Rockwell Automation 22A User Manual

Quick Start

PowerFlex 4 Adjustable Frequency AC Drive

FRN 6.xx

This Quick Start guide summarizes the basic steps needed to install, start-up and program the PowerFlex 4 Adjustable Frequency AC Drive.

The information provided Does Not intended for qualified drive service personnel only.

For detailed PowerFlex 4 information including EMC instructions, application considerations and related precautions refer to the PowerFlex 4 User Manual, Publication 22A-UM001… at

www.rockwellautomation.com/literature.

General Precautions

ATTENTION: The drive contains high voltage capacitors which take time to discharge after removal of mains supply. Before working on drive, ensure isolation of mains supply from line inputs [R, S, T (L1, L2, L3)]. Wait three minutes for capacitors to discharge to safe voltage levels. Failure to do so may result in personal injury or death.

Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels.

ATTENTION: Equipment damage and/or personal injury may result if parameter A092 [Auto Rstrt Tries] or A094 [Start At PowerUp] is used in an inappropriate application. Do not use this function without considering applicable local, national and international codes, standards, regulations or industry guidelines.

replace the User Manual and is

ATTENTION: Only qualified personnel familiar with adjustable

frequency AC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.

ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook.

ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring or application errors, such as, undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system.

English-2

25 mm

(1.0 in.)

120 mm (4.7 in.)

Mounting Option A

No clearance required between drives.

Mounting Option B

Closest object that

may restrict air flow

through the drive heat

sink and chassis

See page 12 for mounting dimensions.

U/T1 V/T2 W/T3

R/L1 S/L2 T/L3

SHLD

Important: The MOV to ground jumper must be removed if the drive is installed on an ungrounded or resistive grounded distribution system.

Tighten screw after jumper removal.

Jumper Location

Mounting Considerations

• Mount the drive upright on a flat, vertical and level surface.

Min. Panel Thickness Screw Size Screw Torque DIN Rail

1.9 mm (0.0747 in.) M4 (#8-32) 1.56-1.96 N-m (14-17 lb.-in.) 35 mm

• Protect the cooling fan by avoiding dust or metallic particles.

• Do not expose to a corrosive atmosphere.

• Protect from moisture and direct sunlight.

Minimum Mounting Clearances

Ambient Operating Temperatures

Ambient Temperature Enclosure Rating Minimum Mounting

Minimum Maximum

IP 20/Open Type Use Mounting Option A IP 30/NEMA 1/UL Type 1

-10°C (14°F)

40°C (104°F)

50°C (122°F) IP 20/Open Type Use Mounting Option B

(1)

Rating requires installation of the PowerFlex 4 IP 30/NEMA 1/UL Type 1 option kit.

Clearances

(1)

Use Mounting Option B

General Grounding Requirements

CE Conformity

Refer to the PowerFlex 4 User Manual for details on how to comply with the Low Voltage (LV) and Electromagnetic Compatibility (EMC) Directives.

English-3

Specifications, Fuses and Circuit Breakers

Drive Ratings

Catalog Number

100 - 120V AC (±10%) – 1-Phase Input, 0 - 230V 3-Phase Output

22A-V1P5N104 0.2 (0.25) 1.5 90-126 0.75 6.0 10 140M-C2E-C10 100-C09 1655 32 22A-V2P3N104 0.4 (0.5) 2.3 90-126 1.15 9.0 15 140M-C2E-C16 100-C12 1655 40 22A-V4P5N104 0.75 (1.0) 4.5 90-126 2.25 18.0 30 140M-D8E-C20 100-C23 1655 55 22A-V6P0N104 1.1 (1.5) 6.0 90-126 3.0 24.0 40 140M-F8E-C32 100-C37 1655 80

200 - 240V AC (±10%) – 1-Phase

22A-A1P4N103 0.2 (0.25) 1.4 180-265 0.7 3.2 6 140M-C2E-B40 100-C09 1655 32 22A-A2P1N103 0.4 (0.5) 2.1 180-265 1.05 5.3 10 140M-C2E-B63 100-C09 1655 40 22A-A3P6N103 0.75 (1.0) 3.6 180-265 1.8 9.2 15 140M-C2E-C16 100-C12 1655 55 22A-A6P8N103 1.5 (2.0) 6.8 180-265 3.4 14.2 25 140M-C2E-C16 100-C16 1655 85 22A-A9P6N103 2.2 (3.0) 9.6 180-265 4.8 19.6 30 140M-D8E-C25 100-C23 1655 125

