22C-UM001J-EN-E PowerFlex 400P ... - Rockwell Automation

1 PowerFlex 400 Adjustable Frequency AC Drive for Fan & Pump ApplicationsCatalog Numbers 22C, Series BUser ManualOriginal InstructionsImportant User InformationRead 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 including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be no event will Rockwell Automation , Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this examples and diagrams in this manual are included solely for illustrative purposes.

2 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 patent liability is assumed by Rockwell Automation , Inc. with respect to use of information, circuits, equipment, or software described in this of the contents of this manual , in whole or in part, without written permission of Rockwell Automation , Inc., is prohibitedThroughout this manual , when necessary, we use notes to make you aware of safety may also be on or inside the equipment to provide specific precautions. 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 : Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.

3 Attentions help you identify a hazard, avoid a hazard, and recognize the information that is critical for successful application and understanding of the HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE). Rockwell Automation Publication 22C-UM001J-EN-E - January 20171 Table of ContentsImportant User Information .. 2 Summary of Changes ..5 Preface ..7 Overview .. 7 Who Should Use This manual ?

4 7 Additional Resources .. 7 manual Conventions .. 8 Drive Frame Sizes .. 8 General Precautions .. 9 Catalog Number Explanation .. 10 Chapter 1 Installation/WiringOpening the Cover .. 12 Frame C Drives .. 12 Frame D Drives .. 12 Frame E Drives .. 13 Frame F Drives .. 13 Frame G Drives .. 14 Frame H Drives .. 14 Mounting Considerations.. 15 Maximum Surrounding Air Temperature.. 15 Minimum Mounting Clearances .. 16 Debris Protection.. 17 Storage .. 18AC Supply Source Considerations .. 18 Ungrounded Distribution Systems .. 18 Input Power Conditioning .. 19 General Grounding Requirements .. 19 Ground Fault Monitoring.. 20 Safety Ground - (PE) .. 20 Motor Ground .. 20 Shield Termination - SHLD .. 20 RFI Filter Grounding .. 20 Fuses and Circuit Breakers .. 21 Fusing .. 21 Bulletin 140M (Self-Protected Combination Controller)/UL489 Circuit Breakers .. 21 Power Wiring .. 22 Motor Cable Types Acceptable for Volt Installations 23 Reflected Wave Protection.

5 24 Output Disconnect .. 24 Power Terminal Block .. 25I/O Wiring Recommendations .. 28 Motor Start/Stop Precautions .. 282 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 Table of ContentsControl Wire Types .. 28I/O Terminal Block .. 28 Maximum Control Wire Recommendations .. 29I/O Wiring Examples .. 32 Typical Multiple Drive Connection Examples .. 36 Start and Speed Reference Control .. 37 Accel/Decel Selection .. 38RS485 Network Wiring .. 38On Drive Connections.. 39 EMC Instructions .. 39CE Conformity .. 39 Low Voltage Directive (2014/35/EU).. 39 EMC Directive (2014/30/EU) .. 39 General Notes .. 40 Essential Requirements for CE Compliance.. 40 FCC Instructions .. 42 FCC Compliance .. 42 Essential Requirements for FCC Compliance .. 42 Chapter 2 Start UpPrepare For Drive Start-Up .. 45 Before Applying Power to the Drive .. 45 Applying Power to the Drive .. 46 Start, Stop, Direction and Speed Control.

6 46 Integral Keypad .. 47 Operator Keys.. 47 LED Status Indicators .. 48 LCD Display .. 48 Viewing and Editing Parameters .. 49 Keypad Hand-Off-Auto Functions .. 50 Hand-Off-Auto Mode .. 50 Local/Remote Mode .. 51 Auto/ manual Mode .. 52No Function Mode .. 53 Chapter 3 Programming and ParametersAbout Parameters .. 55 Parameter Organization .. 56 Basic Display Group .. 58 Basic Program Group .. 61 Terminal Block Group.. 66 Communications Group .. 79 Advanced Program Group .. 83 Aux Relay Card Group .. 98 Advanced Display Group .. 102 Parameter Cross Reference by Name .. 110 Rockwell Automation Publication 22C-UM001J-EN-E - January 20173 Table of ContentsChapter 4 TroubleshootingDrive Status .. 113 LED Indications.. 113 Faults .. 113 Manually Clearing Faults.. 114 Auto Restart (Reset/Run) .. 115 Fault Descriptions.. 115 Common Symptoms and Corrective Actions .. 117 Motor does not Start.

