Allen-Bradley PowerFlex400 User Manual
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Allen-Bradley PowerFlex400 User Manual

Adjustable frequency ac drive for fan & pump applications frn 4.xx
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Summary of Contents for Allen-Bradley PowerFlex400

  • Page 1 Adjustable Frequency AC Drive for Fan & Pump Applications FRN 4.xx User Manual www.abpowerflex.com...
  • Page 2 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.

  • Page 3: Important Statement Regarding Differences In Parameter Defaults For

    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 Information See Page(s) 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].
  • Page 4 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. 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.

  • Page 5: Table Of Contents

    Table of Contents Preface Overview Who Should Use this Manual? ..P-1 Reference Materials ....P-1 Manual Conventions .

  • Page 6: Table Of Contents

    Table of Contents Appendix A Supplemental Drive Information Drive, Fuse & Circuit Breaker Ratings . . . A-1 Specifications..... . . A-2 Input Power Connections.

  • Page 7: Who Should Use This Manual?

    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? Reference Materials Manual Conventions Drive Frame Sizes General Precautions...

  • Page 8: Manual Conventions

    Overview Manual Conventions • In this manual we refer to the PowerFlex 400 Adjustable Frequency AC Drive as; drive, PowerFlex 400 or PowerFlex 400 Drive. • Parameter numbers and names are shown in this format: P031 [Motor NP Volts] Name Number Group b = Basic Display Group...

  • Page 9: General Precautions

    Overview 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.

  • Page 10: Catalog Number Explanation

    Overview Catalog Number Explanation Drive Dash Voltage Rating Rating Enclosure Emission Class Comm Slot Code Code Version 22C PowerFlex 400 RS485 Code Rating Not Filtered Code Voltage 240V AC 3 480V AC 3 Code Interface Module Fixed Keypad Code Enclosure Panel Mount - IP20/UL Open-Type Panel Mount - IP30/NEMA 1/UL Type 1 Flange Mount - IP20/UL Open Type...

  • Page 11: Opening The Cover

    Chapter 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 Fuses and Circuit Breakers 1-9 Mounting Considerations Power Wiring 1-11 AC Supply Source Considerations 1-6 I/O Wiring 1-15 Recommendations...
  • Page 12 Installation/Wiring Frame D Drives 1. Loosen the two captive cover screws. 2. Pull the bottom of the cover out and up to release. Frame E Drives 1. Loosen the four captive cover screws. 2. Pull the bottom of the cover out and up to release.
  • Page 13 Installation/Wiring Frame F Drives 1. Turn the latch counterclockwise. 2. Pull on the latch to swing the door open.

  • Page 14: Mounting Considerations

    Installation/Wiring Mounting Considerations • Mount the drive upright on a flat, vertical and level surface. Frame Screw Size Screw Torque M5 (#10-24) 2.45-2.94 N-m (22-26 lb.-in.) M8 (5/16 in.) 6.0-7.4 N-m (53.2-65.0 lb.-in.) M8 (5/16 in.) 8.8-10.8 N-m (78.0-95.3 lb.-in.) M10 (3/8 in.) 19.6-23.5 N-m (173.6-208.3 lb.-in.) •...
  • Page 15 Installation/Wiring Figure 1.2 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.)

  • Page 16: Ac Supply Source Considerations

    Installation/Wiring AC Supply Source Considerations 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. 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...
  • Page 17 Installation/Wiring 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.A 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.

  • Page 18: General Grounding Requirements

    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 R/L1 U/T1...

  • Page 19: Fuses And Circuit Breakers

    Installation/Wiring RFI 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.
  • Page 20 1-10 Installation/Wiring 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) 140M-D8E-C16 100-C23 – 3-Phase 3.7 (5.0) 140M-F8E-C25 100-C37 5.5 (7.5) 140M-F8E-C32 100-C37...

  • Page 21: Power Wiring

    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.
  • Page 22 1-12 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.
  • Page 23 Installation/Wiring 1-13 Reflected Wave Protection The drive should be installed as close to 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.C for recommendations.
  • Page 24 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 S/L2 T/L3 U/T1 V/T2 W/T3 P2 Frame C DC–...

