Allen-Bradley 22C-B012N103 User Manual
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Allen-Bradley 22C-B012N103 User Manual

Powerflex 400 series adjustable frequency ac drive for fan & pump applications 22c series b series
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User Manual
Original Instructions
PowerFlex 400 Adjustable Frequency AC Drive for Fan
& Pump Applications
Catalog Numbers 22C, Series B
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Summary of Contents for Allen-Bradley 22C-B012N103

  • Page 1 User Manual Original Instructions PowerFlex 400 Adjustable Frequency AC Drive for Fan & Pump Applications Catalog Numbers 22C, Series B...

  • Page 2: Important User Information

    Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

  • Page 3: Table Of Contents

    Table of Contents Important User Information ........2 Summary of Changes .
  • Page 4 Table of Contents Control Wire Types ........28 I/O Terminal Block .
  • Page 5 Table of Contents Chapter 4 Troubleshooting Drive Status ..........113 LED Indications.
  • Page 6 Table of Contents PID Gains ..........162 Guidelines for Adjusting the PID Gains .

  • Page 7: Summary Of Changes

    Summary of Changes This manual contains new and updated information as indicated in the following table. Topic Page CE Conformity updated Programming options updated UL and CE certification updated Internal DC Bus Choke specification for 380-480V AC Input updated from "18.5-160 kW (25-250 HP)" to "11-160 kW (15-250 HP)". Connected Components Workbench and DriveExecutive software compatibility updated New Parameters...
  • Page 8 Summary of Changes Notes: Rockwell Automation Publication 22C-UM001J-EN-E - January 2017...

  • Page 9: Preface

    Provides declarations of conformity, certificates, and www.rockwellautomation.com/global/certification/ other certification details. overview.page You can view or download publications at http://www.rockwellautomation.com/global/literature-library/overview.page. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative. Rockwell Automation Publication 22C-UM001J-EN-E - January 2017...

  • Page 10: Manual Conventions

    Preface 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 11: General Precautions

    Preface General Precautions ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive. Measure the DC bus voltage at the –DC and +DC terminals or at the –DC and P2 terminals on the Power Terminal Block (refer to Chapter 1 Power Terminal...

  • Page 12: Catalog Number Explanation

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

  • Page 13: Installation/Wiring

    Chapter Installation/Wiring This chapter provides information on mounting and wiring the PowerFlex 400 Drive. For information on... See page Opening the Cover Mounting Considerations AC Supply Source Considerations General Grounding Requirements Fuses and Circuit Breakers Power Wiring I/O Wiring Recommendations Start and Speed Reference Control RS485 Network Wiring EMC Instructions...

  • Page 14: Opening The Cover

    Chapter 1 Installation/Wiring Opening the Cover Frame C Drives 1. Press and hold in the tabs on each side of the cover. 2. Pull the cover out and up to release. Frame D Drives 1. Loosen the two captive cover screws. 2.

  • Page 15: Frame E Drives

    Installation/Wiring Chapter 1 Frame E Drives 1. Loosen the four captive cover screws. 2. Pull the bottom of the cover out and up to release. Frame F Drives 1. Turn the latch counterclockwise. 2. Pull on the latch to swing the door open. Rockwell Automation Publication 22C-UM001J-EN-E - January 2017...

  • Page 16: Frame G Drives

    Chapter 1 Installation/Wiring Frame G Drives 1. 1. Loosen the four captive cover screws. 2. Pull the bottom of the cover out and up to release. Frame H Drives 1. Loosen the four captive cover screws. 2. Pull the bottom of the cover out and up to release. Rockwell Automation Publication 22C-UM001J-EN-E - January 2017...

  • Page 17: Mounting Considerations

    Installation/Wiring Chapter 1 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.) M12 (1/2 in.)

  • Page 18: Minimum Mounting Clearances

    Chapter 1 Installation/Wiring Minimum Mounting Clearances Refer to Appendix B for mounting dimensions. Figure 1 - Frame C Mounting Clearances 25 mm (1.0 in.) 120 mm 120 mm (4.7 in.) (4.7 in.) 120 mm 120 mm (4.7 in.) (4.7 in.) Closest object that may restrict air flow through the drive heat...

  • Page 19: Debris Protection

    Installation/Wiring Chapter 1 Figure 3 - Frame F Mounting Clearances 250 mm (9.8 in.) 50 mm 50 mm (2.0 in.) (2.0 in.) 150 mm (6.0 in.) Figure 4 - Frames G & H Mounting Clearances 300 mm (11.8 in.) 200 mm 200 mm (7.9 in.) (7.9 in.)

  • Page 20: Storage

    Chapter 1 Installation/Wiring Storage • Store within an ambient temperature range of -40° to +85°C. • Store within a relative humidity range of 0% to 95%,non-condensing. • Do not expose to a corrosive atmosphere. AC Supply Source Ungrounded Distribution Systems Considerations ATTENTION: PowerFlex 400 drive frames contain protective MOVs that are referenced to ground.

  • Page 21: Input Power Conditioning

    Installation/Wiring Chapter 1 Note: Frame D, G and H drives do not contain a MOV to ground connection and are suitable for operation in both grounded and ungrounded distribution systems without modification. Input Power Conditioning The drive is suitable for direct connection to input power within the rated voltage of the drive (see Appendix A).

  • Page 22: Ground Fault Monitoring

    Chapter 1 Installation/Wiring Ground Fault Monitoring If a system ground fault monitor (RCD) is to be used, only Type B (adjustable) devices should be used to avoid nuisance tripping. Safety Ground - (PE) This is the safety ground for the drive that is required by code. One of these points must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar.

  • Page 23: Fuses And Circuit Breakers

    Installation/Wiring Chapter 1 Fuses and Circuit Breakers The PowerFlex 400 does not provide branch short circuit protection. This product should be installed with either input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations.

  • Page 24: Power Wiring

    Chapter 1 Installation/Wiring Table 2 - Recommended Branch Circuit Protective Devices Voltage Drive Rating Fuse Rating 140M Motor Recommended Min. Enclosure Rating (2)(3) MCS Contactors kW (HP) Amps Protectors Volume Catalog No. Catalog No. Inches 380-480V AC 2.2 (3.0) 140M-D8E-C10 100-C09 5098 –...

  • Page 25: Motor Cable Types Acceptable For 200

    Installation/Wiring Chapter 1 Motor Cable Types Acceptable for 200...600 Volt Installations A variety of cable types are acceptable for drive installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, allow a spacing of 0.3 meters (1 foot) for every 10 meters (32.8 feet) of length.

