"user manual"
Contents
1. 4 Motor Overld 15 StpLogic Out 5 Ramp Reg 16 Timer Out 6 Above Freq 17 Counter Out 7 Above Cur 18 Above PF Ang 8 Above DCVolt 19 Anlg In Loss 9 Retries Exst 20 ParamControl 10 Above Anlg V A059 Opto Out1 Level 0 0 9999 0 1 0 0 A062 Opto Out2 Level A055 A058 amp A061 Setting A056 A059 amp A062 Min Max 6 0 400 Hz 7 0 180 8 0 815 Volts 10 0 100 16 0 1 9999 Secs 17 1 9999 Counts 18 1 180 degs 20 ont English 13 No Parameter Display Options Default A064 Opto Out Logic 0 3 1 0 A064 Option Opto Out1 Logic Opto Out2 Logic 0 NO Normally Open NO Normally Open 1 NC Normally Closed NO Normally Open 2 NO Normally Open NC Normally Closed 3 NC Normally Closed NC Normally Closed A065 Analog Out Sel 0 14 1 0 Maximum Output Value Option Output Range Minimum Output Value Analog Out High DIP Switch Position 0 OutFreq 0 10 0 10V OV 0Hz P035 Maximum Freq 0 10V 1 OutCurr 0 10 0 10V OV 0 Amps 200 Drive Rated FLA 0 10V 2 OutVolt 0 10 0 10V OV 0 Volts 120 Drive Rated Output Volts 0 10V 3 OutPowr 0 10 0 10V OV 0kW 200 Drive Rated Power 0 10V 4 TstData 0 10 0 10V OV 0000 65535 Hex FFFF 0 10V 5 OutFreq 0 22. 4 Min Freq Ref 0 1 Fault F29 5 Max Freq Ref 2 Stop 6 Int Freq Ref 3 Zero Ref A123 10V Bipolar Enbl 10 1 0 Uni Polar In 1 Bi Polar In 0 A124 Var PWM Disable 0 1 0 Enabled 1 Disabled 0 A125 Torque Perf Mode 0 1 0 V Hz 1 Sensrls Vect 1 A126 Motor NP FLA Drive Amps x 0 1 2 0 1 Amps Rated Amps English 15 No Parameter Min Max Display Options Default A127 Autotune 0 2 0 Ready Idle 2 Rotate Tune 0 1 Static Tune A128 IR Voltage Drop 0 0 230 0 VAC 0 1 VAC Rated Volts A129 Flux Current Ref 0 00 Motor NP Volts 0 01 Amps Rated Amps A130 PID Trim Hi 0 0 400 0 0 1 60 0 A131 PID Trim Lo 0 0 400 0 0 1 0 1 A132 PID Ref Sel 0 8 0 PID Disabled 5 Setpnt Trim 0 1 PID Setpoint 6 0 10V Trim 2 0 10V Input 7 4 20mA Trim 3 4 20mA Input 8 Comm Trim 4 Comm Port A133 PID Feedback Sel 0 2 0 0 10V Input 2 Comm Port 0 1 4 20mA Input A134 PID Prop Gain 0 00 99 99 0 01 0 01 A135 PID Integ Time 0 0 999 9 Secs 0 1 0 1 A136 PID Diff Rate 0 00 99 99 1 Secs 0 01 0 01 A137 PID Setpoint 0 0 100 0 0 1 0 0 A138 PID Deadband 0 0 10 0 0 1 0 0 A139
3. Not Active For external 0 10V unipolar or 10V bipolar input P038 supply input impedance 100k ohm or A051 A054 potentiometer wiper A123 A132 14 AnalogCommon For 0 10V In or 4 20mA In Electronically isolated with analog inputs and outputs from digital I O and opto outputs 15 4 20mA In Not Active For external 4 20mA input supply P038 input impedance 250 ohm A051 A054 A132 16 Analog Output OutFreq 0 10 The default analog output is 0 10V To covert to a A065 A066 current value change the Analog Output Select DIP Switch to 0 20mA Program with A065 Analog Out Sel Max analog value can be scaled with A066 Analog Out High Maximum Load 4 20mA 525 ohm 10 5V 0 10V 1k ohm 10mA 17 Opto Output 1 MotorRunning Program with A058 Opto Out Sel A0589 A059 A064 18 Opto Output 2 At Frequency Program with A061 Opto Out2 Sel A061 A062 A064 19 RS485 DSI Shield 1 See Footnote 1 on page 6 2 0 10V In and 4 20mA In are distinct input channels and may be connected simultaneously Inputs may be used independently for speed control or jointly when operating in PID mode Terminal should be connected to safety ground PE when using the RS485 DSI communications port English 8 A m m Prepare For Drive Start Up ATTENTION Power must be applied to the drive to perform the following start up procedures Some of the voltages present are at in
