parameter s P035 T085 T087 Scales the Maximum Output Value for the A065 Analog Out Sel source setting Examples T086 Setting T085 Setting T085 Max Output Value 50 1 OutCurr 0 10 5V for 200 Drive Rated Output Current 90 11 OutPowr 0 20 18mA for 200 Drive Rated Power Values Default 100 0 800 Display 1 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 Default 0 096 Min Max 0 0 100 0 Display 0 196 T088 Anlg Loss Delay Related Parameter s T069 T070 T071 T072 1073 1074 T075 T076 Sets the length of time after power up during which the drive will not detect an analog signal loss The drive response to an analog signal loss is set in T072 or T076 Analog In x Loss Values Default 0 0 Secs
22. 5 Safety Ground 1 8 Shielded Power Cables 1 11 Short Circuit Protection 1 9 Single Phase Input Power Connections A 7 Software 3 1 Start and Speed Reference Selection and Control 1 24 1 25 Start Stop Repeated 1 15 Start Up Checklist 2 1 2 2 Static Discharge ESD P 3 Status LEDs 2 3 2 4 2 6 2 7 2 8 2 9 Supply Source AC 1 6 Index 3 SW OverCurrent Fault 4 4 System Grounding 1 8 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 1 18 1 19 I O 1 15 Examples 1 20 1 23 Power 1 11 Index 4 5011625904 304 Power Control and Information Solutions Headquarters Americas Rockwell Automation 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 Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 22C UM001E EN P November 2005 www rockwellautomation com Supercedes 22C UM001D EN P August 2005 Copyright 2005 Rockwell Automation Inc All rights reserved
23. All items must be read and understood before the actual installation begins ATTENTION The following information is merely a guide for proper installation Rockwell Automation Inc cannot assume responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this drive or associated equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation Opening the Cover Frame C Drives 1 Press and hold in the tabs on each side of the cover 2 Pull the cover out and up to release 1 2 Installation Wiring Frame D Drives 1 Loosen the two captive cover screws 2 Pull the bottom of the cover out and up to release E Frame E Drives 1 Loosen the four captive cover screws 2 Pull the bottom of the cover out and up to release JI 0000000000000000 00000000000 ag 0000001111100000000 Frame F Drives 1 Turn the latch counterclockwise 2 Pullon the latch to swing the door open Installation Wiring 1 4 Installation Wiring Mounting Considerations e Mount the drive upright on a flat vertical and level surface
24. Display 0 1 Hr Programming and Parameters 3 51 Aux Relay Card Group continued 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 setting Values Default 50 0 Min Max 0 0 100 0 Display 0 1 3 52 Programming and Parameters Advance Display Group d301 Control Source Related Parameter s P036 P038 051 054 Displays the active source of the Start Command and Speed Command which are normally defined by the settings of P036 Start Source and P038 Speed Reference but may be overridden by digital inputs Refer to the flowcharts on pages 1 24 and 1 25 for details L oo Start Command Digit 0 0 Keypad 1 Terminal Block 2 Communications Speed Command Digit 1 0 Local Keypad Potentiometer 1 142 Internal Freq 2 Analog Input 1 3 Analog Input 2 4 A143 A146 Preset Freq x 1051 1053 Digital Inx Sel must be set to 4 5 Communications Reserved Digit 2 Reserved Digit 3 Values Default Read Only Min Max 0 99 Display 1 d302 Contrl In Status Related Parameter s 002 P036 051 054 Status of the control terminal block control inputs Important Actual control commands may come from a source other than the control terminal block 1 Condition True 0 Condit
25. Param scd via ADI 2 Varies by ihe parametar Al 12 User In 3 User defined Input 3 Param selected via ADI 3 13 User In 4 User defined Input 4 Param selected via ADI 4 F4 Metasys N2 Table F 9 Binary Outputs Network Point Values Type Address Description ON 1 OFF 0 BO 1 Run Enable Logic Command bit 00 Enable Stop Coast BO 2 Start Stop Logic Command bit 00 amp 01 Start Stop Normal BO 3 Jog Logic Command bit 02 Jog Not Jog BO 4 Clear Faults Logic Command bit 03 Clear Flts Not Clear Fits BO 5 Fwd Rev Logic Command bit 04 amp 05 Forward Reverse BO 6 Not Used Logic Command bit 06 BO 7 MOP Inc Logic Command bit 07 Increment Not Increment BO 8 Accel 1 Logic Command bit 08 Accel Rate 1 Not Accel 1 BO 9 Accel 2 Logic Command bit 09 Accel Rate 2 Not Accel 2 BO 10 Decel 1 Logic Command bit 10 Decel Rate 1 Not Decel 1 BO 11 Decel 2 Logic Command bit 11 Decel Rate 2 Not Decel 2 BO 12 Ref Sel 1 Logic Command bit 12 BO BO 13 Ref Sel 2 Logic Command bit 13 14 13 12 BO 14 Ref Sel 3 Logic Command bit 14 0 0 0 NoCommand 0 0 1 P038 Speed Reference 0 1 0 A142 Internal Freq 0 1 1 Comm Address 8193 0 1 0 0 143 Preset Freq 0 1 0 1 A144 Preset Freq 1 1 1 0 145 Preset Freq 2 1 1 1 A146 Preset Freq 3 BO 15 MOP Dec Logic Command bit 1
26. Start Speed and Direction commands Yes come from Integral Keypad Local Input Enabled and Active Digital Inx Sel 3 Direction is Forward unless an input is programmed for Keypad Jog Direction Run as specified by P038 Speed Reference Auto Input Enabled and Active Digital Inx Sel 2 Yes Start and Direction commands come from P036 Start Source Comm Select Input Enabled and Active Digital Inx Sel 4 Start Speed and Direction commands come from RS485 DSI port Start and Speed commands 1 page 2 iti come from Integral Keypad herer 10 age 248 for additional information on the operation of the Hand Auto Mode Drive is in Hand Local Mode selected by AUTO key 1 Direction is Forward unless an input is programmed for Cmd Reverse Speed commands come from Analog Input 1 I O Terminal 13 Analog Input 1 Override Enabled amp Active Digital Inx Sel 14 Yes Start and Direction follows P036 Start Source Speed commands come from Analog Input 2 I O Terminal 17 Analog Input 2 Override Enabled amp Active Digital Inx Sel 15 Yes Start and Direction follows 036 Start Source Run as specified by P038 Speed Reference Start and Direction commands come from P036 Start Source Run as specified by 144 146 Preset Freq 1 3 Preset Inputs Active T051 T052 T053 8 Star
27. Start Source Stop O Terminal 01 Stop important Terminal 01 is always a coast to stop input Keypad PePox Cow except when 036 Start Source is set to option 1 3 Wire or 3 Wire Per P037 Per P0378 6 2 W Lvl Enbl In three wire control I O Terminal 01 is 2 Wire Per P037 Coast controlled by P037 Stop Mode All other stop sources are R5485 Port Per P037 Coast controlled by 037 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 Two wire control shown For three wire control use a momentary input ao on I O Terminal 02 to command a start If reverse is enabled by A166 use a maintained input o for I O Terminal 03 to change direction 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 When the ENBL enable jumper is removed 1 Terminal 01 will always act as a hardware enable causing coast to stop without software interpretation 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 Common for Analog Input 2 Al2 Electronically isolated from digital I O and opto output Not to be used with An
28. the drive will stop as specified by P037 Stop Mode Drive will not run if I O Terminal 01 is open Drive will coast to stop if opened while running Connection Example Common Stop Run 000000000 0000000000 00000000 Stop Run 24V O0 0 00000 01 02 04 Stop Run Oo Q Q O Q 00000000 01 02 04 Installation Wiring 1 21 Required Settings DIP Switch AO1 20MA Parameters T082 Analog Out1 Sel 14 through 20 Scaling T083 Analog Out1 High T084 Analog Outi Setpt DIP Switch SNK SRC SRC Parameters P036 Start Source 2 3 4 P037 Stop Mode 0 through 7 DIP Switch SNK SRC SRC Parameters P036 Start Source 2 3 4 P037 Stop Mode 0 through 7 DIP Switch SNK SRC SNK Parameters P036 Start Source 2 3 4 P037 Stop Mode 0 through 7 1 22 Installation Wiring Input Output 2 Wire Control Sourcing SRC Internal Supply Run FWD Run REV e Input must be active for the drive to run e When input is opened the drive will stop as specified by P037 Stop Mode e If both Run FWD and Run REV inputs are closed at the same time an undetermined state could occur Drive will not run if I O Terminal 01 is open Drive will coast to stop if opened while running 2
29. 1 26 Installation Wiring RS485 Network Wiring Network wiring consists of a shielded 2 conductor cable that is daisy chained from node to node Figure 1 9 Network Wiring Diagram PowerFlex 400 PowerFlex 400 PowerFlex 400 Node 1 Node 2 Node n Master FRONT 24 RED _ 4 070 4 120 ohm resistor 120 ohm resistor TxRxD TxRxD Tp s D Shield Shield Shield PIN 8 NOTE The shield should be grounded at ONLY ONE location Only pins 4 and 5 on the RJ45 plug should be wired The other pins on the PowerFlex 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 controller used and and TxRxD are shown for illustration purposes only Refer to the master controller s user manual for network terminations Note that there is no standard for the and wires and consequently 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 Connections PowerFlex 400 Frame D E and F drives are equipped with two RS485 DSI ports One is accessible via an access door when the cover is on and one is only accessible with the cover off When one of these ports has a Rockwell DSI device connected the second p
30. 17 Relay Out2 Se 060 Terminal Block 3 16 Relay Out3 Level R222 Relay Card 3 48 Relay Out3 Sel R221 Relay Card 3 47 Relay Out4 Level R225 Relay Card 3 48 Relay Out4 Sel R224 Relay Card 347 Relay Out5 Level R228 Relay Card 3 48 Relay Out5 Sel R227 Relay Card 3 47 Relay Out6 Level R231 Relay Card 3 48 Relay Out6 Sel R230 Relay Card 3 47 Relay Out7 Level R233 Relay Card 3 47 3 60 Programming and Parameters Notes 4 Troubleshooting Chapter 4 provides information to guide you in troubleshooting the PowerFlex 400 drive Included is a listing and description of drive faults with possible solutions when applicable See e page For information on For information on See page Drive Status Fault Descriptions 4 3 Faults m Common Symptoms and 4 5 Corrective Actions Drive Status The condition or state of your drive is constantly monitored Any changes will be indicated through the integral keypad LED Indications See page 2 3 for information on drive status indicators and controls Faults A fault is a condition that stops the drive There are two fault types Type Fault Description CD Auto Reset Run When this type of fault occurs and A163 Auto Rstrt Tries is set to a value greater than 0 a user configurable timer A164 Auto Rstrt Delay begins When the timer reaches zero the drive attempts to automatically reset the fault If the condit
31. 31 Break Voltage A172 Advanced Program 3 39 Language C101 Communications 3 27 Bus Reg Mode A187 Advanced Program 3 43 Load Loss Level 184 Advanced Program 3 42 Comm Data Rate C103 Communications 3 27 Load Loss Time 185 Advanced Program 3 42 Comm Format C102 Communications 3 27 Maximum Freq 035 Basic Program 3 7 Comm Loss Action C105 Communications 3 28 Maximum Voltage A174 Advanced Program 3 40 Comm Loss Time C106 Communications 3 28 Minimum Freq P034 Basic Program 3 7 Comm Node Addr C104 Communications 3 28 Motor NP FLA A200 Advanced Program 3 46 Comm Status 4303 Advanced Display 3 53 Motor NP Hertz P032 Basic Program 3 7 Comm Write Mode C107 Communications 3 28 Motor NP Poles A199 Advanced Program 3 46 Commanded Freq b002 Basic Display 3 4 Motor NP Volts P031 Basic Program 3 7 Programming and Parameters 3 59 Parameter Name Number Group Page Parameter Name Number Group Page Motor OL Current P033 Basic Program 3 7 Relay Out7 Sel R284 Relay Card 3 48 Motor OL Ret P043 Basic Display 3 11 Relay Out8 Level R237 Relay Card 3 48 Motor OL Se
32. 33 5 9 13 0 1321 0 32 1 97 3 81 114 4 50 84 3 32 64 2 50 80 3 13 5x8 20 33 2 3 5 0 1321 DC32 2 B 118 4 63 133 5 25 108 4 25 76 3 00 95 3 75 5 8 20x 33 4 5 10 0 1321 DC40 2 B 97 3 81 114 4 50 95 3 75 76 3 00 80 3 13 5x8 20x 33 3 2 7 0 1321 DC40 4 B 165 6 50 166 6 55 152 6 00 86 3 38 135 5 31 7x13 28x 52 9 5 21 0 Accessories and Dimensions B 15 Figure 8 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 lt 60 gt 130 2 36 90 512 126 7 3 54 297 309 11 69 12 17 297 11 69 5 5 0 22 L 30 16 Accessories and Dimensions Catalog Numbers 22 RFD036 22 RFD050 22 RFD070 22 RFD100 22 RFD150 22 RFD150 126 4 96 1312 12 28 224 8 82 112 4 41 298 11 73 19 5 0 77 22 RFD180 CN PEE D 1 ir C FL 8 SS cc B E cm
33. 5 66 0 2 60 1 12 22 2 0 87 5 9 lt 1112 PURE 4 38 Se Accessories and Dimensions B 9 Figure 2 PowerFlex 400 Frame D Drive Dimensions are in millimeters and inches 250 0 9 84 226 0 8 90 2 90 35 va Z 436 2 383 4 17 17 15 09 5 45j 206 1 8 11 I 192 0 7 56 IK 175 5 6 91 lt 132 0 5 20 42 0 71 6 2 82 1 65 22 2 oo e 0 87 U 2l r TOSSET 167 4 T T 10 Accessories and Dimensions Figure PowerFlex 400 Frame E Drive Dimensions are in millimeters and inches 85 0 33 370 0 14 57 gt I 9289 2 10 21 335 0 13 19 K 4 es 567 4 34 E lt 315 2 12 41 k 240 2 9 46 9 le 130 2 5 13 aai 55 2 2 17 2 47 22 2 0 87 J
34. 5 13 105 8 1382 11 81 417 1 5 44 4 9 amp 325 12 8 1 D Cutout Dimensions B un 164 05 3 0 31 6 46 uf 0 21 307 5 12 11 9 230 6 9 08 291 5 11 48 2 _ ee 153 8 6 06 76 9 8 03 90 t 8 L 854 1 0 31 7 09 Accessories and Dimensions B 13 Figure B 6 Bulletin 1321 3R Series Line Reactors Dimensions are in millimeters and inches Weights are in kilograms and pounds 00 Open 00 Open 45 Amps fundamental and Below 55 Amps fundamental and Above Catalog Number A B C D E Weight 1321 3R8 C 152 6 00 122 4 80 86 3 40 67 2 62 51 2 00 5 0 11 1321 3R8 D 152 6 00 122 4 80 86 3 40 63 248 51 2 00 5 9 13 1321 3R12 A 152 6 00 127 5 00 84 3 30 53 2 10 51 2 00 41 9 1321 3R12 B 152 6 00 127 5 00 76 3 00 53 210 51 2 00 4 5 10 1321 3R12 C 152 6 00 127 5 00 91 3 60 69 2 73 51 2 00 82 18 1321 3R18 B 152 6 00 135 5 30 89 3 50 63 248 51 2 00 5 5 12 1321 3R18 C 183 7 20 146 5 76 92 3 63 66 2 60 76 3 00 7 3 16 1321 3R25 A 183 7 20 146 5 76 85 3 35 60 2 35 76 3 00 49 11 1321 3R25 B 183 7 20 146 5 76 85 3 35 60 0 35 76 3 00 6 3 14 1321 3R25 C 183 7 20 146 5 76 105 4 10
35. 5 5 7 5 20 140M D8E C16 100 C23 7 5 10 25 140M D8E C20 100 23 11 15 30 140M F8E C32 100 30 15 20 40 140M F8E C32 100 37 18 5 25 50 140M F8E C45 100 60 22 30 60 140 CMN 6300 100 60 30 40 80 140 CMN 9000 100 85 37 50 100 140 CMN 9000 100 C85 45 60 125 100 D110 55 75 150 100 0140 75 100 200 100 0180 90 125 250 100 0210 110 150 250 100 0250 1 Recommended Fuse Type UL Class J or Type BS88 600V 550V or equivalent 2 Refer to the Bulletin 140M Motor Protectors Selection Guide publi cation 140M SG001 to determine the frame and breaking capacity required for your application gt P Installation Wiring 1 11 Power Wiring ATTENTION National Codes and standards NEC VDE BSI etc and local codes outline provisions for safely installing electrical equipment Installation must comply with specifications regarding wire types conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage ATTENTION To avoid a possible shock hazard caused by induced voltages unused wires in the conduit must be grounded at both ends For the same reason if a drive sharing a conduit is being serviced or installed all drives using this conduit should be disabled This will help minimize the possible shock hazard from cross coupled power leads Motor Cable Types Acceptable for 200
36. ACCEL RATE 2 83 DECEL RATE 1 84 DECEL RATE 2 85 REF SELECT 1 86 REF SELECT 2 87 REF SELECT 3 88 MOP DEC 92 REFERENCE b022 93 OK FAULT 94 RESET FAULT 99 ERROR STATUS 1 These parameters affect the operation of an optional auxiliary relay board 1 Floor Level Network FLN Using Percent for the Reference The Reference Point 92 for is set as a percentage from 0 to 100 100 0 0 Pr P035 Maximum Freq Value 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 100 50 30 2 30 2 50 25 15 2 15 2 25 0 0 Hz 0 Hz 0 P1 Floor Level Network FLN G 7 Using P1 Configurable Points to Access Parameters Configurable points are inputs and outputs that let you read and write parameter values These objects handle only 15 bit parameter values 0 32767 Important If a parameter has a decimal point the value must be properly scaled by the user For example Accel Time has two decimal places To use the value 60 00 the scaled value 6000 must be communicated to the drive The scaled value 6000 will be returned Reading Parameter Values The configurable points may show any parameter in the drive by configuring the Param in the Read Param point The drive reads the value of the parameter configured in the Param
37. Accel Rate 1 Enable 9 8 10 Accel Rate 2 Enable 8192 11 Hold Accel Rate Selected 00 No Command 01 Decel Rate 1 Enable 10 Decel Rate 2 Enable 11 Hold Decel Rate Selected 000 No Command 001 Freq Source P038 Speed Reference 010 Freq Source A142 Internal Freq 011 Freq Source Comms Addr 8193 100 A143 Preset Freq 0 101 A144 Preset Freq 1 110 A145 Preset Freq 2 111 A146 Preset Freq 3 15 1 MOP Decrement 0 Not Decrement 1 Local Control causes the drive to use C108 Start Source 2 and C109 Speed Ref 2 for start and speed reference control 11 10 14 13 12 Writing 06 Reference The Speed Reference to a PowerFlex 400 drive can be controlled via the network by sending Function Code 06 writes to register address 8193 Reference P038 Speed Reference must be set to 5 RS485 DSI Port in order to accept the Speed Reference Reference Address Decimal Description A decimal value entered as xxx xx where the decimal point is fixed For example a decimal 1000 equals 10 00 Hz and 543 equals 5 43 Hz 8193 Modbus RTU Protocol Reading 03 Logic Status Data The PowerFlex 400 Logic Status data can be read via the network by sending Function Code 03 reads to register address 8448 Logic Status Error Codes Address Decimal Bit s Description 1 Ready 0 Not Ready 1 Active R
38. Add Sets the amount to add to the PID reference once the next auxiliary motor is turned on to compensate for a drop in the pipe due to the increased flow in a typical pump system Values Default 0 0 0 0 100 0 Display 0 1 R250 Aux Start Delay Sets the delay time before turning on the next auxiliary motor once the output frequency has risen above the value set in Aux X Start Freq Values Default 5 0 Secs Min Max 0 0 999 9 Secs Display 0 1 Secs R251 Aux Stop Delay Sets the delay time before turning off the next running 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 between connecting the drive controlled motor contactor and running the drive controlled motor and starting the auxiliary motor control Values Default 0 50 Secs Min Max 0 00 60 00 Secs Display 0 01 Secs R253 Aux AutoSwap Tme Sets the total running time between automatic motor changes Important Proper wiring and parameter configuration of Aux Motor Control functions are especially important when using AutoSwap Improper wiring or configuration could result in line power being applied to the drive outputs Verify system operation before connecting auxiliary motor contactor outputs Values Default 0 0 Hr Min Max 0 0 999 9 Hr
39. Auto Rstrt Tries to a value other than 0 2 Set A164 Auto Rstrt Delay to a value other than 0 Clear an OverVoltage UnderVoltage or Heatsink OvrTmp fault without restarting the drive 1 Set A163 Auto Rstrt Tries to a value other than 0 2 Set A164 Auto Rstrt Delay to 0 Auto Restart Reset Run The Auto Restart feature allows the drive to automatically perform a fault reset followed by a start attempt without user or application intervention This allows remote or unattended operation Only certain faults are allowed to be reset Certain faults Type 2 that indicate possible drive component malfunction are not resettable Caution should be used when enabling this feature since the drive will attempt to issue its own start command based on user selected programming F2 Fault Descriptions Table 4 A Fault Types Descriptions and Actions Description Troubleshooting 4 3 Action Auxiliary input interlock is open F3 Fd 5 F6 F7 F8 F12 F13 F15 F29 1 Fault E Auxiliary Input Power Loss Q UnderVoltage 1 OverVoltage D Motor Stalled 0 Motor Overload 1 Heatsink D OvrTmp HW OverCurrent 2 Ground Fault 2 Load Loss D Analog Input D Loss DC bus voltage remained below 85 of nominal DC bus voltage fell below the minimum value DC bus voltage exceeded maximum value Drive is unable to accelerate motor Int
40. Certain digital input settings can override drive operation Refer to Start and Speed Reference Control on page 1 24 for details 2 8 Start Up Auto Manual Mode In Manual mode Start command is defined by P036 Start Source Speed Reference command is defined by the Digital Speed Increment and Decrement keys Auto key toggles frequency control to AUTO in a bumpless transfer In AUTO mode Auto key LED is illuminated Start command is defined by P036 Start Source Speed Reference command is defined by P038 Speed Reference Auto key switches frequency control to the integral keypad in a bumpless transfer Table 2 C P042 Auto Mode 3 Auto Manual Key e HAND T051 T054 Digital Inx Sel 2 Auto Mode or 3 Local Manual Mode AUTO Mode LED Key Function LED Key Function Off Not active Off Not active Only active if PO36 Start Source _ Only active if P036 Start Source 0 Keypad Starts drive 0 Keypad Starts drive Runs according to Speed Increment Decrement keys Changes speed Off Not active Keys are only active if P038 Speed Reference 0 Drive Pot OFF Changes to AUTO Mode On Changes to Manual Mode If running drive will continue to run _ If running drive will continue to run at reference defined by P038 Speed E a according to Digital Speed Reference Increment and Decrement keys Stops drive N A Stops drive Important Ce
41. Communications Group continued C104 Comm Node Addr Related Parameter s 4303 Sets the drive node address for the RS485 DSI port if using a network connection Important Power to drive must be cycled before any changes will affect drive operation Values Default 100 Min Max 1 247 Display 1 C105 Comm Loss Action Related Parameter s d303 P037 C106 Selects the drive s response to a loss of the communication connection or excessive communication errors Options 0 Fault Default Drive will fault on an F81 Comm Loss and coast to stop 1 Coast Stop Stops drive via coast to stop 2 Stop Stops drive via P037 Stop Mode setting 3 Continu Last Drive continues operating at communication commanded speed saved in RAM 4 Run Preset 0 Drive will run at preset speed 5 Inc Dec Drive will run at keypad digital pot speed C106 Comm Loss Time Related Parameter s d303 C105 Sets the time that the drive will remain in communication loss before implementing the option selected in C105 Comm Loss Action Values Default 5 0 Secs Min Max 0 1 60 0 Secs Display 0 1 Secs C107 Comm Write Mode Determines whether parameter changes made over communication port are saved or stored in RAM only If they are stored in RAM the values will be lost at power down Options 0 Save Default 1 Only ATTENTION Risk of equipment damage exists If co
42. DAY NGT 30 CURRENT LIMIT P033 31 ACCEL TIME 1 039 32 DECEL TIME 1 P040 33 KEYPAD LOCK A198 36 READ PARAM 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 R227 R228 1 46 OPT RELAY 4 R230 R231 1 47 OPT RELAY 5 R233 R234 1 48 OPT RELAY 6 R236 R237 1 49 DIGITAL IN 1 4302 bit 0 I O Terminal 02 50 DIGITAL IN 2 4302 bit 1 I O Terminal 03 51 DIGITAL IN 3 4302 bit 2 I O Terminal 01 52 DIGITAL IN 4 4302 bit 3 I O Terminal 05 53 DIGITAL IN 5 4302 bit 4 I O Terminal 06 54 DIGITAL IN 6 0302 bit 5 I O Terminal 07 55 DIGITAL IN 7 4302 bit 6 I O Terminal 08 60 INPUT REF 1 d305 61 INPUT REF 2 d306 62 ANALOG OUT 1 T082 63 ANALOG OUT 2 T085 64 LAST FAULT b007 65 PID GAIN A154 66 PID INT TIME A155 67 PID DIFF RATE A156 68 PID SETPOINT A157 Table G 2 Point Database for Application 2735 P1 Floor Level Network FLN G 5 Point Number Subpoint Name Parameter 70 CMD DIR MON b006 bit 2 Forward 71 ACCELERATING b006 bit 3 Accelerating 72 DECELERATING b006 bit 4 Decelerating 73 ALARM 74 AT SPEED 75 MAIN FREQ d301 Digit 0 76 OPER d301 Digit 1 77 PARAM LOCK 78 JOG 79 LOCAL CNTRL 80 MOP INC 81 ACCEL RATE 1 82
43. Display 1 VAC A175 Slip Hertz FLA Related Parameter s 033 Compensates for the inherent slip in an induction motor This frequency is added to the commanded output frequency based on motor current Values Default 2 0 Hz Min Max 0 0 10 0 Hz Display 0 1 Hz A176 DC Brake Time Related Parameter s P037 A177 Sets the length of time that DC brake current is injected into the motor when P037 Stop Mode is set to either 4 Hamp 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 Parameter s P037 T051 T054 A176 A178 Defines the maximum DC brake current in amps applied to the motor Values Default Drive Rated Amps x 0 05 Min Max 0 0 Drive Rated Amps x 1 5 Display 0 1 Amps Ramp to Stop Mode DC Injection Braking Mode E Ss a Speed DC Brake Time ILL Volts Speed Volts Speed DC Brake Level Time Stop Command Stop Command ATTENTION If a hazard of injury due to movement of equipment or material exists an auxiliary mechanical braking device must be used ATTENTION This feature should not be used with synchronous or permanent magnet motors Motors may be demagnetized during braking P P Programming and Parameters 3 41 Advance Program Group continued 178 DC Brk TimeGStrt Related Parameter s P
44. 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 About Parameters To configure a drive to operate in a specific way drive parameters may have to be set Three types of parameters exist e ENUM ENUM parameters allow a selection from 2 or more items Each item is represented by a number Numeric Parameters These parameters have a single numerical value i e 0 1 Volts e Bit Parameters Bit parameters have four or more individual bits associated with features or conditions If the bit is 0 the feature is off or the condition is false If the bit is 1 the feature is on or the condition is true Some parameters are marked as follows Stop drive before changing this parameter w 32 bit parameter Parameters marked 32 bit will have two parameter numbers when using RS485 communications and programming software 3 2 Programming and Parameters Parameter Organization Refer to page 3 58 for an alphabetical listing of parameters Group Basic Display Basic Program Terminal Block Communications Advanced Program Parameters Output Freq Commanded Freq Output Current Output Voltage DC Bus Voltage Motor NP Volts Motor NP Hertz Motor OL Current Minimum Freq Digital In1 Sel Digital In2 Sel Digital In3 Sel Digital In4 Sel Relay Out1