200 - 240V AC (±10%) – 1-Phase

22A-A1P5N104 0.2 (0.25) 1.5 180-265 0.75 5.0 10 140M-C2E-B63 100-C09 1655 32 22A-A2P3N104 0.4 (0.5) 2.3 180-265 1.15 6.0 10 140M-C2E-B63 100-C09 1655 40 22A-A4P5N104 0.75 (1.0) 4.5 180-265 2.25 10.0 15 140M-C2E-C16 100-C12 1655 55 22A-A8P0N104 1.5 (2.0) 8.0 180-265 4.0 18.0 30 140M-D8E-C20 100-C23 1655 85

200 - 240V AC (±10%) – 3-Phase Input, 0 - 230V 3-Phase Output

22A-B1P5N104 0.2 (0.25) 1.5 180-265 0.75 1.8 3 140M-C2E-B25 100-C09 1655 32 22A-B2P3N104 0.4 (0.5) 2.3 180-265 1.15 2.5 6 140M-C2E-B40 100-C09 1655 40 22A-B4P5N104 0.75 (1.0) 4.5 180-265 2.25 5.2 10 140M-C2E-C10 100-C09 1655 55 22A-B8P0N104 1.5 (2.0) 8.0 180-265 4.0 9.5 15 140M-C2E-C16 100-C12 1655 85 22A-B012N104 2.2 (3.0) 12.0 180-265 5.5 15.5 25 140M-C2E-C16 100-C16 1655 125 22A-B017N104 3.7 (5.0) 17.5 180-265 8.6 21.0 30 140M-F8E-C25 100-C23 1655 180

380 - 480V AC (±10%) – 3-Phase Input, 0 - 460V 3-Phase Output

22A-D1P4N104 0.4 (0.5) 1.4 340-528 1.4 1.8 3 140M-C2E-B25 100-C09 1655 35 22A-D2P3N104 0.75 (1.0) 2.3 340-528 2.3 3.2 6 140M-C2E-B40 100-C09 1655 50 22A-D4P0N104 1.5 (2.0) 4.0 340-528 4.0 5.7 10 140M-C2E-B63 100-C09 1655 70 22A-D6P0N104 2.2 (3.0) 6.0 340-528 5.9 7.5 15 140M-C2E-C10 100-C09 1655 100 22A-D8P7N104 3.7 (5.0) 8.7 340-528 8.6 9.0 15 140M-C2E-C16 100-C16 1655 150

Input/Output Ratings

Output Frequency: 0-240 Hz (Programmable) Efficiency: 97.5% (Typical)

Digital Control Inputs (Input Current = 6mA) Analog Control Inputs

SRC (Source) Mode:

18-24V = ON 0-6V = OFF

Control Output (Programmable Output, form C relay)

Resistive Rating: 3.0A at 30V DC, 125V AC and 240V AC Inductive Rating: 0.5A at 30V DC, 125V AC, and 240V AC

Recommended Fuses and Circuit Breakers

Fuse: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent. Circuit Breakers: HMCP or Bulletin 140U or equivalent.

Protective Features

Motor Protection: I2t overload protection - 150% for 60 Secs, 200% for 3 Secs (Provides Class 10 protection) Overcurrent: 200% hardware limit, 300% instantaneous fault Over Voltage: 100-120V AC Input – Trip occurs at 405V DC bus voltage (equivalent to 150V AC incoming line)

Under Voltage: 100-120V AC Input – Trip occurs at 210V DC bus voltage (equivalent to 75V AC incoming line)

Control Ride Through: Minimum ride through is 0.5 Secs - typical value 2 Secs Faultless Power Ride Through: 100 milliseconds

Dynamic Braking

Internal brake IGBT included with all ratings except No Brake versions. Refer to Appendix B of the PowerFlex 4 User Manual for DB resistor ordering information.

