Quick Start PowerFlex 400 Adjustable Frequency AC Drive FRN 4.xx This Quick Start guide summarizes the basic steps needed to install, start-up and program the PowerFlex 400 Adjustable Frequency AC Drive. The information provided Does Not replace the User Manual and is intended for qualified drive service personnel only. For detailed PowerFlex 400 information including EMC instructions, application considerations and related precautions refer to the PowerFlex 400 User Manual, Publication 22C-UM001… supplied with the drive or at www.rockwellautomation.com/literature. General Precautions ATTENTION: The drive contains high voltage capacitors which take time to discharge after removal of mains supply. Before working on ! drive, ensure isolation of mains supply from line inputs [R, S, T (L1, L2, L3)]. Wait three minutes for capacitors to discharge to safe voltage levels. Failure to do so may result in personal injury or death. A darkened LCD display and LEDs is not an indication that capacitors have discharged to safe voltage levels. ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or ! implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required ! when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook. English-2 PowerFlex 400 Adjustable Frequency AC Drive Quick Start 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). Mounting Considerations • Mount the drive upright on a flat, vertical and level surface. Frame Screw Size Screw Torque C M5 (#10-24) 2.45-2.94 N-m (22-26 lb.-in.) D M8 (5/16 in.) 6.0-7.4 N-m (53.2-65.0 lb.-in.) E M8 (5/16 in.) 8.8-10.8 N-m (78.0-95.3 lb.-in.) F M10 (3/8 in.) 19.6-23.5 N-m (173.6-208.3 lb.-in.) • 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 Range Minimum Mounting Clearances C IP 20/UL Open-Type -10° to 45°C (14° to 113°F) Figure 1: Option A (1) -10° to 45°C (14° to 113°F) Figure 1: Option B IP 30/NEMA 1/UL Type 1 IP 20/UL Open-Type -10° to 50°C (14° to 122°F) Figure 1: Option B D, E, F IP 30/NEMA 1/UL Type 1 -10° to 45°C (14° to 113°F) Figure 2: (1) Frame C drives require installation of the PowerFlex 400 IP 30/NEMA 1/UL Type 1 option kit to achieve this rating. PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-3 Minimum Mounting Clearances Figure 1: Frame C Mounting Clearances 25 mm (1.0 in.) 120 mm 120 mm (4.7 in.) (4.7 in.) Mounting Option A No clearance required between drives. Mounting Option B 120 mm 120 mm (4.7 in.) (4.7 in.) Figure 2: Frames D, E and F Mounting Clearances Frame D & E Frame F 250 mm (9.8 in.) 150 mm (6.0 in.) 50 mm 50 mm 50 mm 50 mm (2.0 in.) (2.0 in.) (2.0 in.) (2.0 in.) 150 mm 150 mm (6.0 in.) (6.0 in.) General Grounding Requirements L1 L2 L3 PE PE T1 T2 T3 R S T U V W Required Input Fusing Required Branch Circuit Disconnect English-4 PowerFlex 400 Adjustable Frequency AC Drive Quick Start Ungrounded Distribution Systems ATTENTION: PowerFlex 400 drives contain protective MOVs that are referenced to ground. These devices must be disconnected if the ! drive is installed on an ungrounded or resistive grounded distribution system. Phase to Ground MOV Removal Frame C Frame E & F R/L1 S/L2 T/L3 12 3 4 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. CE Conformity Refer to the PowerFlex 400 User Manual supplied with the drive for details on how to comply with the Low Voltage (LV) and Electromagnetic Compatibility (EMC) Directives. EMC Line Filters 240V 50/60 Hz 3-Phase 480V 50/60 Hz 3-Phase Catalog Catalog kW HP Number kW HP Number 2.2 3.0 22-RF034-CS 2.2 3.0 22-RF018-CS 4.0 5.0 22-RF034-CS 4.0 5.0 22-RF018-CS 5.5 7.5 22-RF034-CS 5.5 7.5 22-RF018-CS 7.5 10 22-RF034-CS 7.5 10 22-RF018-CS 11 15 22-RFD070 11 15 22-RF026-CS 15 20 22-RFD100 15 20 22-RFD036 18.5 25 22-RFD100 18.5 25 22-RFD050 22 30 22-RFD150 22 30 22-RFD050 30 40 22-RFD150 30 40 22-RFD070 37 50 22-RFD180 37 50 22-RFD100 45 60 22-RFD100 55 75 22-RFD150 75 100 22-RFD180 90 125 Consult Factory 110 150 Consult Factory PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-5 Specifications, Fuses and Circuit Breakers Drive Ratings Power Output Ratings Input Ratings Branch Circuit Protection Dissipation Catalog Number Amps Voltage Fuses 140M Motor IP20 Open (1) (2) kW (HP) 50°C Range kVA Amps Protectors Contactors Watts 200 - 240V AC – 3-Phase Input, 0 - 230V 3-Phase Output 22C-B012N103 2.2 (3.0) 12 180-265 6.5 15.5 20 140M-F8E-C16 100-C23 146 22C-B017N103 3.7 (5.0) 17.5 180-265 8.8 21 30 140M-F8E-C25 100-C37 207 22C-B024N103 5.5 (7.5) 24 180-265 10.9 26.1 35 140M-F8E-C32 100-C37 266 22C-B033N103 7.5 (10) 33 180-265 14.4 34.6 45 140M-F8E-C45 100-C45 359 22C-B049A103 11 (15) 49 180-265 21.3 51 70 140-CMN-6300 100-C60 488 22C-B065A103 15 (20) 65 180-265 28.3 68 90 140-CMN-9000 100-C85 650 22C-B075A103 18.5 (25) 75 180-265 32.5 78 100 140-CMN-9000 100-D95 734 22C-B090A103 22 (30) 81 180-265 38.3 92 125 – 100-D110 778 22C-B120A103 30 (40) 120 180-265 51.6 124 175 – 100-D180 1055 22C-B145A103 37 (50) 130 180-265 62.4 150 200 – 100-D180 1200 380 - 480V AC – 3-Phase Input, 0 - 460V 3-Phase Output 22C-D6P0N103 2.2 (3.0) 6 340-528 6.3 7.5 10 140M-D8E-C10 100-C09 105 22C-D010N103 4.0 (5.0) 10.5 340-528 10.9 13 20 140M-D8E-C16 100-C16 171 22C-D012N103 5.5 (7.5) 12 340-528 11.9 14.2 20 140M-D8E-C16 100-C23 200 22C-D017N103 7.5 (10) 17 340-528 15.3 18.4 25 140M-D8E-C20 100-C23 267 22C-D022N103 11 (15) 22 340-528 19.2 23 30 140M-F8E-C32 100-C30 329 22C-D030N103 15 (20) 27 340-528 25.8 31 40 140M-F8E-C32 100-C37 435 22C-D038A103 18.5 (25) 38 340-528 33.3 40 50 140M-F8E-C45 100-C60 606 22C-D045A103 22 (30) 45.5 340-528 39.1 47 60 140-CMN-6300 100-C60 738 22C-D060A103 30 (40) 54 340-528 53.3 64 80 140-CMN-9000 100-C85 664 22C-D072A103 37 (50) 72 340-528 60.7 73 100 