Rockwell Automation 25D-40P User Manual

Quick Start

!

PowerFlex® 40P Adjustable
Frequency AC Drive

FRN 1.xx - 3.xx

This Quick Start guide summarizes the basic steps needed to install,
start-up and program the PowerFlex 40P Adjustable Frequency AC
Drive. The information provided Does Not replace the User Manual

and is intended for qualified drive service personnel only.

For detailed PowerFlex 40P information including EMC instructions,
application considerations and related precautions, refer to the
PowerFlex 40P User Manual, Publication 22D-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.

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.

ATTENTION: Risk of injury or equipment damage exists. Drive does
not contain user-serviceable components. Do not disassemble drive
chassis.

English-2

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.)

RUN
REV

FAULT

RUN
REV

FAULT

RUN
REV

FAULT

RUN
REV

FAULT

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

Mounting Considerations

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

Frame Screw Size Screw Torque DIN Rail

B M4 (#8-32) 1.56-1.96 N-m (14-17 lb.-in.) 35 mm
C M5 (#10-24) 2.45-2.94 N-m (22-26 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.

Minimum Mounting Clearances

See page 21 for mounting dimensions.

Ambient Operating Temperatures

(1)

Ambient Temperature Enclosure Rating Minimum Mounting

Minimum Maximum

-10°C (14°F)

40°C (104°F)

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

Clearances

(1)

Use Mounting Option B

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

Rating requires installation of the PowerFlex 40P IP 30/NEMA 1/UL Type 1 option kit.

English-3

SHLD

U/T1
V/T2

W/T3

R/L1
S/L2

T/L3

RUN
REV

FAULT

Typical Grounding

Disconnecting MOVs

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 the figures below.

1. Turn the screw counterclockwise to loosen.

2. Pull the jumper completely out of the drive chassis.

3. Tighten the screw to keep it in place.

Jumper Location

Phase to Ground MOV Removal

Three-Phase

Important: Tighten screw after jumper removal.

AC Input

R/L1
S/L2
T/L3

Jumper

1234

English-4

CE Conformity

Refer to the PowerFlex 40P User Manual for details on how to comply
with the Low Voltage (LV) and Electromagnetic Compatibility (EMC)
Directives.

