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Rockwell Automation 22C User Manual

Adjustable Frequency AC Drive for Fan & Pump Applications
FRN 1.xx - 7.xx
User Manual
www.abpowerflex.com
Important User Information
Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.
Important: Identifies information that is critical for successful application and
understanding of the product.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you:
• identify a hazard
• avoid the hazard
• recognize the consequences
Shock Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures.
PowerFlex is a registered trademark of Rockwell Automation, Inc. DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc. PLC is a registered trademark of Rockwell Automation, Inc.

Summary of Changes

Manual Updates
The information below summarizes the changes to the PowerFlex 400 User Manual since the June 2013 release.
Description of New or Updated Information See Page(s)
Maximum Surrounding Air Temperature table updated. 1-5 Frames G & H Mounting Clearances diagram updated. 1-7 Multiple Digital Input Connections example updated. 1-27 New parameters listed in the table below added to Parameter
Organization table. Parameter T055 [Relay Out1 Sel]: Option 24 “Fault” added. 3-14 Parameter T060 [Relay Out2 Sel]: Option 24 “Fault” added. 3-16 Parameter T065 [Opto Out Sel]: Option 24 “Fault” added. 3-18 Parameter T077 [Sleep-Wake Sel] description updated. 3-23 Parameter T077 [Sleep-Wake Sel]: Option 4 “Ind Slp Wake” added. Parameter T082 [Analog Out1 Sel]: Settings 24...29 added. 3-25 Parameter T085 [Analog Out2 Sel]: Settings 24...29 added. 3-27 Parameter A153 [PID Feedback Sel]: Options 3...8 added. 3-38 Parameter R221...R236 [Relay Outx Sel]: Option 24 “Fault” added. 3-55 Parameter d328 [PID Fdbk Disply]: Minimum value updated from “0.0%”
to “-200.0%”. Maximum value updated from “120.0%” to “200.0%” New parameters listed in the table below added to Parameter
Cross-Reference table. Internal DC Bus Choke specification for 380-480V AC Input updated
from “11-160 kW (15-250 HP)” to “18.5-160 kW (25-250 HP)”. Table D.B Parameter A153 [PID Feedback Sel] Options 3...8 added. D-5 Writing (06) Logic Command Data description updated. E-3 Writing (06) Reference description updated. E-4
3-2
3-65
3-71
A-4
New Parameters
The following parameters have been added with the release of Firmware Release Number (FRN) 7.xx.
Parameter Number Page Parameter Number Page
[Sleep Sel] T090 3-29 [Wake Sel] T091 3-29 [ACT1 Maximum] A207 3-53 [Wake Deviation] A203 3-52 [ACT2 Minimum] A208 3-53 [ACT1 Input] A204 3-52 [ACT2 Maximum] A209 3-53 [ACT2 Input] A205 3-52 [Wake PID Preload] A210 3-54
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
[ACT1 Minimum] A206 3-53
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soc-2
Manual Updates
The information below summarizes the changes to the PowerFlex 400 User Manual since the September 2009 release.
Description of New or Updated Information See Page(s)
Minimum Enclosure Volume column and new footnotes added. 1-13 Drive, Fuse & Circuit Breaker Ratings topic updated. A-1 Electronic Motor Overload Protection description updated. A-3, A-4
, A-2
Manual Updates
The information below summarizes the changes to the PowerFlex 400 User Manual since the October 2006 release.
Description of New or Updated Information See Page(s)
Note on placement of wiring for Frame E 240V, 30-37kW (40-50HP) and 480V, 55-75 kW (75-100HP) drives added.
Parameter T072 [Analog In 1 Loss]: Description revised, and Option 7 ‘Hold Last’ added
Parameter T076 [Analog In 2 Loss]: Description revised, and Option 7 ‘Hold Last’ added
Fault F003 (Power Loss) description changed. 4-3 Fault F004 (UnderVoltage) description changed. 4-3 Fault F017 (Input Phase Loss) description added. 4-4 Fault F032 (Fan Fdbck Loss) description added. 4-4 Altitude derating specification revised. A-3 Internal DC Bus Choke specification corrected. A-4
1-17
3-21
3-23
New Parameters
The following parameters have been added with the release of Firmware Release Number (FRN) 6.xx.