140-CMN-9000 100-C85 1019 22C-D088A103 45 (60) 88 340-528 74.9 90 125 – 100-D110 1245 22C-D105A103 55 (75) 105 340-528 89 107 150 – 100-D140 1487 22C-D142A103 75 (100) 128 340-528 124.8 150 200 – 100-D180 2043 22C-D170A103 90 (125) 170 340-528 142 170 250 – 100-D250 2617 22C-D208A103 110 (150) 208 340-528 167 200 250 – 100-D250 3601 (1) Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent. (2) Refer to the Bulletin 140M Motor Protectors Selection Guide, publication 140M-SG001… to determine the frame and breaking capacity required for your application. English-6 PowerFlex 400 Adjustable Frequency AC Drive Quick Start Category Specification Agency Listed to UL508C and CAN/CSA-22.2 U ® L Certification Listed to UL508C for plenums CUS Certified to AS/NZS, 1997 Group 1, Class A Marked for all applicable European Directives EMC Directive (89/336) EN 61800-3, EN 50081-1, EN 50082-2 Low Voltage Directive (73/23/EEC) EN 50178, EN 60204 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 seconds minimum, 2 seconds typical 2 Electronic Motor Overload I t protection - 110% for 60 seconds (Provides Class 10 Protection: 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 Electrical Efficiency: 97.5% at rated amps, nominal line voltage Output Frequency: 0-320 Hz (programmable) Control Control Digital: Quantity: (3) Semi-programmable Inputs (4) Programmable Type Source Mode (SRC): 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 Control Relay: Quantity: (2) Programmable Form C Outputs 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 & F Only) Relay Specification Card: Resistive Rating: 0.1A at 30V DC Class II circuits, 3.0A at 125V, 3.0A at 240V AC Inductive Rating: 0.1A 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 PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-7 Power Wiring Figure 3: Power Terminal Blocks R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 P2 P1 DC– DC+ BR+ BR– R/L1 S/L2 T/L3 P1 P2 DC– U/T1 V/T2 W/T3 R/L1 S/L2T/L3 P1 P2 DC– U/T1 V/T2W/T3 R/L1 S/L2 T/L3 P1 P2 DC– U/T1 V/T2 W/T3 R/L1 S/L2 T/L3 P1 P2 DC– U/T1 V/T2 W/T3 (1) Terminal Description R/L1, S/L2, T/L3 3-Phase Input U/T1 To Motor U/T1 Switch any two motor leads to change V/T2 To Motor V/T2 = forward direction. 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. English-8 PowerFlex 400 Adjustable Frequency AC Drive Quick Start Power Terminal Block Specifications (1) (1) Frame Maximum Wire Size Minimum Wire Size Recommended Torque 2 2 C 8.4 mm (8 AWG) 1.3 mm (16 AWG) 2.9 N-m (26 lb.-in.) 2 2 D 33.6 mm (2 AWG) 8.4 mm (8 AWG) 5.1 N-m (45 lb.-in.) 2 2 E 480V 33.6 mm (2 AWG) 3.5 mm (12 AWG) 5.6 N-m (49.5 lb.-in.) 37-45 kW (50-60 HP) 2 2 E 240V 107.2 mm (4/0 AWG) 53.5 mm (1/0 AWG) 19.5 N-m (173 lb.-in.) 30-37 kW (40-50 HP) 480V 55-75 kW (75-100 HP) 2 2 F 152.5 mm (300 MCM) 85.0 mm (3/0 AWG) 19.5 N-m (173 lb.-in.) (1) 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. Important: Frame C, D, and F drives utilize a finger guard over the power wiring terminals. Replace the finger guard when wiring is complete. Refer to the PowerFlex 400 User Manual for maximum power cable length recommendations. Input Power Conditions Input Power Condition Corrective Action (1) Low Line Impedance (less than 1% line • Install Line Reactor reactance) • or Isolation Transformer (1) Line has power factor correction capacitors • Install Line Reactor • or Isolation Transformer Line has frequent power interruptions Line has intermittent noise spikes in excess of 6000V (lightning) Phase to ground voltage exceeds 125% of • Remove MOV jumper to ground normal line to line voltage (Frame C, E & F drives only) • or Install Isolation Transformer with Ungrounded distribution system grounded secondary if necessary (1) Refer to the PowerFlex 400 User Manual for accessory ordering information. PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-9 I/O Wiring Recommendations Wire Type(s) Description Minimum Insulation Rating 2 Belden 8760/9460 0.8 mm (18AWG), twisted pair, 100% 300V (1) (or equiv.) shield with drain. 60 degrees C (140 degrees F) 2 Belden 8770 0.8 mm (18AWG), 3 conductor, shielded for (or equiv.) remote pot only. (1) If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessary, but is always recommended. I/O Terminal Block Specifications (2) (2) Frame Maximum Wire Size Minimum Wire Size Torque 2 2 C, D, E, F 1.3 mm (16 AWG) 0.13 mm (26 AWG) 0.5-0.8 N-m (4.4-7 lb.-in.) (2) Maximum/minimum sizes that the terminal block will accept - these are not recommendations. Refer to the PowerFlex 400 User Manual for maximum control cable length recommendations. English-10 PowerFlex 400 Adjustable Frequency AC Drive Quick Start Control Terminal Block Typical Typical Stop/ (1)(4) SRC Wiring SNK Wiring Function Loss 1 of 7 Digital Input Circuits 01 (2) Start/Run FWD 02 (4) Direction/Run REV Enable 03 Jumper Digital Common SNK SRC 04 Digital Input 1 05 ENBL SNK Digital Input 2 06 SRC Digital Input 3 07 Digital Input 4 08 Digital Common 09 Opto Common 10 #1 Relay N.O. R1 +24V +24V DC Source #1 Relay Common R2 11 #1 Relay N.C. Earth Referenced +10V +10V DC Source (5) R3 12 Frames D & E 0-10V Analog Input 1 (AI1) 13 0-20mA #2 Relay N.O. Analog Common 1 R4 14 Pot must be #2 Relay Common 0-10V Analog Output 1 (AO1) R5 1-10k ohm 15 2 Watt Min. #2 Relay N.C. R6 Analog Output 2 (AO2) 16 0-20mA Analog Input 2 (AI2) Isolated 0-10V 17 0-20mA (6) Analog Common 2 18 (3) Common Opto Output 24V 19 30V DC 50mA RS485 Shield Non-inductive 20 RS485 (DSI) (1) Important: I/O Terminal 01 is always a coast to stop input P036 [Start Source] Stop I/O Terminal 01 Stop except when P036 [Start Source] is set to option 1 “3-Wire” or Keypad Per P037 Coast 6 “2-W Lvl/Enbl”. In