  • Page 26: Reflected Wave Protection

    Chapter 1 Installation/Wiring Other types of shielded cable are available, but the selection of these types may limit the allowable cable length. Particularly, some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield. This construction can greatly increase the cable charging current required and reduce the overall drive performance.

  • Page 27: Power Terminal Block

    Installation/Wiring Chapter 1 not be used. If it is necessary to disconnect power to the motor with the drive outputting power, an auxiliary contact should be used to simultaneously disable drive control run commands. Power Terminal Block Frame C, D, F, G and H drives utilize a finger guard over the power wiring terminals.
  • Page 28 Chapter 1 Installation/Wiring Figure 9 - Power Terminal Blocks (Frames E through H) Frame E: 480V 37-45 kW (50-60 HP) R/L1 S/L2 T/L3 P1 P2 DC– U/T1 V/T2 W/T3 Frame E: 240V 480V 30-37 kW 55-75 kW (40-50 HP) (75-100 HP) R/L1 S/L2 T/L3 P1 See note at the bottom DC–...
  • Page 29 Installation/Wiring Chapter 1 Table 5 - Power Terminal Descriptions Terminal Description R/L1, S/L2, T/L3 3-Phase Input U/T1 To Motor U/T1 Switch any two V/T2 To Motor V/T2 motor leads to change forward direction. W/T3 To Motor W/T3 P2, P1 DC Bus Inductor Connection Drives are shipped with a jumper between Terminals P2 and P1.

  • Page 30: I/O Wiring Recommendations

    Chapter 1 Installation/Wiring I/O Wiring Recommendations Motor Start/Stop Precautions ATTENTION: A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor.

  • Page 31: Maximum Control Wire Recommendations

    Installation/Wiring Chapter 1 Maximum Control Wire Recommendations Do not exceed control wiring length of 30 meters (100 feet). Control signal cable length is highly dependent on electrical environment and installation practices. To improve noise immunity, the I/O terminal block Common must be connected to ground terminal/protective earth.
  • Page 32 Chapter 1 Installation/Wiring (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. Table 9 - Control I/O Terminal Designations Signal Default...
  • Page 33 Installation/Wiring Chapter 1 Table 9 - Control I/O Terminal Designations Signal Default Description Param. 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. Opto Output At Frequency Program with T065 [Opto Out Sel].

  • Page 34: I/O Wiring Examples

    Chapter 1 Installation/Wiring 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.
  • Page 35 Installation/Wiring Chapter 1 Input/Output Connection Example Required Settings Analog Input DIP Switch AI1 = 10V Unipolar Speed Reference, 0 to +10V Input Parameters P038 [Speed Reference] = 2 “Analog In1” Common T069 [Analog In 1 Sel] = 2 “0-10V” Scaling T070 [Analog In 1 Lo] T071 [Analog In 1 Hi] Check Results...
  • Page 36 Chapter 1 Installation/Wiring Input/Output Connection Example Required Settings 2 Wire Control DIP Switch SNK/SRC = SRC Sourcing (SRC), External Supply, Parameters Stop-Run Non-Reversing P036 [Start Source] = 2, 3, 4 • Input must be active for P037 [Stop Mode] = 0 through 7 the drive to run.
  • Page 37 Installation/Wiring Chapter 1 Input/Output Connection Example Required Settings 2 Wire Control with DIP Switch Function Loss Function Loss and SW SNK/SRC = SRC Enable Parameters Sourcing (SRC), P036 [Start Source] = 6 “2-W Lvl/Enbl” Run FWD Internal Supply, P037 [Stop Mode] = 0 through 7 Non-Reversing SW Enable •...

  • Page 38: Typical Multiple Drive Connection Examples

    Chapter 1 Installation/Wiring Typical Multiple Drive Connection Examples Input/Output Connection Example Multiple Digital Input Connections Customer Inputs can be wired per the External Supply (SRC) example on page Customer Inputs Optional Ground Connection When connecting a single input such as Run, Stop, Reverse or Preset Speeds to multiple drives, it is important to connect I/O Terminal 04 common together for all drives.

  • Page 39: Start And Speed Reference Control

    Installation/Wiring Chapter 1 Start and Speed Reference The drive speed command can be obtained from a number of different sources. The source is normally determined by P038 [Speed Reference]. The drive Start Control command is normally determined by P036 [Start Source]. However, the settings for these parameters can be overridden by a variety of methods.

  • Page 40: Accel/Decel Selection

    Chapter 1 Installation/Wiring 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.

  • Page 41: On Drive Connections

    Installation/Wiring Chapter 1 Wiring terminations on the master controller will vary depending on the master controller used and “TxRxD+” and “TxRxD-” are shown for illustration purposes only. Refer to the master controller’s user manual for network terminations. Note that there is no standard for the “+” and “-” wires, and consequently Modbus device manufacturers interpret them differently.

  • Page 42: General Notes

    Table 12 - PowerFlex 400 – EN61800-3 Compliance PowerFlex 400 Drive First Environment Restricted First Environment Unrestricted Cat No. Required Filter Restrict Install Required Filter Restrict Install (HP) 22C-... (Allen-Bradley) Motor Drive and Motor Drive and Cable to Filter in Cable to Filter in (Meters) Shielded (Meters)
  • Page 43 Table 12 - PowerFlex 400 – EN61800-3 Compliance PowerFlex 400 Drive First Environment Restricted First Environment Unrestricted Cat No. Required Filter Restrict Install Required Filter Restrict Install (HP) 22C-... (Allen-Bradley) Motor Drive and Motor Drive and Cable to Filter in Cable to Filter in (Meters) Shielded (Meters)

  • Page 44: Fcc Instructions

    Table 13 - PowerFlex 400 – FCC Part 15 Subpart B Compliance PowerFlex 400 Drive Required Filter Restrict Motor Install Drive and Cable to (Meters) Filter in Enclosure kW (HP) Cat No. 200...240 Volts 2.2 (3.0) 22C-B012N103 22-RF034-CS 3.7 (5.0) 22C-B017N103 22-RF034-CS 5.5 (7.5) 22C-B024N103 22-RF034-CS 7.5 (10) 22C-B033N103 22-RF034-CS...
  • Page 45 Installation/Wiring Chapter 1 Table 13 - PowerFlex 400 – FCC Part 15 Subpart B Compliance PowerFlex 400 Drive Required Filter Restrict Motor Install Drive and Cable to (Meters) Filter in Enclosure kW (HP) Cat No. 7.5 (10) 22C-D017N103 22-RF018-CS 11 (15) 22C-D022N103 22-RF026-CS 15 (20)
  • Page 46 Chapter 1 Installation/Wiring Notes: Rockwell Automation Publication 22C-UM001J-EN-E - January 2017...