45. HAND Mode and Stops drive Important Certain digital input settings can override drive operation Refer to Start and Speed Reference Control on page 1 24 for details Start Up 2 7 Local Remote Mode In Local mode e Start command and speed reference come from the integral keypad Start Hand and Digital Speed Increment and Decrement keys e Auto key stops the drive and the drive switches to Remote mode Important If the drive is running and P036 Start Source 3 or 6 2 Wire Control the drive will continue to run at reference defined by P038 Speed Reference if a valid start command is present In Remote mode Auto key LED is illuminated e Start command is defined by P036 Start Source e Speed Reference command is defined by P038 Speed Reference e Auto key stops the drive and the drive switches to Local mode Table 2 B P042 Auto Mode 2 Local Remote 051 054 Digital Inx Sel 2 Auto Mode or 3 Local Key LED Key Function LED Key Function P On Starts drive Off Not active Runs according to Speed Increment _ Only active if PO36 Start Source a Wu Decrement keys 0 Keypad Starts drive HAND On Changes speed Off Not active 247 _ Keys are only active if P038 Speed T Sue Z0 Drive Pot Off Stops drive and changes to Remote Stops drive and changes to Local Mode Stops drive N A Stops drive Important
46. In addition you must have an understanding of the parameter settings and functions Reference Materials The following manuals are recommended for general drive information Title Publication Available Online at Wiring and Grounding DRIVES INOO1 Guidelines for Pulse Width Modulated PWM AC Drives Preventive Maintenance of DRIVES TD001 Industrial Control and Drive System Equipment www rockwellautomation com Safety Guidelines for the SGI 1 1 literature Application Installation and Maintenance of Solid State Control A Global Reference Guide for 100 2 10 Reading Schematic Diagrams 2 Overview Manual Conventions e In this manual we refer to the PowerFlex 400 Adjustable Frequency AC Drive as drive PowerFlex 400 or PowerFlex 400 Drive e Parameter numbers and names are shown in this format 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 The following words are used throughout the manual to describe an action Word Can Meaning 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 Recommend
47. Port The PID will not function with bipolar input It will ignore any negative voltages and treat them like zero Note PID analog reference is scaled through the Analog In x Hi Lo parameters The invert operation is obtained through programming these two parameters A154 PID Prop Gain Sets the value for the PID proportional component when the PID mode is enabled by A152 PID Ref Sel Values Default 1 00 Min Max 0 00 99 99 Display 0 01 A155 PID Integ Time Sets the value for the PID integral component when the PID mode is enabled by A152 PID Ref Sel Values Default 2 0 Secs Min Max 0 0 999 9 Secs Display 0 1 Secs Programming and Parameters 3 35 Advanced Program Group continued A156 PID Diff Rate Sets the value for the PID differential component when the PID mode is enabled by A152 PID Ref Sel Values Default 0 00 1 Secs 0 00 99 99 1 Secs Display 0 01 1 Secs A157 PID Setpoint Provides an internal fixed value for process setpoint when the PID mode is enabled by A152 PID Ref Sel Values Default 0 0 0 0 100 0 Display 0 196 A158 PID Deadband Sets the lower limit of the PID output Values Default 0 0 0 0 10 0 Display 0 196 A159 PID Preload Sets the value used to preload the integral component on start or enable Values Default 0 0 Hz Min Max 0 0 320 0 Hz Display
48. RJ45 SC1 Terminating Resistors RJ45 120 Ohm resistors 2 pieces AK U0 RJ45 TR1 Terminal Block RJ45 Two position terminal block 5 pieces AK U0 RJ45 TB2P DriveExplorer Software Windows based software package that provides an 9306 4EXPO1bENE CD ROM Version 3 01 intuitive means for monitoring or configuring or later Allen Bradley drives and communication adapters online Compatibility Windows 95 98 ME NT 4 0 Service Pack 3 or later 2000 XP and CE DriveExecutive software Windows based software package that provides an 9303 4DTEO1ENE CD ROM Version 1 01 intuitive means for monitoring or configuring or later Allen Bradley drives and communication adapters online and offline Compatibility Windows 98 ME NT 4 0 Service Pack 3 or later 2000 and XP Serial Flash Firmware Use a PC to update drive firmware AK U9 FLSH1 Kit www ab com drives driveexplorer htm for supported devices 6 Accessories and Dimensions Table B 10 Human Interface Module HIM Option Kits and Accessories Item LCD Display Remote Panel Mount Description LCD Display Digital Speed Control CopyCat Capable Includes 2 0 meter cable IP66 NEMA Type 4X 12 indoor use only Catalog Number 22 25 LCD Display Remote Handheld LCD Display Digital Speed Control Full Numeric Keypad CopyCat Capable IP30 NEMA Type 1 Includes 1 0 meter cable Panel Mount with optio
49. T073 Analog In 2 Sel Input Impedance 100k ohm Voltage Mode 250 ohm Current Mode 18 jAnalogCommon2 For Analog Input 2 Electronically isolated from digital I O and opto output With Analog Input 2 provides one fully isolated analog input channel 19 Output AtFrequency Program with T065 Opto Out Sel o gt D lo Ico 20 5485 DSI Shield Terminal connected to Safety Ground PE when using the RS485 DSI Communication Port See Footnotes 1 and 4 on page 1 17 Important information regarding Stop commands and the Digital Inx Sel Purge option is provided on page 3 12 Installation Wiring 1 19 Table 1 H Relay Terminal Designations and DIP Switches No Signal Default Description Param Ri 1 Relay N O Ready Fault Normally open contact for No 1 output relay T055 R2 1 Relay Common Common for output relay 1 Relay Ready Fault Normally closed contact for No 1 output relay 1055 R4 2 Relay Motor Running Normally open contact for No 2 output relay 1060 R5 2 Relay Common Common for output relay Re 2 Relay Motor Running Normally closed contact for No 2 output relay 1060 Selection DIP Switches 0 10V Sets analog output to either voltage or current Analog Input Al1 amp Al2 Settings must match Al1 amp T069 Analog In 1 Sel Analog Output AO1 amp AO2 Al2
50. Termination SHLD Either of the safety ground terminals located on the power terminal block provides a grounding point for the motor cable shield The motor cable shield connected to one of these terminals drive end should also be connected to the motor frame motor end Use a shield terminating or EMI clamp to connect the shield to the safety ground terminal The conduit box may be used with a cable clamp for a grounding point for the cable shield When shielded cable is used for control and signal wiring the shield should be grounded at the source end only not at the drive end Installation Wiring 1 9 Filter Grounding Using an external filter with any drive rating may result in relatively high ground leakage currents Therefore the filter must only be used in installations with grounded AC supply systems and be permanently installed and solidly grounded bonded to the building power distribution ground Ensure that the incoming supply neutral is solidly connected bonded to the same building power distribution ground Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection Some local codes may require redundant ground connections The integrity of all connections should be periodically checked Fuses and Circuit Breakers The PowerFlex 400 does not provide branch short circuit protection This product should be installed with either input
51. added to the Speed Reference In Trim mode the output of the PID loop bypasses the accel decel ramp as shown Trim Control is used when A152 PID Ref Sel is set to option 5 6 7 or 8 Speed Ref 1 PID Loop Accel Decel PID Ref PID Prop Gain jr Ramp PID n d i Error utput tput Fdbk PID Integ Time OS 9b a ele Dit Nate PID Enabled Example In a winder application the PID Reference equals the Equilibrium set point The Dancer 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 winding the Speed Reference is trimmed to compensate Tension is maintained near the Equilibrium set point lt 0 Volts PID Feedback Dancer Pot Signal PID Reference Equilibrium Set Point 10 Volts Speed Reference Jd Application Notes D 5 PID Reference and Feedback Parameter A152 PID Ref Sel is used to enable the PID mode A152 2 0 PID Disabled and to select the source of the PID Reference If A152 PID Ref Sel is not set to 0 PID Disabled PID can still be disabled by select programmable digital input options parameters T051 T054 such as Local or PID Disable Table D A A152 PID Ref Sel Options O
52. are in millimeters and inches Catalog Number 22 HIM B1 11 1 93 0 44 25 2 3 66 lt Y Qr 0 e OOOOO OOOOO 180 E QOOOO 7 09 G OGC OJOS X es Appendix C RJ45 DSI Splitter Cable The PowerFlex 400 drive provides a RJ45 port to allow the connection of a single peripheral device The RJ45 DSI Splitter Cable can be used to connect a second DSI peripheral device to the drive Connectivity Guidelines peripherals may not perform as intended if these Connectivity ATTENTION Risk of injury or equipment damage exists The Guidelines are not followed Precautions should be taken to follow these Connectivity Guidelines Two peripherals maximum can be attached to a drive If a single peripheral is used it must be connected to the Master port on the splitter and configured for Auto default or Master Parameter 9 Device Type on the DSI keypads and Parameter 1 Adapter Cfg on the Serial Converter are used to select the type Auto Master Slave Do not use the RJ45 Splitter 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 port on the drive The internal Comm is always the Master therefore the external peripheral must be configured as Auto for temporar
53. 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 Hz b003 Output Current The output current present at T1 T2 amp T3 U V amp W Values Default Read Only Min Max 0 0 Drive Rated Amps x 2 Display 0 1 Amps b004 Output Voltage Related Parameter s P031 A170 A174 Output voltage present at terminals T1 T2 amp T3 U V amp W Values Default Read Only Min Max 0 510 Display 1 VAC b005 DC Bus Voltage Present DC bus voltage level Values Default Read Only Min Max 0 820 Display 1 VDC Programming and Parameters 3 5 Basic Display Group continued b006 Drive Status Related Parameter s A166 Present operating condition of the drive 1 Condition True 0 Condition False Running Bit 1 Forward Bit 2 Accelerating Bit Decelerating Bit 4 Values Default Read Only Min Max 0 1 Display 1 b007 Fault 1 Code Related Parameter s A186 197 d307 d315 code 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 0 122 Display 1 b008 Process Display Related Parameter s 2001 A160 397 32 bit parameter The output frequency scal
54. controlled directly by the PowerFlex 400 drive System output can vary from 0 auxiliary motors off and drive controlled motor at zero speed to 400 3 auxiliary motors and drive controlled motor at full speed To enable the Auxiliary Motor Control parameter R239 Aux Motor Mode must be set to an option 1 Enabled When enabled the internal PID controller in the PowerFlex 400 uses a reference and feedback signal to adjust the speed of the drive controlled motor such that the feedback signal follows the reference signal When demand exceeds the first motors capacity the PowerFlex 400 Auxiliary Motor Control automatically starts an auxiliary motor The speed of the drive controlled motor is reduced to account for the auxiliary motors additional 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 PowerFlex Auxiliary Motor Control increases the speed of the drive controlled motor to account for lost system output A Motor Interlock input identifies motors that are out of service and causes them to skipped over to the next available motor An AutoSwap function also can be used which allows equal wear to be placed on each motor by periodically swapping the drive controlled and auxiliary motors Each motor in the system will over time be connected to the PowerFlex 400 drive and also directly to the AC li
55. e P036 Start Source is set to option 0 Keypad or option 5 RS485 DSI Port e 1051 T054 Digital Inx Sel is set to option 5 Local and the input is active None Check parameter settings Incorrect input wiring See 1 20 for wiring examples e 2 wire control requires Run Forward Run Reverse or Jog input e wire control requires Start and Stop inputs Stop input is always required None Wire inputs correctly and or install jumper Incorrect Sink Source DIP switch setting None Set switch to match wiring scheme Drive does not Start from Integral Keypad Cause s Indication Corrective Action Integral keypad is not enabled Green LED above Start key is not illuminated Set parameter P036 Start Source to option 0 Keypad e Set parameter T051 T054 Digital Inx Sel to option 5 Local and activate the input I O Terminal 01 Stop input is None not present Wire inputs correctly and or install jumper Troubleshooting 4 7 Drive does not respond to changes in speed command Cause s Indication Corrective Action No value is coming from the The drive Run indicator is lit e Check 0301 Control Source for source of the command and output is 0 Hz correct source e Ifthe source is an analog input check wiring and use a meter to check for presence of signal Check 0002 Commanded Freq to verify
56. exceeds the frequency Hz value set in T061 Relay Out2 Level e Use 061 to set threshold 7 Above e Drive exceeds the current Amps value set in 1061 Relay Out2 Level e Use 061 to set threshold Important Value for 1061 Relay Out2 Level must be entered in percent of drive rated output current 8 Above DCVolt e Drive exceeds the DC bus voltage value set in 1061 Relay Out2 Level e Use 061 to set threshold 9 Above Anlg 2 e Analog input voltage I O Terminal 17 exceeds the value set in T061 Relay Out2 Level e Do not use if 1073 Analog In 2 Sel is set to 3 Voltage Mode Bipolar e This parameter setting can also be used to indicate a PTC trip point when the input I O Terminal 17 is wired to a PTC and external resistor e Use 061 to set threshold 10 Above PF Ang Power Factor angle has exceeded the value set in 1061 Relay Out2 Level e Use 061 to set threshold 11 In Loss Analog input loss has occurred Program 1072 Analog In 1 Loss and or 1076 Analog In 2 Loss for desired action when input loss occurs 12 ParamControl Enables the output to be controlled over network communications by writing to T061 Relay Out2 Level 0 Off 1 On 13 Retries Exst Value set in A163 Auto Rstrt Tries is exceeded 14 NonRec Fault e Number of retries for A163 Auto Rstrt Tries is exceeded OR e Non resettable fault
57. foot ATTENTION Driving the 4 20mA analog input from a voltage source could cause component damage Verify proper configuration prior to applying input signals Control Wire Types Table 1 Recommended Control and Signal Wire Wire Type s Description Minimum Insulation Rating Belden 8760 9460 10 8 mm2 18 AWG twisted pair 100 300V or equiv shield with drain 60 degrees C Belden 8770 0 8 mm 18AWG 3 conductor shielded for 140 degrees or equiv remote pot only 1 Ifthe 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 I O Terminal Block Table 1 F 1 0 Terminal Block Specifications Maximum Wire Size Minimum Wire Size 2 Torque 1 3mm 16 AWG 10 13 mm 26 AWG 0 5 0 8 N m 4 4 7 Ib in 8 Maximum minimum sizes that the terminal block will accept these are not recommendations Maximum Control Wire Recommendations Do not exceed control wiring length of 30 meters 100 feet Control signal cable length is highly dependent on electrical environment and installation practices To improve 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 protective earth Installation Wiring 1 17 Figure 1 7 Control Wiring Block Diagram
58. for Number 6 Output Relay R230 6B 6 Relay Common Common for Number 6 Output Relay 7 Relay N O Ready Faul Normally open contact for Number 7 Output Relay R233 7B 7 Relay Common Common for Number 7 Output Relay 8A 8 Relay Ready Fau Normally open contact for Number 8 Output Relay R236 8B 8 Relay Common Common for Number 8 Output Relay 1 20 Installation Wiring Wiring Examples Input Output Connection Example Potentiometer 1 10k Ohm Potentiometer Recommended 212 2 Watt Minimum Lt 13 Li 14 9 6 Analog Input Bipolar Speed Reference 10V Input S izle Common e I S 5 Analog Input Unipolar Speed Reference 0 to 10V Input nS 9 S 2 Analog Input Unipolar Speed Reference 4 20 mA Input 118 e Analog Output Unipolar 0 to 10V Output e 1k Ohm Minimum le common Silla eS I Required Settings DIP Switch 10V Parameters P038 Speed Reference 2 Analog In1 T069 Analog In 1 Sel 2 0 10V Scaling T070 Analog In 1 Lo T071 Analog In 1 Hi Check Results d305 Analog In 1 DIP Switch Al2 10V Parameters P038 Speed Reference 3 Analog In2 T073 Analog In 2 Sel 3 10 to 10V Scaling T074 Analog In 2 Lo T075 Analog In 2 H
59. for the Read Param point and shows the result in the Read Value point Param for the Read Param point default to commonly accessed parameters and can be changed if desired A 0 disables the fetching of data and a 0 is returned in the Read Value point See Figure G 1 and Table G 4 Figure G 1 Configurable Input Point Operation Controller Drive Set Point 36 with Param to Read Data From Set Point 37 to get Data of Param in Point 36 Table G 4 Configurable Points Inputs Point Name Description Default 36 Read Param Param to read value 0 37 Read Value Value of parameter specified by Point 36 0 1 Floor Level Network FLN Writing Parameter Values These outputs are written each time the Write Value point is written from the network The Param for Write Param point s default to commonly accessed parameters and be changed if desired A value of 07 in the Param for Write Param point field disables the writing of data Figure G 2 Configurable Output Point Operation Controller Set Point 38 with Drive Param to Read Data To Write Point 39 to Write Data to in Point 38 Table 6 5 Configurable Points Outputs Point Name Descipion Deut 38 Write Param to write value 0 39 Write Value New value of parameter specified by Point 38 0 Supply Ground 1 8 S
60. 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 4 Overview Catalog Number Explanation 1 3 4 5 6 8 9 10 11 12 22C 3 Comm Slot Code ode Version 22C PowerFlex 400 3 RS485 Code Rating 0 Not Filtered Code interface Module 1 Fixed Keypad Code Enclosure N Panel Mount IP20 UL Open Type A Panel Mount IP30 NEMA 1 UL Type 19 Flange Mount IP20 UL Open Type Output Current 200 240V 60Hz Input Output Current 380 480V In
61. inputs 11 4 24V DC Drive supplied power for digital inputs Referenced to Digital Common Max Output 100mA 12 10V DC Drive supplied power for 0 10V external potentiometer P038 Referenced to Analog Common Max Output 15mA 13 Analog Input 1 0 10V External 0 10V unipolar 0 20mA 4 20mA input 1069 070 supply or potentiometer wiper Default input is 0 10V 1071 T072 For current mA input set Al1 DIP Switch to 20mA Program with 069 Analog In 1 Sel Input Impedance 100k ohm Voltage Mode 250 ohm Current Mode 14 Analog 1 Common for Analog Input 1 and Analog Output 1 and 2 Electrically isolated from digital 1 0 and opto output 15 Analog Output 1 OutFreq 0 10 Default analog output is 0 10V P038 For current mA value set AO1 DIP Switch to 20mA T051 T054 Program with T082 Analog Out1 Sel A152 Maximum Load 4 20 525 ohm 10 5V 0 10V 1k ohm 10mA 16 Analog Output 2 OutCurr0 10 Default analog output is 0 10V 1082 T084 For a current mA value set AO2 DIP Switch to 20mA 7085 T086 Program with T085 Analog Out Sel 1087 Maximum Load 4 20 525 ohm 10 5V 0 10V 1k ohm 10mA 17 Analog Input 2 0 10V Optically isolated external 0 10V unipolar x10V 1073 1074 bipolar 0 20mA or 4 20 input supply or 1075 107 potentiometer wiper Default input is 0 10V For current mA input set AI2 DIP Switch to 20mA Program with
62. is flashing the drive has been commanded to change direction but is still decelerating Sleep Mode Indication or flashes to indicate that the drive is in sleep mode Parameter Group and Number Basic Display Communications T Terminal Block f Aux Relay Card Basic Program Advanced Program Fault Indication and Fault Number Fault 1 Viewing and Editing Parameters The last user selected Basic Display Group parameter is saved when power is removed and is displayed by default when power is reapplied The following is an example of basic integral keypad and display functions This example provides basic navigation instructions and illustrates how to program the first Basic Program Group parameter Step When power is applied the last user selected Basic Display Group parameter number is displayed with flashing characters The display then defaults to that parameter s current value Example shows the value of b001 Output Freq with the drive stopped Press the Up Arrow or Down Arrow to scroll through the Basic Display Group parameters Only in Display Groups Press Esc once to display the Basic Display Group parameter number shown on power up The parameter number will flash Press Esc again to enter the group menu The group menu letter will flash Press the Up Arrow or Down Arrow to scroll through the group menu b P T C A and d
63. occurs OR e A163 Auto Rstrt Tries is not enabled 15 Reverse Drive is commanded to run in reverse direction 16 Logic In 1 An input is programmed as Logic In 1 and is active 17 Logic In 2 An input is programmed as Logic In 2 and is active 23 Aux Motor Auxiliary Motor is commanded to run Refer to Appendix C for details Programming and Parameters 3 17 Terminal Block Group continued T061 Relay Out2 Level Related Parameter s T060 T063 T064 d318 S 32 bit parameter Sets the trip point for the digital output relay if the value of T060 Relay Out2 Sel is 6 7 8 9 10 or 12 060 Setting T061 Min Max 6 0 320 Hz 7 0 180 8 0 815 Volts 0 100 1 180 degs 0 1 Values Default 0 0 Min Max 0 0 9999 Display 0 1 T063 Relay 2 On Time Related Parameter s 060 061 T064 Sets delay time before Relay energizes after required condition testing Values Default 0 0 Secs Min Max 0 0 600 0 Secs Display 0 1 Secs 064 Relay 2 Off Time Related Parameter s T060 T061 T063 Sets delay time before Relay de energizes after required condition testing ceases Important Do not use this parameter with Auxiliary Motor Control mode AutoSwap enabled Values Default 0 0 Secs Min Max 0 0 600 0 Secs Display 0 1 Secs 3 18 Programming and Parameters Terminal Block Group continued T065 Opto Out Sel Related Parameter s P033 T066 T068 T072 D
64. stop input except when P036 Start Source is set for 9 Wire control When in three wire control I O Terminal 01 is controlled by P037 Stop Mode Hardware Enable Circuitry By default I O Terminal 01 is a coast to stop input The status of the input is interpreted by drive software If the application requires the drive to be disabled without software interpretation a dedicated hardware enable configuration can be utilized This is accomplished 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 Mode Options 0 Ramp Ramp to Stop Stop command clears active fault 1 Coast Default Coast to Stop Stop command clears active fault 2 DC Brake DC Injection Braking Stop Stop command clears active fault 3 DCBrkAuto CF DC Injection Braking Stop with Auto Shutoff e Standard DC Injection Braking for value set in A176 DC Brake Time OR e Drive shuts off if the drive detects that the motor is stopped Stop command clears active fault 4 Ramp Ramp to Stop 5 Coast Coast to Stop 6 DC Brake DC Injection Braking Stop 7 DC BrakeAuto DC Injection Braking Stop with Auto Shutoff e Standard DC Injection Braking for value set in A176 DC Brake Time OR e Drive shuts off if the drive detects that the motor is stopped
65. values These objects handle only 16 bit parameter values Reading Parameter Values The configurable points may show any parameter in the drive by configuring the for INx point The drive reads the value of the parameter configured in the Param for INx point and shows the result in the User INx point The Param for INx s default to commonly accessed parameters and can be changed if desired A 0 disables the fetching of data and 0 is returned in the respective User INx See Figure F 1 and Table F 13 Figure Configurable Input Point Operation Objects Inputs Controller Drive Param ADI for INx s Request ResponseData Al Table 13 Configurable Objects Inputs Network Point Type Address Description Default 10 User IN1 User defined Input 1 0 11 User IN2 User defined Input 2 J0 Al 12 User IN3 User defined Input 3 0 13 User INA User defined Input 4 0 ADI 1 Param for IN1 User IN1 Al 10 b001 Output Freq Hz Data Source Param ADI 2 Param for IN2 User IN2 Al 11 b011 Elapsed MWh Data Source Param ADI 3 Param for IN3 User ING Al 12 b012 Elapsed Run Time Data Source Param ADI 4 Param for IN4 User IN4 Al 13 b014 Drive Temp Data Source Param Metasys 2 F 7 Writing Parameter Values ATTENTION Risk of equipment damage exists If configurable outputs
66. 0 1 180 degs 0 1 Values Default 0 0 Min Max 0 0 9999 Display 0 1 T058 Relay 1 On Time Related Parameter s 1055 T056 T059 Sets delay time before Relay energizes after required condition testing Values Default 0 0 Secs Min Max 0 0 600 0 Secs Display 0 1 Secs T059 Relay 1 Off Time Related Parameter s 1055 T056 T058 Sets delay time before Relay de energizes after required condition testing ceases Important Do not use this parameter with Auxiliary Motor Control mode AutoSwap enabled Values Default 0 0 Secs Min Max 0 0 600 0 Secs Display 0 1 Secs 3 16 Programming and Parameters Terminal Block Group continued T060 Relay Out2 Sel Related Parameter s P033 061 063 064 076 A163 d318 Sets the condition that changes the state of the output relay contacts Options 0 Ready Fault Relay changes state when power is applied This indicates that the drive is ready for operation Relay returns drive to shelf state when power is removed or a fault occurs 1 At Frequency Drive reaches commanded frequency 2 MotorRunning Motor is receiving power from the drive Default 3 Hand Active Active when drive is in local control 4 Motor Overld Motor overload condition exists 5 Ramp Reg Ramp regulator is modifying the programmed accel decel times to avoid an overcurrent or overvoltage fault from occurring 6 Above Freq e Drive