Specifications, Fuses and Circuit Breakers

Drive Ratings

Catalog
Number

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

22D-B2P3 0.4 (0.5) 2.3 180-264 1.15 2.5 6 140M-C2E-B40 100-C07 1655

22D-B5P0 0.75 (1.0) 5.0 180-264 2.45 5.7 10 140M-C2E-C10 100-C09 1655

22D-B8P0 1.5 (2.0) 8.0 180-264 4.0 9.5 15 140M-C2E-C16 100-C12 1655

22D-B012 2.2 (3.0) 12.0 180-264 5.5 15.5 25 140M-C2E-C16 100-C23 1655

22D-B017 3.7 (5.0) 17.5 180-264 8.6 21.0 30 140M-F8E-C25 100-C23 1655

22D-B024 5.5 (7.5) 24.0 180-264 11.8 26.1 40 140M-F8E-C32 100-C37 2069

22D-B033 7.5 (10.0) 33.0 180-264 16.3 34.6 60 140M-G8E-C45 100-C60 2069

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

22D-D1P4 0.4 (0.5) 1.4 342-528 1.4 1.8 3 140M-C2E-B25 100-C07 1655

22D-D2P3 0.75 (1.0) 2.3 342-528 2.3 3.2 6 140M-C2E-B40 100-C07 1655

22D-D4P0 1.5 (2.0) 4.0 342-528 4.0 5.7 10 140M-C2E-B63 100-C09 1655

22D-D6P0 2.2 (3.0) 6.0 342-528 5.9 7.5 15 140M-C2E-C10 100-C09 1655

22D-D010 4.0 (5.0) 10.5 342-528 10.3 13.0 20 140M-C2E-C16 100-C23 1655

22D-D012 5.5 (7.5) 12.0 342-528 11.8 14.2 25 140M-D8E-C20 100-C23 2069

22D-D017 7.5 (10.0) 17.0 342-528 16.8 18.4 30 140M-D8E-C20 100-C23 2069

22D-D024 11.0 (15.0) 24.0 342-528 23.4 26.0 50 140M-F8E-C32 100-C43 2069

460 - 600V AC (±10%) – 3-Phase Input, 0 - 575V 3-Phase Output

22D-E1P7 0.75 (1.0) 1.7 414-660 2.1 2.3 6 140M-C2E-B25 100-C09 1655

22D-E3P0 1.5 (2.0) 3.0 414-660 3.65 3.8 6 140M-C2E-B40 100-C09 1655

22D-E4P2 2.2 (3.0) 4.2 414-660 5.2 5.3 10 140M-D8E-B63 100-C09 1655

22D-E6P6 4.0 (5.0) 6.6 414-660 8.1 8.3 15 140M-D8E-C10 100-C09 1655

22D-E9P9 5.5 (7.5) 9.9 414-660 12.1 11.2 20 140M-D8E-C16 100-C16 2069

22D-E012 7.5 (10.0) 12.2 414-660 14.9 13.7 25 140M-D8E-C16 100-C23 2069

22D-E019 11.0 (15.0) 19.0 414-660 23.1 24.1 40 140M-F8E-C25 100-C30 2069

(1)

(2)

(3)

(4)

Output Ratings Input Ratings Branch Circuit Protection

(1)

kW (HP) Amps

Voltage
Range kVA Amps Fuses

140M Motor
Protectors

(2) (3)

Contactors

Min. Enclosure
Vol um e

Ratings apply to all drive types; Panel Mount (N104), Flange Mount (F104), and Plate Drive
(H204).

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

Motor Protection Circuit Breakers Application Ratings.

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.

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.

(4)

(in.3)

English-5

TUV

Rheinland

Product Safety

.

.

Production inspected

W

E

C

TUV

Rheinland

.

.

Functional

Safety

Bauart geprüft

Type approved

EN 50178

Category Specification
Agency

Certification

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.

Protection Bus Overvoltage Trip

IEC 146 - International Electrical Code.

200-240V AC Input:
380-460V AC Input:
460-600V AC Input:

Bus Undervoltage Trip

200-240V AC Input:
380-480V AC Input:
460-600V AC Input

P042 = 3 “High Voltage”:
P042 = 2 “Low Voltage”:

U

CUS

Power Ride-Thru: 100 milliseconds
Logic Control Ride-Thru: 0.5 seconds minimum, 2 seconds typical
Electronic Motor Overload Protection: Provides class 10 motor overload protection according

Overcurrent: 200% hardware limit, 300% instantaneous fault
Ground Fault Trip: Phase-to-ground on drive output
Short Circuit Trip: Phase-to-phase on drive output

Environment Altitude: 1000 m (3300 ft) max. without derating. Above 1000 m

Maximum Surrounding Air Temperature
without derating:

IP20, Open Type:
IP30, NEMA Type 1, UL Type 1:
Flange and Plate Mount:

Cooling Method

Convection:
Fan:

Storage Temperature: –40 to 85 degrees C (–40 to 185 degrees F)
Atmosphere: Important: Drive must

Relative Humidity: 0 to 95% non-condensing
Shock (operating): 15G peak for 11ms duration (±1.0 ms)
Vibration (operating): 1G peak, 5 to 2000 Hz

Listed to UL508C and CAN/CSA-22.2

L

®

Certified to AS/NZS, 1997 Group 1, Class A

Marked for all applicable European Directives
EMC Directive (89/336)

EN 61800-3, EN 50081-1, EN 50082-2

Low Voltage Directive (73/23/EEC)

EN 50178, EN 60204

Certified to ISO 13849-1; Performance Level d (Safety
Category 3).
Meets Functional Safety (FS) when used with the
DriveGuard Safe-Off Option (Series B).

405V DC bus (equivalent to 290V AC incoming line)
810V DC bus (equivalent to 575V AC incoming line)
1005V DC bus (equivalent to 711V AC incoming line)

210V DC bus (equivalent to 150V AC incoming line)
390V DC bus (equivalent to 275V AC incoming line)

487V DC bus (equivalent to 344V AC incoming line)
390V DC bus (equivalent to 275V AC incoming line)

to NEC article 430 and motor over-temperature
protection according to NEC article 430.126 (A) (2).
UL 508C File 29572.

(3300 ft) derate 3% for every 305 m (1000 ft).