4. PID Preload 0 0 400 0 Hz 0 1 Hz 0 0 Hz A140 Stp Logic 0 7 0001 BAFF 4 Digits 00F1 A147 For a list of digit options refer to the PowerFlex 40 User Manual on the CD supplied with the drive A150 Stp Logic Time 0 7 0 0 999 9 Secs 0 1 Secs 30 0 Secs A157 Fault Codes To clear a fault press the Stop key cycle power or set A100 Fault Clear to 1 or 2 No Fault Description F2 Auxiliary Input y Check remote wiring F3 Power Loss Monitor the incoming AC line for low voltage or line power interruption F4 UnderVoltage Monitor the incoming AC line for low voltage or line power interruption F5 OverVoltagel Monitor the AC line for high line voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install dynamic brake option F6 Motor Stalled Increase Accel Time x or reduce load so drive output current does not exceed the current set by parameter A089 Current Limit F7 Motor Overload An excessive motor load exists Reduce load so drive output current does not exceed the current set by parameter P033 Motor OL Current F8 Heatsink OvrTmp Check for blocked or dirty heat sink fins Verify that ambient temperature has not exceeded 40 C 104 F for IP 30 NEMA 1 UL Type 1 installations or 50 C 122 F for Open type installations Check fan F12 HW OverCurrent Check programming Check for excess load improper DC boost setting DC brake volts set too
5. C 1 3mm 16 AWG 10 13 mm 26 AWG 0 5 0 8 N m 4 4 7 Ib in 8 Maximum minimum that the terminal block will accept these are not recommendations Refer to the PowerFlex 40 User Manual on CD for maximum power and control cable length recommendations English 6 Control Terminal Block Control Wiring Block Diagram Resistive 3 0A 3 0A 3 0A 4 Toe Typical Typical P Stop 1 SRC Wiring SNK Wiring ree 01 a om o a 02 Start Run FWD ae ss v P a 03 Direction Run REV ae eae SNK 5 oS SRC 04 Digital Common VW Digital Input 1 oe ee 06 Digital Input 2 66s oTo 07 Digital Input 3 ar o g o 08 Digital Input 4 eo oo Opto Common 09 N q 2a oe Do HOV 10V DC i 12 i t 0 10V or 10V Input 1 13 tj l T Analog Common Wd i 4 20mA Input Pot must be i 20mA Inpu Y Relay N O l oy 15 Watt Min 2 a Analog Output Relay Common i Fen 3 ya 20mA 16 g Yup ne 3 Relay N C a 0 Opto Output 1 O ody S Opto Output 2 30V DC vy 18 50mA i Non inductive 19 AS485 Shield 4 0 10V lt Analog Output Select Enable 4 01 02 03 04 0 ae sumper N 0 20mA V 02 03 5 06 07 08 09
6. o R1 R2 R3 SNK RS485 00o ie x SRC 1 ANAG Inductive 0 5A 0 5A 0 5A 1 2 3 4 Important I O Terminal 01 is always a coast to stop Pose Start Source Stop UO Terminal 01 Stop input except when P036 Start Source is set to Keypad Per P037 Coast 3 Wire control In three wire control I O Terminal 01 3 Wire Per P037 Per P037 is controlled by P037 Stop Mode All other stop eis Per POS Doan RS485 Port Per P037 Coast sources are controlled by P037 Stop Mode Important The drive is shipped with a jumper installed between I O Terminals 01 and 11 Remove this jumper when using 1 O Terminal 01 as a stop or enable input Two wire control shown For three wire control use a momentary input on I O Terminal 02 to command a start Use a maintained input o for I O Terminal 03 to change direction When using an opto output with an inductive load such as a relay install a recovery diode parallel to the relay as shown to prevent damage to the output When the ENBL jumper is removed I O Terminal 01 will always act as a hardware enable causing a coast to stop Refer to the PowerFlex 40 User Manual on CD for more information English 7 Control I O Terminal Designations No Signal Default Description Param R1 Relay N O Fault Normally open contact for output relay A055 R2 Relay Common Common for output relay R3 Relay N C Fault Nor