67. 037 A177 Sets the length of time that DC brake current is injected into the motor after a valid start command is received Parameter A177 DC Brake Level controls the level of braking current used Values Default 0 0 Secs 0 0 99 9 Secs A setting of 99 9 Continuous Display 0 1 Secs Volts Speed DC Brake Level Time Start Command A179 Current Limit 1 Related Parameter s P03 Maximum output current allowed before current limiting occurs Values Default Drive Rated Amps x 1 1 Min Max 0 0 Drive Rated Amps x 1 5 Display 0 1 Amps A180 Current Limit 2 Related Parameter s P03 Maximum output current allowed before current limiting occurs Values Default Drive Rated Amps x 1 1 0 0 Drive Rated Amps x 1 5 Display 0 1 Amps A181 Motor OL Select Related Parameter s P032 P033 P043 Drive provides Class 10 motor overload protection Settings 0 2 select the derating factor for the Pt overload function Options 0 No Derate Default 1 Derate 2 Derate No Derate Min Derate Max Derate 0 0 0 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 of P032 Motor NP Hertz of P032 Motor NP Hertz of P032 Motor NP Hertz e S s 2 2 m S m m S of P033 Motor OL Curent o
68. 1 P2 DC UM vir SSS olo Frame E sIstete ooo 480V eee ofofofo 37 45kw RIL1S L2T L3 P1 P2 DC 50 60 U TIV T2W T3 1 F E iu ic T 30 37kW 55 75kW 40 50HP 75 100HP Frame F Terminal Description R L1 S L2 T L3 3 Phase Input To Motor U T1 Switch any two motor m mem Dj W T3 To Motor W T3 DC Bus Inductor Connection Drives are shipped with a jumper between Terminals P2 P1 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 Installation Wiring 1 15 Table 1 D Power Terminal Block Specifications Frame Maximum Wire Size Minimum Wire Size Recommended Torque C 8 4 mm 8 AWG 1 3 16 AWG 2 9 N m 26 Ib in D 33 6 2 AWG 8 4 mm 8 AWG 5 1 N m 45 Ib in E 480V 33 6 mm 2 AWG 3 5 mm 12 AWG 5 6 N m 49 5 37 45 kW 50 60 HP E 240V 107 2 mm 4 0 AWG 53 5 mm 1 0 AWG 19 5 N
69. 10 80 216 8 50 172 6 80 80 3 16 92 3 63 19 0 42 1321 3R160 B 279 11 00 216 8 50 178 7 00 88 3 47 92 3 63 23 0 51 1321 3R160 C 287 11 30 216 8 50 229 9 00 118 4 66 92 3 63 33 0 72 1321 3R200 B 274 10 80 216 8 50 210 8 30 112 4 41 92 3 63 31 0 67 1321 3R200 C 274 10 80 216 8 50 254 10 00 150 5 91 92 3 63 46 0 100 14 Accessories and Dimensions Figure B 7 Bulletin 1321 DC Series Bus Inductors Dimensions are in millimeters and inches Weights are in kilograms and pounds Model A Model B lt A gt C 2 o B B E E LA ES Catalog Weight Number Model A B C D E F kg Ibs 1321 DC9 2 95 3 75 83 3 25 51 2 00 80 3 13 4 7 0 19 1321 DC12 1 95 3 75 183 3 25 144 1 75 80 3 13 4 70 19 1321 DC12 2 97 3 81 114 4 50 72 2 82 51 2 00 80 3 13 5x8 20 33 5 9 13 0 1321 DC18 1 95 3 75 183 3 25 151 2 00 80 3 13 4 7 0 19 1321 DC18 4 118 4 63 133 5 25 102 4 00 64 2 50 95 3 75 5x8 20 33 3 6 8 0 1321 0 25 4 97 3 81 114 4 50 76 3 00 64 2 50 80 3 13 5x8 20x
70. 1321 3RA35 B 22 30 45 67 5 0 7 62 1321 3R45 B 1321 3 45 30 140 55 82 5 0 5 67 1321 3855 1321 3 55 37 50 80 120 0 4 86 1321 3R80 B 1321 3RA80 B 45 60 80 120 0 4 86 1321 3R80 B 1321 3RA80 B 55 75 1100 150 0 3 84 1321 3R100 B 1321 3RA100 B 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 22 30 8 12 15 28 1321 3R8 D 1321 3RA8 D 40 50 112 18 42 41 1321 3R12 C 1321 3 12 55 75 12 18 42 41 1321 3R12 C 1321 3 12 75 10 118 27 2 5 43 1321 3R18 C 1321 3RA18 C 11 15 25 37 5 2 0 61 1321 3R25 C 1321 3RA25 C 15 20 35 52 5 12 54 1321 3R35 C 1321 3RA35 C 185 25 35 52 5 12 54 1321 3835 1321 3RA35 C 22 30 145 67 5 12 65 1321 3 45 1321 3RA45 C 30 40 55 82 5 0 85 71 1321 3R55 C 1321 3RA550 C 37 50 80 120 0 7 96 1321 3R80 C 1321 3RA80 C 45 60 80 120 0 7 96 1321 3880 1321 3RA80 C 55 75 100 150 0 45 108 1321 3R100 C 1321 3RA100 C 75 100 130 195 0 3 128 1321 3 130 1321 3RA130 C 90 125 160 240 0 23 138 1321 3R160 C 1321 3RA160 C 110 150 200 300 0 185 146 1321 3 200 1321 3RA200 C Table B 6 Bulletin 1321 DC Series Bus Inductors 200 240V 60 Hz Three Phase Inductance Catalog Number kW HP DC Amps Watts Loss IP00 Open Style 2 2 3 12 0 92 5 1321 DC12 1 3 7 5 18 0 63 5 1321 DC18 1 55 7
71. 25 64 1321 3R55 A 1321 3RA55 A 185 25 80 120 0 2 82 1321 3R80 A 1321 3RA80 A 22 30 180 120 0 2 82 1321 3R80 A 1321 3RA80 A 30 140 100 150 0 15 94 1321 3 100 1321 3RA100 A 37 50 1130 195 0 1 108 1321 3R130 A 1321 3RA130 A 5 Impedance 22 30 12 18 2 5 31 1321 3R12 B 1321 3RA12 B 37 50 18 27 1 5 43 1321 3R18 B 1321 3RA18 B 55 78 25 37 5 1 2 52 1321 3R25 B 1321 3 25 75 10 35 52 5 0 8 54 1321 3R35 B 1321 3RA35 B 11 J15 45 67 5 0 7 62 1321 3R45 B 1321 3RA45 B 15 120 55 82 5 0 5 67 1321 3R55 B 1321 3RA55 B 18 5 25 80 120 0 4 86 1321 3R80 B 1321 3RA80 B 22 30 80 120 0 4 86 1321 3R80 B 1321 3RA80 B 30 140 100 150 0 3 84 1321 3R100 B 1321 3RA100 B 37 50 130 195 0 2 180 1321 3R130 B 1321 3RA130 B Accessories and Dimensions B 3 Table B 5 Bulletin 1321 3R Series Line Reactors 380 480V 60 Hz Three Phase Maximum Catalog Number Fundamental Continuous Watts IP00 IP11 kW HP Amps Inductance Loss Open Style Type 1 3 Impedance 22 30 8 12 5 25 8 1321 3R8 C 1321 3RA8 C 40 50 112 18 2 5 31 1321 3R12 B 1321 3RA12 B 55 75 12 18 25 31 1321 3R12 B 1321 3 12 75 10 118 27 15 43 1321 3R18 B 1321 3RA18 B 11 15 25 37 5 12 52 1321 3R25 B 1321 3RA25 B 15 20 135 52 5 0 8 54 1321 3835 1321 3 5 18 5 25 35 52 5 0 8 54 1321 3R35 B
72. 28 124 8 150 200 100 0180 22C D170A103 90 125 170 170 340 528 142 170 250 100 250 22C D208A103 110 150 208 208 340 528 167 200 250 100 0250 1 Refer to the Bulletin 140M Motor Protectors Selection Guide publication 140 56001 to determine the frame and breaking capacity required for your application Supplemental Drive Information A 3 Category Specification Agency Listed to UL508C and CAN CSA 22 2 Certification rs Listed to UL508C for plenums Certified to 5 25 1997 Group 1 Class A Marked for all applicable European Directives C 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
73. 3 T076 163 0318 Sets the condition that changes the state of the output relay contacts Options 0 Ready Fault Relay changes state when power is applied This indicates Default that the drive is ready for operation Relay returns drive to shelf state when power is removed or a fault occurs 1 At Frequency Drive reaches commanded frequency 2 MotorRunning Motor is receiving power from the drive 3 Hand Active Active when drive is in local control 4 Motor Overld Motor overload condition exists 5 Ramp Reg Ramp regulator is modifying the programmed accel decel times to avoid an overcurrent or overvoltage fault from occurring 6 Above Freq e Drive exceeds the frequency Hz value set in 1056 Relay Level e Use 056 to set threshold 7 Above Cur e Drive exceeds the current Amps value set in T056 Relay Out1 Level e Use 056 to set threshold Important Value for T056 Relay Out Level must be entered in percent of drive rated output current 8 Above DCVolt e Drive exceeds the DC bus voltage value set in T056 Relay Out1 Level e Use 056 to set threshold 9 Above Anlg 2 e Analog input voltage I O Terminal 17 exceeds the value set in T056 Relay Out1 Level Donot use if 1073 Analog In 2 Sel is set to 3 Voltage Mode Bipolar e This parameter setting can also be used to indicate a trip point when the inp
74. 30 12 7 28 0 14 30 9 E 30 40 38 83 8 48 2 106 3 E 37 50 38 83 8 48 2 106 3 480V AC 3 Phase C 2 2 3 0 2 87 6 3 3 39 7 5 C 4 0 5 0 3 03 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 34 4 37 50 36 79 4 462 101 9 45 60 36 79 4 462 101 9 55 75 41 90 4 51 2 112 9 E 75 100 41 90 4 51 2 112 9 F 90 125 78 172 0 88 194 0 F 110 150 78 172 0 88 194 0 240V AC 3 Phase Plate Drive C 2 2 3 0 2 66 5 9 3 26 7 2 C 4 0 5 0 274 6 0 3 34 7 4 C 5 5 7 5 3 15 6 9 3 75 8 3 C 7 5 10 3 21 7 1 3 81 8 4 480V 3 Plate Drive C 2 2 3 0 2 63 5 8 3 23 7 1 C 4 0 5 0 2 77 6 1 3 37 7 4 C 5 5 7 5 3 04 6 7 3 64 8 0 C 7 5 10 3 13 6 9 373 8 2 C 11 15 3 19 7 0 3 79 8 4 C 15 20 3 25 7 2 3 85 8 5 8 Accessories and Dimensions Figure 1 PowerFlex 400 Frame C Drive Dimensions are in millimeters and inches pem 5 1 180 0 7 1 gt i 116 0 4 57 j J Y h Oti lt 107 0 4 21 28
75. 4 Slip Hertz FLA A175 DC Brake Time 176 DC Brake Level 177 DC Brk Time Strt A178 Current Limit 1 A179 Current Limit2 180 Elapsed MWh Elapsed Run Time Torque Current Drive Temp Elapsed kWh Accel Time 1 Decel Time 1 Reset To Defalts Auto Mode Motor OL Ret Sleep Wake Sel Sleep Level Sleep Time Wake Level Wake Time Analog Out Sel Analog Out1 High Analog Out1 Setpt Analog Out2 Sel Analog Out2 High Analog Out2 Setpt Anlg Loss Delay Start Source 2 Speed Ref 2 Motor OL Select Drive OL Mode SW Current Trip Load Loss Level Load Loss Time Stall Fault Time Bus Reg Mode Skip Frequency 1 Skip Freq Band 1 Skip Frequency 2 Skip Freq Band 2 Skip Frequency 3 Skip Freq Band 3 Compensation Reset Meters Testpoint Sel Fault Clear Program Lock Motor NP Poles Motor NP FLA 5011 5012 5013 5014 5015 039 040 041 P042 P043 077 T078 T079 T080 T081 T082 T083 T084 T085 T086 T087 T088 C108 C109 A181 A182 A183 A184 A185 A186 A187 A188 A189 A190 A191 A192 A193 A194 A195 A196 A197 A198 A199 A200 Group Aux Relay Card Advanced Display Parameters Relay Out3 Sel Relay Out3 Level Relay Out4 Sel Relay Out4 Level Relay Out5 Se Relay Out5 Level Relay Out6 Se Relay Out6 Level Relay Out Se Relay Out7 Level Relay Out8 Se Relay Out8 Level Control Source Contrl In Status Comm Status PID Setpnt Displ Analog In 1 Analog In 2 Fault 1 Code Fault 2 Co
76. 43 Relay Card 3 50 Elapsed Time hr 0316 Advanced Display 3 55 Aux 2 Ref Add R246 Relay Card 3 50 Elapsed Time min 4317 Advanced Display 3 55 Aux 3 Ref Add R249 Relay Card 3 50 Fault 1 Code b007 Basic Display 3 5 Aux 1 Start Freq R241 Relay Card 3 49 Fault 1 Code d307 Advanced Display 3 53 Aux 2 Start Freq R244 Relay Card 3 49 Fault 1 4310 Advanced Display 3 54 Aux 3 Start Freq R247 Relay Card 3 49 Fault 1 Time min 0911 Advanced Display 3 54 Aux 1 Stop Freq R242 Relay Card 3 49 Fault 2 Code d308 Advanced Display 3 54 Aux 2 Stop Freq R245 Relay Card 3 49 Fault 2 Time hr d312 Advanced Display 3 54 Aux 3 Stop Freq R248 Relay Card 3 49 Fault 2 Time min 0313 Advanced Display 3 55 Aux AutoSwap Lvl R254 Relay Card 3 51 Fault 3 Code d309 Advanced Display 3 54 Aux AutoSwap Tme 253 Relay Card 3 50 Fault 3 Time hr d314 Advanced Display 3 55 Aux Motor Mode R239 Relay Card 3 48 Fault 3 Time min 4315 Advanced Display 3 55 Aux Motor Qty R240 Relay Card 3 49 Fault Bus Volts d326 Advanced Display 3 57 Aux Prog Delay R252 Relay Card 3 50 Fault Clear A197 Advanced Program 3 45 Aux Start Delay R250 Relay Card 3 50 Fault Current d325 Advanced Display 3 56 Aux Stop Delay R251 Relay Card 3 50 Fault Frequency d324 Advanced Display 3 56 Boost Select A170 Advanced Program 3 38 Flying Start En A167 Advanced Program 3 37 Break Frequency A173 Advanced Program 3 39 Internal Freq A142 Advanced Program 3
77. 5 32 0 85 11 1321 DC32 1 75 10 40 0 75 15 1321 DC40 2 4 Accessories and Dimensions Table B 7 Bulletin 1321 DC Series Bus Inductors 380 480V 60 Hz Three Phase Inductance Catalog Number kW HP DC Amps Watts Loss IP00 Open Style 2 2 3 9 3 68 7 1321 DC9 2 4 0 5 12 2 1 7 1321 DC12 2 5 5 7 5 18 3 75 17 1321 DC18 4 7 5 10 25 1 75 13 1321 DC25 4 11 15 32 2 68 21 1321 DC32 2 l 15 20 40 2 0 29 1321 DC40 4 1 1 Required on 11 and 15 kW 15 and 20 HP Frame C Flange Mount drive ratings Table B 8 EMC Line Filters Drive Ratings Input Voltage kW HP Catalog Number 240V 50 60 Hz 2 2 3 0 22 RF034 CS 3 Phase 40 50 22 RF034 CS 55 7 5 22 RF034 CS 7 5 10 22 RF034 CS 11 15 22 RFD070 15 20 22 RFD100 18 5 25 22 RFD100 22 30 22 RFD150 30 40 22 RFD150 37 50 22 RFD180 480V 50 60 Hz 22 3 0 22 018 5 3 Phase 40 50 22 RFO18 CS 55 7 5 22 RF018 CS 7 5 10 22 018 5 11 15 22 RF026 CS 15 20 22 RFD036 18 5 25 22 RFD050 22 30 22 RFD050 30 40 22 RFD070 37 50 22 RFD100 45 60 22 RFD100 55 75 22 RFD150 75 100 22 RFD180 90 125 Consult Factory 110 150 Consult Factory Accessories and Dimensions Table 9 Communication Option Kits and Accessories B 5 Item Description Catalog Number DeviceNet Embedded communication option for use with the 22 COMM D Communication Adapter Po
78. 5 Decrement Not Decrement BO 16 Pnl Lock Lock out Drive Front Panel Lock Unlock BO 17 Digital Out 1 Relay 1 on Drive On Off Drive Terminal R1 R2 R3 BO 18 Digital Out 2 Relay 2 on Drive On Off Drive Terminal R4 R5 R6 BO 19 Opto Out Terminal 19 On Off Writing 06 Reference page E 3 Table 10 Analog Outputs Network Point Type Address NPA Name Description Units Min Max AO 1 Reference Reference 0 100 2 Accel 1 P039 Accel Time 1 Secs 0 0 600 0 AO 3 Decel 1 P040 Decel Time 1 Secs 0 0 600 0 AO 4 Mtr OL Current P033 Motor OL Current A 0 0 Rated x 2 AO 5 PID Setpoint A157 PID Setpoint 0 100 6 Analog Out1 Drive Analog Output 1 T084 7 Analog Out2 Drive Analog output 2 T087 8 Write Param Param number to write AO 9 0 to Max Param AO 9 Write Value Write value of param selected by AO 8 Based on AO 8 selected param AO 10 Read Param Param number to read in Al 9 0 to Max Param AO 11 User Out 1 User defined Output 1 Param selected via ADI 5 AO 12 User Out 2 User defined Output 2 Param selected via ADI 6 Varies by the parameter AO 13 User Out 3 User defined Output 3 selected Param selected via ADI 7 AO 14 User Out 4 User defined Output 4 Param selected via ADI 8 Metasys 2 F 5 Table 11 Internal Integer Using Percent for the Reference Network Point T
79. 600 Volt Installations A variety of cable types are acceptable for drive installations For many installations unshielded cable is adequate provided it can be separated from sensitive circuits As an approximate guide allow a spacing of 0 3 meters 1 foot for every 10 meters 32 8 feet of length In all cases long parallel runs must be avoided Do not use cable with an insulation thickness less than 15 mils 0 4 mm 0 015 in Do not route more than three sets of motor leads in a single conduit to minimize cross talk If more than three drive motor connections per conduit are required shielded cable must be used UL installations must use 600V 75 C or 90 C wire Use copper wire only Unshielded THHN THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space and or conduit fill rates limits are provided Do not use THHN or similarly coated wire in wet areas Any wire chosen must have a minimum insulation thickness of 15 mils and should not have large variations in insulation concentricity Shielded 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 AC Drive Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales capacitive proximity switches and other devices that may be
80. 79 3 10 76 3 00 8 1 18 1321 3R35 A 193 7 60 146 5 76 91 3 60 66 2 60 76 3 00 6 3 14 1321 3R35 B 183 7 20 147 5 80 95 3 75 79 310 76 3 00 7 3 16 1321 3R35 C 229 9 00 187 7 35 118 4 66 80 3 16 76 3 00 13 6 30 1321 3R45 A 229 9 00 187 7 35 118 4 66 80 3 16 76 3 00 10 4 23 1321 3R45 B 229 9 00 187 7 35 118 4 66 80 316 76 3 00 127 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 27 1321 3R55 C 229 9 00 184 7 25 142 5 60 99 3 90 76 3 00 18 6 41 1321 3R80 A 274 10 80 216 8 50 139 5 47 88 3 47 92 3 63 19 5 43 1321 3R80 B 274 10 80 216 8 50 139 5 47 88 3 47 92 3 63 23 1 51 1321 3R80 C 274 10 80 210 8 26 156 6 16 106 4 16 92 3 63 25 0 55 1321 3R100 A 274 10 80 217 8 55 139 5 48 84 3 30 92 3 63 21 3 47 1321 3R100 B 274 10 80 210 8 25 144 5 66 93 3 66 92 3 63 23 1 51 1321 3R100 C 274 10 80 210 8 25 156 6 16 106 4 16 92 3 63 33 6 74 1321 3R130 A 229 9 00 179 7 04 118 4 66 80 3 16 76 3 00 13 2 29 1321 3R130 B 274 10 80 213 8 40 144 5 66 93 3 66 92 3 63 25 9 57 1321 3R130 C 279 11 00 216 8 50 156 6 16 106 4 16 92 3 63 29 0 64 1321 3R160 A 274
81. 9 Ratings A 1 G General Precautions P 3 Ground Fault 4 3 Grounding Filter 1 9 General 1 8 Index 2 H Heatsink OvrTmp Fault 4 3 HW OverCurrent Fault 4 3 Wiring 1 15 Wiring Examples 1 20 1 23 IO Board Fail Fault 4 5 Input Contactor 1 15 Input Fusing 1 9 Input Power Conditioning 1 7 Installation 1 1 Integral Keypad 2 3 Interference EMC RFI 1 27 1 29 K Keypad 2 3 L LEDs 2 3 2 4 2 6 2 7 2 8 2 9 M Metasys N2 point map F 3 G 2 Minimum Clearances 1 4 Motor Cable Length 1 13 Motor Overload 4 3 Motor Overload Fault 4 3 Motor Stalled Fault 4 3 motor starter 1 9 Mou RO Options and Clearances MOVs 1 6 0 Opening the Cover 1 1 Operator Interface 2 3 OverVoltage Fault 4 3 P Parameter Descriptions 3 1 Types 3 1 Viewing and Editing 2 5 Parameter Checksum Fault 4 4 Parameters 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 2 F 3 6 2 Power Cables Wiring 1 11 Power Conditioning Input 1 7 a Connections Single Phase Power Loss Fault 4 3 Power Unit Fault 4 4 Powering Up the Drive 2 1 2 2 Precautions General P 3 Product Selection B 1 Program Group Parameters 3 7 Programming 3 1 R Ratings A 1 Reflective Wave Protection 1 13 Removing Cover 1 1 Repeated Start Stop 1 15 bs Start Stop Precautions RFI see RWR Reflective Wave Reducer 1 13
82. C D012N103 22 RF018 CS 10 No 7 5 10 22 017 103 22 RF018 CS 10 No 11 15 22C D022N103 22 RF026 CS 10 No 15 20 22C D030N103 22 RFD036 100 No 18 5 25 22 0038 103 22 RFD050 150 No 22 30 22C D045A103 22 RFD050 150 No 30 40 22C D060A103 22 RFD070 50 No 37 50 22C D072A103 22 RFD100 50 No 45 60 22C D088A103 22 RFD100 50 No 55 75 22C D105A103 22 RFD150 150 No 75 100 22C D142A103 22 RFD180 50 No 90 125 22C D170A103 Consult Factory 110 150 22 208 103 Consult Factory Installation Wiring 1 31 Figure 1 12 Connections and Grounding Shielded Enclosure 1 30 NEMA 1 UL Type 1 Option Kit Frame C Drives Only gt Y EMI Fittings and Metal Conduit tel Id EMI Filter TENTI 35 U T1 L3 113 Enclosure Ground Connection Shielded Motor Cable Building Structure Steel 1 Shielded Enclosure required for 200 240V AC 11 22 kW 15 30 HP PowerFlex 400 drives 1 32 Installation Wiring Notes 2 Start Up This chapter describes how to start up the PowerFlex 400 Drive To simplify drive setup the most commonly programmed parameters are organized in a single Basic Program Group Important Read
83. C D060A103 D 37 50 72 72 22C D072A103 E 45 60 88 88 22C D088A103 E 55 75 105 105 22C D105A103 E 75 100 142 128 22C D142A103 E 90 125 170 170 22C D170A103 F 110 150 208 208 22C D208A103 F 2 Accessories and Dimensions Table PowerFlex 400 Flange Mount Drives Drive Ratings Output Current Frame Input Voltage kW HP 45 506 Catalog Number Size 240V 50 60 Hz 22 3 12A 12A 22 012 103 C 3 Phase 37 5 175A 17 5A 22C BO17F103 C 55 75 24A 24A 22C BO24F103 75 10 33A 33A 22 033 103 C 480V 50 60 Hz 22 3 60 60 22C D6POF103 C 3 Phase 40 5 10A 10A 22C DO10F103 C 55 75 12A 12A 22C D012F103 C 75 10 17A 17 22C DO17F103 C 11 15 22A 22C D022F103 0 C 15 20 30A 27A 22C D030F103 7 C 1 ADC bus inductor is required See Table B 7 for ordering information Table B 4 Bulletin 1321 3R Series Line Reactors 200 240V 60 Hz Three Phase Catalog Number Maximum Fundamental Continuous Inductance Watts 00 IP11 kW HP Amps mh Loss OpenStyle Type 1 3 Impedance 22 30 12 18 1 25 26 1321 3R12 A 1321 3RA12 A 37 50 18 27 0 8 36 1321 3R18 A 1321 3RA18 A 55 78 25 37 5 0 5 48 1321 3R25 A 1321 3RA25 A 75 10 9 52 5 04 49 1321 3R35 A 1321 3RA35 A 11 15 45 67 5 0 3 54 1321 3R45 A 1321 3RA45 A 15 120 55 82 5 0
84. Hz 3 8 Programming and Parameters Basic Program Group continued P036 Start Source Related Parameter s P037 P042 A166 d301 Stop drive before changing this parameter Sets the control scheme used to start the drive when in Auto Remote mode Refer to Start and Speed Reference Control on page 1 24 for details about how other drive settings can override the setting of this parameter Important For all settings except options 3 and 6 the drive must receive a leading edge from the start input for the drive to start after a stop input loss of power or fault condition Options 0 Keypad Integral keypad controls drive operation e Terminal 01 Stop Coast to Stop 1 0 Terminal 02 Not Used Terminal 03 Not Used 1 3 Wire O Terminal Block controls drive operation e 1 0 Terminal 01 Stop Per P037 Stop Mode e 1 0 Terminal 02 Start 1 0 Terminal 03 Direction 2 2 Wire Terminal Block controls drive operation e Terminal 01 Stop Coast to Stop e 1 0 Terminal 02 Run FWD e 1 0 Terminal 03 Run REV 3 2 W Lvl Sens Terminal Block controls drive operation Default e Terminal 01 Stop Coast to Stop e 1 0 Terminal 02 Run FWD See Attention IO Terminal 03 Run REV Below Drive will restart after a Stop command when e Stop is removed and Run FWD is held active 4 2 W Hi Speed l O Terminal Block controls drive operati
85. IGITAL IN 4 OFF 1 0 ON OFF 53 LDI DIGITAL IN 5 OFF 1 0 ON OFF 54 LDI DIGITAL IN 6 OFF 1 0 ON OFF 55 LDI DIGITAL IN 7 OFF 1 0 ON OFF 60 LAI INPUT REF 1 0 3 0 1 0 61 LAI INPUT REF 2 0 3 0 1 0 62 LAO ANALOGOUT O PCT 0 1 0 63 LAO ANALOGOUT2 0 PCT 0 1 0 64 LAI LAST FAULT 0 1 0 P1 Floor Level Network FLN G 3 Table G 1 Point Database for Application 2735 Factory Engineering Point Point Default Units Slope Intercept Number Type Subpoint Name 51 Units SI Units SI Units 51 Units Text Text 65 LAO PID GAIN 1 PTC 0 01 0 66 LAO PID INT TIME 2 SEC 01 0 67 LAO PID DIF RATE 0 PERSEC 2 0 01 0 68 LAO PID SETPOINT 0 PTC 0 1 0 70 LDI DIR MON FWD 1 0 REV FWD 71 LDI ACCELERATING OFF 1 0 ON OFF 72 LDI DECELERATING OFF 1 0 ON OFF 73 LDI ALARM NORMAL 1 0 ALARM NORMAL 74 LDI SPEED OFF 1 0 ON OFF 75 LDI MAIN FREQ OFF 1 0 ON OFF 76 LDI OPER CMD OFF 1 0 ON OFF UT LDI PARAM LOCK UNLOCK 1 0 LOCK UNLOCK 78 LDO JOG OFF 1 0 ON OFF 79 LDO LOCALCNTRL 4 OFF 1 0 ON OFF 80 LDO MOP INC OFF 1 0 ON OFF 81 LDO ACCEL RATE 1 OFF 1 0 ON OFF 82 LDO ACCEL RATE 2 OFF 1 0 ON OFF 83 LDO DECEL RATE 1 OFF 1 0 ON OFF 84 LDO DECEL RATE 2 OFF 1 0 ON OFF 85
86. LDO REF SELECT 1 OFF 1 0 ON OFF 86 LDO REFSELECT2 OFF 1 0 ON OFF 87 LDO REF SELECT 3 OFF 1 0 ON OFF 88 LDO MOP DEC OFF 1 0 ON OFF 92 LAO REFERENCE 0 PCT 0 01 0 93 LDI OK FAULT OK 1 0 FAULT 94 LDO RESET FAULT NORMAL 1 0 RESET NORMAL 99 LAO STATUS 0 1 0 Points not listed are not used this application A single value in a column means that the value is the same in English units and in SI units Point numbers that appear in brackets may be unbundled at the field panel Depends on drive model 1 Secs Depending on configuration units can be volts or milliamperes Local Control causes the drive to use C108 Start Source 2 and C109 Speed Ref 2 for start and speed reference control xs tee G4 P1 Floor Level Network FLN Table 6 2 Point Database for Application 2735 Point Number Subpoint Name Parameter 01 CTLR ADDRESS C104 02 APPLICATION 03 FREQ OUTPUT b001 04 PCT OUTPUT d322 05 SPEED d323 06 CURRENT b003 07 TORQUE b013 08 POWER b010 09 DRIVE TEMP b014 11 DRIVE MWH b011 12 RUN TIME b012 13 DC BUS VOLT b005 20 OVRD TIME 21 FWD REV MON 22 CMD FWD REV 23 RUN STOP MON b066 bit 1 Running 24 CMD RUN STOP 25 READY d302 bit 2 I O Terminal 01 26 RUN ENABLE 29
87. Mounting Clearances Frame D amp E Frame F P 250 mm 1 9 8 in 6 0 in v v EE 0 a 50 50 50 3 50 46059 Moon Mon M 201 150 om v Debris Protection Frame C Drives A plastic top panel is included with the drive Install the panel to prevent debris from falling through the vents of the drive housing during installation Remove 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 e Store within an ambient temperature range of 40 to 85 C e Store within a relative humidity range of 0 to 95 non condensing e Do not expose to a corrosive atmosphere 1 6 Installation Wiring AC Supply Source Considerations Ungrounded Distribution Systems are referenced to ground These devices must be disconnected if the drive is installed on an ungrounded or resistive grounded distribution system ATTENTION PowerFlex 400 drives contain protective MOVs that Disconnecting MOVs Drive Frames C E and F only 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 ju
88. N2 master performs read and write commands to these virtual objects and the internal Metasys protocol firmware transfers translates the data between these virtual objects and the drive When a read or write command occurs to a certain dedicated 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 that are used in the virtual objects are binary input binary output BO analog input analog output AO and internal integer ADI The Metasys N2 master also performs cyclic polling of all the virtual objects Metasys 2 Virtual Objects A Metasys N2 node may contain up to 256 virtual objects in each of its seven different data types called regions Table F 1 2 Metasys 2 Table F1 Description of the Regions of a Virtual Object Region Type Short Description Region 1 Analog Input Al 32 bit IEEE standard floats Region2 Binary Input 1 bit Region 3 Analog Output AO 32 bit IEEE standard floats Region4 Binary Output BO 1 Region5 Internal Float 32 bit IEEE standard floats Analog Data Float Region6 Internal Integer ADI 16 bit Analog Data Integer Region 7 Internal Byte DB 8 bit Analog Data Byte Metasys N2 Data Types Table F2 Internal Structure of Metasys Analog Input Al Attribut
89. OUTPUT 0 HZ 0 01 0 04 LAI PCT OUTPUT 0 PCT 0 1 0 05 LAI SPEED 0 RPM 1 0 06 LAI CURRENT 0 AMPS 0 1 0 07 LAI TORQUE 0 AMPS 0 1 0 08 LAI POWER 0 HP 0 1333 0 KW 0 1 0 09 LAI DRIVE TEMP 0 DEG F 1 8 32 DEG 1 0 11 LAI DRIVE MWH 0 MWH 0 1 0 12 LAI RUN TIME 0 HRS 10 0 13 LAI DC BUS VOLT 0 VOLTS 1 0 20 LAO OVRD TIME 1 HRS 1 0 21 LDI FWD REV MON FWD 1 0 REV FWD 22 LDO CMD FWD REV FWD 1 0 REV FWD 23 LDI RUN STOPMON 5 1 0 RUN STOP 24 LDO CMDRUN STOP STOP 1 0 RUN STOP 25 LDI READY READY 1 0 READY NOTRDY 26 LDO RUN ENABLE STOP 1 0 ENABLE STOP 29 LDO DAY DAY 1 0 NIGHT DAY 30 LAO CURRENTLIMT 41 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 UNLOCK 36 LAO READ PARAM 0 1 0 37 LAI READ VALUE 0 1 0 98 LAO WRITE PARAM 0 1 0 39 LAO WRITE VALUE 0 1 0 40 LDO DIGITAL OUT1 OFF 1 0 ON OFF 41 LDO DIGITAL OUT2 OFF 1 0 ON OFF 42 LDO DIGITAL OUT3 OFF 1 0 ON OFF 43 LDO OPT RELAY 1 OFF 1 0 ON OFF 44 LDO OPTRELAY 2 OFF 1 0 ON OFF 45 LDO OPTRELAY 3 OFF 1 0 ON OFF 46 LDO OPTRELAY 4 OFF 1 0 ON OFF 47 LDO OPTRELAY 5 OFF 1 0 ON OFF 48 LDO OPT RELAY 6 OFF 1 0 ON OFF 49 LDI DIGITAL IN 1 OFF 1 0 ON OFF 50 LDI DIGITAL IN 2 OFF 1 0 ON OFF 51 LDI DIGITAL IN 3 OFF 1 0 ON OFF 52 LDI D