three wire control, I/O Terminal 01 is (4) 3-Wire Per P037 Per P037 controlled by P037 [Stop Mode]. All other stop sources are 2-Wire Per P037 Coast controlled by P037 [Stop Mode]. RS485 Port Per P037 Coast 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. (2) Two wire control shown. For three wire control use a momentary input on I/O Terminal 02 to command a start. If reverse is enabled by A166, use a maintained input for I/O Terminal 03 to change direction. (3) 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. (4) When the ENBL enable jumper is removed, I/O Terminal 01 will always act as a hardware enable, causing a coast to stop without software interpretation. (5) 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. (6) Common for Analog Input 2 (AI2). Electronically isolated from digital I/O and opto output. Not to be used with Analog Input 1 (AI1), Analog Output 1 (AO1) or Analog Output 2 (AO2). With Analog Input 2, provides one fully isolated analog input channel. AO1 AO2 AI1 AI2 10V 20MA 10V 20MA 10V 20MA 10V 20MA PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-11 Control I/O Terminal Designations No. Signal Default Description Param. (1) (1) 01 Stop / 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. P036, P037 AUTO Mode: I/O Terminal 02 is active. Program with P036 [Start Source]. 03 Direction/Run REV 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. (2) 05 Digital Input 1 Purge Program with T051 [Digital In1 Sel]. T051 06 Digital Input 2 Local Program with T052 [Digital In2 Sel]. T052 07 Digital Input 3 Clear Fault Program with T053 [Digital In3 Sel]. T053 08 Digital Input 4 Comm Port Program with T054 [Digital In4 Sel]. T054 09 Digital Common – For digital inputs. Tied to I/O Terminal 04. Electronically isolated with digital inputs from analog I/O and opto output. 10 Opto Common – For opto-coupled outputs. Electronically isolated with opto output from analog I/O and digital inputs. 11 +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 or 4-20mA input T069, T070, supply or potentiometer wiper. Default input is 0-10V. T071, T072 For current (mA) input, set AI1 DIP Switch to 20mA. Program with T069 [Analog In 1 Sel]. Input Impedance: 100k ohm (Voltage Mode) 250 ohm (Current Mode) 14 Analog Common 1 – Common for Analog Input 1 and Analog Output 1 and 2. Electrically isolated from digital I/O 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: 4-20mA = 525 ohm (10.5V) 0-10V = 1k ohm (10mA) 16 Analog Output 2 OutCurr 0-10 Default analog output is 0-10V. T082, T084, For a current (mA) value, set AO2 DIP Switch to 20mA. T085, T086, Program with T085 [Analog Out2 Sel]. T087 Maximum Load: 4-20mA = 525 ohm (10.5V) 0-10V = 1k ohm (10mA) 17 Analog Input 2 0-10V Optically isolated external 0-10V (unipolar), ±10V T073, T074, (bipolar), 0-20mA or 4-20mA input supply or T075, T076 potentiometer wiper. Default input is 0-10V. For current (mA) input, set AI2 DIP Switch to 20mA. Program with T073 [Analog In 2 Sel]. Input Impedance: 100k ohm (Voltage Mode) 250 ohm (Current Mode) 18 Analog Common 2 – 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 Opto Output At Frequency Program with T065 [Opto Out Sel]. T065, T066, T068 20 RS485 (DSI) Shield – Terminal connected to Safety Ground - PE when using the RS485 (DSI) Communication Port. (1) See Footnotes (1) and (4) on previous page. (2) See the User Manual for Important information regarding Stop commands and the [Digital Inx Sel] Purge option. 3A 3B 4A 4B 5A 5B 6A 6B 7A 7B 8A 8B English-12 PowerFlex 400 Adjustable Frequency AC Drive Quick Start Relay Terminal Designations and DIP Switches No. Signal Default Description Param. R1 #1 Relay N.O. Ready/Fault Normally open contact for No. 1 output relay. T055 R2 #1 Relay Common – Common for output relay. R3 #1 Relay N.C. Ready/Fault Normally closed contact for No. 1 output relay. T055 R4 #2 Relay N.O. Motor Running Normally open contact for No. 2 output relay. T060 R5 #2 Relay Common – Common for output relay. R6 #2 Relay N.C. Motor Running Normally closed contact for No. 2 output relay. T060 Selection DIP Switches: 0-10V Sets analog output to either voltage or current. Analog Input (AI1 & AI2) Settings must match: AI1 & T069 [Analog In 1 Sel] Analog Output (AO1 & AO2) AI2 & T073 [Analog In 2 Sel] AO1 & T082 [Analog Out1 Sel] AO2 & 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 4: User Installed Auxiliary Relay Card (Frames D, E, & F Only) 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. Refer to Appendix D for more details. User Installed Relay Board Terminal Designations No. Signal Default Description Param. 3A #3 Relay N.O. Ready/Fault Normally open contact for Number 3 Output Relay R221 3B #3 Relay Common – Common for Number 3 Output Relay 4A #4 Relay N.O. Ready/Fault Normally open contact for Number 4 Output Relay R224 4B #4 Relay Common – Common for Number 4 Output Relay 5A #5 Relay N.O. Ready/Fault Normally open contact for Number 5 Output Relay R227 5B #5 Relay Common – Common for Number 5 Output Relay 6A #6 Relay N.O. Ready/Fault Normally open contact for Number 6 Output Relay R230 6B #6 Relay Common – Common for Number 6 Output Relay 7A #7 Relay N.O. Ready/Fault Normally open contact for Number 7 Output Relay R233 7B #7 Relay Common – Common for Number 7 Output Relay 8A #8 Relay N.O. Ready/Fault Normally open contact for Number 8 Output Relay R236 8B #8 Relay Common – Common for Number 8 Output Relay PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-13 Prepare For Drive Start-Up ATTENTION: Power must be applied to the drive to perform the 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 All 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. 