  • Page 25: I/O Wiring Recommendations

    Installation/Wiring 1-15 Table 1.D Power Terminal Block Specifications Frame Maximum Wire Size Minimum Wire Size Recommended Torque 8.4 mm (8 AWG) 1.3 mm (16 AWG) 2.9 N-m (26 lb.-in.) 33.6 mm (2 AWG) 8.4 mm (8 AWG) 5.1 N-m (45 lb.-in.) 480V 33.6 mm (2 AWG)
  • Page 26 1-16 Installation/Wiring Important points to remember about I/O wiring: • Always use copper wire. • Wire with an insulation rating of 600V or greater is recommended. • Control and signal wires should be separated from power wires by at least 0.3 meters (1 foot). ATTENTION: Driving the 4-20mA analog input from a voltage source could cause component damage.
  • Page 27 Installation/Wiring 1-17 Figure 1.7 Control Wiring Block Diagram Typical Typical Stop/ (1)(4) SRC Wiring SNK Wiring Function Loss 1 of 7 Digital Input Circuits Start/Run FWD Direction/Run REV Enable Jumper Digital Common Digital Input 1 ENBL Digital Input 2 Digital Input 3 Digital Input 4 Digital Common Opto Common...
  • Page 28 1-18 Installation/Wiring Table 1.G Control I/O Terminal Designations No. Signal Default Description Param. 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]. Start/Run FWD –...
  • Page 29 Installation/Wiring 1-19 Table 1.H Relay Terminal Designations and DIP Switches No. Signal Default Description Param. #1 Relay N.O. Ready/Fault Normally open contact for No. 1 output relay. T055 #1 Relay Common – Common for output relay. #1 Relay N.C. Ready/Fault Normally closed contact for No.
  • Page 30 1-20 Installation/Wiring I/O Wiring Examples Input/Output Connection Example Required Settings Potentiometer DIP Switch 1-10k Ohm Potentiometer AI1 = 10V Recommended Parameters (2 Watt Minimum) 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...
  • Page 31 Installation/Wiring 1-21 Input/Output Connection Example Required Settings Analog Output DIP Switch Unipolar, 4-20 mA Output AO1 = 20MA • 525 Ohm Maximum Parameters T082 [Analog Out1 Sel] = 14 through 20 Common Scaling T083 [Analog Out1 High] T084 [Analog Out1 Setpt] 2 Wire Control DIP Switch Sourcing (SRC),...
  • Page 32 1-22 Installation/Wiring Input/Output Connection Example Required Settings 2 Wire Control DIP Switch Sourcing (SRC), SNK/SRC = SRC Internal Supply, Parameters Run FWD/Run REV P036 [Start Source] = 2, 3, 4 • Input must be active for the Stop-Run P037 [Stop Mode] = 0 through 7 Forward drive to run.
  • Page 33 Installation/Wiring 1-23 Input/Output Connection Example Required Settings Opto Output Parameters T065 [Opto Out Sel] = 0 through 15 • When using Opto Output with T066 [Opto Out Level] an inductive load such as a T068 [Opto Out Logic] relay, install a recovery diode parallel to the relay as shown to prevent damage to the output.

  • Page 34: Start And Speed Reference Control

    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 P038 [Speed Reference]. The drive Start command is normally normally determined by determined by P036 [Start Source]. However, the settings for these parameters can be overridden by a variety of methods.
  • Page 35 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.

  • Page 36: Rs485 Network Wiring

    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" FRONT Master TxRxD+ TxRxD+ 120 ohm resistor TxRxD+...

  • Page 37: Emc Instructions

    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.
  • Page 38 Table 1.J PowerFlex 400 – EN61800-3 Compliance PowerFlex 400 Drive First Environment Restricted First Environment Unrestricted kW (HP) Cat. No. Required Filter Restrict Install Required Filter Restrict Install 22C-… (Allen-Bradley) Motor Drive and Motor Drive and Cable to Filter in Cable to Filter in (Meters) Shielded...

  • Page 39: Fcc Instructions

    Installation/Wiring 1-29 Figure 1.11 Connections and Grounding Shielded Enclosure (1) IP 30/NEMA 1/UL Type 1 Option Kit (Frame C Drives Only) EMI Fittings and Metal Conduit EMI Filter R/L1 U/T1 S/L2 V/T2 T/L3 W/T3 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...
  • Page 40 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 additional grounding recommendations. 2.
  • Page 41 Installation/Wiring 1-31 Figure 1.12 Connections and Grounding Shielded Enclosure (1) IP 30/NEMA 1/UL Type 1 Option Kit (Frame C Drives Only) EMI Fittings and Metal Conduit EMI Filter R/L1 U/T1 S/L2 V/T2 T/L3 W/T3 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.
  • Page 42 1-32 Installation/Wiring Notes:...

  • Page 43: Prepare For Drive Start-Up

    Chapter 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 the General Precautions section before proceeding. ATTENTION: Power must be applied to the drive to perform the following start-up procedures.
  • Page 44 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.

  • Page 45: Integral Keypad

    Start Up Integral Keypad Operator Keys 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.
  • Page 46 Start Up LED Status Indicators 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.

  • Page 47: Viewing And Editing Parameters

    Start Up 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.

  • Page 48: Keypad Hand-Off-Auto Functions

    Start Up Keypad Hand-Off-Auto Functions Parameter P042 [Auto Mode] defines the operation mode of the control keys on the integral keypad. 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.
  • Page 49 Start Up Local/Remote Mode In Local mode: • Start command and speed reference come from the integral keypad Start/Hand and Digital Speed Increment and Decrement keys. • 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.
  • Page 50 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: •...
  • Page 51 Start Up No Function Mode In No Function mode: • The Auto key has no function • Start command is defined by P036 [Start Source] • Speed Reference command is defined by P038 [Speed Reference] Table 2.D P042 [Auto Mode] = 0 “No Function” T051-T054 [Digital Inx Sel] ≠...
  • Page 52 2-10 Start Up Notes:...