90. Sel Relay Out Level Relay 1 On Time Relay 1 Off Time Relay Out2 Sel Relay Out2 Level Relay 2 On Time Relay 2 Off Time Language Purge Frequency Internal Freq Preset Freq 0 Preset Freq 1 Preset Freq 2 Preset Freq 3 Accel Time 2 Decel Time 2 S Curve PID Trim Hi PID Trim Lo PID Ref Sel PID Feedback Sel PID Prop Gain PID Integ Time PID Diff Rate PID Setpoint PID Deadband PID Preload b001 b002 b003 b004 b005 P031 P032 P033 P034 051 052 053 054 055 056 058 T059 T060 061 063 T064 C101 A141 A142 A143 A144 A145 A146 A147 A148 A149 A150 151 152 153 154 155 156 157 158 159 Drive Status b006 Fault 1 Code b007 Process Display 0008 Output Power 5010 Maximum Freq P035 Start Source P036 Stop Mode P037 Speed Reference P038 Opto Out Sel 065 Opto Out Level T066 Opto Out Logic T068 Analog In 1 Sel 069 Analog In 1 Lo T070 Analog In 1 Hi T071 Analog In 1 Loss T072 Analog 2 Sel 17073 Analog In 2 Lo T074 Analog In 2 Hi T075 Analog 2 Loss T076 Comm Format C102 Comm Data Rate C103 Comm Node Addr C104 Comm Loss Action C105 Comm Loss Time C106 Comm Write Mode C107 Process Factor 160 Auto Rstrt Tries 163 Auto Rstrt Delay 164 Start At PowerUp 165 Reverse Disable A166 Flying Start En 167 PWM Frequency A168 PWM Mode A169 Boost Select A170 Start Boost A171 Break Voltage A172 Break Frequency 173 Maximum Voltage A17
91. Status bit 04 Accelerating Not Accelerating 6 Decel Logic Status bit 05 Decelerating Not Decelerating BI T Alarm Logic Status bit 06 Alarm No Alarm BI 8 Fault Logic Status bit 07 Fault No Fault BI 9 At Speed Logic Status bit 08 At Reference Not at Reference BI 10 Main Freq Logic Status bit 09 Comm Controlled Not Comm Controlled BI 11 Oper Cmd Logic Status bit 10 Comm Controlled Not Comm Controlled BI 12 Param Lock Logic Status bit 11 Locked Not Locked BI 13 Digital In 1 Logic Status bit 12 On Off Drive Terminal 2 BI 14 Digital In 2 Logic Status bit 13 On Off Drive Terminal 3 BI 15 Digital In 3 Logic Status bit 14 On Off Drive Terminal 4 BI 16 Digital In 4 Logic Status bit 15 On Off Drive Terminal 5 BI 17 Digital In 5 Drive Terminal 6 On Off BI 18 Digital In 6 Drive Terminal 7 On Off BI 19 Digital In 7 Drive Terminal 8 On Off Table F 8 Analog Inputs Network Point Type Address NPT NPA Name Description Units Min Max Al 1 Feedback Feedback 0 100 Al 2 Speed d323 Output RPM RPM 0 24000 Al 3 Current b003 Output Current A 0 00 Rated x 2 Al 4 DC Bus Volts 1005 DC Bus Voltage V 0 820 Al 5 Last Fault b307 Fault 1 Code 1 1 100 Al 6 2nd Fault 6308 Fault 2 Code 1 1 100 7 Analog In 1 Drive Analog Input 1 Drive Terminal 13 8 Analog In 2 Drive Analog Input 2 Drive Terminal 47 9 Read Value Read value of Param selected by AO 10 10 User In 1 User defined Input 1 Param selected via ADI 1 i i
92. T074 Analog In 2 Lo to a minimum of 20 i e 2 volts Options 0 Disabled Default 1 Fault F29 F29 Analog Input Loss 2 Stop Uses P037 Stop Mode 3 Zero Ref Drive runs at zero speed reference 4 Min Freq Ref Drive runs at minimum frequency 5 Max Freq Ref Drive runs at maximum frequency 6 Int Freq Ref Drive runs at A143 Preset Freq 0 Programming and Parameters 3 23 Terminal Block Group continued 077 Sleep Wake Sel Related Parameter s T078 079 T080 081 The drive sleeps if the appropriate analog input drops below the set Sleep Level for the time set in Sleep Time and the drive is running When entering sleep mode the drive will ramp to zero and the run indicator 7 on the keypad display will flash indicating the drive is in sleep mode When the appropriate analog input rises above the set Sleep Level the drive will wake and ramp to the commanded frequency Inversion can be accomplished by setting T078 Sleep Level to a higher setting than T080 Wake Level ATTENTION Enabling the Sleep Wake 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 applicable local national amp international codes standards regulations or industry guidelines must be considered Options 0 Disabled Default
93. W 200 Drive Rated Power FilerA 20 mA b01 19 Setpnt4 20 4 20 4mA 0 0 100 0 Setting None 20 T084 20 TstData 4 20 4 20mA 4mA 0000 65535 Hex FFFF None 20 196 7 For settings with the filter enabled if a 0 100 step change occurs the output will reach 95 500 milliseconds 99 in 810 milliseconds and 100 in 910 milliseconds Values Default 0 Min Max 0 20 Display 1 T083 Analog Out High Related Parameter s P035 T082 T084 Scales the Maximum Output Value for the T082 Analog Out1 Sel source setting Examples T083 Setting T082 Setting T082 Max Output Value 50 1 OutCurr 0 10 5V for 200 Drive Rated Output Current 90 11 OutPowr 0 20 18mA for 200 Drive Rated Power Values Default 100 0 800 Display 1 Programming and Parameters Terminal Block Group continued T084 Anlg Out1 Setpt 3 25 Related Parameter s T082 083 Sets direct parameter control over the analog output If enabled this sets the percent value of analog output Values Default 0 0 0 0 100 0 Display 0 1 T085 Analog Sel Related Parameter s P035 T086 T087 Sets the analog output signal mode 0 20 mA 4 20 mA or 0 10V The output is used to provide a signal that is proportional to several drive conditions This parameter must match DIP Switch AO2
94. Wire Control with Function Loss and SW Enable Sourcing SRC Internal Supply Non Reversing e Input must be active for the drive to run e When input is opened the drive will stop as specified by P037 Stop Mode e Drive will not run if I O Terminal 03 is open Drive will coast to stop if opened while running Drive will fault if O Terminal 01 is open Drive will coast to stop if opened while running Requires drive reset once terminal is closed 3 Wire Control Sourcing SRC Internal Supply Non Reversing e A momentary input will start the drive e A stop input to I O Terminal 01 will stop the drive as specified by P037 Stop Mode 3 Wire Control Sourcing SRC Internal Supply Reversing e Amomentary input will start the drive e A stop input to I O Terminal 01 will stop the drive as specified by P037 Stop Mode e 1 0 Terminal 03 determines direction Connection Example CO Stop Run Forward O Stop Run Reverse o o old 01 02 03 Oo 000202020 i mne ro Q 0 0 0 0 0 0 0 6 SW Enable ooooo0Q S 01 3 02 03 01 02 00000000 Direction Q o0 01 02 03 88 Required Settings DIP Switch SNK SRC SRC Parameters 036 Start Source 2 3 4 P037 Stop Mode 0 through 7 A166 Rever
95. affected by electrical noise in the distribution system Applications with large numbers of drives in a similar location imposed EMC regulations or a high degree of communications networking are also good candidates for shielded cable 1 12 Location Standard Option 1 Installation Wiring Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications In addition the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks Refer to Reflected Wave in Wiring and Grounding Guidelines for PWM AC Drives publication DRIVES INO01A EN P Consideration should be given to all of the general specifications dictated by the environment of the installation including temperature flexibility moisture characteristics and chemical resistance In addition a braided shield should be included and be specified by the cable manufacturer as having coverage of at least 75 An additional foil shield can greatly improve noise containment A good example of recommended cable is Belden 295xx xx determines gauge This cable has four 4 XLPE insulated conductors with a 100 coverage foil and an 85 coverage copper braided shield with drain wire surrounded by a PVC jacket Other types of shielded cable are available but the selection of these types may limit the allowabl
96. alog Input 1 Al1 Analog Output 1 AO1 or Analog Output 2 AO2 With Analog Input 2 provides one fully isolated analog input channel 1 18 Installation Wiring Table 1 G Control I O Terminal Designations No Signal Default Description Param 01 Stop 7 Coast Factory installed jumper or a normally closed input must P036 Function Loss be present for the drive to start Program with P036 Start Source 02 Start Run FWD HAND Mode Command comes from Integral Keypad 036 P037 AUTO Mode I O Terminal 02 is active Program with P036 Start Source 03 Direction Run REV Disabled To enable reverse operation program with A166 P036 P037 Reverse Disable A166 Program with P036 Start Source 04 Digital Common For digital inputs Tied to I O Terminal 09 Electronically isolated with digital inputs from analog I O and opto output 05 Digital Input 1 Purge 2 Program with T051 Digital In1 Sel 1051 06 Digital Input 2 Local Program with T052 Digital In2 Sel 1052 07 Digital Input 3 Clear Fault Program with T053 Digital In3 Sel 1053 08 Digital Input 4 Comm Port Program with T054 Digital In4 Sel T054 09 Digital Common For digital inputs Tied 1 0 Terminal 04 Electronically isolated with digital inputs from analog I O and opto output 10 Common For opto coupled outputs Electronically isolated with opto output from analog 1 and digital
97. ameter s b003 Displays the value of b003 Output Current when the last fault occurred Values Default Read Only Min Max 0 0 Drive Rated Amps x 2 Display 0 1 Amps Programming and Parameters 3 57 Advance Display Group continued d326 Fault Bus Volts Related Parameter 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 9 Fault Related Parameter s 006 Displays the value of b006 Drive Status when the last fault occurred Values Default Read Only Min Max 0 1 Display 1 3 58 Programming and Parameters Parameter Cross Reference by Name Parameter Name Number Group Page Parameter Name Number Group Page Accel Time 1 P039 Basic Program 3 10 Compensation A194 Advanced Program 3 45 Accel Time 2 A147 Advanced Program 3 32 In Status d302 Advanced Display 3 52 Analog In 1 d305 Advanced Display 3 53 Control Source d301 Advanced Display 3 52 Analog In 1 Hi T071 Terminal Block 3 20 Control SW Ver d320 Advanced Display 3 56 Analog In 1 Lo T070 Terminal Block 3 20 Current Li
98. amp T073 Analog In 2 Sel AO1 amp 7082 Analog Out1 Sel AO2 amp T085 Analog Out2 Sel Sink Source DIP Switch Source SRC Inputs can be wired as Sink SNK or Source SRC via DIP Switch setting Figure 1 8 User Installed Auxiliary Relay Card Frames D E amp F Only 6 Important If using auxiliary motor control ensure that wiring and parameter configuration are correct before wiring contactor outputs relays on the Auxiliary Relay Card will energize on power up by default Failure to verify proper wiring and parameter configuration can result in improper motor operation or drive damage Refer to Appendix D Table 11 User Installed Relay Board Terminal Designations for more details No Signal Default Description Param 3 Relay Ready Fau Normally open contact for Number Output Relay R221 3B 3 Relay Common Common for Number 3 Output Relay 4 1H Relay N O Ready Fau Normally open contact for Number 4 Output Relay R224 4B 4 Relay Common Common for Number 4 Output Relay 5 Relay Ready Faul Normally open contact for Number 5 Output Relay R227 5B 5 Relay Common Common for Number 5 Output Relay 6A 6 Relay Ready Fau Normally open contact
99. and as defined by A143 A146 Preset Freq x when 1051 1054 Digital Inx Sel are programmed as Preset Frequencies and the digital inputs are active 5 Comm Port External frequency command from the communications port Refer to Appendix D and Appendix E for details Parameter C102 Comm Format is used to select a communications protocol P039 Accel Time 1 Related Parameter s P038 P040 051 054 A141 143 4146 A147 Sets the rate of acceleration for all speed increases Maximum Freq Accel Time Beca Rate Values Default 20 00 Secs Min Max 0 00 600 00 Secs Display 0 01 Secs P035 Maximum Freq Speed 039 or A147 la P040 or A148 0 Accel Time x Decel Time x Time Programming and Parameters 3 11 Basic Program Group continued P040 Decel Time 1 Related Parameter s P038 P039 051 054 A141 A143 A146 A148 Sets the rate of deceleration for all speed decreases Maximum Freq Decel Time Detel Rats Values Default 20 00 Secs Min Max 0 00 600 00 Secs Display 0 01 Secs P035 Maximum Freq Speed 039 or A147 le P040 or A148 0 Accel Time x Decel Time x Time P041 Reset To Defalts Stop drive before changing this parameter Resets all parameter values to factory defaults Options 0 Ready Idle Default 1 Factory Rset e After the reset function is complete this parameter will set it
100. apacitors Line has frequent power interruptions Line has intermittent noise spikes in excess of 6000V lightning Phase to ground voltage exceeds 125 of Remove MOV jumper to ground normal line to line voltage Frame C E amp F drives only or Install Isolation Transformer with grounded secondary if necessary Ungrounded distribution system Refer to Appendix B for accessory ordering information 1 8 Installation Wiring General Grounding Requirements The drive Safety Ground PE must be connected to system ground Ground impedance must conform to the requirements of national and local industrial safety regulations and or electrical codes The integrity of all ground connections should be periodically checked Figure 1 5 Typical Grounding Ground Fault Monitoring If a system ground fault monitor RCD is to be used only Type B adjustable devices should be used to avoid nuisance tripping Safety Ground PE This is the safety ground for the drive that is required by code One of these points must be connected to adjacent building steel girder joist a floor ground rod or bus bar Grounding 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 Shield
101. are programmed to write parameter data to Non Volatile Storage NVS frequently the NVS will quickly exceed its life cycle and cause the drive to malfunction Do not create a program that frequently uses configurable outputs to write parameter data to NVS These outputs are written each time the User OUTXx point is written from the network The Param for OUTx s default to commonly accessed parameters and can be changed if desired A value of 0 in the for OUTx field disables the writing of data for that specific point Figure 2 Configurable Objects Outputs Controller Drive ADI Param for OUTx ue N AO 7 Table 14 Configurable Objects Outputs Network Point Type Address Description Range Default 6 User OUT1 0 AO 7 User OUT2 Varies by the parameter AO 8 User OUT3 un for AO 9 User OUT4 0 ADI 5 User OUT1 A06 0 not in use 1 to A154 PID Prop Gain Destination Param maximum of drive parameters ADI 6 User OUT2 A07 0 not in use 1 to A155 PID Integ Time Destination Param maximum of drive parameters ADI 7 User A08 0 not in use 1 to A156 PID Diff Rate Destination Param maximum of drive parameters ADI 8 User OUTA A09 0 not in use 1 to A158 PID Deadband Destination Param maximum of drive parameters F 8 Metasys N2 Notes Ap
102. ated Parameter s P034 P038 072 073 075 T076 A152 A153 Stop drive before changing this parameter Sets the analog input level that corresponds to P034 Minimum Freq Analog inversion can be accomplished by setting this value larger than T075 Analog In 2 Hi Important If analog inversion is implemented the drive will go to maximum frequency 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 0 096 Min Max 0 0 100 0 Display 0 1 P035 Maximum Freq P034 Minimum Freq 0 T074 Analog In 2 Lo T075 Analog In 2 Hi T075 Analog In 2 Hi Related Parameter s P035 P038 T073 T074 T076 A152 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 In 2 Lo Values Default 100 0 Min Max 0 0 100 0 Display 0 1 T076 Analog In 2 Loss Related Parameter s 055 T060 T065 T073 T074 075 Stop drive before changing this parameter Selects drive action when an input signal loss is detected Signal loss is defined as an analog signal less than 1V or 2mA The signal loss event ends and normal operation resumes when the input signal level is greater than or equal to 1 5V or 3mA If using 0 10V analog input set
103. ations 2 Check fan Check programming Check for excess load improper A170 Boost Select setting DC brake volts set too high or other causes of excess current Check the motor and external wiring to the drive output terminals for a grounded condition Check for load loss i e a broken belt 1 Check parameters 2 Check for broken loose connections at inputs See page 4 1 for a descri 4 4 F33 Description Drive unsuccessfully attempted Action Correct the cause of the fault and F38 F39 F40 F41 F42 F43 F48 F63 F64 F70 F71 F81 F94 F100 Troubleshooting Fault E Auto Rstrt Tries Phase U to Gnd 2 Phase V to Gnd Phase W to Gnd Phase UV Short 2 Phase UW Short Phase VW Short Params Defaulted SW OverCurrent 1 Drive Overload Power Unit Q Net Loss Comm Loss Q Function Loss Parameter Checksum to reset a fault and resume running for the programmed number of A163 Auto Rstrt Tries A phase to ground fault has been detected between the drive and motor in this phase Excessive current has been detected between these two output terminals The drive was commanded to write default values to EEPROM Programmed A183 SW Current Trip has been exceeded Drive rating of 110 for 1 minute or 150 for 3 seconds has been exceeded Failure has been detected in the drive power section The communication networ
104. ay 2 Relay 3 Relay 4 Relay 5 Relay 6 Relay 7 Relay 8 Relay Motor 2 1 AC Line lt Motor 2 Motor 3 2 AC Line ACLine _ Motor 2 Motor 3 Motor 4 3 AC Line ACLine AC Line Motor 1 Motor 1 Motor 2 Motor 2 4 Drive AC Line Drive AC Line Motori Motor 1 Motor 2 Motor 2 Motors3 Motor 3 5 Drive AC Line Drive AC Line Drive AC Line Motor 1 Motor 1 Motor 2 Motor 2 3 Motor 4 Motor 4 6 Drive AC Line Drive AC Line Drive AC Line Drive AC Line 1 Important Proper wiring and parameter configuration of Aux Motor Control functions are especially important when using AutoSwap Improper wiring or configuration could result in line power being applied to the drive outputs Verify system operation before connecting auxiliary motor contactor outputs R241 Aux 1 Start Freq R244 Aux 2 Start Freq R247 Aux 3 Start Freq Sets the frequency that causes the next available auxiliary motor to turn on Values Default 50 0 Hz Min Max 0 0 320 0 Hz Display 0 1 Hz R242 Aux 1 Stop Freq R245 Aux 2 Stop Freq R248 Aux 3 Stop Freq Sets the frequency that causes the next running auxiliary motor to turn off Values Default 25 0 Hz Min Max 0 0 320 0 Hz Display 0 1 Hz 3 50 Programming and Parameters Aux Relay Card Group continued R243 Aux 1 Ref Add R246 Aux 2 Ref Add R249 Aux 3 Ref
105. cations added 5 Supported communication protocols expanded 5 Watts Loss table added A 6 Power Structure detail added to Appendix A 7 Appendix D provides setup information for Damper Control PID Control D 1 and Auxiliary Control schemes Appendix G P1 network protocol added 6 1 New Parameters The following new parameters have been added with the release of Firmware Release Number FRN 3 xx 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 Preface Chapter 1 Chapter 2 Chapter 3 Chapter 4 Overview Installation Wiring Start Up Table of Contents Programming and Parameters Troubleshooting Who Should Use this Manual P 1 Reference Materials P 1 Manual Conventions P 2 Drive Frame 5 2 P 2 General Precautions P 3 Catalog Number Explanation 4 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 Instructions 1 27 FCC
106. cel Time x Decel Time x A148 Decel Time 2 Related Parameter s P040 051 054 A143 A146 When active sets the rate of deceleration for all speed decreases Refer to the flowchart on page 1 25 for details Maximum Freq Decel Time Decel Rale Values Default 30 00 Secs Min Max 0 01 600 00 Secs Display 0 01 Secs Programming and Parameters 3 33 Advanced Program Group continued A149 S Curve Sets the percentage of acceleration or deceleration time that is applied to the ramp as S Curve Time is added 1 2 at the beginning and 1 2 at the end of the ramp Values Default 20 0 100 A setting of 096 disables this parameter Display 196 Example Accel Time 10 Seconds MU S Curve Setting 50 Terast S Curve Time 10 x 0 5 5 Seconds I Total Time 10 5 15 Seconds T 14 1 25 Curve Time Accel Time gt lt 1 2 S Curve Time y 2 5 Seconds 10 Seconds 2 5 Seconds 4 Total Time to Accelerate Accel Time S Curve Time 100 S Curve S Curve Time Accel Time Total Time to Accelerate Accel Time 5 Curve Time A150 PID Trim Hi Sets the maximum positive value that is added to a PID reference when PID trim is used Values Default 60 0 Hz Min Max 0 0 320 0 Hz Display 0 1 Hz A151 PID Trim Lo Sets the minimum positive value that is added to a PID reference when PID trim is used
107. correct command Incorrect reference source is being selected via remote device or digital inputs None e Check d301 Control Source for correct source Check 0302 Contrl In Status to see if inputs are selecting an alternate source Verify settings for 1051 T054 Digital Inx Sel e Check P038 Speed Reference for the source of the speed reference Reprogram as necessary e Review the Speed Reference Control chart on page 1 24 Motor and or drive will not accelerate to commanded speed Cause s Indication Corrective Action Acceleration time is excessive None Reprogram P039 Accel Time 1 or A147 Accel Time 2 Excess load or short None Compare b003 Output Current with acceleration times force the A179 Current Limit 1 drive into current limit slowing Remove excess load or reprogram or stopping acceleration P039 Accel Time 1 or A147 Accel Time 2 Check for improper A170 Boost Select setting Speed command source or None Verify b002 Commanded Freq value is not as expected Check 4301 Control Source for the proper Speed Command Programming is preventing the None Check 035 Maximum Freq to drive output from exceeding limiting values insure that speed is not limited by programming 4 8 Troubleshooting Motor operation is unstable Cause s Indication Corrective Action Motor data was incorrectly entered None 1 Correc
108. de Fault 3 Code R221 R222 R224 R225 R227 R228 R230 R231 R233 R234 R236 R237 d301 d302 d303 d304 8305 0306 4307 4308 4309 Programming and Parameters 3 3 Aux Mo Aux Mo Aux 15 or Mode or Qiy art Freq Aux 1 Stop Freq Aux 1 Ref Add Aux 2 S art Freq Aux 2 Stop Freq Aux 2 Ref Add Aux 3 5 Aux 3 5 art Freq Freq Aux 3 Ref Add Fault 1 Fault 1 Fault 2 Fault 2 Fault 3 Fault 3 ime hr ime min ime hr ime min ime hr ime min Elapsed Time hr Elapsed Time min R239 R240 R241 R242 R243 R244 R245 R246 R247 R248 R249 d310 d311 d312 d313 d314 d315 d316 d317 Aux Start Delay R250 Aux Stop Delay R251 Aux Prog Delay R252 Aux AutoSwap TmeR253 Aux AutoSwap Lvl R254 Output Powr Fctr 0318 Testpoint Data d319 Control SW Ver 4320 Drive Type d321 Output Speed d322 Output RPM d323 Fault Frequency d324 Fault Current d325 Fault Bus Volts d326 Status 0 Fault d327 3 4 Programming and Parameters Basic Display Group b001 Output Freq Related Parameter s 2002 b008 034 P035 P038 Output frequency present at T1 T2 amp T3 U V amp W Values Default Read Only Min Max 0 00 P035 Maximum Freq Display 0 01 Hz b002 Commanded Freq Related Parameter s 2001 P034 P035 P038 d302 Value of the active frequency command Displays the commanded frequency even if the drive is not running Important The frequency command can
109. dication that the damper is in the proper position and that it is safe for the drive to run at commanded speed Damper Position Command System Run Command Damper Limit Switch Outside Air Air Fl Damper 2 gt ON Supply Fan Example The System Run Command can come from a terminal block integral keypad or communication port Configure parameter P036 Start Source per application requirements e Set one of the available digital inputs parameter 7051 7054 Digital Inx Sel to option 36 Damper Input The damper end switch or limit switch should be wired into this input e Set one of the available relay outputs parameter T055 T060 Relay Outx Sel to option 2 Motor Running This output should be used to energize the damper to either open or close D 2 Application Notes PID Setup PID Control Loop The PowerFlex 400 has a built in PID proportional integral differential control loop The PID loop is used to maintain a process feedback such as pressure flow or tension at a desired set point 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 Gains and outputs a frequency to try to reduce the error value to 0 To enable the PID loop parameter A152 PID Ref Sel must be set to an option other than 0 PID Disabled Exclusive Control and Trim Control are two basic c
110. e Description 1 Byte Object Configuration 2 Byte Object Status 3 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 Internal Structure of Metasys N2 Binary Input BI Attribute Description 1 Byte Object Configuration 2 Byte Object Status Table FA Internal Structure of Metasys N2 Analog Output AO Attribute Description 1 Byte Object Configuration 2 Byte Object Status 3 Float Current Value Table F5 Internal Structure of Metasys Binary Output BO Attribute Type Description 1 Byte Object Configuration 2 Byte Object Status 3 Integer Minimum On Time 4 Integer Minimum Off Time 5 Integer Maximum Cycle Hour Table F6 Internal Structure of Metasys Internal Integer ADI Attribute Description 1 Byte Object Status 2 Integer Current Value Signed 16 bit Network Points Table F7 Binary Inputs Metasys N2 F3 Network Point Type Address NPT NPA Name Description ON 1 OFF 0 1 Ready Logic Status bit 00 Ready Not Ready 2 Active Logic Status bit 01 Active Not Active 3 Cmd Dir Logic Status bit 02 Forward Reverse 4 Act Dir Logic Status bit 03 Forward Reverse 5 Accel Logic
111. e 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 increase the cable charging current required and reduce the overall drive performance Unless specified in the individual distance tables as tested with the drive these cables are not recommended and their performance against the lead length limits supplied is not known Recommended Shielded Wire Rating Type Description 600V 90 C 194 F Four tinned copper conductors with XLPE insulation XHHW2 RHW 2 Copper braid aluminum foil combination shield and tinned Anixter copper drain wire B209500 B209507 jacket Belden 29501 29507 or equivalent Standard Option 2 Tray rated 600V 90 Three tinned copper conductors with XLPE insulation 194 F RHH RHW 2 6 5 mil single helical copper tape 25 overlap min with three Anixter OLF 7xxxxx or pare copper grounds in contact with shield equivalent PVC jacket Class amp Il Division amp Tray rated 600V 90 C Three bare copper conductors with XLPE insulation and II 194 F RHH RHW 2 impervious corrugated continuously welded aluminum armor Anixter 7V 7xxxx 3G je Black sunlight resistant PVC jacket overall or equivalent e Three copper grounds on 10 AWG and smaller Installation Wiring 1 13 Reflected Wave Protection The drive should be installed as close to