  • Page 47: 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. For information on... See page Prepare For Drive Start-Up Integral Keypad Viewing and Editing Parameters IMPORTANT Read the General Precautions section before proceeding.

  • Page 48: Applying Power To The Drive

    Chapter 2 Start Up 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.

  • Page 49: Integral Keypad

    Start Up Chapter 2 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 50: Led Status Indicators

    Chapter 2 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. Hand Status Steady Green Indicates that the Run/Start key is enabled.

  • Page 51: Viewing And Editing Parameters

    Start Up Chapter 2 Viewing and Editing 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 Parameters 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 52: Keypad Hand-Off-Auto Functions

    Chapter 2 Start Up Keypad Hand-Off-Auto Parameter P042 [Auto Mode] defines the operation mode of the control keys on the integral keypad. Functions 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 53: Local/Remote Mode

    Start Up Chapter 2 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 54: Auto/Manual Mode

    Chapter 2 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 55: No Function Mode

    Start Up Chapter 2 No Function Mode In No Function mode: • Auto key LED has no function. • Start command is defined by P036 [Start Source]. • Speed Reference command is defined by P038 [Speed Reference]. Table 17 - P042 [Auto Mode] = 0 “No Function” T051-T054 [Digital Inx Sel] ≠...
  • Page 56 Chapter 2 Start Up Notes: Rockwell Automation Publication 22C-UM001J-EN-E - January 2017...

  • Page 57: Programming And Parameters

    Chapter Programming and Parameters This chapter 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 DriveExecutive™ software or Connected Components WorkBench™ version 1.0 or greater software, a personal computer and a serial converter module.

  • Page 58: Parameter Organization

    Chapter 3 Programming and Parameters Some parameters are marked as follows. = Stop drive before changing this parameter. = 32 bit parameter. Parameters marked 32 bit will have two parameter numbers when using RS485 communications and programming software. Parameter Organization Refer to page 110 for an alphabetical listing of parameters.
  • Page 59 Programming and Parameters Chapter 3 Advanced Program Purge Frequency A141 PID Deadband A158 DC Brake Level A177 Compensation A194 Internal Freq A142 PID Preload A159 DC Brk Time@Strt A178 Reset Meters A195 A d v a n c e d P r o g r a m G r o u p...

  • Page 60: Basic Display Group

    Chapter 3 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...
  • Page 61 Programming and Parameters Chapter 3 b007 [Fault 1 Code] Related Parameter(s): A186, A197, d307...d315 A code that represents a drive fault. [Fault 1 Code] is the most recent fault. Repetitive faults will only be recorded once. Refer to Chapter 4 for fault code descriptions.
  • Page 62 Chapter 3 Programming and Parameters b015 [Elapsed kWh] Related Parameter(s): b011, A195 Accumulated output energy of the drive. This parameter works in conjunction with [Elapsed MWh]. When the maximum value of this parameter is reached, this parameter resets to zero and [Elapsed MWh] is incremented. Values Default: Read Only...

  • Page 63: Basic Program Group

    Programming and Parameters Chapter 3 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 64 Chapter 3 Programming and Parameters 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 37 for details about how other drive settings can override the setting of this parameter.
  • Page 65 Programming and Parameters Chapter 3 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...
  • Page 66 Chapter 3 Programming and Parameters P039 [Accel Time 1] Related Parameter(s): P038, P040, T051...T054, A141, A143...A146, A147 Sets the rate of acceleration for all speed increases. Maximum Freq Accel Rate Accel Time Values Default: 20.00 Secs 2.2-110 kW (3.0-150 HP) 60.00 Secs 132-250 kW (200-350 HP) Min/Max: 0.00/600.00 Secs...
  • Page 67 Programming and Parameters Chapter 3 P043 [Motor OL Ret] Related Parameter(s): P033, A181 Enables/disables the Motor Overload Retention function. When Enabled, the value held in the motor overload counter is saved at power-down and restored at power-up. Options 0 “Disabled” (Default) 1 “Enabled”...

  • Page 68: Terminal Block Group

    Chapter 3 Programming and Parameters Terminal Block Group T051 [Digital In1 Sel] (I/O Terminal 05) Related Parameter(s):P036, P038, P039, P040 A141, A142, A143...A146, A147, A148, A166, A177, A180, d301, d302 T052 [Digital In2 Sel] (I/O Terminal 06) T053 [Digital In3 Sel] (I/O Terminal 07) T054 [Digital In4 Sel] (I/O Terminal 08) Stop drive before changing this parameter.
  • Page 69 Programming and Parameters Chapter 3 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” (Default) Relay changes state when power is applied. This indicates that the drive is ready for operation. Relay returns drive to shelf state when power is removed or a fault occurs.
  • Page 70 Chapter 3 Programming and Parameters T058 [Relay 1 On Time] Related Parameter(s): T055, T056, T059 Sets delay time before Relay energizes after required condition testing. Values Default: 0.0 Secs Min/Max: 0.0/600.0 Secs Display: 0.1 Secs T059 [Relay 1 Off Time] Related Parameter(s): T055, T058, T058 Sets delay time before Relay de-energizes after required condition testing ceases.
  • Page 71 Programming and Parameters Chapter 3 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 72 Chapter 3 Programming and Parameters 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. Opto output is inactive when power is removed or a fault occurs.
  • Page 73 Programming and Parameters Chapter 3 T068 [Opto Out Logic] Related Parameter(s): T065, T066 Determines the logic (Normally Open/NO or Normally Closed/NC) of the opto output. T058 Option Opto Out Logic NO (Normally Open) NC (Normally Closed) Note: Setting output to NC may cause output to “glitch” on power-up. The off/reset state of all outputs is open. Values Default: Min/Max:...
  • Page 74 Chapter 3 Programming and Parameters 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. The signal loss event ends and normal operation resumes when the input signal level is greater than or equal to 1.5V or 3mA.
  • Page 75 Programming and Parameters Chapter 3 T075 [Analog In 2 Hi] Related Parameter(s): P035, P038, T073, T074, T076, A152, A153 Stop drive before changing this parameter. Sets the analog input level that corresponds to P035 [Maximum Freq]. Analog inversion can be accomplished by setting this value smaller than T074 [Analog In 2 Lo].
  • Page 76 Chapter 3 Programming and Parameters T079 [Sleep Time] Related Parameter(s): T077, T078, T080, T081 Sets the analog input time the drive must stay below to enter sleep mode. Values Default: 0.0 Secs Min/Max: 0.0/600.0 Secs Display: 0.1 Secs T080 [Wake Level] Related Parameter(s): T077, T078, T079, T081 Sets the analog input level the drive must reach to wake from sleep mode.
  • Page 77 Programming and Parameters Chapter 3 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 78 Chapter 3 Programming and Parameters 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, T087 Sets the analog output signal mode (0-20 mA, 4-20 mA, or 0-10V).
  • Page 79 Programming and Parameters Chapter 3 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 80 Chapter 3 Programming and Parameters T091 [Wake Sel] Related Parameter(s): T077, T080, A203, d304, d305, d306, d328 (with FRN 7.xx and later.) Selects the operation of the wake function. Options 0 “AI1 > WakLvl” (Default) Wake enabled from Analog Input 1 (d305 [Analog In 1]) above wake-up level. 1 “AI1 <...