  • Page 53: About Parameters

    Chapter 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.

  • Page 54: Parameter Organization

    Programming and Parameters Parameter Organization Refer to page 3-58 for an alphabetical listing of parameters. Group Parameters Basic Display Output Freq b001 Drive Status b006 Elapsed MWh b011 Commanded Freq b002 Fault 1 Code b007 Elapsed Run Time b012 B a s i c D i s p l Output Current b003...
  • Page 55 Programming and Parameters Group Parameters Aux Relay Card Relay Out3 Sel R221 Aux Motor Mode R239 Aux Start Delay R250 Relay Out3 Level R222 Aux Motor Qty R240 Aux Stop Delay R251 A u x R e l a y C a r d Relay Out4 Sel R224...

  • Page 56: Basic Display Group

    Programming and Parameters Basic Display Group b001 [Output Freq] Related Parameter(s): b002, b008, P034, P035, P038 Output frequency present at T1, T2 & T3 (U, V & W). Values Default: Read Only Min/Max: 0.00/P035 [Maximum Freq] Display: 0.01 Hz b002 [Commanded Freq] Related Parameter(s): b001, P034, P035, P038, d302 Value of the active frequency command.
  • Page 57 Programming and Parameters 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 3 Decelerating Bit 4 Values Default: Read Only Min/Max:...
  • Page 58 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].

  • Page 59: Basic Program Group

    Programming and Parameters Basic Program Group P031 [Motor NP Volts] Related Parameter(s): b004, 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]...
  • Page 60 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.
  • Page 61 Programming and Parameters 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 stop input except when P036 [Start Source] is set for...
  • Page 62 3-10 Programming and Parameters Basic Program Group (continued) P038 [Speed Reference] Related Parameter(s): b001, b002, P038, P040, P042, T051-T054, T070, T071, T073, T074, T075, C102, A141, A142, A143-A146, A152, d301 Sets the source of the speed reference to the drive. The drive speed command can be obtained from a number of different sources.
  • Page 63 Programming and Parameters 3-11 Basic Program Group (continued) P040 [Decel Time 1] Related Parameter(s): P038, P039, T051-T054, A141, A143-A146, A148 Sets the rate of deceleration for all speed decreases. Maximum Freq Decel Rate Decel Time Values Default: 20.00 Secs Min/Max: 0.00/600.00 Secs Display: 0.01 Secs...

  • Page 64: Terminal Block Group

    3-12 Programming and Parameters Terminal Block Group T051 [Digital In1 Sel] Related Parameter(s): P036, P038, P039, P040 A141, A142 A143-A146, A147 (I/O Terminal 05) A148, A166, A177, A180, d301, d302 T052 [Digital In2 Sel] (I/O Terminal 06) Stop drive before changing this parameter. T053 [Digital In3 Sel] (I/O Terminal 07) T054 [Digital In4 Sel]...
  • Page 65 Programming and Parameters 3-13 T051- 14 “Anlg1 InCtrl” Selects Analog Input 1 control for the frequency reference. T054 Options 15 “Anlg2 InCtrl” Selects Analog Input 2 control for the frequency (Cont.) reference. 16 “MOP Up” Increases the value of A142 [Internal Freq] at the current Accel rate if P038...
  • Page 66 3-14 Programming and Parameters Terminal Block Group (continued) T055 [Relay Out1 Sel] Related Parameter(s): P033, T056, T058, T059, T069 T072, T073, T076, 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.
  • Page 67 Programming and Parameters 3-15 Terminal Block Group (continued) T056 [Relay Out1 Level] Related Parameter(s): T055, T058, T059, d318 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 0/320 Hz...
  • Page 68 3-16 Programming and Parameters Terminal Block Group (continued) T060 [Relay Out2 Sel] Related Parameter(s): P033, T061, T063, T064, T076 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.
  • Page 69 Programming and Parameters 3-17 Terminal Block Group (continued) T061 [Relay Out2 Level] Related Parameter(s): T060, T063, T064, d318 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. T060 Setting T061 Min/Max 0/320 Hz...
  • Page 70 3-18 Programming and Parameters Terminal Block Group (continued) T065 [Opto Out Sel] Related Parameter(s): P033, T066, T068, T072 T076, A163, d318 Determines 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.
  • Page 71 Programming and Parameters 3-19 Terminal Block Group (continued) T066 [Opto Out Level] Related Parameter(s): T065, T068, A163, d318 32 bit parameter. Determines the on/off point for the opto output when T065 [Opto Out Sel] is set to option 6, 7, 8, 9, 10 or 12.
  • Page 72 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 Hi]. Important: If analog inversion is implemented the drive will go to maximum frequency in the event the analog input is lost.
  • Page 73 Programming and Parameters 3-21 Terminal Block Group (continued) T072 [Analog In 1 Loss] Related Parameter(s): T055, T060, T065, T069, T070 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.
  • Page 74 3-22 Programming and Parameters Terminal Block Group (continued) T074 [Analog In 2 Lo] Related Parameter(s): P034, P038, T072, T073, T075 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].
  • Page 75 Programming and Parameters 3-23 Terminal Block Group (continued) T077 [Sleep-Wake Sel] Related Parameter(s): T078, T079, T080, T081 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 ( ) on the keypad display will flash indicating the drive is in “sleep”...
  • Page 76 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.
  • Page 77 Programming and Parameters 3-25 Terminal Block Group (continued) T084 [Anlg Out1 Setpt] Related Parameter(s): T082, T083 Sets direct parameter control over the analog output. If enabled, this sets the percent value of analog output. Values Default: 0.0% Min/Max: 0.0/100.0% Display: 0.1% T085 [Analog Out2 Sel] Related Parameter(s): P035, T086,...
  • Page 78 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 1 “OutCurr 0-10” 5V for 200% Drive Rated Output Current 11 “OutPowr 0-20”...