Parameter Number Page Parameter Number Page
[PID Invert Error] A201 3-52 [MOP Reset Sel] A202 3-52 [Fault 5 Time-min] d340 3-68 [PID Fdbk Display] d328 3-65 [Fault 6 Time-hr] d341 3-68 [DC Bus Ripple V] d329 3-65 [Fault 6 Time-min] d342 3-68 [Fault 4 Code] d330 3-66 [Fault 7 Time-hr] d343 3-69 [Fault 5 Code] d331 3-66 [Fault 7 Time-min] d344 3-69 [Fault 6 Code] d332 3-66 [Fault 8 Time-hr] d345 3-69 [Fault 7 Code] d333 3-66 [Fault 8 Time-min] d346 3-69 [Fault 8 Code] d334 3-67 [Fault 9 Time-hr] d347 3-69
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[Fault 5 Time-hr] d339 3-68
soc-3
Parameter Number Page Parameter Number Page
[Fault 9 Code] d335 3-67 [Fault 9 Time-min] d348 3-70 [Fault 10 Code] d336 3-67 [Fault10 Time-hr] d349 3-70 [Fault 4 Time-hr] d337 3-67 [Fault10 Time-min] d350 3-70 [Fault 4 Time-min] d338 3-68
Manual Updates
The information below summarizes the changes to the PowerFlex 400 User Manual since the November 2005 release.
Description of New or Updated Information See Page(s)
Information for Frames G and H added Throughout Frame C mounting requirements clarified 1-6 Analog Output DIP switch setting corrected 1-25 Parameter T072 [Analog In 1 Loss]: Option 6 renamed “Preset Freq0” 3-21 Parameters T082 and T085 [Analog Outx Sel]: Settings 18, 19 and 20
added Parameter C107 [Comm Write Mode] description clarified. 3-32 Parameter A170 [Boost Select]: Options added for Frames G and H 3-43 Parameters R221-R236 [Relay Outx Sel]: Default changed from option
0 to option 23 Current rating for Single Phase operation corrected to 35% A-4 EMC Line Filters added for Frames G and H B-5, B-19, B-20
3-25
3-55
New Parameter
The following parameter has been added with the release of Firmware Release Number (FRN) 5.xx.
Parameter Number Page
[Analog In Filter] T089 3-28
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
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Notes:
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Preface Overview
Who Should Use this Manual? . . . . . . . . . P-1
Reference Materials . . . . . . . . . . . . . . . . . P-1
Manual Conventions . . . . . . . . . . . . . . . . . P-2
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . P-2
General Precautions . . . . . . . . . . . . . . . . . P-3
Catalog Number Explanation . . . . . . . . . . P-4
Chapter 1 Installation/Wiring
Opening the Cover . . . . . . . . . . . . . . . . . . 1-1
Mounting Considerations . . . . . . . . . . . . . 1-5
AC Supply Source Considerations . . . . . . 1-9
General Grounding Requirements . . . . . 1-11
Fuses and Circuit Breakers . . . . . . . . . . . 1-12
Power Wiring . . . . . . . . . . . . . . . . . . . . . 1-14
I/O Wiring Recommendations . . . . . . . . 1-19
Start and Speed Reference Control . . . . . 1-28
RS485 Network Wiring. . . . . . . . . . . . . . 1-30
EMC Instructions . . . . . . . . . . . . . . . . . . 1-31
FCC Instructions . . . . . . . . . . . . . . . . . . . 1-34
Chapter 2 Start Up
Prepare For Drive Start-Up . . . . . . . . . . . . 2-1
Integral Keypad. . . . . . . . . . . . . . . . . . . . . 2-3
Viewing and Editing Parameters. . . . . . . . 2-5
Keypad Hand-Off-Auto Functions . . . . . . 2-6
Chapter 3 Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . 3-1
Parameter Organization. . . . . . . . . . . . . . . 3-2
Basic Display Group . . . . . . . . . . . . . . . . . 3-4
Basic Program Group . . . . . . . . . . . . . . . . 3-7
Terminal Block Group. . . . . . . . . . . . . . . 3-12
Communications Group . . . . . . . . . . . . . 3-31
Advanced Program Group. . . . . . . . . . . . 3-35
Aux Relay Card Group . . . . . . . . . . . . . . 3-55
Advanced Display Group . . . . . . . . . . . . 3-60
Parameter Cross-Reference – by Name . 3-71
Chapter 4 Troubleshooting
Drive Status. . . . . . . . . . . . . . . . . . . . . . . . 4-1
Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fault Descriptions . . . . . . . . . . . . . . . . . . . 4-3
Common Symptoms and Corrective Actions . .