  • Page 81: Communications Group

    Programming and Parameters Chapter 3 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”...
  • Page 82 Chapter 3 Programming and Parameters 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 83 Programming and Parameters Chapter 3 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 84 Chapter 3 Programming and Parameters 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. Refer to the flowchart on page 37 for more information on speed reference control priority.

  • Page 85: Advanced Program Group

    Programming and Parameters Chapter 3 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 Values Default:...
  • Page 86 Chapter 3 Programming and Parameters 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 38 for details. Accel Rate = [Maximum Freq]/[Accel Time] P035 [Maximum Freq] Speed P039 or A147...
  • Page 87 Programming and Parameters Chapter 3 A151 [PID Trim Lo] Sets the minimum positive value that is added to a PID reference when PID trim is used. Values Default: 0.0 Hz Min/Max: 0.0/320.0 Hz Display: 0.1 Hz A152 [PID Ref Sel] Related Parameter(s): P038, T070, T071, T072, T074, T075 Stop drive before changing this parameter.
  • Page 88 Chapter 3 Programming and Parameters A155 [PID Integ Time] Sets the value for the PID integral component when the PID mode is enabled by A152 [PID Ref Sel]. Values Default: 2.0 Secs Min/Max: 0.0/999.9 Secs Display: 0.1 Secs A156 [PID Diff Rate] Sets the value for the PID differential component when the PID mode is enabled by A152 [PID Ref Sel].
  • Page 89 Programming and Parameters Chapter 3 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 90 Chapter 3 Programming and Parameters A168 [PWM Frequency] Related Parameter(s): A169 Sets the carrier frequency for the PWM output waveform. The chart below provides derating guidelines based on the PWM frequency setting. IMPORTANT Ignoring derating guidelines can cause reduced drive performance. Carrier Frequency (kHz) Values Default:...
  • Page 91 Programming and Parameters Chapter 3 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. A174 [Maximum Voltage] can be set anywhere.
  • Page 92 Chapter 3 Programming and Parameters 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”. A174 [Maximum Voltage] P031 [Motor NP Volts] A173 [Break Frequency]...
  • Page 93 Programming and Parameters Chapter 3 A176 [DC Brake Time] Related Parameter(s): P037, A177 Sets the length of time that DC brake current is “injected” into the motor when P037 [Stop Mode] is set to either 4 “Ramp” or 6 “DC Brake”. Refer to parameter A177 [DC Brake Level].
  • Page 94 Chapter 3 Programming and Parameters A181 [Motor OL Select] Related Parameter(s): P032, P033, P043 Drive provides Class 10 motor overload protection. Settings 0-2 select the derating factor for the I t overload function. No Derate Min Derate Max Derate Options 0 “No Derate”...
  • Page 95 Programming and Parameters Chapter 3 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 9 for important information on bus regulation. Options 0 “Disabled”...
  • Page 96 Chapter 3 Programming and Parameters 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. Frequency Command Frequency...
  • Page 97 Programming and Parameters Chapter 3 A195 [Reset Meters] Related Parameter(s): d310...d317 Resets the marker that indicates Fault Times and Energy usage. Options 0 “Ready/Idle” (Default) 1 “Reset MWh” Also resets kWh marker. 2 “Reset Time” min, hr, and x10hr A196 [Testpoint Sel] Related Parameter(s): d319 Used by Rockwell Automation field service personnel.
  • Page 98 Chapter 3 Programming and Parameters A202 [MOP Reset Sel] Related Parameter(s): A142 (With FRN 6.xx and later.) Set the drive to save the current MOP reference command. Options 0 “Zero MOP Ref” This option clamps A142 [Internal Freq] at 0.0 Hz when the drive is not running. 1 “Save MOP Ref”...
  • Page 99 Programming and Parameters Chapter 3 A208 [ACT2 Minimum] Related Parameter(s): A205 (with FRN 7.xx and later.) Sets the minimum value of the actual (ACT) 2 input. Used with the analog input min/max settings to scale the analog input for use as the PID feedback. Can be used in a normal and inverted mode.

  • Page 100: Aux Relay Card Group

    Chapter 3 Programming and Parameters Aux Relay Card Group R221 [Relay Out3 Sel] Related Parameters for the Aux Relay Card Group: R224 [Relay Out4 Sel] Aux Parameters R227 [Relay Out5 Sel] PID Parameters R230 [Relay Out6 Sel] Digital Inputs R233 [Relay Out7 Sel] Relays 1 and 2 R236 [Relay Out8 Sel] Note: Auxiliary Relay Card option is not available for Frame C drives.
  • Page 101 Programming and Parameters Chapter 3 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 102 Chapter 3 Programming and Parameters R241 [Aux 1 Start Freq] R244 [Aux 2 Start Freq] R247 [Aux 3 Start Freq] Sets the frequency that causes the next available auxiliary motor to turn on. Values Default: 50.0 Hz Min/Max: 0.0/320.0 Hz Display: 0.1 Hz R242 [Aux 1 Stop Freq]...
  • Page 103 Programming and Parameters Chapter 3 R253 [Aux AutoSwap Tme] Sets the total running time between automatic motor changes. IMPORTANT Proper wiring and parameter configuration of Aux Motor Control functions are especially important when using AutoSwap. Improper wiring or configuration could result in line power being applied to the drive outputs. Verify system operation before connecting auxiliary motor contactor outputs. Values Default: 0.0 Hr...