  • Page 79: Communications Group

    Programming and Parameters 3-27 Communications Group C101 [Language] Selects the language displayed by the integral LCD display and remote communications option. Options 1 “English” (Default) 2 “Français” 3 “Español” 4 “Italiano” 5 “Deutsch” 6 “Reserved” 7 “Português” 8 “Reserved” 9 “Reserved” 10 “Nederlands”...
  • Page 80 3-28 Programming and Parameters Communications Group (continued) C104 [Comm Node Addr] Related Parameter(s): d303 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: Min/Max:...
  • Page 81 Programming and Parameters 3-29 Communications Group (continued) C108 [Start Source 2] Related Parameter(s): P037, P042, A166, d301 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.
  • Page 82 3-30 Programming and Parameters Communications Group (continued) C109 [Speed Ref 2] Related Parameter(s): b001, b002, P038, P040, P042, T051-T054, T070, T071, T073, 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.

  • Page 83: Advanced Program Group

    Programming and Parameters 3-31 Advanced Program Group A141 [Purge Frequency] Related Parameter(s): P038, P039, P040, T051-T054 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.
  • Page 84 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 Rate Accel Time Values Default:...
  • Page 85 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: Min/Max:...
  • Page 86 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 details.
  • Page 87 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) Min/Max: 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].
  • Page 88 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.
  • Page 89 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 reverse disabled.
  • Page 90 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 Volts per Hz curve. Drive may add additional voltage unless Option 5 is selected. Options 0 “Custom V/Hz”...
  • Page 91 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”.
  • Page 92 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 Display: 1 VAC A175 [Slip Hertz @ FLA] Related Parameter(s): P033 Compensates for the inherent slip in an induction motor.
  • Page 93 Programming and Parameters 3-41 Advance Program Group (continued) A178 [DC Brk Time@Strt] Related Parameter(s): P037, 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...
  • Page 94 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 1st”...
  • Page 95 Programming and Parameters 3-43 Advance Program Group (continued) A187 [Bus 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 for important information on bus regulation. Options 0 “Disabled”...
  • Page 96 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 disables this parameter.
  • Page 97 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) Some drive/motor combinations have inherent instabilities which are exhibited as non-sinusodial motor currents. This setting attempts to correct this condition.
  • Page 98 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”...

  • Page 99: Aux Relay Card Group

    Programming and Parameters 3-47 Aux Relay Card Group R221 [Relay Out3 Sel] Related Parameters for the Aux Relay Card Group: Aux Parameters R224 [Relay Out4 Sel] PID Parameters R227 [Relay Out5 Sel] Digital Inputs R230 [Relay Out6 Sel] Relays 1 and 2 R233 [Relay Out7 Sel] R236 [Relay Out8 Sel] Sets the condition that changes the state of the output relay contacts.
  • Page 100 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 Out7 Level] R237 [Relay Out8 Level] Sets the trip point for the digital output relay if the value of [Relay OutX Sel] is 6, 7, 8, 9, 10 or 12. [Relay OutX Select Setting [Relay OutX Level] Min/Max 0/320 Hz...
  • Page 101 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 Mtr” (Default) 1 Auxiliary Motor 2 “2 Aux Mtr” 2 Auxiliary Motors 3 “3 Aux Mtr”...
  • Page 102 3-50 Programming and Parameters Aux Relay Card Group (continued) R243 [Aux 1 Ref Add] R246 [Aux 2 Ref Add] R249 [Aux 3 Ref 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.
  • Page 103 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%...

  • Page 104: Advance Display Group

    3-52 Programming and Parameters Advance Display Group d301 [Control Source] Related Parameter(s): P036, P038, T051-T054 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.
  • Page 105 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...
  • Page 106 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 (b007 [Fault 1 Code] = the most recent fault). Repetitive faults will only be recorded once.
  • Page 107 Programming and Parameters 3-55 Advance Display Group (continued) d313 [Fault 2 Time-min] Related Parameter(s): A195, d317 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, d316 Displays the value of the...
  • Page 108 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: 0/FFFF Display: 1 Hex d320 [Control SW Ver] Main Control Board software version. Values Default: Read Only...