4-5
Appendix A Supplemental Drive Information
Drive, Fuse & Circuit Breaker Ratings. . . A-1
Specifications . . . . . . . . . . . . . . . . . . . . . . A-2
Input Power Connections . . . . . . . . . . . . . A-7
Appendix B Accessories and Dimensions
Product Selection . . . . . . . . . . . . . . . . . . . B-1
Product Dimensions . . . . . . . . . . . . . . . . . B-8

Table of Contents

PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
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2 Table of Contents
Appendix C RJ45 DSI Splitter Cable Appendix D Application Notes
Damper Control Setup. . . . . . . . . . . . . . . . D-1
PID Setup. . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Auxiliary Motor Control Setup . . . . . . . . D-12
Appendix E Modbus RTU Protocol
Network Wiring. . . . . . . . . . . . . . . . . . . . . E-1
Parameter Configuration . . . . . . . . . . . . . . E-2
Supported Modbus Function Codes . . . . . E-2
Writing (06) Logic Command Data. . . . . . E-3
Writing (06) Reference . . . . . . . . . . . . . . . E-4
Reading (03) Logic Status Data. . . . . . . . . E-4
Reading (03) Feedback . . . . . . . . . . . . . . . E-4
Reading (03) Drive Error Codes . . . . . . . . E-5
Reading (03) and Writing (06) Drive
Parameters . . . . . . . . . . . . . . . . . . . . . . . E-5
Additional Information . . . . . . . . . . . . . . . E-5
Appendix F Metasys N2
Understanding Metasys N2 . . . . . . . . . . . . F-1
Network Points . . . . . . . . . . . . . . . . . . . . . F-3
Using Percent (%) for the Reference. . . . . F-5
Using Metasys Configurable Objects to Access
Parameters . . . . . . . . . . . . . . . . . . . . . . . F-6
Appendix G P1 – Floor Level Network (FLN)
Understanding P1-FLN . . . . . . . . . . . . . . . G-1
Network Points . . . . . . . . . . . . . . . . . . . . . G-2
Using Percent (%) for the Reference. . . . . G-6
Using P1 Configurable Points to Access
Parameters . . . . . . . . . . . . . . . . . . . . . . . G-7
Index
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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 P-1 Manual Conventions P-2 Drive Frame Sizes P-2 General Precautions P-3 Catalog Number Explanation P-4
Who Should Use this Manual?
This manual is intended for qualified personnel. You must be able to program and operate Adjustable Frequency AC Drive devices. In addition, you must have an understanding of the parameter settings and functions.
P-1
Reference Materials
The following manuals are recommended for general drive information:
Title Publication Available Online at …
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives
Preventive Maintenance of Industrial Control and Drive System Equipment
Safety Guidelines for the Application, Installation and Maintenance of Solid State Control
A Global Reference Guide for Reading Schematic Diagrams
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
DRIVES-IN001…
DRIVES-TD001…
SGI-1.1
100-2.10
www.rockwellautomation.com/ literature
Publication 22C-UM001I-EN-P
P-2 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]
• The following words are used throughout the manual to describe an
action:
Word Meaning
Can Possible, able to do something Cannot Not possible, not able to do something May Permitted, allowed Must Unavoidable, you must do this Shall Required and necessary Should Recommended Should Not Not Recommended
Name Number Group b = Basic Display Group
P = Basic Program Group T = Terminal Block Group C = Communications Group A = Advanced Program Group R = Aux Relay Card Group d = Advanced Display Group
Drive Frame Sizes
Similar PowerFlex 400 drive sizes are grouped into frame sizes to simplify spare parts ordering, dimensioning, etc. A cross reference of drive catalog numbers and their respective frame sizes is provided in
Appendix
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B.