112. e disabled Options 0 Rev Enabled 1 Rev Disabled Default A167 Flying Start En Related Parameter s A200 Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM Important When this parameter is enabled verify that A200 Motor 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 chart below provides derating guidelines based on the PWM frequency setting Important Ignoring derating guidelines can cause reduced drive performance Values Default 4 0 kHz Min Max 2 0 10 0 kHz Frame C and D drives 2 0 8 0 kHz Frame E and F drives Display 0 1 kHz 100 96 92 88 84 80 876 Sn amp eB 968 60 56 52 50 48 1 2 3 4 5 6 7 8 9 10 Carrier Frequency kHz A169 PWM Mode Related Parameter s 168 Selects the PWM algorithm used Options 0 Space Vector 3 Phase Modulation Provides quiet operation and produces less motor losses 1 2 Phase Default 2 Phase Modulation Provides less drive losses and best performance with long motor cable runs 3 38 Programming and Parameters Advance Program Group continued A170 Boost Select Related Parameter s b004 P031 P032 A171 A172 A173 Sets the boost voltage of P031 Motor NP Volts and redefines the V
113. e other than zero Note If the parameter is not set to zero and Auto Rstrt Time is set to zero auto fault clear is enabled This feature automatically clears faults but does not restart the drive Values Default 1 0 Secs Min Max 0 0 160 0 Secs Display 0 1 Secs A165 Start At PowerUp Related Parameter s P036 Stop drive before changing this parameter Enables disables a feature that allows a Start or Run command to automatically cause the drive to resume running at commanded speed after drive input power is restored Requires a digital input configured for Run or Start and a valid start contact This parameter will not function if parameter P036 Start Source is set to 4 2 W Hi Speed ATTENTION Equipment damage and or personal injury may result if this parameter is used in an inappropriate application Do not use this function without considering applicable local national and international codes standards regulations or industry guidelines Options 0 Disabled Default 1 Enabled Programming and Parameters 3 37 Advance Program Group continued A166 Reverse Disable Related Parameter s b006 P036 T051 T054 Stop drive before changing this parameter Enables disables the function that allows the direction of motor rotation to be changed The reverse command may come from a digital or a serial command All reverse inputs including two wire Run Reverse will be ignored with revers
114. ed Drive Frame Sizes 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 P P P b D 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 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 publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection
115. ed by A160 Process Factor Output Process _ Process Freq X Factor Display Values Default Read Only Min Max 0 00 9999 99 Display 0 01 1 b010 Output Power Output power present at T1 T2 amp T3 U V amp W Values Default Read Only Min Max 0 0 999 9 Display 0 1 kW 3 6 Programming and Parameters Basic Display Group continued b011 Elapsed MWh Related Parameter s b015 A195 Accumulated output energy of the drive Values Default Read Only Min Max 0 3276 7 Display 0 1 MWh b012 Elapsed Run Time Related Parameter s A195 Displays the accumulated time that the drive has output power since the last A195 Reset Meter Time is displayed in 10 hour increments Values Default Read Only Min Max 0 9999 Hrs Display 12 10 Hrs b013 Torque Current Displays the torque portion of the output current Values Default Read Only Min Max 0 0 Drive Rated Amps x 2 Display 0 1 Amps b014 Drive Temp Present operating temperature of the drive power section Values Default Read Only Min Max 0 120 degC Display 1 degC b015 Elapsed kWh Related Parameter s 2011 A195 Accumulated output energy of the drive This parameter works in conjunction with Elapsed MWh When the maximum value of this parameter is reached this parameter resets to zero and Elapsed MWh is incremented Values Default Read Only Min Max 0 0 100 0 kWh Di
116. ements Intermittent Overload 110 Overload capability for up to 1 minute Electronic Motor Overload Protection Class 10 protection with speed sensitive response Control Inputs Digital Quantity 8 Semi programmable 4 Programmable Type Source Mode SRO 18 24V ON 0 6V OFF Sink Mode SNK 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 10 bit 0 to 10V DC Analog 100k ohm input impedance 4 20mA Analog 250 ohm input impedance External Pot 1 10k ohm 2 Watt minimum Supplemental Drive Information A 5 Category Specification Control Outputs Relay Quantity 2 Programmable Form C Specification Resistive Rating 3 0A at 30V DC 3 0A at 125V 3 0A at 240V AC Inductive Rating 0 5A at 30V DC 0 5A at 125V 0 5A at 240V AC Optional Quantity 6 Optional Programmable Form A Drive Frames D E Relay Card amp F Only Specification Resistive Rating at 30V DC Class II circuits 3 0A at 125V 3 0A at 240V AC Inductive Rating 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 10 bit 0 to 10V DC Analog 1k ohm minimum 4 20mA Analog 525 ohm maximum Keypad Display Integral 2 line by 16 character LCD with 5 LED Indicators Com
117. er C102 Comm Format is used to select a communications protocol Programming and Parameters 3 81 Advanced Program Group A141 Purge Frequency Related Parameter s P038 P039 P040 051 054 Provides a fixed frequency command value when T051 T054 Digital Inx Sel is set to 1 Purge An active purge input will override speed command as shown in the flowchart on page 1 24 Values Default 5 0 Hz Min Max 0 0 320 0 Hz Display 1 0 Hz A142 Internal Freq Related Parameter s 038 051 054 Provides the frequency command to the drive when P038 Speed Reference is set to 1 Internal Freq When enabled this parameter will change the frequency command in real time using the digital speed keys when in program mode Important Once the desired command frequency is reached the Enter key must be pressed to store this value to EEPROM memory If the ESC key is used before the Enter key the frequency will return to the original value following the normal accel decel curve If T051 T054 Digital Inx Sel is set to 16 Up or 17 Down this parameter acts as the 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 Related Parameter s P038 P039 P040 051 052 A144 Preset Freq 1 st Lte A145 Preset Freq 2 A146 Preset Freq 3 Values 143 Defau
118. er Page 3 27 communication port are saved or stored in RAM only If they are stored in RAM the values will be lost at power down Supported Modbus Function Codes The peripheral interface DSI used on PowerFlex 400 drives supports some of the Modbus function codes Modbus Function Code Command 03 Read Holding Registers 06 Preset Write Single Register Important Modbus devices can be 0 based registers are numbered starting at 0 or 1 based registers are numbered starting at 1 Depending on the Modbus Master used the register addresses listed on the following pages may need to be offset by 1 For example Logic Command may be register address 8192 for some master devices e g ProSoft 3150 MCM SLC Modbus scanner and 8193 for others e g Panel Views Modbus RTU Protocol E 3 Writing 06 Logic Command Data The PowerFlex 400 drive can be controlled via the network by sending Function Code 06 writes to register address 8192 Logic Command P036 Start Source must be set to 5 RS485 DSI Port in order to accept the commands Logic Command Address Decimal Bit s Description 0 1 Stop 0 Not Stop 1 1 Start 0 Not Start 2 1 0 No Jog 3 1 Clear Faults 0 Not Clear Faults 00 No Command 01 Forward Command 5 4 10 Reverse Command 11 No Command 6 1 Local Control 0 Comm Control 7 1 MOP Increment 0 Not Increment 00 No Command 01
119. ernal electronic overload trip Heatsink temperature exceeds a predefined value The drive output current has exceeded the hardware current limit current path to earth ground has been detected at one or more of the drive output terminals Output current has dropped below the level set in 184 Load Loss Level An analog input is configured to fault on signal loss A signal loss has occurred Configure with T072 Analog In Loss ption of fault types 1 Check remote wiring 2 Verify communications programming for intentional fault 1 Monitor the incoming AC line for low voltage or line power interruption 2 Check input fuses Monitor the incoming AC line for low voltage or line power interruption Monitor the AC line for high line voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install dynamic brake option Increase P039 A147 Accel Time x or reduce load so drive output current does not exceed the current set by parameter A179 Current Limit 1 1 An excessive motor load exists Reduce load so drive output current does not exceed the current set by parameter 033 Motor OL Current 2 Verify A170 Boost Select setting Check for blocked or dirty heat sink fins Verify that ambient temperature has not exceeded 45 C 113 F for IP 30 NEMA 1 UL Type 1 installations or 50 C 122 F for IP20 Open type install
120. es the PID Reference The value sent over the network is scaled so that P035 Maximum Freq x 10 100 reference For example with Maximum Freq 60 Hz a value of 600 sent over the network would represent 100 reference A153 PID Feedback Sel is used to select the source of the PID feedback Table D B 153 PID Feedback Sel Options Option Description 0 Analog In 1 Selects the Analog In 1 Input default setting 1 Analog In 2 Selects the Analog In 2 Input Note that the PID will not function with a bipolar analog input It will ignore any negative voltages and treat them like a zero 2 Comm Port The reference word from a communication network see Appendix E for details on the reference word such as Modbus RTU or DeviceNet becomes the PID Feedback The value sent over the network is scaled so that P035 Maximum Freq x 10 100 Feedback For example with Maximum Freq 60 Hz a value of 600 sent over the network would represent 100 Feedback Application Notes Analog PID Reference Signals Parameters T070 Analog In 1 Lo T071 Analog In 1 Hi T074 Analog In 2 Lo and T075 Analog In 2 Hi are used to scale or invert an analog PID Reference Examples Scale Function For a 0 5 volt signal the following parameter settings are used so that a 0 volt signal 2 0 PID Reference and a 5 volt signal 100 PID Reference e 17069 Analog In 1 Sel or T073 Analog In 2 Sel 2 Vol
121. etermines the operation of the programmable opto output Options 0 Ready Fault Opto output is active when power is applied This indicates that the drive is ready for operation Opto output is inactive when power is removed or a fault occurs 1 At Frequency Drive reaches commanded frequency Default 2 MotorRunning Motor is receiving power from the drive 3 Hand Active Active when drive is in local control 4 Motor Overld Motor overload condition exists 5 Ramp Reg Ramp regulator is modifying the programmed accel decel times to avoid an overcurrent or overvoltage fault from occurring 6 Above Freq e Drive exceeds the frequency Hz value set in T066 Opto Out Level e Use 066 to set threshold 7 Above Cur e Drive exceeds the current Amps value set in T066 Opto Out Level e Use 066 to set threshold Important Value for T066 Opto Out Level must be entered in percent of drive rated output current 8 Above DCVolt e Drive exceeds the DC bus voltage value set in T066 Opto Out Level e Use T066 to set threshold 9 Above Anlg 2 e Analog input voltage I O Terminal 17 exceeds the value set in T066 Opto Out Level e Do not use if T073 Analog In 2 Sel is set to 3 Voltage Mode Bipolar e This parameter setting can also be used to indicate a PTC trip point when the input I O Terminal 17 is wired to a PTC and external resistor e Use 066 to
122. etwork using Modbus protocol in RTU mode ger 5er Controller For information regarding DeviceNet or other communication protocols refer to the appropriate user manual Network Wiring Network wiring consists of a shielded 2 conductor cable that is daisy chained from node to node Figure E 1 Network Wiring Diagram PowerFlex 400 PowerFlex 400 PowerFlex 400 Node 1 Node 2 Node n Master FRONT 24 RED 0 4 070 4 120 ohm resistor 120 ohm resistor TxRxD TxRxD TxRxD 5 5 oh Shield Shield Shield PIN 8 NOTE The shield should be grounded at ONLY ONE location Only pins 4 and 5 on the RJ45 plug should be wired The other pins on the PowerFlex 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 controller used and TxRxD and TxRxD are shown for illustration purposes only Refer to the master controller s user manual for network terminations Note that there is no standard for the and wires and consequently Modbus device manufacturers interpret them differently If you have problems with initially establishing communications try swapping the two network wire
123. f P033 Motor OL Curent of P033 Motor OL Curent 3 42 Programming and Parameters Advance Program Group continued A182 Drive OL Mode Related Parameter s P032 P033 Determines how the drive handles overload conditions that would otherwise cause the drive to fault Options 0 Disabled 1 Reduce CLim 2 Reduce PWM 3 Both PWM 15 Default A183 SW Current Trip Related Parameter s P033 Enables disables a software instantaneous within 100 ms current trip Values Default 0 0 Disabled Min Max 0 0 Drive Rated Amps x 1 8 Display 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 Disabled Min Max 0 0 Drive Rated Amps Display 0 1 Amps A185 Load Loss Time Related Parameter s P033 Sets the required time for the current to be below Load Loss Level before a Load Loss fault occurs Values Default 0 Secs Disabled Min Max 0 9999 Secs Display 1 Secs A186 Stall Fault Time Sets the time that the drive will remain in stall mode before a fault is issued Options 0 60 Seconds Default 1 120 Seconds 240 Seconds 360 Seconds 480 Seconds N Fit Disabled Programming and Parameters 3 43 Advance Program Group continued A187 Bu
124. fault code descriptions Values Default Read Only Min Max 0 122 Display 1 3 54 Programming and Parameters Advance Display Group continued d308 Fault 2 Code Related Parameter s A197 A code that represents the second most recent drive fault The codes will appear in these parameters in the order they occur 2007 Fault 1 Code the most recent fault Repetitive faults will only be recorded once As faults occur this parameter will be overwritten by Fault 1 Code The value of this parameter is then moved to Fault 3 Code Refer to Chapter 4 for fault code descriptions Values Default Read Only Min Max 0 122 Display 1 d309 Fault 3 Code Related Parameter s A197 A code that represents the second most recent drive fault The codes will appear in these parameters in the order they occur 2007 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 to Chapter 4 for fault code descriptions Values Default Read Only Min Max 0 122 Display 1 d310 Fault 1 Time hr Related Parameter s A195 d316 Displays the value of the d316 Elapsed Time hr parameter when the fault occurred Values Default Read Only Min Max 0 9999 Hr Display 1Hr d311 Fault 1 Time min Related Parameter s A195 4317 Displays the value of the d317 Elapsed Time min parameter whe
125. fuses or an input circuit breaker National and local industrial safety regulations and or electrical codes may determine additional requirements for these installations Fusing The ratings in the table that follows are the recommended values for use with each drive rating The devices listed in this table are provided to serve as a guide Bulletin 140M Self Protected Combination Controller UL489 Circuit Breakers When using Bulletin 140M or ULA89 rated circuit breakers the guidelines listed below must be followed in order to meet the NEC requirements for branch circuit protection Bulletin 140M can be used in single and group motor applications e Bulletin 140M can be used up stream from the drive without the need for fuses 1 10 Installation Wi ring Table 1 B Recommended Branch Circuit Protective Devices Voltage Drive Rating Fuse Rating 140M Motor Recommended Rating kW HP Amps Protectors MCS Contactors Catalog No Catalog No 200 240V AC 2 2 3 0 20 140M D8E C16 100 C23 3 Phase 31154 30 140M F8E C25 100 37 5 5 7 5 35 140M F8E C32 100 37 7 5 10 45 140M F8E C45 100 C45 11 15 70 140 CMN 6300 100 60 15 20 90 140 CMN 9000 100 C85 18 5 25 100 140 CMN 9000 100 D95 22 30 125 100 0110 30 40 175 100 0180 37 50 200 100 0180 380 480 2 2 3 0 10 140M D8E C10 100 09 SPhase 4054 20 140M D8E C16 100 16
126. i Check Results d306 Analog In 2 DIP Switch 10V Parameters P038 Speed Reference 2 Analog In1 T069 Analog In 1 Sel 2 0 10V Scaling 070 Analog In 1 Lo T071 Analog In 1 Hi Check Results d305 Analog In 1 DIP Switch 20MA Parameters P038 Speed Reference 2 Analog In1 069 Analog In 1 Sel 1 4 20 mA Scaling 070 Analog In 1 Lo T071 Analog In 1 Hi Check Results d305 Analog In 1 DIP Switch AO1 10V Parameters 1082 Analog Sel 0 through 6 Scaling T083 Analog Outt High 1084 Analog Out1 Setpt Input Output Analog Output Unipolar 4 20 mA Output 525 Ohm Maximum 2 Wire Control Sourcing SRC Internal Supply Non Reversing Input must be active for the drive to run When input is opened the drive will stop as specified by P037 Stop Mode Drive will not run if I O Terminal 01 is open Drive will coast to stop if opened while running 2 Wire Control Sourcing SRC External Supply Non Reversing Input must be active 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 1 0 Terminal 01 is open Drive will coast to stop if opened while running 2 Wire Control Sinking SNK Internal Supply Non Reversing Input must be active for the drive to run When input is opened
127. ion Important statement regarding differences in parameter defaults for 3 11 packaged drives added to parameter P041 Reset To Defalts Important statement regarding related parameter added to parameter 3 37 A167 Flying Start En New Parameter The following new parameter has been added with the release of Firmware Release Number FRN 4 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 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 1 28 First Environment Unrestricted Important statement regarding differences in parameter defaults for 9 11 packaged drives added to parameter P041 Reset To Defalts Fault F64 Drive Overload description corrected 4 4 Overcurrent protection for hardware limit and instantaneous fault levels 3 corrected 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 specifi
128. ion that caused the fault is no longer present the fault will be reset and the drive will be restarted 2 Non Resetable This type of fault may require drive or motor repair or is caused by wiring or programing errors The cause of the fault must be corrected before the fault can be cleared 4 2 Troubleshooting Fault Indication e Flashing fault number PROGRAM FAULT Drive is indicating a fault The integral keypad provides Flashing fault indicator e 38 Press the Escape key to regain Esc aL C V control of the integral keypad visual notification of a fault Manually Clearing Faults condition by displaying the following 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 0007 Fault 1 Code to view the most recent fault information 2 Address the condition that caused the fault The cause must be corrected before the fault can be cleared See Table 4 A 3 After corrective action has been taken clear the fault by one of these methods e Press Stop if P037 Stop Mode is set to a value between 0 and 3 e Cycle drive power Set A197 Fault Clear to 1 or 2 e Cycle digital input if 1051 1054 Digital Inx Sel is set to option 10 Clear Fault Automatically Clearing Faults Clear a Type 1 fault and restart the drive 1 Set A163
129. ion False Start FWD In W O Terminal 02 Dir REV In VO Terminal 03 Stop Input l O Terminal 01 Digital In 1 Terminal 05 Digital In 2 W O Terminal 06 Digital In 3 l O Terminal 07 Digital In 4 W O Terminal 08 Not Used Values Default Read Only 0 1 Display 1 Programming and Parameters 3 53 Advance Display Group continued d303 Comm Status Related Parameter s C102 C103 Status of the communications ports 1 Condition True 0 Condition False Received Good Message Packet Digit 0 Transmitting Message Digit 1 DSI Peripheral Connected Digit 2 Received Bad Message Packet Digit 3 Values Default Read Only Min Max 0 1111 Display 1 d304 PID Setpnt Displ Related Parameter s C102 C103 Displays the active PID Setpoint value Values Default 0 0 0 0 100 0 Display 0 196 d305 Analog In 1 Related Parameter s C102 C103 Displays the status of Analog Input 1 Values Default 0 0 0 0 120 0 Display 0 196 d306 Analog In 2 Related Parameter s C102 C103 Displays the status of Analog Input 2 Values Default 0 0 0 0 120 0 Display 0 196 d307 Fault 1 Code Related Parameter s A197 A code that represents a drive fault The codes will appear in these parameters in the order they occur 0007 Fault 1 Code the most recent fault Repetitive faults will only be recorded once Refer to Chapter 4 for
130. isables this parameter Values Default 0 0 Hz Min Max 0 0 30 0 Hz Display 0 1 Hz Frequency Command Frequency Drive Output Frequency Skip Frequency P I Skip Frequency Band Time 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 Min Max 0 320 Hz Display 1 Hz A193 Skip Freq Band 3 Related Parameter s A192 Determines the bandwidth around A192 Skip Frequency 3 A193 Skip Freq Band 3 is split applying 1 2 above and 1 2 below the actual skip frequency A setting of 0 0 disables this parameter Values Default 0 0 Hz Min Max 0 0 30 0 Hz Display 0 1 Hz Frequency Command Frequency Drive Output aFrequency Skip Frequency P Time Programming and Parameters 3 45 Advance Program Group continued A194 Compensation Enables disables correction options that may improve problems with motor instability Options 0 Disabled 1 Electrical Default 7 Some drive motor combinations have inherent instabilities which are exhibited as non sinusodial motor currents This setting attempts to correct this condition 2 Mechanical Some motor load combinations have mechanical resonances which can be excited by the drive current regulator This setting slows down the current regulator response and attempts to correct this c
131. ith side openings less than 12 5 mm 0 5 in and top openings less than 1 0 mm 0 04 in to maintain compliance with the LV Directive 1 28 Installation Wiring Essential Requirements for CE Compliance Conditions 1 4 listed below must be satisfied for PowerFlex drives to meet the requirements of EN61800 3 1 Grounding as described in Figure 1 11 Refer to page 1 9 for additional grounding recommendations 2 Output power control I O and signal wiring must be braided shielded cable with a coverage of 75 or better metal conduit or equivalent attenuation 3 Allshielded cables should terminate with the proper shield connector 4 Conditions in Table 1 7 Table 1 PowerFlex 400 EN61800 3 Compliance First Environment Unrestricted Required Filter Restrict Install Motor Drive and Cable to Filter in Meters Shielded PowerFlex 400 Drive First Environment Restricted kW HP Cat No RequiredFilter Restrict Install 22C Allen Bradley Motor Drive and Cable to Filter in Meters Shielded Enclosure Enclosure 200 240 Volts 2 2 3 0 012 103 22 RF034 CS 10 22 RF034 CS 1 Required 3 7 5 0 017 103 22 RF034 CS 10 No 22 RF034 CS 1 Required 5 5 7 5 B024N103 22 RF034 CS 10 No 22 RF034 CS 1 Required 7 5 10 033 103 22 RF034 CS 10 No 22 RF034 CS 1 Required 11 15 B049A103 22 RFDO70 150 Required MIF Series 50 Required 15 20 065 103 22 RFD100 150 Re
132. k has faulted RS485 DSI port stopped communicating P036 Start Source is set to setting 6 The input to terminal 01 has been opened The checksum read from the board does not match the manually clear Check the wiring between the drive and motor 2 Check motor for grounded phase 3 Replace drive if fault cannot be cleared Checkthe motor and drive output terminal wiring for a shorted condition 2 Replace drive if fault cannot be cleared 1 Clear the fault or cycle power to the drive 2 Program the drive parameters as needed Check load requirements and A183 SW Current Trip setting Reduce load or extend Accel Time Cycle power 2 Replace drive if fault cannot be cleared Cycle power Check communications cabling Check network adapter setting Check external network status Check RS485 wiring connection Check if a communications adapter or HIM was disconnected 3 Increase C106 Comm Loss Time to an appropriate time for application 4 Change C105 Comm Loss Action to a value other than 0 fault if appropriate for the application Close input to terminal 01 and re start the drive RO Set P041 Reset To Defalts to option 1 Reset Defaults checksum calculated Troubleshooting 4 5 No E CNN Action F122 I O Board Fail Failure has been detected in the 1 Cycle power drive control and 1 0 sectio
133. l 03 Run REV 3 2 W Lvl Sens O Terminal Block controls drive operation Default e O Terminal 01 Stop Coast to Stop e Terminal 02 Run FWD See Attention IO Terminal 03 Run REV Below Drive will restart after a Stop command when e Stop is removed and Run FWD is held active 4 2 W Hi Speed I O Terminal Block controls drive operation 1 0 Terminal 01 Stop Coast to Stop e Terminal 02 Run FWD e 1 0 Terminal 03 Run REV Outputs are kept in a ready to run state The drive will respond to a Start command within 10 ms Important There is greater potential voltage on the output terminals when using this option 5 Comm Port Remote communications controls drive operation 1 0 Terminal 01 Stop Coast to Stop 1 0 Terminal 02 Not Used Terminal 03 Not Used 6 2 W Lvl Enbl l O Terminal Block controls drive operation e Terminal 01 Function Loss Fault and Coast to Stop See Attention e I O Terminal 02 Run FWD Below Terminal 03 SW Enable Drive will restart after a Stop command when Stop is removed and Run FWD is held active ATTENTION Hazard of injury exists due to unintended operation When P036 Start Source is set to option 3 or option 6 and the Run input is maintained the Run inputs do not need to be toggled after a Stop input or a fault clear for the drive to run again The drive will stop only when the stop co
134. l speed of drive Default is active Increment and Control is activated by parameter P038 Speed Reference or Decrement Arrows P042 Auto Mode parameter P042 Auto Mode Control is activated by parameter P036 Start Source or HAND P042 Auto Mode Auto 0 Used to select Auto control mode Controlled by parameter P042 Auto Mode AUTO Stop Off Used to stop the drive or clear a fault This key is always active Controlled by parameter P037 Stop Mode OFF Important Certain digital input settings can override drive operation Refer to Start and Speed Reference Control on page 1 24 for details 2 4 Start Up LED Status Indicators LED LED State Description Program Status Steady Red Indicates parameter value can be changed Selected digit will flash Fault Status WE Flashing Red Indicates that the drive is faulted e Speed Status Steady Green Indicates that the digital speed control keys are e C3 enabled Hand Status Steady Green Indicates that the Run Start key is enabled Auto Status Steady Yellow Indicates that the drive is in Auto mode Description I Parameter Name Run Stop Status g Ts Stopped Running flashes to indicate that the drive is stopping but is still decelerating flashes when DC Injection is commanded Direction Indication The Direction Arrow g indicates the commanded direction of rotation If the Arrow