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. Important: The default control scheme is Source (SRC). The Stop terminal is jumpered (I/O 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 or 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 I/O DIP Switches are set to 10 volts. Applying Power to the Drive ❏ 7. Apply AC power and control voltages to the drive. ❏ 8. Familiarize yourself with the integral keypad features 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 page 25 for an explanation of the fault code. For complete troubleshooting information, refer to the PowerFlex 400 User Manual supplied with the drive. English-14 PowerFlex 400 Adjustable Frequency AC Drive Quick Start Intergral Keypad 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. Down Arrow Increase/decrease the value of a flashing digit. Enter Advance one step in programming menu. Save a change to a parameter value. Digital Speed Used to control speed of drive. Default is active. Increment and Control is activated by parameter P038 [Speed Reference] or Decrement Arrows P042 [Auto Mode]. (1) Run/Start & Hand Used to start the drive. Default is Hand mode as controlled by parameter P042 [Auto Mode]. Control is activated by parameter P036 [Start Source] or P042 [Auto Mode]. (1) Auto Used to select Auto control mode. Controlled by parameter P042 [Auto Mode]. Stop/Off Used to stop the drive or clear a fault. This key is always active. Controlled by parameter P037 [Stop Mode]. (1) Important: Certain digital input settings can override drive operation. Refer to the PowerFlex 400 User Manual for details. PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-15 LED Status Indicators LED LED State Description Program Status Steady Red Indicates parameter value can be changed. Selected digit will flash. Fault Status Flashing Red Indicates that the drive is faulted. Speed Status Steady Green Indicates that the digital speed control keys are 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. LCD Display ➊ ➋➌ No. Description Parameter Name ➊ Run/Stop Status: = Stopped / = Running ➋ flashes to indicate that the drive is stopping, but is still decelerating. flashes when DC Injection is commanded. Direction Indication: The Direction Arrow indicates the commanded direction of rotation. If the Arrow is flashing, the drive has been commanded to change direction, but is still decelerating. Sleep Mode Indication: flashes to indicate that the drive is in sleep mode. Parameter Group and Number: ➌ = Basic Display = Basic Program = Terminal Block = Communications = Advanced Program = Aux Relay Card = Advanced Display ➍ ➎ Fault Indication and Fault Number ➍ Fault Name ➎ English-16 PowerFlex 400 Adjustable Frequency AC Drive Quick Start Keypad Hand-Off-Auto Functions Parameter P042 [Auto Mode] defines the operation mode of the control keys on the integral keypad. Hand-Off-Auto is the default operation mode for PowerFlex 400 drives. For detailed information on other operation modes, refer to the PowerFlex 400 User Manual supplied with the drive. Hand-Off-Auto Mode In HAND mode: • Control keys operate as Hand-Off-Auto. • 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. • Start command is defined by P036 [Start Source]. • Speed Reference command is defined by P038 [Speed Reference]. • Start/Hand key switches control to the integral keypad in a bumpless transfer and switches the speed reference to the integral keypad. • Stop key stops the drive and the drive switches to HAND mode. Table 4.A P042 [Auto Mode] = 1 “Hnd-Off-Auto” (Default) T051-T054 [Digital Inx Sel] ≠ 2 “Auto Mode” or 3 “Local” HAND Mode AUTO Mode Key LED Key Function LED Key Function On Starts drive. On Changes to HAND Mode and Starts drive. Runs according to Speed Increment/ Runs according to Speed Increment/ Decrement keys. Decrement keys. On Changes speed. Off Not active. Keys are only active if P038 [Speed Source] = 0 “Drive Pot”. Off Changes to AUTO Mode. On Not active. N/A Stops drive. N/A Changes to HAND Mode and Stops drive. PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-17 Viewing and Editing Parameters 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 Key(s) Example Displays 1. 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.) 2. Press the Up Arrow or Down Arrow to scroll or through the Basic Display Group parameters. (Only in Display Groups) 3. Press Esc once to display the Basic Display Group parameter number shown on power-up. The parameter number will flash. 4. Press Esc again to enter the group menu. The group menu letter will flash. 5. Press the Up Arrow or Down Arrow to scroll or through the group menu (b, P, T, C, A and d). 6. Press Enter or Sel to enter a group. The right or digit of the last viewed parameter in that group will flash. 7. Press the Up Arrow or Down Arrow to scroll or through the parameters that are in the group. 8. Press Enter or Sel to view the value of a or parameter. If you do not want to edit the value, press Esc to return to the parameter number. 