Overview P-3
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 zero.
A darkened LCD display and LEDs is not an indication that capacitors have discharged to safe voltage levels.
ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook.
1 Power Terminal descriptions). The voltage must be
ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring or application errors, such as, undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system.
ATTENTION: The bus regulator function is extremely useful for preventing nuisance overvoltage faults resulting from aggressive decelerations, overhauling loads, and eccentric loads. However, it can also cause either of the following two conditions to occur.
1. Fast positive changes in input voltage or imbalanced input voltages can cause uncommanded positive speed changes;
2. Actual deceleration times can be longer than commanded deceleration times However, a “Stall Fault” is generated if the drive remains in this state for 1 minute. If this condition is unacceptable, the bus regulator must be disabled (see parameter A187
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
).
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P-4 Overview
Code Vol ta ge Ph.
B 240V AC 3 D 480V AC 3
Code Vers ion
3 RS485
Code Interface Module
1 Fixed Keypad
Code Enclosure
N Panel Mount - IP20/UL Open-Type
(1)
A Panel Mount - IP30/NEMA 1/UL Type 1
(2)
F Flange Mount - IP20/UL Open Type
(3)
1-3 4 5 6-8 9 10 11 12
22C - D 038 A 1 0 3
Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Comm Slot
Output Current @ 200-240V 60Hz Input
Code Amps kW (HP) Frame
012 12 2.2 (3.0) C 017 17.5 3.7 (5.0) C 024 24 5.5 (7.5) C 033 33 7.5 (10) C 049 49 11 (15) D 065 65 15 (20) D 075 75 18.5 (25) D 090 90 22 (30) D 120 120 30 (40) E 145 145 37 (50) E
Code Rating
0 Not Filtered
Output Current @ 380-480V Input
Code Amps kW (HP) Frame
6P0 6.0 2.2 (3.0) C 010 10.5 4.0 (5.0) C 012 12 5.5 (7.5) C 017 17 7.5 (10) C 022 22 11 (15) C 030 30 15 (20) C 038 38 18.5 (25) D 045 45.5 22 (30) D 060 60 30 (40) D 072 72 37 (50) E 088 88 45 (60) E 105 105 55 (75) E 142 142 75 (100) E 170 170 90 (125) F 208 208 110 (150) F 260 260 132 (200) G 310 310 160 (250) G 370 370 200 (300) H 460 460 250 (350) H
Code
22C PowerFlex 400
(1)
Frame C drives only available with IP20/UL Open-Type enclosure. Field installed conversion kit available to achieve IP30/NEMA 1/UL Type 1 rating.
(2)
Frame D, E, F, G and H drives only available with IP30/NEMA 1/UL Type 1 enclosure.
(3)
Frame C drives only.
Additional accessories, options and adapters are available. See Appendix B for details.
Catalog Number Explanation
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Chapter 1

Installation/Wiring

This chapter provides information on mounting and wiring the PowerFlex 400 Drive.
For information on… See page For information on… See page
Opening the Cover Mounting Considerations 1-5 Power Wiring 1-14 AC Supply Source Considerations 1-9 I/O Wiring
General Grounding Requirements 1-11 EMC Instructions 1-31
Most start-up difficulties are the result of incorrect wiring. Every precaution must be taken to assure that the wiring is done as instructed. All items must be read and understood before the actual installation begins.
ATTENTION: The following information is merely a guide for proper installation. Rockwell Automation, Inc. cannot assume responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.
1-1 Fuses and Circuit Breakers 1-12
1-19
Recommendations
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.
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
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1-2 Installation/Wiring
Frame D Drives
1. Loosen the two captive cover screws.
2. Pull the bottom of the cover out and up to release.
Frame E Drives
1. Loosen the four captive cover screws.
2. Pull the bottom of the cover out and up to release.
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Frame F Drives
1. Turn the latch counterclockwise.
2. Pull on the latch to swing the door open.
Installation/Wiring 1-3
Frame G Drives
1. Loosen the four captive cover screws.
2. Pull the bottom of the cover out and up to release.
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
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1-4 Installation/Wiring
Frame H Drives
1. Loosen the four captive cover screws.
2. Pull the bottom of the cover out and up to release.
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Installation/Wiring 1-5
Mounting Considerations
• Mount the drive upright on a flat, vertical and level surface.