135. le Disables PID function Drive uses the next valid non PID speed reference 6 PID Hold Drive output remains at current value The integrator for Process PID loop is also clamped at current value 7 PID Reset The integrator for the Process PID loop is reset to zero and drive output is set to Preload value 8 Preset Freq Preset speed inputs that enable the use of preset speeds 9 Aux Fault If input is enable but not active the drive will immediately fault 10 Clear Fault T053 Default Clears an active fault 11 RampStop CF The drive immediately ramps to stop Can also be used to clear a fault 12 CoastStop CF The drive immediately coasts to stop Can also be used to clear a fault 13 DCInjStop CF The drive immediately begins a DC Injection stop Can also be used to clear a fault T051 14 Anlgt InCtr 0 054 Programming and Parameters 3 13 Selects Analog Input 1 control for the frequency reference Options 15 Anig2 Inctr Cont Selects Analog Input 2 control for the frequency reference 16 Up Increases the value of 142 Internal Freq at the current Accel rate if P038 Speed Reference is set to 1 InternalFreq Default for A142 is 60 Hz 17 MOP Down Decreases the value of A142 Internal Freq at the current Decel rate if P038 Speed Reference is set to 1 InternalFreq Default for A142 is 60 Hz 18 Acc amp Dec 2 0 e Whe
136. lect A181 Advanced Program 3 41 Relay Out8 Sel R236 Relay Card 3 47 Opto Out Level T066 Terminal Block 3 19 Reset Meters A195 Advanced Program 3 45 Opto Out Logic T068 Terminal Block 3 19 Reset To Defalts P041 Basic Program 3 11 Opto Out Sel T065 Terminal Block 3 18 Reverse Disable A166 Advanced Program 3 37 Output Current b003 Basic Display 34 S Curve A149 Advanced Program 3 33 Output Freq b001 Basic Display 3 4 Skip Freq Band 1 A189 Advanced Program 3 43 Output Power b010 Basic Display 3 5 Skip Freq Band2 A191 Advanced Program 3 44 Output Powr Fetr 0318 Advanced Display 3 55 Skip Freq Band 3 193 Advanced Program 3 44 Output RPM d323 Advanced Display 3 56 Skip Frequency 1 A188 Advanced Program 3 43 Output Speed d322 Advanced Display 3 56 Skip Frequency 2 A190 Advanced Program 3 43 Output Voltage b004 Basic Display 3 4 Skip Frequency 3 A192 Advanced Program 3 44 PID Deadband A158 Advanced Program 3 35 Sleep Level T078 Terminal Block 3 23 PID Diff Rate A156 Advanced Program 3 15 Sleep Time T079 Terminal Block 3 23 PID Feedback Sel A153 Advanced Program 3 34 Sleep Wake Sel 7077 Terminal Block 323 PID Integ Time A155 Advanced Program 3 34 Slip Hertz FLA A175 Advanced Program 3 40 PID Preload A159 Advanced Program 3 35 Speed Ref 2 C109 Communications 3 30 PID Prop Gain A154 Advanced Program 3 34 Speed Reference P038 Basic Program 3 10 Ref Sel A152 Advanced Progra
137. lerance 200 240V 10 380 480V 10 Frequency Tolerance 48 63 Hz Input Phases Three phase input provides full rating Single phase operation provides 50 rated current Displacement Power Factor 0 98 across entire speed range Efficiency 97 5 at rated amps nominal line voltage Maximum Short Circuit Rating 100 000 Amps Symmetrical Frame C Drives 200 000 Amps Symmetrical Frame D E F Drives Actual Short Circuit Rating Determined by AIC Rating of installed fuse circuit breaker Transistor Type Isolated Gate Bipolar IGBT Internal DC Bus Choke 200 240V AC Input 11 37 kW 15 50 HP Panel Mount Drives 380 480V AC Input 11 110 kW 15 150 HP Panel Mount Drives Control Method Sinusoidal PWM Volts Hertz Carrier Frequency Frames C and D Frames E and F 2 10 kHz Drive rating based on 4 kHz 2 8 kHz Drive rating based on 4 kHz Frequency Accuracy Digital Input Within 0 05 of set output frequency Analog Input Within 0 5 of maximum output frequency 10 Bit resolution Analog Output 2 of full scale 10 Bit resolution Speed Regulation Open Loop with Slip 1 of base speed across a 60 1 speed range Compensation Output Frequency 0 320 Hz programmable Stop Modes Multiple programmable stop modes including Ramp Coast DC Brake Ramp to Hold and S Curve Accel Decel Two independently programmable accel and decel times Each time may be programmed from 0 600 seconds in 0 1 second incr
138. lt 0 0 Hz A144 Default 5 0 Hz A145 Default 10 0 Hz A146 Default 20 0 Hz Min Max 0 0 320 0 Hz Display 0 1 Hz Provides a fixed frequency command value when T051 1052 Digital Inx Sel is set to 8 Preset Freq An active preset input will override speed command as shown in the flowchart on page page 1 24 1 To activate A143 Preset Freq 0 set P038 Speed Reference to option 4 Preset Freq Input State Input State of Digital In 1 of Digital In 2 I O Terminal 05 I O Terminal 06 when 051 8 when T052 8 Frequency Source Accel Decel Parameter Used 0 0 A143 Preset Freq 0 Accel Time 1 Decel Time 1 1 0 A144 Preset Freq 1 Accel Time 1 Decel Time 1 0 1 A145 Preset Freq 2 Accel Time 2 Decel Time 2 1 1 A146 Preset Freq 3 Accel Time 2 Decel Time 2 0 When a Digital Input is set to Accel 2 amp Decel 2 and the input is active that input overrides the settings in this table 3 32 Programming and Parameters Advanced Program Group continued A147 Accel Time 2 Related Parameter s P039 T051 T054 A143 A146 When active sets the rate of acceleration for all speed increases Refer to the flowchart on page 1 25 for details Maximum Freq Accel Time goes n Values Default 30 00 Secs Min Max 0 00 600 00 Secs Display 0 01 Secs P035 Maximum Freq Speed Time 039 or A147 la P040 or A148 0 Ac
139. ly Closed NC of the opto output T068 Option Opto Out Logic 0 NO Normally Open 1 NC Normally Closed Note 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 T069 Analog In 1 Sel Related Parameter s 1055 T070 071 T072 Sets the analog input signal mode 0 20mA 4 20mA or 0 10V This parameter must match DIP Switch Al1 setting on the control board T069 Option Setting Input Range DIP Switch Al1 Setting 0 Current Mode 0 20 mA 20 mA 1 Current Mode 4 20 mA 20 mA 2 Voltage Mode Unipolar 0 10V 10V 4 Current Mode Square Root 0 20 mA 20 mA 5 Current Mode Square Root 4 20 mA 20 mA 6 Voltage Mode Unipolar Square Root 0 10V 10V Values Default 2 Min Max 0 6 Display 1 3 20 Programming and Parameters Terminal Block Group continued T070 Analog In 1 Lo Related Parameter s P034 P038 T069 T071 T072 A152 A153 Stop drive before changing this parameter Sets the analog input level that corresponds to P034 Minimum Freq Analog inversion can be accomplished by setting this value larger than T071 Analog In 1 Hil Important If analog inversion is implemented the drive will go to maximum frequency 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
140. m 3 34 Stall Fault Time A186 Advanced Program 3 42 PID Setpnt Disp d304 Advanced Display 3 53 Start At PowerUp 165 Advanced Program 3 36 PID Setpoint A157 Advanced Program 3 35 Start Boost A171 Advanced Program 3 39 PID Trim Hi A150 Advanced Program 3 33 Start Source P036 Basic Program 3 8 Trim Lo A151 Advanced Program 3 33 Start Source 2 C108 Communications 3 29 Preset Freq 0 A143 Advanced Program 3 31 Status Fault d327 Advanced Display 3 57 Preset Freq 1 A144 Advanced Program 3 31 Stop Mode P037 Basic Program 39 Preset Freq 2 145 Advanced Program 3 31 SW Current Trip A183 Advanced Program 3 42 Preset Freq 3 A146 Advanced Program 3 31 Testpoint Data d319 Advanced Display 3 56 Process Display 1008 Basic Display 3 5 Testpoint Sel A196 Advanced Program 3 45 Process Factor A160 Advanced Program 3 35 Torque Current b013 Basic Display 3 6 Program Lock A198 Advanced Program 3 46 Wake Level 7080 Terminal Block 323 Purge Frequency A141 Advanced Program 3 31 Wake Time T081 Terminal Block 3 23 PWM Frequency A168 Advanced Program 3 37 PWM Mode A169 Advanced Program 3 37 Relay 1 Off Time 059 Terminal Block 3 15 Relay 1 On Time T058 Terminal Block 3 15 Relay 2 Off Time T064 Terminal Block 3 17 Relay 2 On Time 063 Terminal Block 3 17 Relay Out Level T056 Terminal Block 3 15 Relay Out Se 055 Terminal Block 3 14 Relay Out2 Level T061 Terminal Block 3
141. m 173 Ib in 30 37 kW 40 50 HP 480V 55 75 kW 75 100 HP F 152 5 mm 300 85 0 mm 3 0 AWG 19 5 N m 173 Ib in 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 Wiring Recommendations Motor Start Stop Precautions ATTENTION 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 damage The drive is designed to use control input signals that will start and stop the motor If used the input device must not exceed one operation per minute or drive damage can occur ATTENTION drive start stop control circuitry includes solid state components If hazards due to accidental contact with moving machinery or unintentional flow of liquid gas or solids exist an additional hardwired stop circuit may be required to remove the AC line to the drive When the AC line is removed there will be a loss of any inherent regenerative braking effect that might be present the motor will coast to a stop An auxiliary braking method may be required 1 16 Installation Wiring Important points to remember about I O wiring e Always use copper wire e Wire with an insulation rating of 600V or greater is recommended e Control and signal wires should be separated from power wires by at least 0 3 meters 1
142. mit 1 A179 Advanced Program 3 41 Analog In 1 Loss T072 Terminal Block 3 21 Current Limit 2 A180 Advanced Program 3 41 Analog In 1 Sel T069 Terminal Block 3 19 DC Brake Level A177 Advanced Program 3 40 Analog In 2 d306 Advanced Display 3 53 DC Brake Time A176 Advanced Program 3 40 Analog In 2 Hi T075 Terminal Block 3 22 DC Bus Voltage 6005 Basic Display 3 4 Analog In 2 Lo T074 Terminal Block 3 22 DC Brk Time Strt A178 Advanced Program 3 41 Analog 2 Loss T076 Terminal Block 3 22 Decel Time 1 P040 Basic Program 3 11 Analog In 2 Sel T073 Terminal Block 3 21 Decel Time 2 A148 Advanced Program 3 32 Analog Out High T083 Terminal Block 3 24 Digital In1 Sel T051 Terminal Block 3 12 Analog Out Sel T082 Terminal Block 3 24 Digital In2 Sel T052 Terminal Block 3 12 Analog Out2 High T086 Terminal Block 3 26 Digital In3 Sel T053 Terminal Block 3 12 Analog Out2 Sel 085 Terminal Block 3 25 Digital In4 Sel 054 Terminal Block 3 12 Anlg Loss Delay T088 Terminal Block 3 26 Drive OL Mode A182 Advanced Program 3 42 Anlg Outi Setpt T084 Terminal Block 3 25 Drive Status b006 Basic Display 3 5 Anlg Out2 7087 Terminal Block 3 26 Drive Temp b014 Basic Display 3 6 Auto Mode P042 Basic Program 3 11 Drive Type d321 Advanced Display 3 56 Auto Rstrt Delay 164 Advanced Program 3 36 Elapsed MWh b011 Basic Display 3 6 Auto Rstrt Ties 163 Advanced Program 3 36 Elapsed Run Time 012 Basic Display 3 6 Aux 1 Ref Add R2
143. mmand is maintained or the drive is faulted 3 30 Programming and Parameters Communications Group continued C109 Speed Ref 2 Related Parameter s 0001 6002 P038 P040 P042 051 054 1070 T071 073 T074 T075 C102 A141 A142 A143 A146 A152 d301 Sets the source of the speed reference to the drive when in Comm Control and the communication network commands the drive to run from Local Control Refer to the flowchart on page 1 24 for more information on speed reference control priority Options 0 Drive Keypad Internal frequency command from the digital speed keys on the integral keypad 1 InternalFreq Internal frequency command from 4142 Internal Freq Must be set when using MOP function 2 Analog In 1 Default External frequency command from an analog source as determined by 1069 Analog In 1 Sel and DIP Switch on the control board Default Dip Switch setting is 10V 3 Analog In 2 External frequency command from an analog source as determined by 1073 Analog In 2 Sel and DIP Switch AI2 on the control board Default Dip Switch setting is 10V 4 Preset Freq External frequency command as defined by A143 146 Preset Freq x when T051 1054 Digital Inx Sel are programmed as Preset Frequencies and the digital inputs are active 5 Comm Port External frequency command from the communications port Refer to Appendix D and Appendix E for details Paramet
144. motor poles This is used to calculate 4323 Output RPM Values Default 4 Min Max 2 40 Display 1 A200 Motor NP FLA Related Parameter s 167 Set to the motor nameplate rated full load amps Values Default Drive Rated Amps Min Max 0 1 Drive Rated Amps x 2 Display 0 1 Amps Programming and Parameters 3 47 Aux Relay Card Group R221 Relay Out3 Sel Related Parameters for the Aux Relay Card Group R224 Relay Out4 Sel Aux Parameters R227 Relay Out5 Sel PID Parameters R230 Relay Out6 Sel 4 R233 Relay Out7 Sel eee R236 Relay Out8 Sel Sets the condition that changes the state of the output relay contacts Options 0 Ready Fault Relay changes state when power is applied This indicates Default that the drive is ready for operation Relay returns drive to shelf state when power is removed or a fault occurs 1 At Frequency Drive reaches commanded frequency 2 MotorRunning Motor is receiving power from the drive 3 Hand Active Active when drive is in local control 4 Motor Overld Motor overload condition exists 5 Ramp Reg Ramp regulator is modifying the programmed accel decel times to avoid an overcurrent or overvoltage fault from occurring 6 Above Freq Drive exceeds the frequency Hz value set in Relay OutX Level e Use T056 to set threshold 7 Above e Drive exceeds the current Amps value set in Relay OutX Level e Use T056 to
145. mper shown in Figure 1 4 Figure 1 3 Phase to Ground MOV Removal Three Phase BE AC Input S L2 I aps 1 2 4 un H 1 Figure 1 4 Jumper Location Frame C Frame E amp F 0 0 0 0 0 0 0 Important Tighten screw after jumper 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 Installation Wiring 1 7 Input Power Conditioning The drive is suitable for direct connection to input power within the rated voltage of the drive see Appendix A Listed in Table 1 are certain input power conditions which may cause component damage or reduction in product life If any of the conditions exist as described in Table 1 A install one of the devices listed under the heading Corrective Action on the line side of the drive Important Only one device per branch circuit is required The device should be mounted 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 Install Line Reactor reactance e or Isolation Transformer Install Line Reactor or Isolation Transformer Line has power factor correction c
146. munication Languages English Francais Espafiol Italiano Deutsch Portugu s Nederlands Type Serial RS485 Supported Drive Serial Interface 051 Protocols Modbus Standard Metasys N2 Supported DeviceNet Protocols EtherNet IP Optional PROFIBUS DP ControlNet LonWorks P1 Floor Level Network FLN Software Windows Based Optional Pocket PC Windows Mobile 2003 6 Supplemental Drive Information PowerFlex 400 Watts Loss Rated Load Speed amp PWM Panel Mount Watts Flange Mount Watts Voltage KW HP Total External Internal Total 200 240V AC 2 2 3 0 146 119 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 p 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 5 7 5 200 161 39 200 7 5 10 267 229 39 267 11 15 329 285 44 329 15 20 435 380 55 435 18 5 25 606 22 30 738 30 40 664 37 50 1019 45 60 1245 55 75 1487 75 100 2043 90 125 2617 110 150 3601 Supplemental Drive Information A 7 Input Power Connections Figure A 1 Frame C D and E Connections
147. n 2 Replace drive if fault cannot be cleared 0 See page 4 1 for a description of fault types Common Symptoms and Corrective Actions Motor does not Start Cause s Indication Corrective Action No output voltage to the motor None Check the power circuit e Check the supply voltage e Check all fuses and disconnects Check the motor e Verify that the motor is connected properly Check the control input signals e Verify that a Start signal is present If 2 Wire control is used verify that either the Run Forward or Run Reverse signal is active but not both Verify that I O Terminal 01 is active e Verify that 036 Start Source matches your configuration e Verify that A166 Reverse Disable is not prohibiting movement Drive is Faulted Flashing red status light Clear fault e Press Stop e Cycle power Set A197 Fault Clear to option 1 Clear Faults e Cycle digital input if T051 T054 Digital Inx Sel is set to option 7 Clear Fault 4 6 Troubleshooting Drive does not Start from Start or Run Inputs wired to the terminal block Cause s Indication Corrective Action Drive is Faulted Flashing red status light Clear fault e Press Stop e Cycle power Set A197 Fault Clear to option 1 Clear Faults e Cycle digital input if T051 T054 Digital Inx Sel is set to option 7 Clear Fault Incorrect programming
148. n active A147 Accel Time 2 and 148 Decel Time 2 are used for all ramp rates e Can only be tied to one input Refer to the flowchart on page 1 25 for more information on Accel Decel selection 19 Current Lmt2 When active 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 ignoring A176 DC Brake Time while the input is applied 21 Mtr l Lock 1 Can be used as a protective motor interlock in Auxiliary 22 Mtr l Lock 2 Motor Control mode When programmed but not active SEHE T input will prevent corresponding motor from operating Refer to Appendix C for details 24 Mtr l Lock 4 25 Cmd Reverse When programmed and active the drive will run in the reverse direction when started from the integral keypad 31 Logi c In 1 Input 1 used by digital output settings 32 Logi c In 2 Input 2 used by digital output settings 36 Damper Input e When active drive is allowed to run normally e When inactive drive is forced into sleep mode and is prevented from accelerating to commanded speed 1 This function may be tied to one input only 3 14 Programming and Parameters Terminal Block Group continued T055 Relay Out1 Sel Related Parameter s P033 T056 T058 T059 T069 T072 T07
149. n the fault occurred Values Default Read Only Min Max 0 0 60 0 Min Display 0 1 Min d312 Fault 2 Time hr Related Parameter s 4195 d316 Displays the value of the d316 Elapsed Time hr parameter when the fault occurred Values Default Read Only Min Max 0 9999 Hr Display 1Hr Programming and Parameters 3 55 Advance Display Group continued d313 Fault 2 Time min Related Parameter s A195 4317 Displays the value of the d317 Elapsed Time min parameter when the fault occurred Values Default Read Only Min Max 0 0 60 0 Min Display 0 1 Min d314 Fault 3 Time hr Related Parameter s A195 4316 Displays the value of the d316 Elapsed Time hr parameter when the fault occurred Values Default Read Only Min Max 0 9999 Hr Display 1Hr d315 Fault 3 Time min Related Parameter s A195 4317 Displays the value of the d317 Elapsed Time min parameter when the fault occurred Values Default Read Only Min Max 0 0 60 0 Min Display 0 1 Min d316 Elapsed Time hr Related Parameter s 195 d310 4312 4314 Displays the total elapsed powered up time in hours since timer reset The timer stops when it reaches maximum Values Default Read Only Min Max 0 32767 Display 1Hr d317 Elapsed Time min Related Parameter s A195 4311 d313 d315 Displays the total elapsed powered up time in minutes since timer reset The timer will increment the hour parameter when a
150. nal Bezel Kit 22 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 Table B 11 Frame C IP30 NEMA 1 UL Type 1 Kit 22 HIM H10 22 HIM H30 Drive Item Description Frame Catalog Number IP30 NEMA 1 UL Type 1 Field installed kit Converts drive to IP30 C 22 JBAC Kit NEMA 1 UL Type 1 enclosure Includes conduit box with mounting screws and plastic top panel IP30 NEMA 1 UL Type 1 Field installed kit Converts drive to IP30 C 22 JBCC Kit for Communication NEMA 1 UL Type 1 enclosure Includes Option communication option conduit box with mounting screws and plastic top panel Table B 12 Field Installed Option Item Auxiliary Relay Board Field installed kit Expands drive output capabilities Catalog Number AK U9 RLB1 Accessories and Dimensions B 7 Product Dimensions Table B 13 PowerFlex 400 Frames and Weights Drive Weight Packaged Weight Frame kW HP kg Ibs kg Ibs 240V AC 3 Phase C 2 2 3 0 2 89 6 4 3 41 7 5 C 4 0 5 0 2 97 6 5 3 49 7 7 C 5 5 7 5 3 72 8 2 4 27 9 4 C 7 5 10 3 78 8 3 4 33 9 5 D 11 15 12 1 26 7 13 4 29 5 D 15 20 12 7 28 0 14 30 9 D 18 5 25 12 7 28 0 14 30 9 D 22
151. ne During an AutoS wap the motor directly connected to the PowerFlex 400 drive is stopped and the contactor is opened The contactor of the next motor that will be controlled by the PowerFlex 400 drive is opened if running across the AC line A contactor is closed connecting this motor directly to the PowerFlex 400 drive and is started An additional motor is line started if required D 12 Application Notes Example 1 One External Motor without AutoSwap Three Phase Power PowerFlex 400 PID Reference Feedback 2 Drive Relays Auxiliary Relay Card MaL e Auxiliary Motor Control is enabled via Parameter R239 Aux Motor Mode e Number of auxiliary motors is set via Parameter R240 Aux Motor Qty Relays are configured for Auxiliary Motor Control via parameters T055 060 R222 and R225 The frequency of Motor 1 that Motor 2 turns on at is set via Parameter R241 Aux 1 Start Freq e time that Motor 1 is above the value set by R241 Aux 1 Start Freq before turning on Motor 2 is set via Parameter R250 Aux Start Delay The frequency of Motor 1 that Motor 2 turns off at is set via Parameter R242 Aux 1 Stop Freq e 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 e PID setup is d
152. nfigurable outputs are programmed to write parameter data to Non Volatile Storage NVS frequently the NVS will quickly exceed its life cycle and cause the drive to malfunction Do not create a program that frequently uses configurable outputs to write parameter data to NVS Programming and Parameters 3 29 Communications Group continued C108 Start Source 2 Related Parameter s P037 P042 166 4301 Stop drive before changing this parameter Sets the control scheme used to start the drive when in Comm Control and the communication network commands the drive to run from Local Control This function is normally used by Point 79 of a P1 FLN Refer to Start and Speed Reference Control on page 1 24 for details about how other drive settings can override the setting of this parameter Important For all settings except options 3 and 6 the drive must receive a leading edge from the start input for the drive to start after a stop input loss of power or fault condition Options 0 Keypad Integral keypad controls drive operation e Terminal 01 Stop Coast to Stop e 1 0 Terminal 02 Not Used 1 0 Terminal 03 Not Used 1 3 Wire O Terminal Block controls drive operation e O Terminal 01 Stop Per P037 Stop Mode e 1 0 Terminal 02 Start Terminal 03 Direction 2 2 O Terminal Block controls drive operation e O Terminal 01 Stop Coast to Stop e Terminal 02 Run FWD e 1 0 Termina
153. nother common such as earth ground or separate apparatus ground only one point of the daisy chain of I O Terminal 04 should be connected ATTENTION 1 0 Common terminals should not be tied together when using SNK Internal Supply mode In SNK mode if power is removed from one drive inadvertent operation of other drives that share the same I O Common connection may occur Multiple Analog 000000000 000000000 000000000 Connections 4 T 020000000 00 00000 Remote Potentiometer 7 7 7 Optional Ground Connection When connecting a single potentiometer to multiple drives it is important to connect I O Terminal 14 common together for all drives I O Terminal 14 common and I O Terminal 13 potentiometer wiper should be daisy chained to each drive All drives must be powered up for the analog signal to be read correctly 1 24 Installation Wiring Start and Speed Reference Control The drive speed command can be obtained from a number of different sources The source is normally determined by P038 Speed Reference The drive Start command is normally determined by P036 Start Source However the settings for these parameters can be overridden by a variety of methods See the chart below for the override priority Drive will Start and Run as Purge Input L Yes specified by A141 Purge Frequency Enabled and Active Digital Inx Sel 1 Direction is always Forward
154. ntry state or local codes may require different ratings Fusing If fuses are chosen as the desired protection method refer to the recommended types listed below If available amp ratings do not match the tables provided the closest fuse rating that exceeds the drive rating should be chosen e IEC BS88 British Standard Parts 1 amp 2 EN60269 1 Parts 1 amp 2 type gG or equivalent should be used e UL UL Class CC T or J must be used 2 Circuit Breakers Refer to listings in the following tables for recommended circuit breakers inverse time or instantaneous trip and 140M Self Protecting Motor Starters 1 Typical designations include but may not be limited to the following Parts 1 amp 2 AC AD BC BD CD DD ED EFS EF FF FG GF GG GH Typical designations include CC KTK R FNQ R Type J JKS LPJ Type T JJS JJN 2 Supplemental Drive Information Specifications Drive Ratings Output Ratings Input Ratings Branch Circuit Protection Catalog Number Amps Voltage 140M Motor kW HP 45 50 Range kVA Amps Fuses Protectors Contactors 200 240V AC 3 Phase Input 0 230V 3 Phase Output 22C B012N103 2 2 3 0 12 12 180 265 6 5 155 20 140M F8E C16 100 23 22C B017N103 3 7 5 0 17 5 17 1180 265 8 8 21 30 140M F8E C25 100 37 22 024 103 5 5 7 5 24 24 180 265 109 261 35 140M F8E C32 100 C37 22 033 103 7 5 10 33 33 180 265 144 346 45 140
155. o some value below the point where the 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 Ifthe response is too slow see Figure D 2 or the PID Feedback does not become equal to the PID Reference decrease A155 PID Integ Time is a lot of oscillation in the PID Feedback before settling out see Figure D 3 increase A155 PID Integ Time 3 Atthis point the differential gain may not be needed However if after determining the values for A154 PID Prop Gain and A155 PID Integ Time Response is still slow after a step change increase A156 PID Diff Rate Response is still unstable decrease A156 PID Diff Rate D 10 Application Notes The following figures show some typical responses of the PID loop at different points during adjustment of the PID Gains Figure D 1 Unstable PID Reference PID Feedback Time Figure D 2 Slow Response Over Damped PID Reference PID Feedback Time Figure D 3 Oscillation Under Damped PID Reference PID Feedback Time Figure D 4 Good Response Critically Damped PID Reference PID Feedback Time Application Notes D 11 Auxiliary Motor Control Setup The PowerFlex 400 has a built in Auxiliary Motor Control feature This feature allows operation of up to three 3 line started motors in addition to the motor