7. 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 Mounting Considerations Mount the drive upright on a flat vertical and level surface Frame Screw Torque DIN Rail B M4 8 32 1 56 1 96 N m 14 17 Ib in 35 mm C M5 10 24 2 45 2 94 N m 22 26 lb in Do not expose to a corrosive atmosphere Protect from moisture and direct sunlight Minimum Mounting Clearances See page 16 for mounting dimensions aK 120 a a 4 7 in v Mounting Option A No clearance required between drives PowerFlex PowerFlex Mou nting Option B P
8. 0 0 20mA OmA 0Hz P035 Maximum Freq 0 20mA 6 OutCurr 0 20 0 20mA 0 mA 0 Amps 200 Drive Rated FLA 0 20mA 7 OutVolt 0 20 0 20mA 0 mA 0 Volts 120 Drive Rated Output Volts 0 20mA 8 OutPowr 0 20 0 20mA OmA 0kW 200 Drive Rated Power 0 20mA 9 TstData 0 20 0 20mA 0 mA 0000 65535 Hex FFFF 0 20mA 10 OutFreq 4 20 4 20mA 4mA 0Hz P035 Maximum Freq 0 20mA 11 OutCurr 4 20 4 20mA 4 mA 0 Amps 200 Drive Rated FLA 0 20mA 12 OutVolt 4 20 4 20mA 4mA 0 Volts 120 Drive Rated Output Volts 0 20mA 13 OutPowr 4 20 4 20mA 4mA 0kW 200 Drive Rated Power 0 20mA 14 TstData 4 20 4 20mA 4 mA 0000 65535 Hex FFFF 0 20mA A066 Analog Out High 0 800 1 100 A067 Accel Time 2 0 0 600 0 Secs 0 1 Secs 20 0 Secs A068 Decel Time 2 0 1 600 0 Secs 0 1 Secs 20 0 Secs A069 Internal Freq 0 0 400 0 Hz 0 1 Hz 60 0 Hz A070 Preset Freq 0 10 0 400 0 Hz 0 1 Hz 0 0 Hz A071 Preset Freq 1 5 0 Hz A072 Preset Freq 2 10 0 Hz A073 Preset Freq 3 20 0 Hz A074 Preset Freq 4 30 0 Hz A075 Preset Freq 5 40 0 Hz A076 Preset Freq 6 50 0 Hz A077 Preset Freq 7 60 0 Hz To activate Preset Freq 0 set P038 Speed Reference to option 4 Input State Input State Input State 2 of Digital In 1 of Digital In 2 of Digital In 3 Frequency Source Accel Decel Parameter Used I O Terminal 05 I O Terminal 06 I O Terminal 07 0 0 0 Preset Freq 0 Accel Time 1 Decel Time 1 1 0 0 Preset Freq 1 Acc
9. 0 75 1 0 5 0 90 126 2 45 20 3 35 140M xxE C20 100 C23 56 22B V6PON104 1 1 1 5 6 0 90 126 3 0 24 0 40 140M xxE C32 100 C37 70 200 240V AC 1 Phase Input 0 230V 3 Phase Output 22B A2P3N104 0 4 0 5 2 3 180 265 1 15 6 0 10 140M xxE B63 100 C09 30 22B A5P0N104 0 75 1 0 5 0 180 265 2 45 12 0 20 140M xxE C16 100 C12 55 22B A8PON104 1 5 2 0 8 0 180 265 4 0 18 0 30 140M xxE C20 100 C23 80 22B A012N104 2 2 3 0 12 0 180 265 5 5 25 0 40 140M xxE C32 100 C37 110 200 240V AC 3 Phase Input 0 230V 3 Phase Output 22B B2P3N104 0 4 0 5 2 3 180 265 1 15 2 5 6 140M xxE B40 100 CO7 30 22B B5P0N104 0 75 1 0 5 0 180 265 2 45 5 7 10 140M xxE C10 100 CO9 55 22B B8PON104 1 5 2 0 8 0 180 265 4 0 9 5 15 140M xxE C16 100 C12 80 22B B012N104 2 2 3 0 12 0 180 265 5 5 15 5 25 140M xxE C16 100 C23 115 22B B017N104 3 7 5 0 17 5 180 265 86 21 0 35 140M xxE C25 100 C23 165 22B B024N104 5 5 7 5 24 0 180 265 11 8 26 1 40 140M xxE C32 100 C37 226 22B B033N104 7 5 10 0 33 0 180 265 16 3 34 6 60 140M xxE C45 100 C60 290 380 480V AC 3 Phase Input 0 460V 3 Phase Output 22B D1P4N104 0 4 0 5 1 4 340 528 14 1 8 3 140M xxE B25 100 C07 30 22B D2P3N104 0 75 1 0 2 3 340 528 2 3 3 2 6 140M xxE B40 100 CO7 40 22B D4P0N104 1 5 2 0 4 0 340 528 4 0 5 7 10 140M xxE B63 100 CO9 60 22B D6PON104 2 2 3 0 6 0 340 5