Frame Screw Size Screw Torque
C M5 (#10-24) 2.45-2.94 N-m (22-26 lb.-in.) D M8 (5/16 in.) 6.0-7.4 N-m (53.2-65.0 lb.-in.) E M8 (5/16 in.) 8.8-10.8 N-m (78.0-95.3 lb.-in.) F M10 (3/8 in.) 19.6-23.5 N-m (173.6-208.3 lb.-in.) G M12 (1/2 in.) 33.5-41.0 N-m (296.5-362.9 lb.-in.) H M12 (1/2 in.) 33.5-41.0 N-m (296.5-362.9 lb.-in.)
• Protect the cooling fan by avoiding dust or metallic particles.
• Do not expose to a corrosive atmosphere.
• Protect from moisture and direct sunlight.
Maximum Surrounding Air Temperature
Frame Enclosure Rating Temperature
C IP 20/UL Open-Type -10° to 45°C
IP 30/NEMA 1/UL Type 1
IP 20/UL Open-Type -10° to 50°C
D IP 30/NEMA 1/UL Type 1 -10° to 45°C
E
FSee Figure 1.3
GSee Figure 1.4
H
(1)
Frame C drives require installation of the PowerFlex 400 IP 30/NEMA 1/UL Type 1 option kit to achieve this rating.
Range
(14° to 113°F)
(1)
-10° to 45°C (14° to 113°F)
(14° to 122°F)
(14° to 113°F)
Minimum Mounting Clearances
See Figure 1.1 Mounting Option A
See Figure 1.1 Mounting Option B
See Figure 1.1 Mounting Option B
See Figure 1.2
,
,
,
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
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1-6 Installation/Wiring
120 mm (4.7 in.)
120 mm (4.7 in.)
25 mm
(1.0 in.)
120 mm (4.7 in.)
120 mm (4.7 in.)
120 mm (4.7 in.)
120 mm (4.7 in.)
120 mm (4.7 in.)
120 mm (4.7 in.)
Closest object that
may restrict air flow
through the drive heat
sink and chassis.
Mounting Option A
No clearance required
between drives.
Mounting Option B
150 mm (6.0 in.)
150 mm (6.0 in.)
50 mm
(2.0 in.)
50 mm (2.0 in.)
Minimum Mounting Clearances
Refer to Appendix B for mounting dimensions.
Figure 1.1 Frame C Mounting Clearances
Figure 1.2 Frames D & E Mounting Clearances
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Figure 1.3 Frame F Mounting Clearances
300 mm
(11.8 in.)
300 mm
(11.8 in.)
200 mm
(1)
(7.9 in.)
200 mm
(1)
(7.9 in.)
(1) If the drive is installed with a side gap of 200 mm, it has to be removed from
the shelf to change the fan. If the drive is installed with a side gap of 300 mm, it does not need to be removed from the shelf to change the fan.
250 mm (9.8 in.)
Installation/Wiring 1-7
50 mm
(2.0 in.)
Figure 1.4 Frames G & H Mounting Clearances
150 mm (6.0 in.)
50 mm
(2.0 in.)
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1-8 Installation/Wiring
Debris Protection
Frame C Drives – A plastic top panel is included with the drive. Install the panel to prevent debris from falling through the vents of the drive housing during installation. Remove the panel for IP 20/Open Type applications.
Frame D, E, F, G and H Drives – These drives have built-in debris protection. Installation of a protective panel is not required.
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.
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Installation/Wiring 1-9
Important:
Tighten screw after jumper removal.
Frame C
Frame E and F (Typical)
AC Supply Source Considerations
Ungrounded Distribution Systems
ATTENTION: PowerFlex 400 drive frames 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 125% of the nominal line-to-line voltage. To disconnect these devices, remove the jumper shown in Figure 1.6
Figure 1.5 Phase to Ground MOV Removal
Figure 1.6 MOV Jumper Location
.
Three-Phase
AC Input
R/L1 S/L2 T/L3
Jumper
123
4
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.