9. Press Enter or Sel to enter program mode to edit the parameter value. The right digit will or 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 or 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 b001 [Output Freq] is displayed. Press Enter or Sel to enter the last group menu viewed. English-18 PowerFlex 400 Adjustable Frequency AC Drive Quick Start Basic Display Group Parameters The Basic Program Group contains the most commonly changed parameters. No. Parameter Min/Max Display/Options b001 [Output Freq] 0.00/[Maximum Freq] 0.01 Hz b002 [Commanded Freq] 0.00/[Maximum Freq] 0.01 Hz b003 [Output Current] 0.0/(Drive Amps × 2) 0.1 Amps b004 [Output Voltage] 0/510 1 VAC b005 [DC Bus Voltage] 0/820 1 VDC b006 [Drive Status] 0/1 (1 = Condition True) Bit 4 Bit 3 Bit 2 Bit 1 Decelerating Accelerating Forward Running b007 [Fault 1 Code] 0/122 1 b008 [Process Display] 0.00/9999.99 0.01 b010 [Output Power] 0.0/999.9 kW 0.1 kW b011 [Elapsed MWh] 0/3276.7 MWh 0.1 MWh b012 [Elapsed Run Time] 0/9999 Hrs 1 = 10 Hrs b013 [Torque Current] 0.0/(Drive Amps × 2) 0.1 Amps b014 [Drive Temp] 0/120 degC 1 degC b015 [Elapsed kWh] 0.0/100.0 kWh 0.1 kWh Smart Start-Up with Basic Program Group The PowerFlex 400 is designed so that start up is simple and efficient. The Program Group contains the most commonly used parameters. = Stop drive before changing this parameter. No. Parameter Min/Max Display/Options Default P031 [Motor NP Volts] 20/Drive Rated Volts 1 VAC Based on Drive Rating Set to the motor nameplate rated volts. P032 [Motor NP Hertz] 15/320 Hz 1 Hz 60 Hz Set to the motor nameplate rated frequency. P033 [Motor OL Current] 0.0/(Drive Amps × 2) 0.1 Amps Based on Drive Rating Set to the maximum allowable motor current. P034 [Minimum Freq] 0.0/320.0 Hz 0.1 Hz 0.0 Hz Sets the lowest frequency the drive will output continuously. P035 [Maximum Freq] 0.0/320.0 Hz 0.1 Hz 60.0 Hz Sets the highest frequency the drive will output. P036 [Start Source] 0/6 0 = “Keypad” 3 1 = “3-Wire” Sets the control scheme used to start the drive 2 = “2-Wire” when in Auto/Remote mode. 3 = “2-W Lvl Sens” 4 = “2-W Hi Speed” 5 = “Comm Port” 6 = “2-W Lvl/Enbl” (1) P037 [Stop Mode] 0/7 0 = “Ramp, CF” 0 (1) 1 = “Coast, CF” Active stop mode for all stop sources [e.g. keypad, (1) 2 = “DC Brake, CF” run forward (I/O Terminal 02), run reverse (I/O (1) 3 = “DCBrkAuto,CF” Terminal 03), RS485 port] except as noted below. 4 = “Ramp” Important: I/O Terminal 01 is always a coast to 5 = “Coast” stop input except when P036 [Start Source] is set 6 = “DC Brake” for “3-Wire” control. When in three wire control, I/O 7 = “DC BrakeAuto” Terminal 01 is controlled by P037 [Stop Mode]. (1) Stop input also clears active fault. PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-19 = Stop drive before changing this parameter. No. Parameter Min/Max Display/Options Default P038 [Speed Reference] 0/5 0 = “Drive Keypad” 2 1 = “InternalFreq” Sets the source of the speed reference to the drive. 2 = “Analog In 1” Important: When T051 – T054 [Digital Inx Sel] is 3 = “Analog In 2” set to option 1, 2, 3, 4, 5, 8, 14, 15, 16 or 17 and 4 = “Preset Freq” the digital input is active, or if A152 [PID Ref Sel] is 5 = “Comm Port” not set to option 0, the speed reference commanded by this parameter will be overridden. Refer to Chapter 1 of the PowerFlex 400 User Manual for details. P039 [Accel Time 1] 0.00/600.00 Secs 0.01 Secs 20.00 Secs Sets the rate of accel for all speed increases. P040 [Decel Time 1] 0.00/600.00 Secs 0.01 Secs 20.00 Secs Sets the rate of decel for all speed decreases. P041 [Reset To Defalts] 0/1 0 = “Ready/Idle” 0 1 = “Factory Rset” Resets all parameter values to factory defaults. P042 [Auto Mode] 0/3 1 0 = “No Function” 1 = “Hnd-Off-Auto” Determines the operation of the “Auto” key on the 2 = “Local/Remote” integral keypad. 3 = “Auto/Manual” P043 [Motor OL Ret] 0/1 0 = “Disabled” 0 = “Disabled” 1 = “Enabled” Enables/disables the Motor Overload Retention function. Terminal Block Group Parameters No. Parameter Min/Max Display/Options Default T051 [Digital In1 Sel] 0/36 0 = “Not Used” 14 = “Anlg1 InCtrl” 1 I/O Terminal 05 1 = “Purge” 15 = “Anlg2 InCtrl” T052 [Digital In2 Sel] 2 = “Auto Mode” 16 = “MOP Up” 3 I/O Terminal 06 3 = “Local” 17 = “MOP Down” T053 [Digital In3 Sel] 4 = “Comm Port” 18 = “Acc & Dec 2” 10 I/O Terminal 07 5 = “PID Disable” 19 = “Current Lmt2” T054 [Digital In4 Sel] 6 = “PID Hold” 20 = “Force DC” 4 I/O Terminal 08 7 = “PID Reset” 21 = “Mtr I-Lock 1” 8 = “Preset Freq” 22 = “Mtr I-Lock 2” 9 = “Aux Fault” 23 = “Mtr I-Lock 3” 10 = “Clear Fault” 24 = “Mtr I-Lock 4” 11 = “RampStop,CF” 25 = “Cmd Reverse” 12 = “CoastStop,CF” 31 = “Logic In 1” 13 = “DCInjStop,CF” 32 = “Logic In 2” 36 = “Damper Input” T055 [Relay Out1 Sel] 0/23 0 = “Ready/Fault” 9 = “Above Anlg 2” 0 T060 [Relay Out2 Sel] 1 = “At Frequency” 10 = “Above PF Ang” 2 2 = “MotorRunning” 11 = “Anlg In Loss” 3 = “Hand Active” 12 = “ParamControl” 4 = “Motor Overld” 13 = “Retries Exst” 5 = “Ramp Reg” 14 = “NonRec Fault” 6 = “Above Freq” 15 = “Reverse” 7 = “Above Cur” 16 = “Logic In 1” 8 = “Above DCVolt” 17 = “Logic In 2” 23 = “Aux Motor” T056 [Relay Out1 Level] 0.0/9999 0.1 0.0 T058 [Relay 1 On Time] 0.0/600.0 Secs 0.1 Secs 0.0 Secs T059 [Relay 1 Off Time] 0.0/600.0 Secs 0.1 Secs 0.0 Secs T061 [Relay Out2 Level] 0.0/9999 0.1 0.0 T060 Setting T061 Min/Max 6 0/320 Hz 7 0/180% 8 0/815 Volts 9 0/100% 10 1/180 degs 12 0/1 T063 [Relay 2 On Time] 0.0/600.0 Secs 0.1 Secs 0.0 Secs English-20 PowerFlex 400 Adjustable Frequency AC Drive Quick Start No. Parameter Min/Max Display/Options Default T064 [Relay 2 Off Time] 0.0/600.0 Secs 0.1 Secs 0.0 Secs T065 [Opto Out Sel] 0/17 0 = “Ready/Fault” 9 = “Above Anlg 2” 1 1 = “At Frequency” 10 = “Above PF Anlg” 2 = “MotorRunning” 11 = “Anlg In Loss” 3 = “Hand Active” 12 = “ParamControl” 4 = “Motor Overld” 13 = “Retries Exst” 5 = “Ramp Reg” 14 = “NonRec Fault” 6 = “Above Freq” 15 = “Reverse” 7 = “Above Cur” 16 = “Logic In 1” 8 = “Above DCVolt” 17 = “Logic In 2” T066 [Opto Out Level] 0.0/9999 0.1 0.0 T065 Setting T066 Min/Max 6 0/400 Hz 7 0/180% 8 0/815 Volts 9 0/100% 10 1/180 degs 12 0/1 T068 [Opto Out Logic] 0/1 1 0 T068 Option Opto Out Logic 0 NO (Normally Open) 1 NC (Normally Closed) T069 [Analog In 1 Sel] 0/6 1 2 T069 Option Setting Input Range DIP Switch AI1 Setting 0 Current Mode 0-20 mA 