  • Page 104: Advanced Display Group

    Chapter 3 Programming and Parameters Advanced 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 Chapter 3 d304 [PID Setpnt Displ] Related Parameter(s): A152 Displays the active PID Setpoint value. Values Default: 0.0% Min/Max: 0.0/100.0% Display: 0.1% d305 [Analog In 1] Related Parameter(s): T069-T071 Displays the status of Analog Input 1. Values Default: 0.0% Min/Max:...
  • Page 106 Chapter 3 Programming and Parameters d311 [Fault 1 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 d312 [Fault 2 Time-hr] Related Parameter(s): A195, d316 Displays the value of the...
  • Page 107 Programming and Parameters Chapter 3 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 108 Chapter 3 Programming and Parameters d327 [Status @ Fault] Related Parameter(s): b006 Displays the value of b006 [Drive Status] when the last fault occurred. Values Default: Read Only Min/Max: Display: d328 [PID Fdbk Display] Related Parameter(s): b006 (With FRN 7.xx and later.) Displays the active PID Feedback value.
  • Page 109 Programming and Parameters Chapter 3 d333 [Fault 7 Code] Related Parameter(s): A197 (With FRN 6.xx and later.) A code that represents the seventh most recent drive fault. The codes will appear in these parameters in the order they occur (d307 [Fault 1 Code] = the most recent fault).
  • Page 110 Chapter 3 Programming and Parameters d338 [Fault 4 Time-min] Related Parameter(s): A195, d317 (With FRN 6.xx and later.) 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: 0.1Min d339 [Fault 5 Time-hr] Related Parameter(s): A195, d316...
  • Page 111 Programming and Parameters Chapter 3 d345 [Fault 8 Time-hr] Related Parameter(s): A195, d316 (With FRN 6.xx and later.) Displays the value of the d316 [Elapsed Time-hr] parameter when the fault occurred. Values Default: Read Only Min/Max: 0/32767 Hr Display: 1 Hr d346 [Fault 8 Time-min] Related Parameter(s): A195, d317...

  • Page 112: Parameter Cross Reference By Name

    Chapter 3 Programming and Parameters Parameter Cross Reference by Name Parameter Name Number Group Page Parameter Name Number Group Page Accel Time 1 P039 Basic Program Aux Stop Delay R251 Relay Card Accel Time 2 A147 Advanced Program Boost Select A170 Advanced Program ACT1 Input...

  • Page 113: Rockwell Automation Publication 22C-Um001J-En-E - January

    Programming and Parameters Chapter 3 Parameter Name Number Group Page Parameter Name Number Group Page Fault 2 Time-min d313 Advanced Display Opto Out Logic T068 Terminal Block Fault 3 Code d309 Advanced Display Opto Out Sel T065 Terminal Block Fault 3 Time-hr d314 Advanced Display Output Current...
  • Page 114 Chapter 3 Programming and Parameters Parameter Name Number Group Page Parameter Name Number Group Page Relay Out6 Level R231 Relay Card Slip Hertz @ FLA A175 Advanced Program Relay Out6 Sel R230 Relay Card Speed Ref 2 C109 Communications Relay Out7 Level R233 Relay Card Speed Reference...

  • Page 115: Drive Status

    Chapter Troubleshooting This chapter 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 Drive Status Faults Fault Descriptions Common Symptoms and Corrective Actions Drive Status The condition or state of your drive is constantly monitored.

  • Page 116: Manually Clearing Faults

    Chapter 4 Troubleshooting Fault Indication Condition Display Drive is indicating a fault. The integral LCD display 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.

  • Page 117: Auto Restart (Reset/Run)

    Troubleshooting Chapter 4 Auto Restart (Reset/Run) The Auto Restart feature allows the drive to automatically perform a fault reset followed by a start attempt without user or application intervention. This allows remote or “unattended” operation. Only certain faults are allowed to be reset.
  • Page 118 Chapter 4 Troubleshooting Table 18 - Fault Types, Descriptions and Actions Fault Type Description Action HW OverCurrent The drive output current has Check programming. Check for exceeded the hardware current limit. excess load, improper A170 [Boost Select] setting, DC brake volts set too high or other causes of excess current.

  • Page 119: Common Symptoms And Corrective Actions

    Troubleshooting Chapter 4 Table 18 - Fault Types, Descriptions and Actions Fault Type Description Action Comm Loss RS485 (DSI) port stopped 1. Check RS485 wiring connection. communicating. 2. Check if a communications adapter or HIM was disconnected. 3. Increase C106 [Comm Loss Time] to an appropriate time for application.

  • Page 120: Terminal Block

    Chapter 4 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 121: Motor And/Or Drive Will Not Accelerate To Commanded Speed

    Troubleshooting Chapter 4 Drive does not respond to changes in speed command. Cause(s) Indication Corrective Action No value is coming from the source of the command. The drive “Run” indicator • Check d301 [Control Source] for correct source. is lit and output is 0 Hz. •...

  • Page 122: Drive Does Not Power Up

    Chapter 4 Troubleshooting Drive does not power up. Cause(s) Indication Corrective Action No input power to drive. None • Check the power circuit. • Check the supply voltage. • Check all fuses and disconnects. Jumper between Power Terminals P2 and P1 not installed and/ None Install jumper or connect DC Bus Inductor.

  • Page 123: Drive, Fuse & Circuit Breaker Ratings

    Appendix Supplemental Drive Information For information on... See page Drive, Fuse & Circuit Breaker Ratings Specifications Input Power Connections Drive, Fuse & Circuit Breaker The tables on the following pages provide recommended AC line input fuse and circuit breaker information. See Fusing and Circuit Breakers below for UL Ratings and IEC requirements.

  • Page 124: Specifications

    Amps Fuses 140M Motor Contactors Min. (1)(2) Range Protectors Enclosure 45 °C 50 °C Volumes (in. 200...240V AC – 3-Phase Input, 0 - 230V 3-Phase Output 22C-B012N103 2.2 (3.0) 180-265 15.5 140M-F8E-C16 100-C23 5098 22C-B017N103 3.7 (5.0) 17.5 17.5 180-265...
  • Page 125 Supplemental Drive Information Appendix A Agency Certification Specification Listed to UL508C and CAN/CSA-22.2 ® Certified to AS/NZS, 1997 Group 1, Class A Marked for all applicable European Directives EMC Directive (2014/30/EU) EN 61800-3 Low Voltage Directive (2014/35/EU) EN 61800-5-1 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.
  • Page 126 Appendix A Supplemental Drive Information Specification Atmosphere: Important: Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas, vapors or dust. If the drive is not going to be installed for a period of time, it must be stored in an area where it will not be exposed to a corrosive atmosphere.
  • Page 127 Supplemental Drive Information Appendix A Control Specification Method: Sinusoidal PWM, Volts/Hertz Carrier Frequency Frames C and D: 2...10 kHz, Drive rating based on 4 kHz Frames E – H: 2...8 kHz, Drive rating based on 4 kHz Frequency Accuracy Digital Input: Within ±0.05% of set output frequency Analog Input: Within 0.5% of maximum output frequency, 10-Bit resolution...
  • Page 128 Appendix A Supplemental Drive Information Control Outputs Specification Relay Quantity: (2) Programmable Form C Specification Resistive Rating: 3.0 A @ 30V DC, 3.0 A @ 125V, 3.0 A @ 240V AC Inductive Rating: 0.5 A @ 30V DC, 0.5 A @ 125V, 0.5 A @ 240V AC Optional Relay Quantity: (6) Optional Programmable Form A...