7 117 Drive does not Start from Start or Run Inputs wired to the terminal block.. 118 Drive does not Start from Integral Keypad.. 118 Motor and/or drive will not accelerate to commanded speed.. 119 Motor operation is unstable.. 119 Drive will not reverse motor direction.. 119 Drive does not power up.. 120 Appendix ASupplemental Drive InformationDrive, Fuse & Circuit Breaker Ratings .. 121 Fusing .. 121 Circuit Breakers .. 121 Specifications .. 122 PowerFlex 400 Watts Loss (Rated Load, Speed & PWM) .. 127 Input Power Connections.. 128 Appendix BAccessories and DimensionsProduct Selection .. 129 Product Dimensions.. 136 Appendix CRJ45 DSI Splitter CableConnectivity Guidelines .. 153 DSI Cable Accessories .. 153 Connectivity Examples .. 154 Appendix DApplication NotesDamper Control Setup .. 157 PID Setup .. 157 PID Control Loop.. 157 Exclusive Control .. 158 Trim Control .. 159 PID Reference and Feedback.

8 159 Analog PID Reference Signals .. 161 PID Deadband .. 162 PID Preload.. 162 PID Limits .. 1624 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 Table of ContentsPID Gains .. 162 Guidelines for Adjusting the PID Gains .. 163 Auxiliary Motor Control Setup.. 165 Appendix EModbus RTU ProtocolNetwork Wiring .. 169 Parameter Configuration .. 170 Supported Modbus Function Codes .. 170 Writing (06) Logic Command Data .. 170 Writing (06) Reference .. 171 Reading (03) Logic Status Data .. 172 Reading (03) Feedback .. 172 Reading (03) Drive Error Codes .. 172 Reading (03) and Writing (06) Drive Parameters .. 173 Additional Information.. 173 Appendix FMetasys N2 Understanding Metasys N2 .. 175 Metasys N2 Virtual Objects .. 175 Metasys N2 Data Types .. 176 Network Points .. 177 Using Percent (%) for the Reference .. 180 Using Metasys Configurable Objects to Access Parameters.

9 181 Reading Parameter Values .. 181 Writing Parameter Values .. 182 Appendix GP1 Floor Level Network (FLN)Understanding P1-FLN .. 183P1-FLN Points .. 183 Network Points .. 184 Using Percent (%) for the Reference .. 188 Using P1 Configurable Points to Access Parameters .. 188 Reading Parameter Values .. 188 Writing Parameter Values .. 189 Index .. 191 Rockwell Automation Publication 22C-UM001J-EN-E - January 20175 Summary of ChangesThis manual contains new and updated information as indicated in the following ParametersNo new parameters have been added with the release of Firmware Release Number (FRN) Conformity updated 39 Programming options updated 55UL and CE certification updated 123 Internal DC Bus Choke specification for 380-480V AC Input updated from " kW (25-250 HP)" to "11-160 kW (15-250 HP)".124 Connected Components Workbench and DriveExecutive software compatibility updated1346 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 Summary of ChangesNotes: Rockwell Automation Publication 22C-UM001J-EN-E - January 20177 PrefaceOverviewThe purpose of this manual is to provide you with the basic information needed to install, start-up and troubleshoot the PowerFlex 400 Adjustable Fre quenc y AC Dri Should Use This manual ?

10 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 ResourcesThese documents contain additional information concerning related products from Rockwell can view or download publications To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001 Provides basic information to install, protect, wire, and ground pulse width modulated (PWM) AC Maintenance of Industrial Control and Drive System Equipment, publication DRIVES-TD001 Provides a checklist as a guide in performing preventive Guidelines for the Application, Installation, and Maintenance of Solid-State Control, publication Provide general guidelines for the application, installation, and maintenance of solid-state control in the form of individual devices or packaged assemblies incorporating solid-state Automation Wiring and Grounding Guidelines, publication general guidelines for installing a Rockwell Automation industrial Certifications website, declarations of conformity, certificates, and other certification Automation Publication 22C-UM001J-EN-E - January 2017 PrefaceManual Conventions In this manual we refer to the PowerFlex 400 Adjustable Frequency AC Drive as; drive, PowerFlex 400 or PowerFlex 400 Drive.