  • Page 109: Drive Status

    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 @ Fault] Related Parameter(s): b006 Displays the value of...
  • Page 110 3-58 Programming and Parameters Parameter Cross-Reference – by Name Parameter Name Number Group Page Parameter Name Number Group Page Compensation A194 Advanced Program 3-45 Accel Time 1 P039 Basic Program 3-10 Contrl In Status d302 Advanced Display 3-52 Accel Time 2 A147 Advanced Program 3-32...
  • Page 111 Programming and Parameters 3-59 Parameter Name Number Group Page Parameter Name Number Group Page Relay Out7 Sel R234 Relay Card 3-48 Motor OL Current P033 Basic Program Relay Out8 Level R237 Relay Card 3-48 Motor OL Ret P043 Basic Display 3-11 Relay Out8 Sel R236...
  • Page 112 3-60 Programming and Parameters Notes:...

  • Page 113: Fault Descriptions

    Chapter 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). For information on… See page… For information on… See page… Drive Status Fault Descriptions Faults Common Symptoms and...
  • Page 114 Troubleshooting Fault Indication Condition Drive is indicating a fault. The integral keypad provides visual notification of a fault condition by displaying the following. • Flashing fault number • Flashing fault indicator Press the Escape key to regain control of the integral keypad. Manually Clearing Faults Step Key(s)
  • Page 115 Troubleshooting Fault Descriptions Table 4.A Fault Types, Descriptions and Actions Fault Description Action ➀ Auxiliary Input Auxiliary input interlock is open. 1. Check remote wiring. 2. Verify communications programming for intentional fault. ➁ Power Loss DC bus voltage remained below 1.
  • Page 116 Troubleshooting Fault Description Action ➁ F33 Auto Rstrt Tries Drive unsuccessfully attempted Correct the cause of the fault and to reset a fault and resume manually clear. running for the programmed number of A163 [Auto Rstrt Tries]. ➁ F38 Phase U to Gnd A phase to ground fault has been 1.
  • Page 117 Troubleshooting Fault Description Action ➁ F122 I/O Board Fail Failure has been detected in the 1. Cycle power. drive control and I/O section. 2. Replace drive if fault cannot be cleared. page 4-1 for a description of fault types. Common Symptoms and Corrective Actions Motor does not Start.
  • Page 118 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. • Press Stop • Cycle power • Set A197 [Fault Clear] to option 1 “Clear Faults”.
  • Page 119 Troubleshooting Drive does not respond to changes in speed command. Cause(s) Indication Corrective Action • Check No value is coming from the The drive “Run” indicator is lit d301 [Control Source] for source of the command. and output is 0 Hz. correct source.
  • Page 120 Troubleshooting Motor operation is unstable. Cause(s) Indication Corrective Action Motor data was incorrectly None 1. Correctly enter motor nameplate entered. 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...

  • Page 121: Drive, Fuse & Circuit Breaker Ratings

    Appendix Supplemental Drive Information For information on… See page… Drive, Fuse & Circuit Breaker Ratings Specifications Drive, Fuse & 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.

  • Page 122: Specifications

    Supplemental Drive Information Specifications Drive Ratings Output Ratings Input Ratings Branch Circuit Protection Catalog Number Amps 140M Motor Voltage kW (HP) 45°C 50°C Range Amps Fuses Protectors Contactors 200 - 240V AC – 3-Phase Input, 0 - 230V 3-Phase Output 22C-B012N103 2.2 (3.0) 180-265...
  • Page 123 Supplemental Drive Information Category Specification Agency Listed to UL508C and CAN/CSA-22.2 Certification Listed to UL508C for plenums ® 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:...
  • Page 124 Supplemental Drive Information Category Specification Electrical Voltage Tolerance: 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)
  • Page 125 Supplemental Drive Information 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...
  • Page 126 Supplemental Drive Information PowerFlex 400 Watts Loss (Rated Load, Speed & PWM) Panel Mount Watts Flange Mount Watts Voltage kW (HP) Total External Internal Total 200-240V AC 2.2 (3.0) 3.7 (5.0) 5.5 (7.5) 7.5 (10) 11 (15) – – – 15 (20) –...

  • Page 127: Input Power Connections

    Supplemental Drive Information Input Power Connections Figure A.1 Frame C, D, and E Connections Input Protection Input Protection Three Phase Input Single Phase Input Figure A.2 Frame F Connections Input Protection Input Protection Three Phase Input Single Phase Input Note: UL Approval pending for Single-Phase operation.
  • Page 128 Supplemental Drive Information Notes:...