  • Page 129: Powerflex 400 Watts Loss (Rated Load, Speed & Pwm)

    Supplemental Drive Information Appendix A PowerFlex 400 Watts Loss (Rated Load, Speed & PWM) Voltage kW (HP) Panel Mount Watts Flange Mount Watts Total External Internal Total 200-240V AC 2.2 (3.0) 3.7 (5.0) 5.5 (7.5) 7.5 (10) 11 (15) – –...

  • Page 130: Input Power Connections

    Appendix A Supplemental Drive Information Input Power Connections Figure 16 - Frame C, D, and E Connections Input Protection Input Protection Three Phase Input Single Phase Input Figure 17 - Frame F Connections Input Protection Input Protection Three Phase Input Single Phase Input Note: Frames G and H do not support single-phase operation.

  • Page 131: Product Selection

    Emission Class Comm Slot Table 20 - PowerFlex 400 Drives Drive Ratings Catalog Number Frame Size Input Voltage Normal Duty Output Current (Amps) 45°C 50°C 240V 50/60 Hz 22C-B012N103 3-Phase 17.5 17.5 22C-B017N103 22C-B024N103 22C-B033N103 22C-B049A103 22C-B065A103 18.5 22C-B075A103 22C-B090A103 22C-B120A103...
  • Page 132 Appendix B Accessories and Dimensions Table 20 - PowerFlex 400 Drives Drive Ratings Catalog Number Frame Size Input Voltage Normal Duty Output Current (Amps) 45°C 50°C 480V 50/60 Hz 22C-D6P0N103 3-Phase 10.5 10.5 22C-D010N103 22C-D012N103 22C-D017N103 22C-D022N103 22C-D030N103 18.5 22C-D038A103 45.5 45.5 22C-D045A103...
  • Page 133 Accessories and Dimensions Appendix B Table 22 - Bulletin 1321-3R Series Line Reactors – 200...240V, 60 Hz, 3-Phase Fundamental Maximum Inductance Watts Loss Catalog Number Amps Continuous IP00 IP11 Amps (Open Style) (NEMA Type 1) 3% Impedance 1.25 1321-3R12-A 1321-3RA12-A 1321-3R18-A 1321-3RA18-A 37.5...
  • Page 134 Appendix B Accessories and Dimensions Table 23 - Bulletin 1321-3R Series Line Reactors – 380...480V, 60 Hz, 3-Phase Fundamental Maximum Inductance Watts Loss Catalog Number Amps Continuous IP00 IP11 Amps (Open Style) 200 250 0.09 1321-3R250-B 1321-3RA250-B 250 320 0.075 1321-3R320-B 1321-3RA320-B 300 400 0.06...
  • Page 135 Accessories and Dimensions Appendix B Table 25 - Bulletin 1321 - DC Series Bus Inductors – 380...480V, 60 Hz, 3-Phase DC Amps Inductance Watts Loss Catalog Number IP00 (Open Style) 1.75 1321-DC25-4 2.68 1321-DC32-2 1321-DC40-4 (1) Required on 11 and 15 kW (15 and 20 HP) Frame C Flange Mount drive ratings. Table 26 - EMC Line Filters Drive Ratings Catalog Number...
  • Page 136 DriveExecutive software Windows based software package that provides an intuitive 9303-4DTE01ENE (CD-ROM) Version 1.01 or means for monitoring or configuring Allen-Bradley drives later and communication adapters online and offline. Compatibility: Windows 98, ME, NT 4.0 (Service Pack 3 or later), 2000, XP, 7 Professional (Service Pack 1, 32-bit), and Vista (Service Pack 1 and 2, 32-bit).
  • Page 137 Accessories and Dimensions Appendix B Table 28 - Human Interface Module (HIM) Option Kits and Accessories Item Description Catalog Number LCD Display, LCD Display 22-HIM-C2S Remote Panel Mount Digital Speed Control CopyCat Capable IP66 indoor use only Includes 2.0 meter cable LCD Display, LCD Display 22-HIM-A3...