–10 to 50° C (14 to 122° F)
–10 to 40° C (14 to 104° F)
Heatsink: –10 to 40° C (14 to 104° F)
Drive: –10 to 50° C (14 to 122° F)

0.4 kW (0.5 HP) drives and all Flange and Plate drives
All other drive ratings

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.

not be installed in an area

English-6

Category Specification
Electrical Voltage Tolerance: 200-240V ±10%

Frequency Tolerance: 48-63 Hz
Input Phases: Three-phase input provides full rating. Single-phase

Displacement Power Factor: 0.98 across entire speed range
Maximum Short Circuit Rating: 100,000 Amps Symmetrical
Actual Short Circuit Rating: Determined by AIC Rating of installed fuse/circuit

Control Method: Sinusoidal PWM, Volts/Hertz, and Sensorless Vector

Control Inputs Digital: Bandwidth: 10 Rad/Secs for open and closed loop

Encoder Type: Incremental, dual channel

Transistor Type: Isolated Gate Bipolar (IGBT)

Carrier Frequency 2-16 kHz, Drive rating based on 4 kHz.
Frequency Accuracy

Digital Input:
Analog Input:

Analog Output:

Speed Regulation

Open Loop with Slip Compensation:
With Encoder:

Output Frequency: 0-500 Hz (programmable)
Efficiency: 97.5% (typical)
Stop Modes: Multiple programmable stop modes including - Ramp,

Accel/Decel: Four independently programmable accel and decel

Intermittent Overload: 150% Overload capability for up to 1 minute

Electronic Motor Overload Protection Provides class 10 motor overload protection according

Quantity: (2) Semi-programmable

Current: 6 mA
Typ e

Source Mode (SRC):

Analog: Quantity: (2) Isolated, –10 to 10V and 4-20mA

Supply: 12V, 250 mA. 12V, 10 mA minimum inputs isolated

Quadrature: 90°, ±27 degrees at 25 degrees C.
Duty Cycle: 50%, +10%
Requirements: Encoders must be line driver type, quadrature (dual

Sink Mode (SNK):

Specification

Resolution:
0 to 10V DC Analog:
4-20mA Analog:
External Pot:

380-480V ±10%
460-600V ±10%

operation provides 35% rated current.

breaker

Within ±0.05% of set output frequency
Within 0.5% of maximum output frequency, 10-Bit
resolution
±2% of full scale, 10-Bit resolution

±1% of base speed across a 80:1 speed range
±0.3% of base speed across a 80:1 speed range
±0.05% of base speed across a 20:1 speed range

Coast, DC-Brake, and Ramp-to-Stop

times. Each time may be programmed from 0 - 600
seconds in 0.1 second increments.

200% Overload capability for up to 3 seconds

to NEC article 430 and motor over-temperature
protection according to NEC article 430.126 (A) (2).
UL 508C File 29572.

(5) Programmable

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

10-bit
100k ohm input impedance
250 ohm input impedance
1-10k ohm, 2 Watt minimum

with differential transmitter, 250 kHz maximum.

channel) or pulse (single channel), 3.5-26V DC output,
single-ended or differential and capable of supplying a
minimum of 10 mA per channel. Allowable input is DC
up to a maximum frequency of 250 kHz. The encoder
I/O automatically scales to allow 5V, 12V and 24V DC
nominal voltages.

Category Specification

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

BR+ BR-DC- DC+

V/T2T/L3S/L2R/L1 U/T1 W/T3 P2 P1

BR+ BR-DC- DC+

B Frame C Frame

Control Outputs Relay: Quantity: (1) Programmable Form C

Opto: Quantity:

Analog: Quantity: (1) Non-Isolated 0-10V or 4-20mA

Specification

Resistive Rating:
Inductive Rating:

Specification: 30V DC, 50mA Non-inductive

Specification

Resolution:
0 to 10V DC Analog:
4-20mA Analog:

3.0A at 30V DC, 3.0A at 125V, 3.0A at 240V AC

0.5A at 30V DC, 0.5A at 125V, 0.5A at 240V AC

(2) Programmable

10-bit
1k ohm minimum
525 ohm maximum

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

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

Power Terminal Block

Anixter OLF-7xxxxx,
Belden 29501-29507 or
equivalent

Anixter 7V-7xxxx-3G
Shawflex 2ACD/3ACD or
equivalent

English-7

(1)

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

DC Bus Inductor Connection (C Frame drives only.)

P2, P1

The C Frame drive is 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.

DC+, DC- DC Bus Connection

BR+, BR- Dynamic Brake Resistor Connection

Safety Ground - PE

(1)

Important: Terminal screws may become loose during shipment. Ensure that all
terminal screws are tightened to the recommended torque before applying power to
the drive.

(2)

Single-phase operation requires a 65% derate of drive rated current.

(2)

=

Switch any two motor
leads to change
forward direction.