  • Page 129: Product Selection

    Appendix Accessories and Dimensions Product Selection Table B.1 Catalog Number Description 22C - Drive Voltage Rating Rating Enclosure Emission Class Comm Slot Table B.2 PowerFlex 400 Drives Drive Ratings Output Current (Amps) Frame Input Voltage 45°C 50°C Catalog Number Size 240V 50/60 Hz 22C-B012N103 3-Phase...
  • Page 130 Accessories and Dimensions Table B.3 PowerFlex 400 Flange Mount Drives Drive Ratings Output Current Frame Input Voltage 45°C 50°C Catalog Number Size 240V 50/60 Hz 22C-B012F103 3-Phase 17.5A 17.5A 22C-B017F103 22C-B024F103 22C-B033F103 480V 50/60 Hz 6.0A 6.0A 22C-D6P0F103 3-Phase 22C-D010F103 22C-D012F103 22C-D017F103 22C-D022F103...
  • Page 131 Accessories and Dimensions Table B.5 Bulletin 1321-3R Series Line Reactors – 380-480V, 60 Hz, Three-Phase Catalog Number Maximum Fundamental Continuous Watts IP00 IP11 Amps Amps Inductance Loss (Open Style) (MENA Type 1) 3% Impedance 25.3 1321-3R8-C 1321-3RA8-C 1321-3R12-B 1321-3RA12-B 1321-3R12-B 1321-3RA12-B 1321-3R18-B 1321-3RA18-B...
  • Page 132 Accessories and Dimensions Table B.7 Bulletin 1321 - DC Series Bus Inductors - 380-480V, 60 Hz, Three-Phase Inductance Catalog Number DC Amps Watts Loss IP00 (Open Style) 3.68 1321-DC9-2 1321-DC12-2 3.75 1321-DC18-4 1.75 1321-DC25-4 2.68 1321-DC32-2 1321-DC40-4 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...
  • Page 133 Windows based software package that provides an 9306-4EXP01ENE (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...
  • Page 134 Accessories and Dimensions Table B.10 Human Interface Module (HIM) Option Kits and Accessories Item Description Catalog Number LCD Display, Remote Panel LCD Display 22-HIM-C2S Mount Digital Speed Control CopyCat Capable IP66 (NEMA Type 4X/12) indoor use only Includes 2.0 meter cable LCD Display, Remote Handheld LCD Display 22-HIM-A3 Digital Speed Control...

  • Page 135: Product Dimensions

    Accessories and Dimensions Product Dimensions Table B.13 PowerFlex 400 Frames and Weights Drive Weight Packaged Weight Frame kW (HP) kg (lbs.) kg (lbs.) 240V AC – 3-Phase 2.2 (3.0) 2.89 (6.4) 3.41 (7.5) 4.0 (5.0) 2.97 (6.5) 3.49 (7.7) 5.5 (7.5) 3.72 (8.2) 4.27 (9.4) 7.5 (10)
  • Page 136 Accessories and Dimensions Figure B.1 PowerFlex 400 Frame C Drive - Dimensions are in millimeters and (inches) 130.0 (5.1) 180.0 (7.1) 116.0 (4.57) (12.6) (10.2) (9.7) ∅ 28.5 107.0 (4.21) (1.12) 66.0 (2.60) ∅ 22.2 24.0 (0.94) (0.87) 152.2 (5.99) 111.2 (4.38)
  • Page 137 Accessories and Dimensions Figure B.2 PowerFlex 400 Frame D Drive - Dimensions are in millimeters and (inches) ∅ 9.0 250.0 (9.84) 226.0 (8.90) (0.35) 383.4 436.2 (15.09) (17.17) 206.1 (8.11) 192.0 (7.56) 175.5 (6.91) 132.0 (5.20) ∅ 42.0 71.6 (2.82) (1.65) ∅...
  • Page 138 B-10 Accessories and Dimensions Figure B.3 PowerFlex 400 Frame E Drive - Dimensions are in millimeters and (inches) 370.0 (14.57) 259.2 (10.21) ∅ 8.5 (0.33) 335.0 (13.19) 605.5 (23.84) 567.4 (22.34) 315.2 (12.41) 240.2 (9.46) 130.2 (5.13) ∅ 62.7 55.2 (2.17) (2.47) ∅...
  • Page 139 Accessories and Dimensions B-11 Figure B.4 PowerFlex 400 Frame F Drive - Dimensions are in millimeters and (inches) 425.0 (16.73) 264.0 (10.39) ∅ 13.0 165.8 (6.53) 381.0 (15.00) (0.51) 850.0 (33.46) 678.0 (26.69) 647.5 (25.49) 381.0 (15.00) 280.0 (11.02) 370.0 (14.57) 287.5 (11.32) ∅...
  • Page 140 B-12 Accessories and Dimensions Figure B.5 PowerFlex 400 Frame C Flange Mount Drive - Dimensions are in millimeters and (inches) 130.3 (5.13) 105.8 138.2 (11.81) (4.17) (5.44) (12.8) 22B-CCC Cutout Dimensions (6.46) (0.21) (0.31) 307.5 (12.11) 230.6 (9.08) 291.5 (11.48) 153.8 (6.06) 76.9...
  • Page 141 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). IP00 (Open) – IP00 (Open) – 45 Amps (fundamental) and Below 55 Amps (fundamental) and Above Catalog Number Weight 1321-3R8-C...
  • Page 142 B-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 Catalog Weight Number Model kg (lbs.) 1321-DC9-2 95 (3.75) 83 (3.25) 51 (2.00) – 80 (3.13) 4.7 (0.19) 1321-DC12-1 A...
  • Page 143 Accessories and Dimensions B-15 Figure B.8 EMC Line Filters – Dimensions are in millimeters and (inches) Catalog Numbers: 22-RF018-CS, 22-RF018-CL, 22-RF026-CS, 22-RF026-CL, 22-RF026-CL, 22-RF034-CS (2.36) (5.12) (3.54) (1.26) (11.69) (12.17) (11.69) 5.5 (0.22) (0.67) (1.18)
  • Page 144 B-16 Accessories and Dimensions Catalog Numbers: 22-RFD036, 22-RFD050, 22-RFD070, 22-RFD100, 22-RFD150, 22-RFD180 Catalog Number 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)
  • Page 145 Accessories and Dimensions B-17 Figure B.9 Remote (Panel Mount) Small HIM – Dimensions are in millimeters and (inches) Catalog Number: 22-HIM-C2S (0.98) (3.66) (7.09) (2.64) (2.36) (6.06) 19.1 (3.03) (0.75) (0.19) 23.5 (0.93)
  • Page 146 B-18 Accessories and Dimensions Figure B.10 NEMA Type 1 Bezel – Dimensions are in millimeters and (inches) Catalog Number: 22-HIM-B1 11.1 (0.44) (3.66) 25.2 (0.99) (7.09) (2.64) (2.36) (6.06) (0.19) (3.03) 19.1 (0.75) 23.5 (0.93)
  • Page 147 Appendix 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 ATTENTION: Risk of injury or equipment damage exists.
  • Page 148 RJ45 DSI Splitter Cable DSI Cable Accessories RJ45 Splitter Cable – Catalog Number: AK-U0-RJ45-SC1 Slave Port Master Port PIN 1 PIN 8 RJ45 Two-Position Terminal Block Adapter – Catalog Number: AK-U0-RJ45-TB2P (PIN 5) PIN 8 (PIN 4) PIN 1 RJ45 Adapter with Integrated Termination Resistor –...
  • Page 149 RJ45 DSI Splitter Cable Connecting One Temporary Peripheral DSI Drive Hand Held Serial Converter 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"...
  • Page 150 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"...