0-10V 1 Current Mode 4-20 mA 0-10V 2 Voltage Mode - Unipolar 0-10V 0-10V 4 Current Mode (Square Root) 0-20 mA 0-10V 5 Current Mode (Square Root) 4-20 mA 0-10V 6 Voltage Mode - Unipolar (Square Root) 0-10V 0-20 mA T070 [Analog In 1 Lo] 0.0/100.0% 0.1% 0.0% T074 [Analog In 2 Lo] T071 [Analog In 1 Hi] 0.0/100.0% 0.1% 100.0% T075 [Analog in 2 Hi] T072 [Analog In 1 Loss] 0/6 0 = “Disabled” 3 = “Zero Ref” 0 T076 [Analog In 2 Loss] 1 = “Fault (F29)” 4 = “Min Freq Ref” 2 = “Stop” 5 = “Max Freq Ref” 6 = “Int Freq Ref” T073 [Analog In 2 Sel] 0/7 1 2 T073 Option Setting Input Range DIP Switch AI1 Setting 0 Current Mode 0-20 mA 20 mA 1 Current Mode 4-20 mA 20 mA 2 Voltage Mode - Unipolar 0-10V 10V 3 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 T077 [Sleep-Wake Sel] 0/3 0 = “Disabled” 2 = “Analog In 2” 0 1 = “Analog In 1” 3 = “Command Freq” T078 [Sleep Level] 0.0/100.0% 0.1% 10.0% T079 [Sleep Time] 0.0/600.0 Secs 0.1 Secs 0.0 Secs T080 [Wake Level] 0.0/100.0% 0.1% 15.0% T081 [Wake Time] 0.0/600.0 Secs 0.1 Secs 0.0 Secs PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-21 No. Parameter Min/Max Display/Options Default T082 [Analog Out1 Sel] 0/20 1 0 T085 [Analog Out2 Sel] 1 Output Min. Output DIP Switch Related Setting Range Value Max. Output Value Filter AO1 Parameter 0 OutFreq 0-10 0-10V 0V = 0 Hz [Maximum Frequency] None 10V b001 1 OutCurr 0-10 0-10V 0V = 0 Amps 200% Drive Rated FLA Filter A 10V b003 2 OutTorq 0-10 0-10V 0V = 0 Amps 200% Drive Rated FLA Filter A 10V b013 3 OutVolt 0-10 0-10V 0V = 0 Volts 120% Drive Rated Output V None 10V b004 4 OutPowr 0-10 0-10V 0V = 0 kW 200% Drive Rated Power Filter A 10V b010 5 Setpnt 0-10 0-10V 0V = 0.0% 100.0% Setting None 10V T084 6 TstData 0-10 0-10V 0V = 0000 65535 (Hex FFFF) None 10V A196 7 OutFreq 0-20 0-20 mA 0 mA = 0 Hz [Maximum Frequency] None 20 mA b001 8 OutCurr 0-20 0-20 mA 0 mA = 0 Amps 200% Drive Rated FLA Filter A 20 mA b003 9 OutTorq 0-20 0-20 mA 0 mA = 0 Amps 200% Drive Rated FLA Filter A 20 mA b013 10 OutVolt 0-20 0-20 mA 0 mA = 0 Volts 120% Drive Rated Output V None 20 mA b004 11 OutPowr 0-20 0-20 mA 0 mA = 0 kW 200% Drive Rated Power Filter A 20 mA b010 12 Setpnt 0-20 0-20 mA 0 mA = 0.0% 100.0% Setting None 20 mA T084 13 TstData 0-20 0-20 mA 0 mA = 0000 65535 (Hex FFFF) None 20 mA A196 14 OutFreq 4-20 4-20 mA 4 mA = 0 Hz [Maximum Frequency] None 20 mA b001 15 OutCurr 4-20 4-20 mA 4 mA = 0 Amps 200% Drive Rated FLA Filter A 20 mA b003 16 OutTorq 4-20 4-20 mA 4 mA = 0 Amps 200% Drive Rated FLA Filter A 20 mA b013 17 OutVolt 4-20 4-20 mA 4 mA = 0 Volts 120% Drive Rated Output V None 20 mA b004 18 OutPowr 4-20 4-20 mA 4 mA = 0 kW 200% Drive Rated Power Filter A 20 mA b010 19 Setpnt 4-20 4-20 mA 4 mA = 0.0% 100.0% Setting None 20 mA T084 20 TstData 4-20 4-20 mA 4 mA = 0000 65535 (Hex FFFF) None 20 mA A196 T083 [Analog Out1 High] 0/800% 1% 100% T086 [Analog Out2 High] 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” 18 mA for 200% Drive Rated Power T084 [Anlg Out1 Setpt] 0.0/100.0% 0.1% 0.0% T087 [Anlg Out2 Setpt] T088 [Anlg Loss Delay] 0.0/20.0 Secs 0.1 Secs 0.0 Secs Communications Group Parameters No. Parameter Min/Max Display/Options Default C101 [Language] 1/10 1 = “English” 6 = “Reserved” 1 2 = “Français” 7 = “Português” 3 = “Español” 8 = “Reserved” 4 = “Italiano” 9 = “Reserved” 5 = “Deutsch” 10 = “Nederlands” C102 [Comm Format] 0/9 0 = “RTU 8-N-1” 5 = “RTU 8-O-2” 0 1 = “RTU 8-E-1” 6 = “MetaSys N2” Power to drive must be cycled before any 2 = “RTU 8-O-1” 7 = “P1 8-N-1” changes will affect drive operation. 3 = “RTU 8-N-2” 8 = “P1 8-E-1” 4 = “RTU 8-E-2” 9 = “P1 8-O-1” C103 [Comm Data Rate] 0/5 0 = “1200” 3 = “9600” 0 1 = “2400” 4 = “19.2K” 2 = “4800” 5 = “38.4K” C104 [Comm Node Addr] 1/247 1 100 C105 [Comm Loss Action] 0/5 0 = “Fault” 3 = “Continu Last” 0 1 = “Coast Stop” 4 = “Run Preset 0” 2 = “Stop” 5 = “Kypd Inc/Dec” C106 [Comm Loss Time] 0.1/60.0 Secs 0.1 Secs 5.0 Secs C107 [Comm Write Mode] 0/1 0 = “Save” 1 = “RAM Only” 0 C108 [Start Source 2] 0/6 0 = “Keypad” 3 = “2-W Lvl Sens” 3 1 = “3-Wire” 4 = “2-W Hi Speed” Sets the control scheme used to start the drive 2 = “2-Wire” 5 = “Comm Port” when in Auto/Remote mode. 6 = “2-W Lvl/Enbl” C109 [Speed Ref 2] 0/5 0 = “Drive Keypad” 3 = “Analog In 2” 2 1 = “InternalFreq” 4 = “Preset Freq” 2 = “Analog In 1” 5 = “Comm Port” English-22 PowerFlex 400 Adjustable Frequency AC Drive Quick Start Advanced Program Group Parameters No. Parameter Min/Max Display/Options Default A141 [Purge Frequency] 0.0/320.0 Hz 0.1 Hz 5.0 Hz A142 [Internal Freq] 0.00/320.00 Hz 0.01 Hz 60.00 Hz A143 [Preset Freq 0] 0.0/320.0 Hz 0.1 Hz 0.0 Hz A144 [Preset Freq 1] 5.0 Hz A145 [Preset Freq 2] 10.0 Hz A146 [Preset Freq 3] 20.0 Hz A147 [Accel Time 2] 0.00/600.00 Secs 0.01 Secs 30.00 Secs A148 [Decel Time 2] 0.00/600.00 Secs 0.01 Secs 30.00 Secs A149 [S Curve %] 0/100% 1% 20% A150 [PID Trim Hi] 0.0/320.0 Hz 0.1 Hz 60.0 Hz A151 [PID Trim Lo] 0.0/320.0 Hz 0.1 Hz 0.0 Hz A152 [PID Ref Sel] 0/8 0 = “PID Disabled” 4 = “Comm Port” 0 1 = “PID Setpoint” 5 = “Setpnt, Trim” 2 = “Analog In 1” 6 = “A-In 1, Trim” 3 = “Analog In 2” 7 = “A-In 2, Trim” 8 = “Comm, Trim” A153 [PID Feedback Sel] 0/2 0 = “Analog In 1” 2 = “Comm Port” 0 1 = “Analog In 2” A154 [PID Prop Gain] 0.00/99.99 0.01 1.00 A155 [PID Integ Time] 0.0/999.9 Secs 0.1 Secs 2.0 Secs A156 [PID Diff Rate] 0.00/99.99 (1/Secs) 0.01 (1/Secs) 0.00 (1/Secs) A157 [PID Setpoint] 0.0/100.0% 0.1% 0.0% A158 [PID Deadband] 0.0/10.0% 0.1% 0.0% A159 [PID Preload] 0.0/320.0 Hz 0.1 Hz 0.0% A160 [Process Factor] 0.1/999.9 0.1 30.0 A163 [Auto Rstrt Tries] 0/9 1 0 A164 [Auto Rstrt Delay] 0.0/160.0 Secs 0.1 Secs 1.0 Secs A165 [Start At PowerUp] 0/1 0 = “Disabled” 1 = “Enabled” 0 A166 [Reverse Disable] 0/1 0 = “Rev Enabled” 1 = “Rev Disabled” 1 A167 [Flying Start En] 0/1 0 = “Disabled” 1 = “Enabled” 0 A168 [PWM Frequency] 2.0/8.0, 10.0 kHz 0.1 kHz 4.0 kHz A169 [PWM Mode] 0/1 0 = “Space Vector” 1 = “2-Phase” 1 A170 [Boost Select] 0/15 Settings in % of base voltage. 