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
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1-10 Installation/Wiring
Input Power Conditioning
The drive is suitable for direct connection to input power within the rated voltage of the drive (see Appendix 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
Action on the line side of the drive.
Important: Only one device per branch circuit is required. The device
Table 1.A Input Power Conditions
Input Power Condition Corrective Action
Low Line Impedance (less than 1% line reactance)
Line has power factor correction capacitors • Install Line Reactor
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
Ungrounded distribution system
(1)
, install one of the devices listed under the heading Corrective
should be mounted closest to the branch and sized to handle the total current of the branch circuit.
Refer to Appendix B for accessory ordering information.
A). Listed in Table 1.A are certain
• Install Line Reactor
• or Isolation Transformer
• or Isolation Transformer
• Remove MOV jumper to ground
(Frame C, E and F drives only)
• or Install Isolation Transformer with
grounded secondary if necessary
(1)
(1)
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Installation/Wiring 1-11
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 1.7 Typical Grounding
R/L1 S/L2 T/L3
SHLD
U/T1 V/T2 W/T3
Ground Fault Monitoring
If a system ground fault monitor (RCD) is to be used, only Type B (adjustable) devices should be used to avoid nuisance tripping.
Safety Ground - (PE)
This is the safety ground for the drive that is required by code. One of these points must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar. Grounding points must comply with national and local industrial safety regulations and/or electrical codes.
Motor Ground
The motor ground must be connected to one of the ground terminals on the drive.
Shield Termination - SHLD
Either of the safety ground terminals located on the power terminal block provides a grounding point for the motor cable shield. The motor cable shield connected to one of these terminals (drive end) should also be connected to the motor frame (motor end). Use a shield terminating or EMI clamp to connect the shield to the safety ground terminal. The conduit box may be used with a cable clamp for a grounding point for the cable shield.
When shielded cable is used for control and signal wiring, the shield should be grounded at the source end only, not at the drive end.
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22C-UM001I-EN-P
1-12 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. Ensure that the incoming supply neutral is solidly connected (bonded) to the same building power distribution ground. Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection. Some local codes may require redundant ground connections. The integrity of all connections should be periodically checked.
Fuses and Circuit Breakers
The PowerFlex 400 does not provide branch short circuit protection. This product should be installed with either input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations.
Fusing
The ratings in the table that follows are the recommended values for use with each drive rating. The devices listed in this table are provided to serve as a guide.
Bulletin 140M (Self-Protected Combination Controller)/UL489 Circuit Breakers
When using Bulletin 140M or UL489 rated circuit breakers, the guidelines listed below must be followed in order to meet the NEC requirements for branch circuit protection.
• Bulletin 140M can be used in single and group motor applications.
• Bulletin 140M can be used up stream from the drive without the
need for fuses.
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Installation/Wiring 1-13
Table 1.B Recommended Branch Circuit Protective Devices
Voltage Rating
200-240V AC – 3-Phase
Drive Rating
kW (HP)
Fuse Rating
Amps
2.2 (3.0) 20 140M-F8E-C16 100-C23 5098
3.7 (5.0) 30 140M-F8E-C25 100-C37 5098
5.5 (7.5) 35 140M-F8E-C32 100-C37 5098
7.5 (10) 45 140M-F8E-C45 100-C45 5098
11 (15) 70 – 100-C60 –
15 (20) 90 – 100-C85 –
18.5 (25) 100 – 100-D95 –
22 (30) 125 – 100-D110 –
30 (40) 175 – 100-D180 –
37 (50) 200 – 100-D180 –
380-480V AC – 3-Phase
2.2 (3.0) 10 140M-D8E-C10 100-C09 5098
4.0 (5.0) 20 140M-D8E-C16 100-C16 5098
5.5 (7.5) 20 140M-D8E-C16 100-C23 5098
7.5 (10) 25 140M-D8E-C20 100-C23 5098
11 (15) 30 140M-F8E-C32 100-C30 5098
15 (20) 40 140M-F8E-C32 100-C37 5098
18.5 (25) 50 140M-F8E-C45 100-C60 9086
22 (30) 60 – 100-C60 –
30 (40) 80 – 100-C85 –
37 (50) 100 – 100-C85 –
45 (60) 125 – 100-D110 –
55 (75) 150 – 100-D140 –
75 (100) 200 – 100-D180 –
90 (125) 250 – 100-D210 –
110 (150) 250 – 100-D250 –
132 (200) 300 – 100-D300 –
160 (250) 400 – 100-D420 –
200 (300) 500 – 100-D420 –
250 (350) 600 – 100-D630 –
(1)
Recommended Fuse Class: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.