  • Page 138: Product Dimensions

    Appendix B Accessories and Dimensions Product Dimensions Table 31 - PowerFlex 400 Frames and Weights Frame kW (HP) Drive Weight Packaged Weight 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)
  • Page 139 Accessories and Dimensions Appendix B Table 31 - PowerFlex 400 Frames and Weights Frame kW (HP) Drive Weight Packaged Weight kg (lbs.) kg (lbs.) 4.0 (5.0) 2.77 (6.1) 3.37 (7.4) 5.5 (7.5) 3.04 (6.7) 3.64 (8.0) 7.5 (10) 3.13 (6.9) 3.73 (8.2) 11 (15) 3.19 (7.0)
  • Page 140 Appendix B Accessories and Dimensions Figure 18 - 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...
  • Page 141 Accessories and Dimensions Appendix B Figure 19 - 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 142 Appendix B Accessories and Dimensions Figure 20 - 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 143 Accessories and Dimensions Appendix B Figure 21 - 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 144 Appendix B Accessories and Dimensions Figure 22 - PowerFlex 400 Frame G Drive Dimensions are in millimeters and (inches) 425.0 (16.73) 381.0 (15.00) 264.0 (10.39) 892.0 (35.12) 819.5 (32.26) 367.5 (14.47) 302.5 (11.91) 92.0 122.5 (4.82) (3.62) 22.0 57.5 (2.26) (0.87) 244.6 (9.62)
  • Page 145 Accessories and Dimensions Appendix B Figure 23 - PowerFlex 400 Frame H Drive Dimensions are in millimeters and (inches) 529.2 (20.83) 480.0 (18.90) 1119.0 (44.06) 1363.8 (53.69) 358.6 (14.12) 489.6 (19.28) 413.7 (16.29) 117.5 (4.63) 115.5 (4.55) 22.3 39.6 (1.56) (0.88) 310.2 (12.21)
  • Page 146 Appendix B Accessories and Dimensions Figure 24 - 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 (0.21) (6.46) (0.31) 307.5 (12.11) 230.6 (9.08) 291.5 (11.48) 153.8 (6.06)
  • Page 147 Accessories and Dimensions Appendix B Figure 25 - 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 148 Appendix B Accessories and Dimensions Catalog Number Weight 1321-3R160-A 274 (10.80) 216 (8.50) 172 (6.80) 80 (3.16) 92 (3.63) 19.0 (42) 1321-3R160-B 279 (11.00) 216 (8.50) 178 (7.00) 88 (3.47) 92 (3.63) 23.0 (51) 1321-3R160-C 287 (11.30) 216 (8.50) 229 (9.00) 118 (4.66) 92 (3.63) 33.0 (72)
  • Page 149 Accessories and Dimensions Appendix B Figure 27 - EMC Line Filters Dimensions are in millimeters and (inches) Catalog Numbers: 22-RF018-CS, 22-RF018-CL, 22-RF026-CS, 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) Catalog Numbers: 22-RFD036, 22-RFD050, 22-RFD070, 22-RFD100, 22-RFD150, 22-RFD180 Catalog Number 22-RFD036...
  • Page 150 Appendix B Accessories and Dimensions Catalog Number: 22-RFD208 1000 (39.37) (36.93) (35.43) (35.94) (0.26) (3.15) (4.33) (11.81) Rockwell Automation Publication 22C-UM001J-EN-E - January 2017...
  • Page 151 Accessories and Dimensions Appendix B Catalog Numbers: 22-RFD323 and 22-RFD480 (0.24) ø 9 (0.35) 12.5 45° (0.49) (0.39) (1.97) (2.36) (2.36) (0.12) (2.52) Ø 10.8 (0.71) (0.43) (11.81) (0.98) Catalog Number 22-RFD323 300 (11.81) 735 (28.94) 145 (5.71) 275 (10.83) 689 (27.13) 64 (2.52) 180 (7.09) 22-RFD480 300 (11.81) 882 (34.72) 145 (5.71)
  • Page 152 Appendix B Accessories and Dimensions Figure 28 - 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) Rockwell Automation Publication 22C-UM001J-EN-E - January 2017...
  • Page 153 Accessories and Dimensions Appendix B Figure 29 - 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) Rockwell Automation Publication 22C-UM001J-EN-E - January 2017...
  • Page 154 Appendix B Accessories and Dimensions Notes: Rockwell Automation Publication 22C-UM001J-EN-E - January 2017...

  • Page 155: Connectivity Guidelines

    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 156: Connectivity Examples

    Appendix C RJ45 DSI Splitter Cable Figure 31 - RJ45 Two-Position Terminal Block Adapter Catalog Number: AK-U0-RJ45-TB2P (PIN 5) PIN 8 (PIN 4) PIN 1 Figure 32 - RJ45 Adapter with Integrated Termination Resistor Catalog Number: AK-U0-RJ45-TR1 PIN 8 PIN 1 Connectivity Examples Figure 33 - Connecting One Temporary Peripheral DSI Drive...
  • Page 157 RJ45 DSI Splitter Cable Appendix C Figure 34 - Connecting One Temporary Peripheral and One Permanent Peripheral 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 1 [Adapter Cfg] set to "Auto"...
  • Page 158 Appendix C RJ45 DSI Splitter Cable Figure 36 - Connecting an RS-485 Network DSI Drives AK-U0-RJ45-TB2P Two-position Terminal Block AK-U0-RJ45-TR1 Terminating Resistor (end of network) Customer supplied RJ45 male-to-RJ45 male cables with wires connected at pins 4 and 5 only. Both the Master (M) and Slave (S) ports on the RJ45 Splitter Cable operate as standard RS-485 ports in this configuration.

  • Page 159: 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. Relay outputs can be used to energize the damper to either open or close.

  • Page 160: Exclusive Control

    Appendix D Application Notes Exclusive Control and Trim Control are two basic configurations where the PID loop may be used. 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.

  • Page 161: Trim Control

    Application Notes Appendix D 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. Speed Ref PID Loop Accel/Decel...
  • Page 162 Appendix D Application Notes Table 32 - A152 [PID Ref Sel] Options Option Description 0 “PID Disabled” Disables the PID loop (default setting) 1 “PID Setpoint“ Selects Exclusive Control. [PID Setpoint] will be used to set the value of the PID Reference.

  • Page 163: Analog Pid Reference Signals

    Application Notes Appendix D 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...

  • Page 164: Pid Deadband

    Appendix D 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% •...

  • Page 165: Guidelines For Adjusting The Pid Gains

    Application Notes Appendix D • A154 [PID Prop Gain] The proportional gain (unitless) affects how the regulator reacts to the magnitude of the error. The proportional component of the PID regulator outputs a speed command proportional to the PID error. For example, a proportional gain of 1 would output 100% of max frequency when the PID error is 100% of the analog input range.
  • Page 166 Appendix D Application Notes – If there is a lot of oscillation in the PID Feedback before settling out (see Figure 39), increase A155 [PID Integ Time]. 3. At this point, the differential gain may not be needed. However, if after determining the values for A154 [PID Prop Gain] and...

  • Page 167: Auxiliary Motor Control Setup

    Application Notes Appendix D Figure 40 - Good Response – Critically Damped PID Reference PID Feedback Time Auxiliary Motor Control 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 Setup the motor controlled directly by the PowerFlex 400 drive.
  • Page 168 Appendix D Application Notes Example 1 Figure 41 - 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 169 Application Notes Appendix D 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.
  • Page 170 Appendix D Application Notes 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.

  • Page 171: 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 172: Parameter Configuration

    Appendix E Modbus RTU Protocol Standard RS485 wiring practices apply. Termination resistors need to be applied at each end of the network cable. RS485 repeaters may need to be used for long cable runs, or if greater than 32 nodes are needed on the network. Parameter Configuration The following PowerFlex 400 parameters are used to configure the drive to operate on a network.

  • Page 173: Writing (06) Reference

    Modbus RTU Protocol Appendix E In addition to being written, register address 8192 can be read using Function Code 03. Logic Command Address (Decimal) Bit(s) Description 8192 1 = Stop, 0 = Not Stop 1 = Start, 0 = Not Start 1 = Jog, 0 = No Jog 1 = Clear Faults, 0 = Not Clear Faults 5, 4...

  • Page 174: Reading (03) Logic Status Data

    Appendix E Modbus RTU Protocol Reference Address (Decimal) Description 8193 A decimal value entered as xxx.xx where the decimal point is fixed. For example, a decimal “1000” equals 10.00 Hz and “543” equals 5.43 Hz. Reading (03) Logic Status The PowerFlex 400 Logic Status data can be read via the network by sending Function Code 03 reads to register address 8448 (Logic Status).