4 Only active when A125 [Torque Perf Mode] is 0 = “Custom V/Hz” set to 0 “V/Hz”. Variable Torque Constant Torque 1 = “30.0, VT” 5 = “0.0, no IR” 10 = “10.0, CT” 2 = “35.0, VT” 6 = “0.0” 11 = “12.5, CT” 3 = “40.0, VT” 7 = “2.5, CT” 12 = “15.0, CT” 4 = “45.0, VT” 8 = “5.0, CT” 13 = “17.5, CT” 9 = “7.5, CT” 14 = “20.0, CT” 15 = “Kepco” A171 [Start Boost] 0.0/25.0% 1.1% 2.5% Only active when A084 [Boost Select] and A125 [Torque Perf Mode] are set to “0”. A172 [Break Voltage] 0.0/100.0% 0.1% 25.0% Only active when A084 [Boost Select] and A125 [Torque Perf Mode] are set to “0”. A173 [Break Frequency] 0.0/320.0 Hz 0.1 Hz 15.0 Hz Only active when A084 [Boost Select] and A125 [Torque Perf Mode] are set to “0”. A174 [Maximum Voltage] 20/Rated Volts 1 VAC Rated Volts A175 [Slip Hertz @ FLA] 0.0/10.0 Hz 0.1 Hz 2.0 Hz A176 [DC Brake Time] 0.0/99.9 Secs 0.1 Secs 0.0 Secs A177 [DC Brake Level] 0.0/(Drive Amps × 1.5) 0.1 Amps Amps × 0.05 A178 [DC Brk Time@Strt] 0.0/99.9 Secs 0.1 Secs 0.0 Secs A179 [Current Limit 1] 0.0/(Drive Amps × 1.5) 0.1 Amps Amps × 1.1 A180 [Current Limit 2] A181 [Motor OL Select] 0/2 0 = “No Derate” 1 = “Min Derate” 0 2 = “Max Derate” PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-23 No. Parameter Min/Max Display/Options Default A182 [Drive OL Mode] 0/3 0 = “Disabled” 2 = “Reduce PWM” 3 1 = “Reduce CLim” 3 = “Both-PWM 1st” A183 [SW Current Trip] 0.0/(Drive Amps × 1.8) 0.1 Amps 0.0 (Disabled) A184 [Load Loss Level] 0.0/Drive Amps 0.1 Amps 0.0 (Disabled) A185 [Load Loss Time] 0/9999 Secs 1 Secs 0 (Disabled) A186 [Stall Fault Time] 0/5 0 = “60 Seconds” 3 = “360 Seconds” 0 1 = “120 Seconds” 4 = “480 Seconds” 2 = “240 Seconds” 5 = “Flt Disabled” A187 [Bus Reg Mode] 0/1 0 = “Disabled” 1 = “Enabled” 1 A188 [Skip Frequency 1] 0/320 Hz 1 Hz 0 Hz A189 [Skip Freq Band 1] 0.0/30.0 Hz 0.1 Hz 0.0 Hz A190 [Skip Frequency 2] 0/320 Hz 1 Hz 0 Hz A191 [Skip Freq Band 2] 0.0/30.0 Hz 0.1 Hz 0.0 Hz A192 [Skip Frequency 3] 0/320 Hz 1 Hz 0 Hz A193 [Skip Freq Band 3] 0.0/30.0 Hz 0.1 Hz 0.0 Hz A194 [Compensation] 0/3 0 = “Disabled” 2 = “Mechanical” 3 1 = “Electrical” 3 = “Both” A195 [Reset Meters] 0/2 0 = “Ready/Idle” 1 = “Reset MWh” 0 2 = “Reset Time” A196 [Testpoint Sel] 1024/65535 1 1024 A197 [Fault Clear] 0/2 0 = “Ready/Idle” 1 = “Reset Fault” 0 2 = “Clear Buffer” A198 [Program Lock] 0/3 0 = “Unlocked” 2 = “Locked” (Not Network) 0 1 = “Locked” (All) 3 = “Locked” (P035, A170) A199 [Motor NP Poles] 2/40 1 4 A200 [Motor NP FLA] 0.1/(Drive Amps × 2) 0.1 Amps Rated Amps Aux Relay Card Group Parameters No. Parameter Min/Max Display/Options Default R221 [Relay Out3 Sel] 0/23 0 = “Ready/Fault” 9 = “Above Anlg 2” 0 R224 [Relay Out4 Sel] 1 = “At Frequency” 10 = “Above PF Ang” R227 [Relay Out5 Sel] 2 = “MotorRunning” 11 = “Anlg In Loss” R230 [Relay Out6 Sel] 3 = “Hand Active” 12 = “ParamControl” R233 [Relay Out7 Sel] 4 = “Motor Overld” 13 = “Retries Exst” R236 [Relay Out8 Sel] 5 = “Ramp Reg” 14 = “NonRec Fault” 6 = “Above Freq” 15 = “Reverse” 7 = “Above Cur” 16 = “Logic In 1” 8 = “Above DCVolt” 17 = “Logic In 2” 23 = “Aux Motor” R222 [Relay Out3 Level] 0.0/9999 Hz 0.1 0.0 R225 [Relay Out4 Level] R228 [Relay Out5 Level] R231 [Relay Out6 Level] R234 [Relay Out7 Level] R237 [Relay Out8 Level] [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 R239 [Aux Motor Mode] 0/1 0 = “Disabled” 1 = “Enabled” 0 R240 [Aux Motor Qty] 1/6 1 = “1 Aux Mtr” 4 = “1 Mtr + Swap” 1 2 = “2 Aux Mtr” 5 = “2 Mtr + Swap” 3 = “3 Aux Mtr” 6 = “3 Mtr + Swap” R241 [Aux 1 Start Freq] 0.0/320.0 Hz 0.1 Hz 50.0 Hz R244 [Aux 2 Start Freq] R247 [Aux 3 Start Freq] English-24 PowerFlex 400 Adjustable Frequency AC Drive Quick Start No. Parameter Min/Max Display/Options Default R242 [Aux 1 Stop Freq] 0.0/320.0 Hz 0.1 Hz 25.0 Hz R245 [Aux 2 Stop Freq] R248 [Aux 3 Stop Freq] R243 [Aux 1 Ref Add] 0.0/100.0% 0.1% 0.0% R246 [Aux 2 Ref Add] R249 [Aux 3 Ref Add] R250 [Aux Start Delay] 0.0/999.9 Secs 0.1 Secs 5.0 Secs R251 [Aux Stop Delay] 0.0/999.9 Secs 0.1 Secs 3.0 Secs R252 [Aux Prog Delay] 0.00/60.00 Secs 0.01 Secs 0.50 Secs R253 [Aux AutoSwap Tme] 0.0/999.9 Hrs 0.1 Hrs 0.0 Hr R254 [Aux AutoSwap Lvl] 0.0/100.0% 0.1% 50.0% Advanced Display Group Parameters No. Parameter Min/Max Display/Options Default d301 [Control Source] 0/99 Digit 0: Start Command Digit 1: Speed Command Read Only 0 = Keypad 0 = Local Keypad Pot 1 = Terminal Block 1 = A142 2 = Communications 2 = Analog Input 1 3 = Analog Input 2 4 = A143-146 5 = Communications d302 [Control In Status] 0/1 Read Only (1 = Condition True) Display Digit (Right to Left) I/O Terminal Control Input 0 02 Start/FWD In 1 03 Dir/Rev In 2 01 Stop Input 3 05 Digital In 1 4 06 Digital In 2 5 07 Digital In 3 6 08 Digital In 4 d303 [Comm Status] 0/1 Digit 0: Received Good Message Packet Read Only (1 = Condition True) Digit 1: Transmitting Message Digit 2: DSI Peripheral Connected Digit 3: Received Bad Message Packet d304 [PID Setpnt Displ] 0.0/100.0% 0.1% 0.0% d305 [Analog In 1] 0.0/120.0% 0.1% 0.0% d306 [Analog In 2] d307 [Fault 1 Code] 0/122 1 Read Only d308 [Fault 2 Code] d309 [Fault 3 Code] d310 [Fault 1 Time-hr] 0/9999 Hrs 1 Hrs Read Only d312 [Fault 2 Time-hr] d314 [Fault 3 Time-hr] d311 [Fault 1 Time-min] 0.0/60.0 Min 0.1 Min Read Only d313 [Fault 2 Time-min] d315 [Fault 3 Time-min] d316 [Elapsed Time-hr] 0/32767 1 Hr Read Only d317 [Elapsed Time-min] 0.0/60.0 Min 0.1 Min Read Only d318 [Output Powr Fctr] 0.0/180.0 deg 0.1 deg Read Only d319 [Testpoint Data] 0/FFFF 1 Hex Read Only d320 [Control SW Ver] 1.00/99.99 0.01 Read Only d321 [Drive Type] Used by Rockwell Automation field service personnel. d322 [Output Speed] 0.0/100.0% 0.1% Read Only d323 [Output RPM] 0/24000 RPM 1 RPM Read Only d324 [Fault Frequency] 0.00/320.00 Hz 0.01 Hz Read Only d325 [Fault Current] 0.0/(Drive Amps × 2) 0.1 Amps Read Only d326 [Fault Bus Volts] 0/820 VDC 1 VDC Read Only d327 [Status @ Fault] 0/1 1 Read Only PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-25 Fault Codes To clear a fault, press the Stop key, cycle power or set A100 [Fault Clear] to 1 or 2. No. Fault Description (1) F2 Auxiliary Input Check remote wiring. F3 Power Loss Monitor the incoming AC line for low voltage or line power interruption. (1) F4 UnderVoltage Monitor the incoming AC line for low voltage or line power interruption. (1) F5 OverVoltage 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 a dynamic brake chopper. (1) F6 Motor Stalled Increase [Accel Time x] or reduce load so drive output current does not exceed the current set by parameter A089 [Current Limit]. (1) F7 Motor Overload An excessive motor load exists. Reduce load so drive output current does not exceed the current set by parameter P033 [Motor OL Current]. (1) F8 Heatsink OvrTmp Check for blocked or dirty heat sink fins. Verify that ambient temperature has not exceeded 40°C (104°F) for IP 30/NEMA 1/UL Type 1 installations or 50°C (122°F) for Open type installations. Check fan. F12 HW OverCurrent Check programming. Check for excess load, improper DC boost setting, DC brake volts set too high or other causes of excess current. F13 Ground Fault Check the motor and external wiring to the drive output terminals for a grounded condition. F15 Load Loss Check for load loss (i.e., a broken belt). (1) F29 Analog Input Loss An analog input is configured to fault on signal loss. A signal loss has occurred. F33 Auto Rstrt Tries Correct the cause of the fault and manually clear. F38 Phase U to Gnd Check the wiring between the drive and motor. Check motor for grounded phase. Replace drive if fault cannot be cleared. F39 Phase V to Gnd F40 Phase W to Gnd F41 Phase UV Short Check the motor and drive output terminal wiring for a shorted condition. Replace drive if fault cannot be cleared. F42 Phase UW Short F43 Phase VW Short F48 Params Defaulted The drive was commanded to write default values to EEPROM. Clear the fault or cycle power to the drive. Program the drive parameters as needed. (1) F63 SW OverCurrent Check load requirements and A098 [SW Current Trip] setting. F64 Drive Overload Reduce load or extend Accel Time. F70 Power Unit Cycle power. Replace drive if fault cannot be cleared. F71 Net Loss The communication network has faulted. F81 Comm Loss If adapter was not intentionally disconnected, check wiring to the port. Replace wiring, port expander, adapters or complete drive as required. Check connection. An adapter was intentionally disconnected. Turn off using C105 [Comm Loss Action]. F94 Function Loss Close input to terminal 01 and re-start the drive. F100 Parameter Checksum Restore factory defaults. F122 I/O Board Fail Cycle power. Replace drive if fault cannot be cleared. (1) Auto-Reset/Run type fault. Configure with parameters A092 and A093. For a complete listing of Faults and Alarms, refer to the PowerFlex 400 User Manual. English-26 PowerFlex 400 Adjustable Frequency AC Drive Quick Start Dimensions PowerFlex 400 Frames Output Power Frame Size kW HP 208-240V AC Input 400-480V AC Input 2.2-7.5 3-10 C C 11-15 15-20 D C 18.5-22 25-30 D D 30-37 40-50 E E 45-75 60-100 – E 90-110 125-150 – F Figure 5: PowerFlex 400 Frames C-F IP20/66 (NEMA Type 1/4X/12) Flange Mount A 300 244 D C (11.81) (9.61) E 325 B (12.8) 24.5 105.8 138.2 F (0.96) (4.17) (5.44) Dimensions are in millimeters and (inches). (1) Weight FrameABCDE F kg (lbs.) C 130.0 (5.1) 260.0 (10.2) 180.0 (7.1) 116.0 (4.57) 246.0 (9.7) 5.8 (0.23) 4.33 (9.5) D 250.0 (9.84) 436.2 (17.17) 206.1 (8.11) 226.0 (8.90) 383.4 (15.09) 9.0 (0.35) 14.0 (30.9) E 370.0 (14.57) 605.5 (23.84) 259.2 (10.21) 335.0 (13.19) 567.4 (22.34) 8.5 (0.33) 51.2 (112.9) F 425.0 (16.73) 850.0 (33.46) 264.0 (10.39) 381.0 (15.00) 647.5 (25.49) 13.0 (0.51) 88.0 (194.0) (1) Weights include HIM and Standard I/O. EMC Line Filters Figure 6: Catalog Numbers: 22-RF018-CS, 22-RF018-CL, 22-RF026-CS, 22-RF026-CL, 22-RF026-CL, 22-RF034-CS 130 60 (5.12) (2.36) 90 32 (3.54) (1.26) 309 297 (12.17) (11.69) 297 (11.69) 17 30 5.5 (0.22) (0.67) (1.18) PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-27 Figure 7: Catalog Numbers: 22-RFD036, 22-RFD050, 22-RFD070, 22-RFD100, 22-RFD150, 22-RFD180 A D C F B E G Catalog NumberABCD 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 (0.28) 22-RFD050 93 (3.66) 312 (12.28) 190 (7.48) 79 (3.11) 298 (11.73) 13.5 (0.53) 7 (0.28) 22-RFD070 93 (3.66) 312 (12.28) 190 (7.48) 79 (3.11) 298 (11.73) 13.5 (0.53) 7 (0.28) 22-RFD100 93 (3.66) 312 (12.28) 190 (7.48) 79 (3.11) 298 (11.73) 13.5 (0.53) 7 (0.28) 22-RFD150 126 (4.96) 312 (12.28) 224 (8.82) 112 (4.41) 298 (11.73) 19.5 (0.77) 7 (0.28) 22-RFD180 126 (4.96) 312 (12.28) 224 (8.82) 112 (4.41) 298 (11.73) 27 (1.06) 7 (0.28) Dimensions are in millimeters and (inches). Figure 8: Catalog Numbers: 22-RFD330 235 (9.25) 40 15 68 65 65 (1.57) (0.59) (2.68) (2.56) (2.56) 55 25 386 120 (2.17) (0.98) (15.20) (4.72) ∅ 12 (2.56) 306 (12.05) 120 (4.72) ∅ 10.5 (2.56) www.rockwellautomation.com 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 F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846 Publication 22C-QS001A-EN-P – February 2006 Copyright © 2006 Rockwell Automation, Inc. All rights reserved. Printed in Taiwan.