  • Page 151: Damper Control Setup

    Appendix 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. A system Run command can be wired directly into one of the drive inputs.

  • Page 152: Pid Setup

    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.
  • Page 153 Application Notes 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.
  • Page 154 Application Notes Trim Control In Trim Control, the PID Output is 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.
  • Page 155 Application Notes PID Reference and Feedback Parameter A152 [PID Ref Sel] is used to enable the PID mode (A152 = 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”...
  • Page 156 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 = 0% PID Reference and a 5 volt signal = 100% PID Reference.
  • Page 157 Application Notes PID Deadband Parameter A158 [PID Deadband] is used to set a range, in percent, of the PID Reference that the drive will ignore. Example • [PID Deadband] is set to 5.0 • The PID Reference is 25.0% • The PID Regulator will not act on a PID Error that falls between 20.0 and 30.0% PID Preload The value set in...
  • Page 158 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.
  • Page 159 Application Notes 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: –...
  • Page 160 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 –...

  • Page 161: Auxiliary Motor Control Setup

    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 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).
  • Page 162 D-12 Application Notes Example 1 One External Motor without AutoSwap Three-Phase Power PowerFlex 400 Reference Feedback Drive Relays Auxiliary Relay Card • Auxiliary Motor Control is enabled via Parameter R239 [Aux Motor Mode]. • Number of auxiliary motors is set via Parameter R240 [Aux Motor Qty].
  • Page 163 Application Notes D-13 Example 2 One External Motor with AutoSwap Three-Phase Power PowerFlex 400 Reference Feedback Drive Relays 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.
  • Page 164 D-14 Application Notes Notes:...

  • Page 165: Network Wiring

    Appendix 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 network using Modbus protocol in RTU mode.

  • Page 166: Parameter Configuration

    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.

  • Page 167: Writing (06) Logic Command Data

    Modbus RTU Protocol 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.

  • Page 168: Reading (03) Logic Status Data

    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 (Running), 0 = Not Active 1 = Cmd Forward, 0 = Cmd Reverse 1 = Rotating Forward, 0 = Rotating Reverse...

  • Page 169: Reading (03) Drive Error Codes

    Modbus RTU Protocol 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 No Fault Auxiliary Input Power Loss...
  • Page 170 Modbus RTU Protocol Notes:...

  • Page 171: Network Points

    Appendix 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 Network Points Using Percent (%) for the Reference Using Metasys Configurable Objects to Access Parameters F-6 Understanding Metasys N2 Metasys nodes are built up by the use of several virtual objects.
  • Page 172 Metasys N2 Table F.1 Description of the Regions of a Virtual Object Region Type Short Description Region 1 Analog Input 32-bit, IEEE-standard floats Region 2 Binary Input 1-bit Region 3 Analog Output 32-bit, IEEE-standard floats Region 4 Binary Output 1-bit Region 5 Internal Float 32-bit, IEEE-standard floats (Analog Data Float)
  • Page 173 Metasys N2 Network Points Table F.7 Binary Inputs Network Point Type Address (NPT) (NPA) Name Description ON (“1”) OFF (“0”) Ready Logic Status bit 00 Ready Not Ready Active Logic Status bit 01 Active Not Active Cmd Dir Logic Status bit 02 Forward Reverse Act Dir...