(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.
(1)
140M Motor Protectors
Catalog No.
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Recommended
(2) (3)
MCS Contactors
Catalog No.
Min. Enclosure Vol um e
Inches
Publication 22C-UM001I-EN-P
(4)
3
1-14 Installation/Wiring
Power Wiring
ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.
ATTENTION: To avoid a possible shock hazard caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled. This will help minimize the possible shock hazard from “cross coupled” power leads.
Motor Cable Types Acceptable for 200-600 Volt Installations
A variety of cable types are acceptable for drive installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, allow a spacing of 0.3 meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases, long parallel runs must be avoided. Do not use cable with an insulation thickness less than 15 mils (0.4 mm/0.015 in.). Do not route more than three sets of motor leads in a single conduit to minimize “cross talk”. If more than three drive/motor connections per conduit are required, shielded cable must be used. UL installations must use 600V, 75°C or 90°C wire. Use copper wire only.
Unshielded
THHN, THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space and/or conduit fill rates limits are provided. Do not use THHN or similarly coated wire in wet areas. Any wire chosen must have a minimum insulation thickness of 15 mils and should not have large variations in insulation concentricity.
Shielded/Armored Cable
Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC Drive. Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations or a high degree of communications / networking are also good candidates for shielded cable.
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Installation/Wiring 1-15
Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks. Refer to Reflected Wave in “Wiring and Grounding Guidelines for PWM AC Drives,” publication DRIVES-IN001A-EN-P.
Consideration should be given to all of the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics and chemical resistance. In addition, a braided shield should be included and be specified by the cable manufacturer as having coverage of at least 75%. An additional foil shield can greatly improve noise containment.
A good example of recommended cable is Belden® 295xx (xx determines gauge). This cable has four (4) XLPE insulated conductors with a 100% coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a PVC jacket.
Other types of shielded cable are available, but the selection of these types may limit the 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. Unless specified in the individual distance tables as tested with the drive, these cables are not recommended and their performance against the lead length limits supplied is not known.
Recommended Shielded Wire
Location Rating/Type Description
Standard (Option 1)
Standard (Option 2)
Class I & II; Division I & II
600V, 90°C (194°F) XHHW2/RHW-2 Anixter B209500-B209507, Belden 29501-29507, or equivalent
Tray rated 600V, 90°C (194°F) RHH/RHW-2 Anixter OLF-7xxxxx or equivalent
Tray rated 600V, 90°C (194°F) RHH/RHW-2 Anixter 7V-7xxxx-3G or equivalent
• Four tinned copper conductors with XLPE insulation.
• Copper braid/aluminum foil combination shield and tinned
copper drain wire.
• PVC jacket.
• Three tinned copper conductors with XLPE insulation.
• 5 mil single helical copper tape (25% overlap min.) with three
bare copper grounds in contact with shield.
• PVC jacket.
• Three bare copper conductors with XLPE insulation and
impervious corrugated continuously welded aluminum armor.
• Black sunlight resistant PVC jacket overall.
• Three copper grounds on #10 AWG and smaller.
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
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1-16 Installation/Wiring
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
The reflected wave data applies to all frequencies 2 to 10 kHz. For 240V ratings, reflected wave effects do not need to be considered.
Table 1.C Maximum Cable Length Recommendations
Reflected Wave
380-480V Ratings Motor Insulation Rating Motor Cable Only
(1)
Longer cable lengths can be achieved by installing devices on the output of the drive. Consult factory for recommendations.
Output Disconnect
The drive is intended to be commanded by control input signals that will start and stop the motor. A device that routinely disconnects then reapplies output power to the motor for the purpose of starting and stopping the motor should not be used. If it is necessary to disconnect power to the motor with the drive outputting power, an auxiliary contact should be used to simultaneously disable drive control run commands.
for recommendations.