156. olts per Hz curve Drive may add additional voltage unless Option 5 is selected Options 0 Custom V Hz 1 900 VT 35 0 40 0 45 0 VT Default Typical Fan Pump Curves 0 0 no IR 0 0 2 5 5 0 7 5 10 0 Boost Curves 11 12 5 12 15 0 13 17 5 14 20 0 15 Kepco Curve o0 C hn 174 Maximum Voltage can be set anywhere Settings greater than P031 Motor NP Volts define a point on the V Hz curve Settings less than P031 Motor NP Volts function as limits only and do not change the V Hz curve Setting Boost Voltage of Base 0 0 no IR Comp added 5 i ee 6 0 0 7 25 8 5 0 9 1 5 T 10 10 0 5 11 12 5 12 15 0 1213 17 5 i 44 20 0 2 4 15 Curve 1 c 5 3 3 NE Setting Fan Pump Curves EN 1 0 0 2 35 0 3 400 4 45 0 1 2 Motor NP Hertz 50 P035 Maximum Freq can be set anywhere P032 Motor NP Hertz Settings greater than P032 Motor NP Hertz define a point on the V Hz curve P035 Maximum Freq can be set anywhere Settings less than P032 Motor NP Hertz function as limits only and do not change the V Hz curve P034 Minimum Freq can be set anywhere Functions as a limit only and does not change the V Hz curve 1 Kepco Curve is used in specific systems to meet re
157. on e 1 0 Terminal 01 Stop Coast to Stop e Terminal 02 Run FWD e Terminal 03 Run REV Outputs are kept in a ready to run state The drive will respond to a Start command within 10 ms Important There is greater potential voltage on the output terminals when using this option 5 Comm Port Remote communications controls drive operation e 1 0 Terminal 01 Stop Coast to Stop Terminal 02 Not Used Terminal 03 Not Used 6 2 W Lvl Enbl l O Terminal Block controls drive operation e O Terminal 01 Function Loss Fault and Coast to Stop See Attention e 1 Terminal 02 Run FWD Below e 1 0 Terminal 03 SW Enable Drive will restart after a Stop command when e Stop is removed and Run FWD is held active ATTENTION Hazard of injury exists due to unintended operation When P036 Start Source is set to option 3 or option 6 and the Run input is maintained the Run inputs do not need to be toggled after a Stop input or a fault clear for the drive to run again The drive will stop only when the stop command is maintained or the drive is faulted Programming and Parameters 3 9 Basic Program Group continued P037 Stop Mode Related Parameter s P036 C105 A176 A177 A178 Active stop mode for all stop sources e g keypad run forward I O Terminal 02 run reverse I O Terminal 03 RS485 port except as noted below Important I O Terminal 01 is always a coast to
158. on on speed reference control priority Related Parameter s P036 P038 P039 P040 A141 A142 A143 A146 A147 A148 A166 A177 A180 d301 d302 Stop drive before changing this parameter Options 0 Not Used Terminal has no function but can be read over network communications via d302 Contrl In Status 1 Purge 7 7051 Default Starts the drive at Purge speed regardless of the selected start source Purge can occur and is operational at any time whether the drive is running or stopped If a valid stop condition is present other than from the Comm Port or SW Enable input I O Terminal 03 the drive will not start on the Purge Input Transition ATTENTION Purge command will take precedence over a stop command from the Comm Port Network and over a SW Enable command from the terminal block Insure that another stop method is available such as I O Terminal 01 of the control terminal block if stopping is necessary during a purge 2 Auto Mode 7 When active forces drive into Auto control mode Start source determined by P036 Start Source and speed reference determined by P038 Speed Reference 3 Local T052 Default When active sets integral keypad as start source and digital speed keys on the integral keypad as speed Source 4 Comm 7 When active sets communication device as default start T054 Default speed command source 5 PID Disab
159. ondition 3 Bot O 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 0310 0317 Resets the marker that indicates Fault Times and Energy usage Options 0 Ready Idle Default 1 Reset MWh Also resets kWh marker 2 Reset Time min hr and x10hr A196 Testpoint Sel Related Parameter s d319 Used by Rockwell Automation field service personnel Values Default 1024 Min Max 1024 65535 Display 1 A197 Fault Clear Related Parameter s b007 4307 d308 d309 Stop drive before changing this parameter Resets a fault and clears the fault queue Used primarily to clear a fault over network communications Options 0 Ready Idle Default 1 Reset Fault 2 Clear Buffer Clears all fault buffers 3 46 Programming and Parameters Advance Program Group continued A198 Program Lock Protects parameters against change by unauthorized personnel Enter a user selected password to lock the parameters via Option 1 Enter the same password to unlock the parameters Options 0 Unlocked Default 1 Locked Locks all parameters 2 Locked Parameter edits allowed over communications network 3 Locked Locks P035 Maximum Freq and 170 Boost Select A199 Motor NP Poles Related Parameter s 4323 Sets the
160. one via Parameters A150 through A159 See Appendix D for additional information Frequency R241 Aux 1 Start Freq R242 Aux 1 Stop Freq 251 Aux Stop Delay i R250 Aux Start Delay Time Important If using auxiliary motor control ensure that wiring and parameter configuration are correct before wiring contactor outputs All relays on the Auxiliary Relay Card will energize on power up by default Failure to verify proper wiring and parameter configuration can result in improper motor operation or drive damage Application Notes D 13 Example 2 One External Motor with AutoSwap Three Phase Power PowerFlex 400 Reference Feedback PD Drive Relays T Auxiliary Relay Card 1 Mechanically interlocked contactors are recommended to ensure that the drive contactor and the line contactor do not close at the same time If the drive and line contactor close at the same time drive damage may result Auxiliary Motor Control is enabled via Parameter R239 Aux Motor Mode Number of auxiliary motors is set via Parameter R240 Aux Motor Qty Relays are configured for Auxiliary Motor Control via parameters T055 T060 R222 R225 R228 R231 R234 and R237 The frequency of Motor 1 that Motor 2 turns on at is set via Parameter R241 Aux 1 Start Freq e time
161. onfigurations where the PID loop may be used Application Notes D 3 Exclusive Control In Exclusive Control the Speed Reference becomes 0 and the PID Output becomes the entire Freq Command Exclusive Control is used when A152 PID Ref Sel is set to option 1 2 3 or 4 This configuration does not require a master reference only a desired set point such as a flow rate for a pump PID Loop PID Ref PID Prop Gain du l rror utput I i Accel Decel Freq PID Fdbk PID Integ Time Q Ramp I gt Command Tf PID Diff Rate PID Enabled Example In a pumping application the PID Reference equals the Desired System Pressure set point The Pressure Transducer signal provides 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 to correct for the PID Error value The Desired System Pressure set point is maintained as valves in the system are opened and closed causing changes in flow When the PID Control Loop is disabled the Commanded Speed is the Ramped Speed Reference Feedback Pressure Transducer Signal dm 7 1 PID Reference Desired System Pressure D 4 Application Notes Trim Control In Trim Control the PID Output is
162. ort cannot be used Figure 1 10 Frame D E and F RS485 Ports Second RS485 DSI Connection 5485 DSI Network Connection Installation Wiring 1 27 EMC Instructions CE Conformity Conformity with the Low Voltage LV Directive and Electromagnetic Compatibility EMC Directive has been demonstrated using harmonized European Norm EN standards published in the Official Journal of the European Communities PowerFlex Drives comply with the EN standards listed below when installed according to the User Manual CE Declarations of Conformity are available online at http Avww ab com certification ce docs Low Voltage Directive 73 23 EEC e EN50178 Electronic equipment for use in power installations EMC Directive 89 336 EEC e EN61800 3 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods General Notes All Drive Frames e The motor cable should be kept as short as possible in order to avoid electromagnetic emission as well as capacitive currents e Use of line filters in ungrounded systems is not recommended e Conformity of the drive with CE EMC requirements does not guarantee an entire machine installation complies with CE EMC requirements Many factors can influence total machine installation compliance Frame C Drives Only e If the plastic top panel is removed or the optional conduit box is not installed the drive must be installed in an enclosure w
163. oss 4 Undervoltage 5 Overvoltage 6 Motor Stalled Motor Overload 8 Heatsink Overtemperature 12 HW Overcurrent 30096 13 Ground Fault 15 Load Loss 29 Analog Input Loss 33 Auto Restart Tries 38 Phase U to Ground Short 8449 39 Phase V to Ground Short 40 Phase W to Ground Short 41 Phase UV Short 42 Phase UW Short 43 Phase VW Short 48 Params Defaulted 63 Software Overcurrent 64 Drive Overload 70 Power Unit Fail 71 Net Loss 81 Communication Loss 94 Function Loss 100 Parameter Checksum Error 122 I O Board Fail Reading 03 and Writing 06 Drive Parameters To access drive parameters the Modbus register address equals the parameter number For example a decimal 1 is used to address Parameter b001 Output Freq and decimal 39 is used to address Parameter P039 Accel Time 1 Additional Information Refer to http www ab com drives for additional information E 6 Modbus RTU Protocol Notes Appendix F Metasys N2 Appendix F provides information about controlling a PowerFlex 400 drive setting its Reference and accessing its parameters through configurable objects when the Metasys N2 network protocol is selected Topic Page Understanding Metasys N2 FA Network Points F 3 Using Percent for the Reference F 5 Using Metasys Configurable Objects to Access Parameters 6 Understanding Metasys N2 Metasys nodes are built up by the use of several virtual objects The Metasys
164. ounding Shielded Enclosure 7 m 1 IP 30 NEMA 1 UL Type 1 Option Kit Frame C Drives Only EMI Fittings and Metal Conduit U T1 L3 L3 EMI Filter L D 12 819 pts o Enclosure Ground Connection Shielded Motor Cable Building Structure Steel 1 Shielded Enclosure required to meet EN61800 3 First Environment Restricted for 200 240V AC 11 22 kW 15 30 HP PowerFlex 400 drives and to meet EN61800 3 First Environment Unrestricted for all PowerFlex 400 ratings FCC Instructions FCC Compliance This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules when installed according to the User Manual These limits are designed to provide reasonable protection 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 accordance with the User Manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at their own expense
165. ource 1 6 Ungrounded 1 6 Armored Cable 1 11 Auto Rstrt Tries Fault 4 4 Auxiliary Input Fault 4 3 B Before Applying Power 2 1 2 2 Bus Capacitors Discharging P 3 C Cable Length 1 16 Cable Power 1 11 Capacitors Discharging P 3 Catalog Number Explanation P 4 CE Conformity 1 27 Checklist Start Up 2 1 2 2 Circuit Breakers Input 1 9 Comm Loss Fault 4 4 Command Sources for Start and Speed 1 24 Common Symptoms and Corrective Action 4 5 Contactors Input 1 15 Control 2 and 3 Wire 1 20 1 23 Conventions Manual P 2 Cover Opening 1 1 D Dimensions Drive B 7 Minimum Clearances 1 4 Discharging Bus Capacitors P 3 Display 2 3 2 4 2 6 2 7 2 8 2 9 Display Group Parameters 3 4 eee Systems Ungrounded Drive Frame Size P 2 B 7 Drive Grounding 1 8 Drive Overload Fault 4 4 Index Drive Ratings P 4 A 1 DriveExecutive 3 1 DriveExplorer 3 1 E Earthing see Grounding EMC RFI Grounding Filter 1 9 Interference 1 27 1 29 ESD Static Discharge P 3 F Faults Auto Rstrt Tries 4 4 Auxiliary Input 4 3 Comm Loss 4 4 Drive Overload 4 4 Ground Fault 4 3 Heatsink OvrTmp 4 3 HW OverCurrent 4 3 l O Board Fail 4 5 Motor Overload 4 3 Motor Stalled 4 3 OverVoltage 4 3 Parameter Checksum 4 4 Phase Short 4 4 Phase to Ground Short 4 4 Power Loss 4 3 Power Unit 4 4 SW OverCurrent 4 4 UnderVoltage 4 3 Filter 1 9 Frame Designations P 2 A 1 B 7 Fuses Input 1
166. pendix G P1 Floor Level Network FLN Appendix G provides information about controlling a PowerFlex 400 drive setting its Reference and accessing its parameters through configurable points when the P1 FLN protocol is selected The P1 FLN protocol is a serial communication protocol used by the Siemens APOGEE system Topic Page Understanding P1 FLN 9 1 Network Points G2 Using Percent for the Reference 6 6 Using P1 Configurable Points to Access Parameters G 7 Understanding P1 FLN The P1 FLN master performs read and write 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 the point is refreshed from or transferred to the drive The P1 FLN master also performs cyclic polling of all the virtual objects P1 FLN Points A P1 FLN node may contain up to 99 points 6 2 1 Floor Level Network FLN Network Points Table G 1 Point Database for Application 2735 Factory Engineering Point Point Default Units Slope Intercept Number Subpoint Name SI Units SI Units SI Units Sl Units Text Text 01 LAO CTLR ADDRESS 99 1 0 02 LAO APPLICATION 2735 1 0 03 LAI FREQ
167. ppropriate Values Default Read Only Min Max 0 0 60 0 Min Display 0 1 Min d318 Output Powr Fctr Related Parameter s T055 T056 T060 T061 T065 066 The angle in electrical degrees between motor voltage and motor current Values Default Read Only Min Max 0 0 180 0 deg Display 0 1 deg 3 56 Programming and Parameters Advance Display Group continued d319 Testpoint Data Related Parameter s A196 The present value of the function selected in A196 Testpoint Sel Values Default Read Only Min Max O FFFF Display 1 Hex d320 Control SW Ver Main Control Board software version Values Default Read Only Min Max 1 00 99 99 Display 0 01 d321 Drive Type Used by Rockwell Automation field service personnel d322 Output Speed Related Parameter s P034 Displays current output frequency 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 0 196 4323 Output RPM Related Parameter s A199 Displays current output frequency in RPM The scale is based on A199 Motor NP Poles Values Default Read Only Min Max 0 24000 RPM Display 1 RPM 4324 Fault Frequency Related Parameter s 5001 Displays the value of b001 Output Freq when the last fault occurred Values Default Read Only Min Max 0 00 320 00 Hz Display 0 01 Hz d325 Fault Current Related Par
168. ption 0 PID Disabled Description Disables the PID loop default setting 1 PID Setpoint Selects Exclusive Control A157 PID Setpoint will be used to set the value of the PID Reference 2 Analog In 1 Selects Exclusive Control Selects the Analog In 1 Input 3 Analog In 2 Selects Exclusive Control Selects the Analog In 2 Input Note that the PID will not function with a bipolar analog input It will ignore any negative voltages and treat them like a zero 4 Comm Port Selects Exclusive Control The reference word from a communication network see Appendix E for details on the reference word such as Modbus RTU or DeviceNet becomes the PID Reference The value sent over the network is scaled so that P035 Maximum Freq x 10 100 reference For example 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 0 10V Trim Selects Trim Control Selects the 0 10V Input Note that the PID will not function with a bipolar analog input It will ignore any negative voltages and treat them like a zero 7 4 20mA Trim Selects Trim Control Selects the 4 20mA Input 8 Comm Trim Selects Trim Control The reference word from a communication network see Appendix E for details on the reference word such as Modbus RTU or DeviceNet becom
169. put Code Amps Frame Code Amps Frame 012 12 2 2 3 0 6P0 60 2 2 3 0 017 175 3 7 5 0 00 10 5 4 0 024 24 5 5 7 5 012 12 5 5 7 5 033 33 7 5 10 017 17 7 5 10 022 22 11 15 030 30 15 20 038 38 18 5 25 045 455 22 30 060 60 30 40 072 72 37 50 088 88 45 60 105 105 55 75 142 142 75 100 170 170 90 125 208 208 110 150 049 49 110 065 65 15 20 05 75 18 5 25 090 90 22 90 120 120 30 40 145 145 37 50 g mmgcooococooooo TT ITI C C gG O0 CO CO OO CD 0 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 Frame D E and F drives only available with IP30 NEMA 1 UL Type 1 enclosure 9 Frame C drives only Additional accessories options and adapters are available See Appendix B for details Chapter 1 Installation Wiring This chapter provides information on mounting and wiring the PowerFlex 400 Drive For information on 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 Wiring 1 15 Recommendations General Grounding Requirements 1 8 EMC Instructions 1 27 Most start up difficulties are the result of incorrect wiring Every precaution must be taken to assure that the wiring is done as instructed
170. quency when the PID error is 100 for 2 seconds A larger value for PID Integ Time makes the integral component less responsive and a smaller value makes it more responsive Setting PID Integ Time to 0 disables the integral component of the PID loop A156 PID Diff Rate The Differential gain units of 1 seconds affects the rate of change of the PID output The differential gain is multiplied by the difference between the previous error and current error Thus with a large error the D has a large effect and with a small error the D has less of an effect This parameter is scaled so that when it is set to 1 00 the process response is 0 1 of Maximum Freq when the process error is changing at 196 second A larger value for PID Diff Rate makes the differential term have more of an effect and a small value makes it have less of an effect In many applications the D gain is not needed Setting PID Diff Rate to 0 00 factory default disables the differential component of the PID loop Application Notes D 9 Guidelines for Adjusting the PID Gains 1 Adjust the proportional gain During this step it may be desirable to disable the integral gain and differential gain by setting them to 0 After a step change in the PID Feedback Ifthe response is too slow increase A154 PID Prop Gain Ifthe response is too quick and or unstable see Figure D 1 decrease A154 PID Prop Gain Typically A154 PID Prop Gain is set t
171. quired MIF Series 50 Required 18 5 25 075 103 22 RFD100 150 Required Deltron MIF Series 50 Required 22 30 B090A103 22 RFD150 150 Required MIF Series 50 Required 30 40 B120A103 22 RFD150 150 No Deltron MIF Series 50 Required 37 50 145 103 22 RFD180 150 Deltron MIF Series 75 Required 380 480 Volts 2 2 3 0 D6PON103 22 018 5 10 22 RF018 CS 1 Required 4 0 5 0 010 103 22 RF018 CS 10 No 22 RF018 CS 1 Required 5 5 7 5 D012N103 22 RF018 CS 10 No 22 RF018 CS 1 Required 7 5 10 D017N103 22 RF018 CS 10 No 22 RF018 CS 1 Required 11 15 D022N103 22 RF026 CS 10 No 22 RF026 CS 1 Required 15 20 D030N103 22 RFDO36 100 No Deltron MIF Series 5 Required 18 5 25 0038 103 22 RFD050 150 No Deltron MIF Series 5 Required 22 30 D045A103 22 RFD050 150 No Deltron MIF Series 5 Required 30 40 D060A103 22 RFD070 50 No Deltron MIF Series 5 Required 37 50 D072A103 22 RFD100 50 Deltron MIF Series 5 Required 45 60 D088A103 22 RFD100 50 No Deltron MIF Series 5 Required 55 75 D105A103 22 RFD150 150 No Deltron MIF Series 5 Required 75 100 D142A103 22 RFD180 50 Deltron MIF Series 5 Required 90 125 D170A103 Consult Factory Consult Factory 110 150 D208A103 Consult Factory Consult Factory gt Installation Wiring 1 29 Figure 1 11 Connections and Gr
172. quirements of the Korean Electric Power Company Programming and Parameters 3 39 Advance Program Group continued A171 Start Boost Related Parameter s P031 P032 P034 P035 A170 A172 A173 A174 Sets the boost voltage of P031 Motor NP Volts and redefines the Volts per Hz curve when A170 Boost Select 0 Custom V Hz Values Default 2 596 Min Max 0 0 25 0 Display 1 1 A174 Maximum Voltage P031 Motor NP Volts Voltage ls Ww PIX cl d A173 Break Frequency P032 Motor NP Hertz A034 Minimum Freq Frequency P035 Maximum Freq A172 Break Voltage Related Parameter s P031 P032 P034 P035 170 171 173 174 Sets the break voltage applied at the break frequency when A170 Boost Select 0 Custom V Hz Values Default 25 0 0 0 100 0 Display 0 196 A173 Break Frequency Related Parameter s P031 P032 P034 P035 A170 A171 A172 A174 Sets the frequency where break frequency is applied when A170 Boost Select 0 Custom V Hz Values Default 15 0 Hz Min Max 0 0 320 0 Hz Display 0 1 Hz 3 40 Programming and Parameters Advance Program Group continued A174 Maximum Voltage Related Parameter s b004 A171 A172 A173 Sets the highest voltage the drive will output Values Default Drive Rated Volts Min Max 20 Drive Rated Volts
173. r the drive will not start Important If I O Terminal 01 is used as a stop input the jumper between I O Terminals 01 and 11 must be removed 6 Verify that the Analog Switches are set to 10 volts Start Up Applying Power to the Drive 7 Apply AC power and control voltages to the drive 8 Familiarize yourself with the integral keypad features see page 2 3 before 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 start stop and control speed directly from the integral keypad If a fault appears on power up refer to Fault Descriptions on page 4 3 for an explanation of the fault code Integral Keypad de ju Start Up 2 3 6000 HAND AUTO Allen Bradley Run Start amp Hand Used to start the drive Default is Hand mode as controlled by Operator Keys Key Name Description Escape Back one step in programming menu Cancel a change to a parameter value and exit Program Mode Select Advance one step in programming menu Select a digit when viewing parameter value Up Arrow Scroll through groups and parameters A 69 Down Arrow Increase decrease the value of a flashing digit Enter Advance one step in programming menu e Save a change to a parameter value Digital Speed Used to contro
174. rtain digital input settings can override drive operation Refer to Start and Speed Reference Control on page 1 24 for details Start Up 2 9 No Function Mode In No Function mode The Auto key has no function e Start command is defined by P036 Start Source e Speed Reference command is defined by P038 Speed Reference Table 2 D P042 Auto Mode 0 Function 051 054 Digital Inx Sel 2 Auto Mode or 3 Local Key LED Key Function Off e Not active active if P036 Start Source 9 0 Keypad Starts drive HAND On Not active Only active if P038 Speed O Reference 0 Drive Pot Changes drive speed Off Not active N A Stops drive OFF Important Certain digital input settings can override drive operation Refer to Start and Speed Reference Control on page 1 24 for details 2 10 Start Up Notes 3 Programming and Parameters Chapter 3 provides a complete listing and description of the PowerFlex 400 parameters Parameters are programmed viewed edited using the integral keypad As an alternative programming can also be performed using DriveExplorer or DriveExecutive software a personal computer and a serial converter module Refer to Appendix B for catalog numbers For information on See page About Parameters 3 1 Parameter Organization 32 Basic Display Group 34 Basic Program
175. s Reg Mode Controls the operation of the drive voltage regulation which is normally operational at decel or when the bus voltage rises Refer to the Attention statement on page P 3 for important information on bus regulation Options 0 Disabled 1 Enabled Default A188 Skip Frequency 1 Related Parameter s A189 Sets the frequency at which the drive will not operate A setting of 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 4188 Skip Frequency 1 A189 Skip Freq Band 1 is split applying 1 2 above and 1 2 below the actual skip frequency setting of 0 0 disables this parameter Values Default 0 0 Hz Min Max 0 0 30 0 Hz Display 0 1 Hz Frequency Command Frequency b Drive Output k Frequency Skip Frequency P i Skip Frequency Band A190 Skip Frequency 2 Related Parameter s A191 Sets the frequency at which the drive will not operate A setting of 0 disables this parameter Values Default 0 Hz Min Max 0 320 Hz Display 1 Hz 3 44 Programming and Parameters Advance Program Group continued A191 Skip Freq Band 2 Related Parameter s A190 Determines the bandwidth around A190 Skip Frequency 2 A191 Skip Freq Band 2 is split applying 1 2 above and 1 2 below the actual skip frequency A setting of 0 0 d
176. s at the master controller Modbus RTU Protocol Standard RS485 wiring practices apply Termination resistors need to be applied at each end of the network cable RS485 repeaters may need to be used for long cable runs or if greater than 32 nodes are needed on the network Parameter Configuration The following PowerFlex 400 parameters are used to configure the drive to operate on a network Parameter Details Reference P036 Start Source Set to 5 RS485 DSI Port if Start is controlled from Page 3 8 the network P038 Speed Reference Set to 5 RS485 DSI Port if the Speed Reference is Page 3 10 controlled from the network C102 Comm Format Sets the transmission mode data bits parity and stop Page 3 27 bits for the RS485 DSI Port All nodes on the network must be set to the same setting C103 Comm Data Rate Sets the data rate for the RS485 DSI Port All nodes Page 3 27 on the network must be set to the same data rate C104 Comm Node Addr Sets the node address for the drive on the network Page 3 28 Each device on the network requires a unique node address C105 Comm Loss Action Selects the drive s response to communication Page 3 28 problems C106 Comm Loss Time Sets the time that the drive will remain in Page 3 28 communication loss before the drive implements C105 Comm Loss Action C107 Comm Write Mode Determines whether parameter changes made ov