  • Page 174: Parameters

    Metasys N2 Table F.9 Binary Outputs Network Point Values Type Address (NPT) (NPA) Name Description ON (“1”) OFF (“0”) Run Enable Logic Command bit 00 Enable Stop (Coast) Start/Stop Logic Command bit 00 & 01 Start Stop (Normal) Logic Command bit 02 Not Jog Clear Faults Logic Command bit 03...

  • Page 175: Using Percent (%) For The Reference

    Metasys N2 Table F.11 Internal Integer Network Point Type Address (NPT) (NPA) Name Description Min/Max Default Param# IN1 User IN 1 (AI 10) 0/Max Drive Params. b001 [Output Freq] (Hz) Data Source (Param#) Param# IN2 User IN 2 (AI 11) 0/Max Drive Params.
  • Page 176 Metasys N2 Using Metasys Configurable Objects to Access Parameters Configurable objects are inputs and outputs that let you read and write parameter 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 Param# for INx point.
  • Page 177 Metasys N2 Writing Parameter Values ATTENTION: Risk of equipment damage exists. If configurable 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.
  • Page 178 Metasys N2 Notes:...

  • Page 179: Understanding P1-Fln

    Appendix 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 ®...
  • Page 180 P1 – Floor Level Network (FLN) Network Points Table G.1 Point Database for Application 2735 Factory Engineering Point Point Default Units Slope Intercept Number Type Subpoint Name (SI Units) (SI Units) (SI Units) (SI Units) On Text Off Text CTLR ADDRESS –...
  • Page 181 P1 – Floor Level Network (FLN) Table G.1 Point Database for Application 2735 Factory Engineering Point Point Default Units Slope Intercept Number Type Subpoint Name (SI Units) (SI Units) (SI Units) (SI Units) On Text Off Text PID GAIN 0.01 –...
  • Page 182 P1 – Floor Level Network (FLN) Table G.2 Point Database for Application 2735 Point Number Subpoint Name Parameter CTLR ADDRESS C104 APPLICATION – FREQ OUTPUT b001 PCT OUTPUT d322 SPEED d323 CURRENT b003 TORQUE b013 POWER b010 DRIVE TEMP b014 DRIVE MWH b011 RUN TIME...
  • Page 183 P1 – Floor Level Network (FLN) Table G.2 Point Database for Application 2735 Point Number Subpoint Name Parameter CMD DIR MON b006, bit 2 (Forward) ACCELERATING b006, bit 3 (Accelerating) DECELERATING b006, bit 4 (Decelerating) ALARM – AT SPEED – MAIN FREQ d301 (Digit 0) OPER CMD...
  • Page 184 P1 – Floor Level Network (FLN) Using Percent (%) for the Reference The Reference (Point 92) for P1 is set as a percentage from 0% to +100%. 100% 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)
  • Page 185 P1 – Floor Level Network (FLN) 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.
  • Page 186 P1 – 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 can be changed if desired. A value of “0” in the Param# for Write Param point field disables the writing of data.
  • Page 187 Index Drive Ratings, P-4, A-1 DriveExecutive, 3-1 AC Supply DriveExplorer, 3-1 Ground, 1-8 Source, 1-6 Ungrounded, 1-6 Earthing, see Grounding Armored Cable, 1-11 EMC/RFI Auto Rstrt Tries Fault, 4-4 Grounding, Filter, 1-9 Auxiliary Input Fault, 4-3 Interference, 1-27, 1-29 ESD, Static Discharge, P-3 Before Applying Power, 2-1, 2-2 Bus Capacitors, Discharging, P-3 Faults...
  • Page 188 Index-2 Parameters Display Group, 3-4 Heatsink OvrTmp Fault, 4-3 Program Group, 3-7 HW OverCurrent Fault, 4-3 PE Ground, 1-8 Phase Short Fault, 4-4 Phase to Ground Fault, 4-4 Wiring, 1-15 point map Wiring Examples, 1-20, 1-23 Metasys N2, F-3, G-2 I/O Board Fail Fault, 4-5 Power Cables/Wiring, 1-11 Input Contactor, 1-15...
  • Page 189 Index-3 SW OverCurrent Fault, 4-4 System Grounding, 1-8 Terminal Block I/O, 1-16 Power, 1-15 Three Wire Control, 1-20, 1-23 Two Wire Control, 1-20, 1-23 UnderVoltage Fault, 4-3 Ungrounded Supply, 1-6 Unshielded Power Cables, 1-11 Wiring, 1-1 Block Diagram, 1-17, 1-18, 1-19 I/O, 1-15 I/O Examples, 1-20, 1-23 Power, 1-11...
  • Page 190 Index-4...
  • Page 192 *T304* 5011625904-T304 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-UM001E-EN-P –...

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