(1)
1000 Vp-p 7.6 meters (25 feet)
1200 Vp-p 22.9 meters (75 feet)
1600 Vp-p 152.4 meters (500 feet)
Power Terminal Block
Frame C, D, F, G and H drives utilize a finger guard over the power wiring terminals. Replace the finger guard when wiring is complete.
Figure 1.8 Power Terminal Blocks (Frames C through D)
R/L1 S/L2 T/L3
R/L1
S/L2
T/L3
Publication 22C-UM001I-EN-P
U/T1 V/T2
W/T3
P2 P1
BR–BR+DC+DC–
P1
P2
DC–
U/T1
V/T2
W/T3
Frame C
Frame D
Installation/Wiring 1-17
Wire
Jumper
Wire Jumper
Correct
Incorrect
Bottom view of terminal block and wire
Figure 1.9 Power Terminal Blocks (Frames E through H)
R/L1
S/L2
T/L3
P1
P2
DC–
U/T1
V/T2
W/T3
R/L1
S/L2
T/L3
P1
P2
DC–
U/T1
V/T2
W/T3
R/L1
S/L2
T/L3
P1
P2
DC–
U/T1
V/T2
W/T3
P2
R/L1
S/L2
T/L3
P1
DC–
U/T1
V/T2
W/T3
Frame E: 480V 37-45 kW (50-60 HP)
Frame E: 240V 480V 30-37 kW 55-75 kW (40-50 HP) (75-100 HP)
See note at the bottom of this page.
Frame F
Frame G
R/L1
S/L2
T/L3
DC+
DC–
U/T1
V/T2
W/T3
Important: For Frame E, 240V 30-37 kW (40-50 HP) and 480V
55-75 kW (75-100 HP) drives, take care to place the wire beneath the jumper and not above it when connecting to terminals P1 and P2.
P1 P2 DC- P1 P2 DC-
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Frame H
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1-18 Installation/Wiring
Table 1.D Power Terminal Descriptions
(1)
Terminal
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
P2, P1
DC–, DC+ DC Bus Connection (Frame C and H Drives) P2, DC– DC Bus Connection (Frame D, E, F and G Drives) BR+, BR– Not Used
(1)
Important: Terminal screws may become loose during shipment. Ensure that all terminal screws are tightened to the recommended torque before applying power to the drive.
Table 1.E Power Terminal Block Specifications
Frame Maximum Wire Size
C 8.4 mm
D 33.6 mm
E 480V
37-45 kW (50-60 HP)
E 240V
30-37 kW (40-50 HP)
480V 55-75 kW (75-100 HP)
F 152.0 mm
G 152.0 mm
H 253.0 mm
(1)
Maximum/minimum sizes that the terminal block will accept - these are not recommendations. If national or local codes require sizes outside this range, lugs may be used. Some ratings will require a pair of wires.
Description
Switch any two motor
=
leads to change forward direction.
DC Bus Inductor Connection Drives are shipped with a jumper between Terminals
P2 and P1. Remove this jumper only when a DC Bus Inductor will be connected. Drive will not power up without a jumper or inductor connected.
Safety Ground - PE
(1)
Minimum Wire Size
2
(8 AWG) 1.3 mm2 (16 AWG) 2.9 N-m (26 lb.-in.)
2
(2 AWG) 8.4 mm2 (8 AWG) 5.1 N-m (45 lb.-in.)
2
(2 AWG) 3.5 mm2 (12 AWG) 5.6 N-m (49.5 lb.-in.)
33.6 mm
2
107.2 mm
(4/0 AWG) 53.5 mm2 (1/0 AWG) 19.5 N-m (173 lb.-in.)
2
(300 MCM) 85.0 mm2 (3/0 AWG) 19.5 N-m (173 lb.-in.)
2
(300 MCM) 107.2 mm2 (4/0 AWG) 29.4 N-m (260 lb.-in.)
2
(500 MCM) 152.0 mm2 (300 MCM) 40.0 N-m (354 lb.-in.)
(1)
Recommended Tor que
Publication 22C-UM001I-EN-P
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