177. s regulating from there PID Enabled PID Output Freq Cmd PID Pre load Value 0 PID Limits A150 PID Trim Hi and A151 PID Trim Lo are used to limit the PID output and are only used in trim mode PID Trim Hi sets the maximum frequency for the PID output in trim mode PID Trim Lo sets the reverse frequency limit for the PID output in trim mode Note that when the PID reaches the Hi or Lo limit the PID regulator stops integrating so that windup does not occur Application Notes PID Gains The proportional integral and differential gains make up the PID regulator A154 PID Prop Gain The proportional gain unitless affects how the regulator reacts to the magnitude of the error The proportional component of the PID regulator outputs a speed command proportional to the PID error For example a proportional gain of 1 would output 100 of max frequency when the PID error is 10046 of the analog input range A larger value for PID Prop Gain makes the proportional component more responsive and a smaller value makes it less responsive Setting PID Prop Gain to 0 00 disables the proportional component of the PID loop A155 PID Integ Time The integral gain units of seconds affects how the regulator reacts to error over time and is used to get rid of steady state error For example with an integral gain of 2 seconds the output of the integral gain component would integrate up to 10096 of max fre
178. se Disable 0 Enabled DIP Switch SNK SRC SRC Parameters P036 Start Source 6 2 W Lvl Enbl P037 Stop Mode 0 through 7 DIP Switch SNK SRC SRC Parameters P036 Start Source 1 3 Wire P037 Stop Mode 0 through 7 DIP Switch SNK SRC SRC Parameters P036 Start Source 1 3 Wire P037 Stop Mode 0 through 7 A166 Reverse Disable 0 Rev Enabled Installation Wiring 1 23 Input Output Connection Example Required Settings Opto Output S Parameters i T065 Opto Out Sel 0 through 15 When using Opto Output with an inductive load such as a 1066 Opto m mes relay install a recovery diode 068 Opto Out Logic parallel to the relay as shown to prevent damage to the output Opto Output is rated 30V DC 50 mA non inductive Un 19 je 09 24V Common Typical Multiple Drive Connection Examples Input Output Connection Example Multiple Digital 0 04 o2 04 o2 4 Input Connections 2 202002002 20202022020 292000000 4 External Supply SRC E Customer Inputs 7 7 7 Optional Ground Connection When connecting a single input such as Run Stop Reverse or Preset Speeds to multiple drives it is important to connect 1 Terminal 04 common together for all drives If they are to be tied into a
179. seconds minimum 2 seconds typical Electronic Motor Overload Protection protection 110 for 60 seconds Provides Class 10 protection 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 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 10 to 50 degrees C 14 to 122 degrees F 10 to 45 degrees C 14 to 113 degrees F Cooling Method Fan All drive ratings Storage Temperature 40 to 70 degrees C 40 to 158 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 Seismic Rating Meets the seismic requirements of the 2003 International Building Code as specified by AC156 4 Supplemental Drive Information Category Specification Electrical Voltage To
180. self back to 0 e Causes F48 Params Defaulted fault Important Drives packaged for fan and pump applications 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 22 002 for packaged drive default settings P042 Auto Mode Related Parameter s 036 P038 Stop drive before changing this parameter Determines the operation of the Auto key on the integral keypad Refer to page 2 6 for details Options 0 No function LED above Auto key is always dark 1 Hnd Off Auto Toggles control start and frequency to and from keypad Default starts drive 2 Local Remote Toggles control start and frequency to and from keypad 3 Auto Manual Toggles only the frequency control to and from keypad P043 Motor OL Ret Related Parameter s P033 A181 Enables disables the Motor Overload Retention function When Enabled the value held in the motor overload counter is saved at power down and restored at power up Options 0 Disabled Default 1 Enabled 3 12 Programming and Parameters Terminal Block Group 051 Digital Ini Sel VO Terminal 05 T052 Digital In2 Sel VO Terminal 06 T053 Digital In3 Sel O Terminal 07 T054 Digital In4 Sel VO Terminal 08 Selects the function for the digital inputs Refer to the flowchart on page 1 24 for more informati
181. set threshold 10 Above PF Ang e Power Factor angle has exceeded the value set in 1066 Opto Out Level e Use T066 to set threshold 11 In Loss Analog input loss has occurred Program T072 Analog In 1 Loss and or 1076 Analog In 2 Loss for desired action when input loss occurs 12 ParamControl Enables the output to be controlled over network communications by writing to T066 Opto Out Level 0 Off 1 On 13 Retries Exst Value set in A163 Auto Rstrt Tries is exceeded 14 NonRec Fault e Number of retries for A163 Auto Rstrt Tries is exceeded OR e Non resettable fault occurs OR e A163 Auto Rstrt Tries is not enabled 15 Reverse Drive is commanded to run in reverse direction 16 Logic In 1 An input is programmed as Logic In 1 and is active 17 Logic In 2 An input is programmed as Logic In 2 and is active Programming and Parameters 3 19 Terminal Block Group continued T066 Opto Out Level Related Parameter s T065 T068 A163 d318 Z 32 bit parameter Determines the on off point for the opto output when 1065 Opto Out Sel is set to option 6 7 8 9 10 or 12 T065 Setting 066 0 400 2 7 0 180 8 0 815 Volts 9 0 100 1 180 degs 0 1 Values Default 0 0 Min Max 0 0 9999 Display 0 1 T068 Opto Out Logic Related Parameter s T065 T066 Determines the logic Normally Open NO or Normal
182. set threshold Important Value for Relay OutX Level must be entered in percent of drive rated output current 8 Above DCVolt e Drive exceeds the DC bus voltage value set in Relay OutX Level e Use 056 to set threshold 9 Above Anlg 2 e Analog input voltage I O Terminal 17 exceeds the value set in Relay OutX Level e Do not use if 1073 Analog In 2 Sel is set to 3 Voltage Mode Bipolar e This parameter setting can also be used to indicate a PTC trip point when the input I O Terminal 17 is wired to a PTC and external resistor e Use 056 to set threshold 10 Above PF Ang e Power Factor angle has exceeded the value set in Relay OutX Level e Use T056 to set threshold 11 Anlg In Loss Analog input loss has occurred Program T072 Analog In 1 Loss and or 1076 Analog In 2 Loss for desired action when input loss occurs 12 ParamControl Enables the output to be controlled over network communications by writing to Relay OutX Level 0 Off 1 On 13 Retries Exst Value set in A163 Auto Rstrt Tries is exceeded 14 NonRec Fault e Number of retries for Restart Tries is exceeded OR e Non resettable fault occurs OR e Auto retries is not enabled 15 Reverse Drive is commanded to run in reverse direction 16 Logic In 1 An input is programmed as Logic In 1 and is active 17 Logic In 2 An input is programmed as Logic In 2 and is active
183. splay 0 1 kWh Programming and Parameters 3 7 Basic Program Group P031 Motor NP Volts Related Parameter s 0004 A170 A171 A172 A173 Stop drive before changing this parameter Set to the motor nameplate rated volts Values Default Based on Drive Rating Min Max 20 Drive Rated Volts Display 1 VAC P032 Motor NP Hertz Related Parameter s A170 A171 A172 A173 A181 A182 Stop drive before changing this parameter Set to the motor nameplate rated frequency Values Default 60 Hz Min Max 15 320 Hz Display 1 Hz P033 Motor OL Current Related Parameter s P042 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 Values Default Drive Rated Amps Min Max 0 0 Drive Rated Amps x 2 Display 0 1 Amps P034 Minimum Freq Related Parameter s b001 b002 P035 T070 T074 A171 A172 A173 d302 Sets the lowest frequency the drive will output continuously Values Default 0 0 Hz Min Max 0 0 320 0 Hz Display 0 1 Hz P035 Maximum Freq Related Parameter s b001 b002 P034 T071 T075 T082 T083 T085 T086 A171 A172 A173 d302 Stop drive before changing this parameter Sets the highest frequency the drive will output Values Default 60 0 Hz Min Max 0 0 320 0 Hz Display 0 1
184. t Min Output Max Output Value 1 Related Setting Range Value Analog Output Hi Filter Setting Parameter 0 OutFreq0 10 0 10V 0 0 2 Maximum Frequency None 10V b001 1 OutCurr0 10 0 10V OV 20 Amps 200 Drive Rated FLA Filter A 10V b003 2 OutTorq0 10 0 10V OV 0 Amps 200 Drive Rated FLA Filter A 10 b013 3 OutVolt0 10 0 10V OV 0 Volts 120 Drive Rated Output V None 10 b004 4 OutPowr 0 10 0 10V OV 0kW 200 Drive Rated Power Filter A 10V b010 5 Setpnt0 10 0 10V 0 0 0 100 0 Setting None 10V 1084 6 TstData0 10 0 10V 0 0000 65535 Hex FFFF None 10V Al 7 OutFreq 0 20 0 20mA 0 0 Hz Maximum Frequency None 20 b001 8 OutCurr0 20 0 20 0 200 Drive Rated FLA FilterA 20 mA b003 9 0 20 0 20mA 0 0 200 Drive Rated FLA Filter A 20 b013 10 OutVolt 0 20 0 20 0 Volts 120 Drive Rated Output V None 20 b004 11 OutPowr0 20 0 20mA 0mA 0kW 200 Drive Rated Power FilterA 20 b010 12 Setpnt0 20 0 20 0 0 0 100 0 Setting None 20 1084 13 TstData 0 20 0 20 0000 65535 Hex FFFF None 20 196 14 OutFreq 4 20 4 20 4 0 Hz Maximum Frequency None 20 b001 15 OutCurr4 20 4 20 4 0 200 Drive Rated FLA Filter A 20 b003 16 OutTorq 4 20 4 20mA 4mA 0Amps 200 Drive Rated FLA Filter A 20 b013 17 OutVolt 4 20 4 20 4mA 0 Volts 120 Drive Rated Output V None 20 b004 18 OutPowr 4 20 4 20mA 4mA 0 k
185. t follows P036 Start Source Direction follows Preset Frequency settings Run as specified by A152 PID Ref Sel PID Enabled 152 PID Ref Sel 10 Yes Start and Direction commands come from 036 Start Source Run as specified by 038 Speed Reference Start and Direction commands come from P036 Start Source Installation Wiring 1 25 Accel Decel Selection The Accel Decel rate can be obtained by a variety of methods The default rate is determined by P039 Accel Time 1 and P040 Decel Time 1 Alternative Accel Decel rates can be made through digital inputs RS485 DSI communications and or parameters See the chart below for the override priority Either P039 Accel Time 1 040 Decel Time 1 RS485 DSI Port or Controls Speed A147 Accel Time 2 A148 Decel Time 2 can be selected when RS485 DSI port is active is programmed as Acc amp Dec 2 Digital Inx Sel 18 A147 Accel Time 2 148 Decel Time 2 is active when input is active P039 Accel Time 1 P040 Decel Time 1 A147 Accel Time 2 148 Decel Time 2 determined by the active Preset Frequency See A143 A146 Preset Freq 0 3 Speed is controlled by Preset Freq x A147 Accel Time 2 A148 Decel Time 2 Drive is performing an i are used Auxiliary Motor AutoSwap Yes P039 Accel Time 1 P040 Decel Time 1 are used
186. t minimum frequency 5 Max Freq Ref Drive runs at maximum frequency 6 Int Freq Ref Drive runs at A143 Preset Freq 0 T073 Analog In 2 Sel Related Parameter s P038 T055 T065 T074 T075 076 A152 Sets the analog input signal mode 0 20mA 4 20mA 0 10V 10 to 10V This parameter must match DIP Switch Al2 setting on the control board T073 Option Setting Input Range DIP Switch Al2 Setting 0 Current Mode 0 20 mA 20 mA 1 Current Mode 4 20 mA 20 mA 2 Voltage Mode Unipolar 0 10V 10V 30 Voltage Mode Bipolar 10 to 10V 10V 4 Current Mode Square Root 0 20 mA 20 mA 5 Current Mode Square Root 4 20 mA 20 mA 6 Voltage Mode Unipolar Square Root 0 10V 10V 7 Voltage Mode Bipolar Square Root 10 to 10V 10V 1 Setting 3 is only available on Analog In 2 Sel Input 2 is isolated and supports a bi polar input so that setting 3 determines if the voltage input is enabled for bipolar control If bipolar is selected 034 Minimum Freq and T074 Analog In 2 Lo are ignored If input 2 is set up for current control Bipolar mode is not possible If the analog input is inverted Analog In 2 Lo Analog In 2 Hi Bipolar mode is disabled and this input uses unipolar control only negative values are treated like zero Values Default 2 Min Max 0 7 Display 1 3 22 Programming and Parameters Terminal Block Group continued T074 Analog In 2 Lo Rel
187. tage Mode Unipolar e T070 Analog In 1 Lo or 7074 Analog In 2 Lo 0 0 e T071 Analog In 1 Hi or T075 Analog In 2 Hi 50 0 e A152 PID Ref Sel 0 0 10 Input Input Volts 0 10 20 30 40 50 60 70 80 90 100 PID Reference Invert Function For a 4 20mA signal the following parameter settings are used so that a 20mA signal 0 PID Reference and a 4mA signal 100 PID Reference 17069 Analog 1 Sel or T073 Analog In 2 Sel 1 Current Mode 4 20 mA e T070 Analog In 1 Lo or T074 Analog In 2 Lo 100 0 T071 Analog In 1 Hi or T075 Analog In 2 Hi 0 0 e A152 PID Ref Sel 2 Analog In 1 or 3 Analog In 2 24 20 26 0 512 N b 4 0 10 20 30 40 50 60 70 80 90 100 PID Reference Application Notes D 7 PID Deadband Parameter A158 PID Deadband is used to set a range in percent of the PID Reference that the drive will ignore Example e PID Deadband is set to 5 0 e PID Reference is 25 0 The PID Regulator will not act on a PID Error that falls between 20 0 and 30 096 PID Preload The value set in A159 PID Preload in Hertz will be pre loaded into the integral component of the PID at any start or enable This will cause the drive s frequency command to initially jump to that preload frequency and the PID loop start
188. ters A 9 x HAND Start Up Keypad Hand 0ff Auto Functions Parameter P042 Auto Mode defines the operation mode of the control keys on the integral keypad Hand 0ff Auto Mode In HAND mode e Control keys operate as Hand Off Auto e Start command and speed reference come from the integral keypad Start Hand and Digital Speed Increment and Decrement keys Auto key switches control from HAND mode to AUTO mode in a bumpless transfer as long as there is an active Run command In AUTO mode Auto key LED is illuminated e Start command is defined by P036 Start Source e Speed Reference command is defined by P038 Speed Reference e Start Hand key switches control to the integral keypad a bumpless transfer and switches the speed reference to the integral keypad e Stop key stops the drive and the drive switches to HAND mode Table 2 A P042 Auto Mode 1 Hnd Off Auto Default 051 054 Digital Inx Sel 2 Auto Mode or 3 Local HAND Mode AUTO Mode LED Key Function LED Key Function On Starts drive On Changes to HAND Mode and Starts 22 Runs according to Speed Increment drive Decrement keys Runs according to Speed Increment Decrement keys On Changes speed Off Not active i Keys are only active if P038 Speed Source 0 Drive Pot J OO AUTO Off Changes to AUTO Mode On Not active Stops drive N A Changes to
189. that Motor 1 is above the value set by R241 Aux 1 Start Freq before turning on Motor 2 is set via Parameter R250 Aux Start Delay frequency of Motor 1 that Motor 2 turns off at is set via Parameter R242 Aux 1 Stop 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 e The running time between the PowerFlex 400 switching control from Motor 1 to Motor 2 is set via R253 Aux AutoSwap Time PID setup is done via Parameters A150 through A159 See Appendix D for additional information The maximum PID output level that an AutoSwap can occur is set via Parameter R254 Aux AutoSwap Lvl AutoSwap will be delayed until the PID output drops below this parameter setting Important If using auxiliary motor control ensure that wiring and parameter configuration are correct before wiring contactor outputs All relays on the Auxiliary Relay Card will energize on power up by default Failure to verify proper wiring and parameter configuration can result in improper motor operation or drive damage D 14 Application Notes Notes Appendix E Modbus RTU Protocol PowerFlex 400 drives support the RS485 DSI protocol to allow efficient operation with Rockwell Automation peripherals In addition some Modbus functions are supported to allow simple networking PowerFlex 400 drives can be multi dropped on an RS485 n
190. the General Precautions section before proceeding following start up procedures Some of the voltages present are at incoming line potential To avoid electric shock hazard or damage to equipment only qualified service personnel should perform the following procedure Thoroughly read and understand the procedure before beginning If an event does not occur while performing this procedure Do Not Proceed Remove Power including user supplied control voltages User supplied voltages may exist even when main AC power is not applied to the drive Correct the malfunction before continuing ATTENTION Power must be applied to the drive to perform the Prepare For Drive Start Up Before Applying Power to the Drive 1 Confirm that all inputs are connected to the correct terminals and are secure 2 Verify that AC line power at the disconnect device is within the rated value of the drive 3 Verify that any digital control power is 24 volts 4 Verify that the Sink SNK Source SRC Setup DIP Switch is set to match your control wiring scheme See Table 1 G on page 1 18 for location Important The default control scheme is Source SRC The Stop terminal is jumpered 1 Terminals 01 and 11 to allow starting from the keypad If the control 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 o
191. the motor as possible Installations with long motor cables may require the addition of external devices to limit voltage reflections at the motor reflected wave phenomena See Table 1 for recommendations The reflected wave data applies to all frequencies 2 to 10 kHz For 240V ratings reflected wave effects do not need to be considered Table 1 Maximum Cable Length Recommendations Reflected Wave 380 480V Ratings Motor Insulation Rating Motor Cable Only 1000 Vp p 7 6 meters 25 feet 1200 Vp p 22 9 meters 75 feet 1600 Vp p 152 4 meters 500 feet 1 Longer cable lengths can be achieved by installing devices on the output of the drive Consult factory for recommendations Output Disconnect The drive 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 stopping the motor should not be used If it is necessary to disconnect power to the motor with the drive outputting power an auxiliary contact should be used to simultaneously disable drive control run commands 1 14 Installation Wiring Power Terminal Block Frame C D and F drives utilize a finger guard over the power wiring terminals Replace the finger guard when wiring is complete Figure 1 6 Power Terminal Blocks R L1 512 T L3 UMI 2 P2 P1 Frame C 542 T3 P
192. tly enter motor nameplate data into P031 P032 and P033 2 Enable A194 Compensation 3 Use A170 Boost Select to reduce boost level Drive will not reverse motor direction Cause s Indication Corrective Action Digital input is not selected for None Check T051 T054 Digital Inx Sel reversing control and P036 Start Source Choose correct input and program for reversing mode Digital input is incorrectly None Check input wiring See page 1 18 wired Motor wiring is improperly None Switch two motor leads phased for reverse Reverse is disabled None Check A166 Reverse Disable Drive does not power up Cause s Indication Corrective Action No input power to drive None Check the power circuit e Check the supply voltage Check all fuses and disconnects Jumper between Power None Install jumper or connect DC Bus Terminals P2 and P1 not installed and or DC Bus Inductor not connected Inductor Appendix Supplemental Drive Information For information on Drive Fuse amp Circuit Breaker Ratings 1 Specifications 2 Drive Fuse amp Circuit Breaker Ratings The tables on the following pages provide drive ratings and recommended AC line input fuse and circuit breaker information Both types of short circuit protection are acceptable for UL and IEC requirements Sizes listed are the recommended sizes based on 40 degree C and the U S N E C Other cou
193. ts 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 that can cause an explosion in a hazardous environment which may WARNING Identifies information about practices or circumstances lead to personal injury or death property damage or economic loss Important Identifies information that is critical for successful application and understanding of the product ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you e identify a hazard e avoid the hazard e recognize the consequences 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 Shock Hazard labels may be located or inside the equipment e g 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 Summary of Changes Manual Updates The information below summarizes the changes to the PowerFlex 400 User Manual since the August 2005 release Description of New or Updated Informat
194. unning 0 Not Active 1 Forward 0 Reverse 1 Rotating Forward 0 Rotating Reverse 1 Accelerating 0 Not Accelerating 1 Decelerating 0 Not Decelerating 1 Alarm 0 No Alarm 1 Faulted 0 Not Faulted 1 At Reference 0 Not At Reference 1 Reference Controlled by Comm 1 Operation Controlled by Comm 1 Parameters have been locked Digital Input 1 Status Digital Input 2 Status Digital Input 3 Status Digital Input 4 Status 8448 co oc A e e A Reading 03 Feedback The Feedback Output Frequency from the PowerFlex 400 drive can be read via the network by sending Function Code 03 reads to register address 8451 Feedback Feedback Address Decimal Description A xxx xx decimal value where the decimal point is fixed For example a decimal 1234 equals 12 34 Hz and 300 equals 3 00 Hz 1 Returns the same data as Reading 03 Parameter b001 Output Freq 8451 Modbus RTU Protocol E 5 Reading 03 Drive Error Codes The PowerFlex 400 Error Code data can be read via the network by sending Function Code 03 reads to register address 8449 Drive Error Codes Logic Status Address Decimal Value Decimal Description 0 No Fault 2 Auxiliary Input 3 Power L
195. ut I O Terminal 17 is wired to a PTC and external resistor e Use T056 to set threshold 10 Above PF Ang e Power Factor angle has exceeded the value set in T056 Relay Out1 Level e Use T056 to set threshold 11 In Loss Analog input loss has occurred Program T072 Analog In 1 Loss and or 1076 Analog In 2 Loss for desired action when input loss occurs 12 ParamControl Enables the output to be controlled over network communications by writing to T056 Relay Out1 Level 0 Off 1 On 13 Retries Exst Value set in A163 Auto Rstrt Tries is exceeded 14 NonRec Fault e Number of retries for Restart Tries is exceeded OR e Non resettable fault occurs OR e Auto retries is not enabled 15 Reverse Drive is commanded to run in reverse direction 16 Logic In 1 An input is programmed as Logic In 1 and is active 17 Logic In 2 An input is programmed as Logic In 2 and is active 23 Aux Motor Auxiliary Motor is commanded to run Refer to Appendix C for details Programming and Parameters 3 15 Terminal Block Group continued T056 Relay Out1 Level Related Parameter s T055 T058 T059 4318 Z 32 bit parameter Sets the trip point for the digital output relay if the value of T055 Relay Out1 Sel is 6 7 8 9 10 or 12 T055 Setting T056 Min Max 6 0 320 Hz 7 0 180 8 0 815 Volts 9 0 10
196. werFlex family of drives Requires a Communication Adapter Cover when used with Frame C PowerFlex 400 drives Ordered Separately EtherNet IP Embedded communication option for use with the 22 COMM E Communication Adapter PowerFlex family of drives Requires a Communication Adapter Cover when used with Frame C PowerFlex 400 drives Ordered Separately Profibus DP Embedded communication option for use with the 22 COMM P Communication Adapter PowerFlex family of drives Requires a Communication Adapter Cover when used with Frame C PowerFlex 400 drives Ordered Separately Communication Adapter Cover that houses the communication adapter Cover Frame C Drive 22C CCC Serial Converter Module Provides serial communication via DF1 protocol for 22 SCM 232 95485 RS232 use with DriveExplorer DriveExecutive software Includes DSI to RS232 serial converter one 1203 SFC serial cable one 22 RJ45CBL C20 cable one DriveExplorer Lite CD one 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 and a 9 pin sub miniature D female connector to connect to a computer 1203 SFC Null Cable Converter For use when connecting the serial converter to DriveExplorer on a handheld PC 1203 SNM Splitter Cable RJ45 one to two port splitter cable AK U0
197. y connections or Slave for permanent connections If two peripherals will be powered up at the same time one must be configured as the Master and connected to the Master port M and the other must be connected as the Slave and connected to the Slave port S RJ45 DSI Splitter Cable DSI Cable Accessories RJ45 Splitter Cable Catalog Number AK U0 RJ45 SC1 o P al Slave Port E 2 _ RRRRR gt lt t Master Port Id PIN 1 PIN 8 RJ45 Two Position Terminal Block Adapter Catalog Number AK UO RJA5 TB2P TB2 PIN 5 PIN 8 TB Z ES PIN 4 PIN 1 RJ45 Adapter with Integrated Termination Resistor Catalog Number AK U0 RJ45 TR1 PIN 8 PIN 1 RJ45 DSI Splitter Cable C 3 Connecting One Temporary Peripheral DSI Drive DSI Serial Converter Hand Held Parameter 1 Adapter Cfg set to Auto default or Master and connected to Master port M on RJ45 Splitter Cable Parameter 9 Device Type set to Auto default or Master and connected to Master port M on RJ45 Splitter Cable Connecting One Temporary Peripheral and One Permanent Peripheral NEMA 1 Bezel NEMA4 with DSI Hand Held Panel Mount Unit DSI Drive
198. ype Address NPT NPA Name Description Min Max Default ADI 1 Param IN1 User IN 1 Al 10 0 Drive Params 001 Output Freq Hz Data Source Param ADI 2 IN2 User 2 Al 11 0 Drive Params 0011 Elapsed MWh Data Source Param ADI 3 Param IN3 User IN 3 12 0 Drive Params 6012 Elapsed Run Time Data Source Param ADI 4 Parami IN4 User IN 4 13 0 Drive Params 0014 Drive Temperature Data Source Param ADI 5 Param OUT1 User OUT 1 AO 11 0 Drive Params A154 PID Gain Data Source Param ADI 6 Param OUT2 User OUT 2 AO 12 0 Drive Params A155 PID Integral Time Data Source Param ADI 7 Param OUT3 User OUT 3 AO 13 0 Drive Params A156 PID Diff Rate Data Source Param ADI 8 Param OUT4 User OUT 4 AO 14 0 Drive Params A158 PID Deadband Data Source Param The Reference AO 1 for Metasys N2 is set as a percentage from 0 to 100 100 0 Pr P035 Maximum Freq Value Table F 12 Example Speed Reference and Feedback for a PowerFlex 400 P035 60 Hz Reference AO 1 Feedback Al 1 Percent Speed Speed Percent 100 60 Hz 60 Hz 100 50 30 2 30 2 50 25 15 Hz 15 2 25 0 0 Hz 0 Hz 0 F 6 Metasys N2 Using Metasys Configurable Objects to Access Parameters Configurable objects are inputs and outputs that let you read and write parameter

Adjustable Frequency AC Drive for Fan & Pump Applications

Contents

Download Pdf Manuals

Related Search

Related Contents

Adjustable Frequency AC Drive for Fan &amp; Pump Applications

Contents

Download Pdf Manuals

Related Search

Related Contents

Adjustable Frequency AC Drive for Fan & Pump Applications