  • Page 175: Reading (03) And Writing (06) Drive Parameters

    Modbus RTU Protocol Appendix E Error Code Address (Decimal) Value (Decimal) Description 8449 No Fault Auxiliary Input Power Loss Undervoltage Overvoltage Motor Stalled Motor Overload Heatsink Overtemperature HW Overcurrent (300%) Ground Fault Load Loss Analog Input Loss Auto Restart Tries Phase U to Ground Short Phase V to Ground Short Phase W to Ground Short...
  • Page 176 Appendix E Modbus RTU Protocol Notes: Rockwell Automation Publication 22C-UM001J-EN-E - January 2017...

  • Page 177: Understanding Metasys N2

    Appendix Metasys N2 This appendix 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. For information on... See page Understanding Metasys N2 Network Points Using Percent (%) for the Reference Using Metasys Configurable Objects to Access Parameters Understanding Metasys N2...

  • Page 178: Metasys N2 Data Types

    Appendix F Metasys N2 Table 34 - 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...

  • Page 179: Network Points

    Metasys N2 Appendix F Table 38 - Internal Structure of Metasys N2 Binary Output (BO) Attribute Type Description Integer Minimum On-Time Integer Minimum Off-Time Integer Maximum Cycle/Hour Table 39 - Internal Structure of Metasys N2 Internal Integer (ADI) Attribute Type Description Byte Object Configuration...
  • Page 180 Appendix F Metasys N2 Table 41 - Analog Inputs Network Point Name Description Units Min/Max Type Address (NPT) (NPA) Feedback Feedback 0/100 Speed d323 [Output RPM] 0/24000 Current b003 [Output Current] 0.00/Rated × 2 DC Bus Volts b005 [DC Bus Voltage] 0/820 Last Fault d307 [Fault 1 Code]...
  • Page 181 Metasys N2 Appendix F Table 42 - Binary Outputs Network Point Name Description ON (“1”) OFF (“0”) Type Address (NPT) (NPA) Ref Sel 1 Logic Command bit 12 14 13 12 Ref Sel 2 Logic Command bit 13 0 0 0 = No Command 0 0 1 = P038 [Speed Reference] Ref Sel 3 Logic Command bit 14...

  • Page 182: Using Percent (%) For The Reference

    Appendix F Metasys N2 Table 44 - Internal Integer Network Point Name Description Min/Max Default Type Address (NPT) (NPA) 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 183: Using Metasys Configurable Objects To Access Parameters

    Metasys N2 Appendix F Using Metasys Configurable Configurable objects are inputs and outputs that let you read and write parameter values. These objects handle only 16-bit parameter values. Objects to Access Parameters Reading Parameter Values The configurable points may show any parameter in the drive by configuring the Param# for INx point.

  • Page 184: Writing Parameter Values

    Appendix F 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.

  • Page 185: Understanding P1-Fln

    Appendix P1 – Floor Level Network (FLN) This appendix provides information about controlling a PowerFlex 400 drive, setting its Reference, and accessing its parameters through configurable points when the P1-FLN protocol is selected. The P1-FLN protocol is a serial communication protocol used by the Siemens APOGEE® system. For information on...

  • Page 186: Network Points

    Appendix G P1 – Floor Level Network (FLN) Network Points Table 48 - Point Database for Application 2735 Point Point Subpoint Factory Engineering Slope Intercept On Text Off Text Number Type Name Default Units (SI Units) (SI Units) (1) (2) (SI Units) (SI Units) CTLR ADDRESS 99...
  • Page 187 P1 – Floor Level Network (FLN) Appendix G Table 48 - Point Database for Application 2735 (continued) Point Point Subpoint Factory Engineering Slope Intercept On Text Off Text Number Type Name Default Units (SI Units) (SI Units) (1) (2) (SI Units) (SI Units) {50} DIGITAL IN 2...
  • Page 188 Appendix G P1 – Floor Level Network (FLN) (1) Points not listed are not used in this application. (2) Point numbers that appear in brackets { } may be unbundled at the field panel. (3) Local Control causes the drive to use C108 [Start Source 2] and C109...
  • Page 189 P1 – Floor Level Network (FLN) Appendix G Table 49 - Point Database for Application 2735 Point Number Subpoint Name Parameter OPT RELAY 3 R227, R228 OPT RELAY 4 R230, R231 OPT RELAY 5 R233, R234 OPT RELAY 6 R236, R237 DIGITAL IN 1 d302, bit 0 (I/O Terminal 02) DIGITAL IN 2...

  • Page 190: Using Percent (%) For The Reference

    Appendix G P1 – Floor Level Network (FLN) Table 49 - Point Database for Application 2735 Point Number Subpoint Name Parameter REFERENCE b002 OK.FAULT – RESET FAULT – ERROR STATUS – (1) These parameters affect the operation of an optional auxiliary relay board. Using Percent (%) for the The Reference (Point 92) for P1 is set as a percentage from 0% to +100%.

  • Page 191: Writing Parameter Values

    P1 – Floor Level Network (FLN) Appendix G the fetching of data and a “0” is returned in the Read Value point. See Figure 46 andTable Figure 46 - Configurable Input Point Operation Controller Drive Set Point 36 with Param# to Read Data From.
  • Page 192 Appendix G P1 – Floor Level Network (FLN) Notes: Rockwell Automation Publication 22C-UM001J-EN-E - January 2017...

  • Page 193: Index

    Index Faults Analog Input Loss 116 AC Supply Auto Rstrt Tries 116 Ground 19 Auxiliary Input 115 Source 18 Comm Loss 117 Ungrounded 18 Drive Overload 116 Analog Input Loss Fault 116 Fan Fdbck Loss 116 Armored Cable 23 Function Loss 117 Ground Fault 116 Auto Rstrt Tries Fault 116 Heatsink OvrTmp 115...

  • Page 194: Rockwell Automation Publication 22C-Um001J-En-E - January

    Index Keypad 47 Ratings 121 Reflective Wave Protection 24 Removing Cover 12 Repeated Start/Stop 28 LEDs 45 Repeated Start/Stop Precautions 28 Load Loss Fault 116 RFI, see EMC/RFI RWR (Reflective Wave Reducer) 24 Metasys N2 point map 177 Safety Ground 20 Minimum Clearances 15 Shielded Power Cables 23 Motor Cable Length 24...
  • Page 196 How Are We Doing? form at http://literature.rockwellautomation.com/idc/groups/literature/documents/du/ra-du002_-en-e.pdf. Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, Rockwell Software, PowerFlex, DriveExecutive, SCANport and Rockwell Automation are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

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