(1)

Output Ratings

kW (HP) Amps

Input Ratings Branch Circuit Protection

Voltage Range kVA Amps Fuses

(1)

Input, 0 - 230V 3-Phase Output, NO BRAKE

(1)

Input, 0 - 230V 3-Phase Output

140M Motor Protectors

(2) (3)

Contactors

Min. Enclosure Vol um e

(4)

(in.3)

Power Dissipation

IP20 Open Watt s

Approvals

UL508C CSA 22.2

No. 14

CUS

SNK (Sink) Mode:

0-6V = ON 18-24V = OFF

200-240V AC Input – Trip occurs at 405V DC bus voltage (equivalent to 290V AC incoming line) 380-460V AC Input – Trip occurs at 810V DC bus voltage (equivalent to 575V AC incoming line)

200-240V AC Input – Trip occurs at 210V DC bus voltage (equivalent to 150V AC incoming line) 380-480V AC Input – Trip occurs at 390V DC bus voltage (equivalent to 275V AC incoming line)

200-240V AC - 1-Phase drives are also available with an integral EMC filter. Catalog suffix changes from N103 to N113 and N104 to N114.

4-20mA Analog: 250 ohm input impedance 0-10V DC Analog: 100k ohm input impedance External Pot: 1-10k ohms, 2 Watt minimum

EMC Directive 89/336/EEC, LV Dir. 73/23/EEC LV: EN 50178 EMC: EN 61800-3

English-4

V/T2T/L3S/L2R/L1 U/T1 W/T3

BR+

BR-

(2)

The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See Bulletin 140M Motor Protection

Circuit Breakers Application Ratings.

(3)

Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 208 Wye or Delta, 240 Wye or Delta, 480Y/ 277 or 600Y/347. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground systems.

(4)

When using a Manual Self-Protected (Type E) Combination Motor Controller, the drive must be installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this column. Application specific thermal considerations may require a larger enclosure.

Power Wiring

Power Wire Rating Recommended Copper Wire

Unshielded 600V, 75°C (167°F) THHN/THWN 15 Mils insulated, dry location

Shielded 600V, 75°C or 90°C (167°F or 194°F) RHH/RHW-2 Belden 29501-29507 or equivalent

Shielded Tray rated 600V, 75°C or 90°C (167°F or 194°F) RHH/RHW-2 Shawflex 2ACD/3ACD or equivalent

Power Terminal Block (A Frame Shown)

Terminal Description

R/L1, S/L2 1-Phase Input

R/L1, S/L2, T/L3 3-Phase Input

U/T1 To Motor U/T1

V/T2 To Motor V/T2

W/T3 To Motor W/T3

BR+, BR- Dynamic Brake Resistor Connection [0.75 kW (1 HP) ratings and higher]

Safety Ground - PE

Power Terminal Block Specifications

Frame Maximum Wire Size

A 3.3 mm2 (12 AWG) 0.8 mm2 (18 AWG)

B 5.3 mm

(1)

Maximum/minimum sizes that the terminal block will accept - these are not recommendations.

(10 AWG)

(1)

Minimum Wire Size

1.3 mm

(16 AWG)

Input Power Conditions

Input Power Condition Corrective Action

Low Line Impedance (less than 1% line reactance) • Install Line Reactor

Greater than 120 kVA supply transformer

Line has power factor correction capacitors

Line has frequent power interruptions

Line has intermittent noise spikes in excess of 6000V (lightning) Phase to ground voltage exceeds 125% of normal line to line voltage • Remove MOV jumper to ground.

Ungrounded Distribution System

(2)

Refer to Appendix B of the PowerFlex 4 User Manual for accessory ordering information.

I/O Wiring Recommendations

• or Isolation Transformer

• or Install Isolation Transformer with

(3)

Switch any two motor leads to change forward direction.

(1)

Tor que

1.7-2.2 N-m (16-19 lb.-in.)

(2)

grounded secondary if necessary.

Wire Type(s) Description Minimum Insulation Rating

Belden 8760/9460 (or equiv.)

Belden 8770 (or equiv.)

(3)

If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessary, but is always recommended.

0.8 mm2(18AWG), twisted pair, 100% shield with drain.

0.8 mm

(18AWG), 3 conductor, shielded for

remote pot only.

300V 60 degrees C (140 degrees F)

I/O Terminal Block Specifications

Maximum Wire Size

1.3 mm2 (16 AWG) 0.13 mm2 (26 AWG) 0.5-0.8 N-m (4.4-7 lb.-in.)

(4)

Maximum / minimum that the terminal block will accept - these are not recommendations.

(4)

Minimum Wire Size

(4)

Torque

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