10. 1 7 2 2 N m 16 19 Ib in c 8 4 mm 8 AWG 1 3mm 16 AWG 2 9 3 7 N m 26 33 Ib in 2 Maximum minimum sizes that the terminal block will accept these are not recommendations English 5 Input Power Conditions Input Power Condition Corrective Action Low Line Impedance less than 1 line reactance e Install Line Reactor Greater than 120 kVA supply transformer e or Isolation 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 e or Install Isolation Transformer with grounded secondary if necessary Ungrounded distribution system 1 Refer to Appendix B of the PowerFlex 40 User Manual on CD for accessory ordering information 1 0 Wiring Recommendations Wire Type s Description Minimum Insulation Rating Belden 8760 9460 0 8 mm2 18AWG twisted pair 100 shield or equiv with drain 300V 7 60 degrees C Belden 8770 0 8 mm 18AWG 3 conductor shielded for 140 degrees F or equiv remote pot only 2 Ifthe 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 1 0 Terminal Block Specifications Frame Maximum Wire Size Minimum Wire Size Torque B amp
11. 28 5 9 7 5 15 140M xxE C10 100 CO9 90 22B D010N104 4 0 5 0 10 5 340 528 10 3 13 0 20 140M xxE C16 100 C23 150 22B D012N104 5 5 7 5 12 0 340 528 11 8 14 2 25 140M xxE C20 100 C23 160 17 0 340 528 168 184 30 140M xxE C20 100 C23 200 D urs0ec Ut esa 22 2 Pp EMC Directive 89 336 C LV EN 50178 EN 60204 EMC EN 61800 3 EN 50081 1 EN 50082 2 Digital Control Inputs Input Current 6mA Analog Control Inputs SRC Source Mode SNK Sink Mode 4 20mA Analog 250 ohm input impedance 18 24V ON 0 6V ON 0 10V DC Analog 100k ohm input impedance 0 6V OFF 18 24V OFF External Pot 1 10k ohms 2 Watt minimum Control Output Programmable Output form C relay Opto Outputs Analog Outputs 10 bit Resistive Rating 3 0A at 30V DC 3 0A at 125V AC 3 0A at 240V AC 30V DC 50mA 0 10V 1k ohm Min Inductive Rating 0 5A at 30V DC 0 5A at 125V AC 0 5A at 240V AC Non inductive 4 20mA 525 ohm Max Fuses and Circuit Breakers Recommended Fuse Type UL Class J CC T or Type BS88 600V 550V or equivalent Recommended Circuit Breakers HMCP circuit breakers or equivalent Protective Features Motor Protection t 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 200 240V AC Input Trip occu
12. 36 and A095 Stop Used to stop the drive or clear a fault This key is always active Controlled by parameter P037 English 10 Viewing and Editing Parameters The last user selected Display Group parameter is saved when power is removed and is displayed by default when power is reapplied The following is an example of basic integral keypad and display functions This example provides basic navigation instructions and illustrates how to program the first Program Group parameter Step 1 When power is applied the last user selected Display Group parameter number is briefly displayed with flashing characters The display then defaults to that parameter s current value Example shows the value of d001 Output Freq with the drive stopped Press Esc once to display the Display Group parameter number shown on power up The parameter number will flash Press Esc again to enter the group menu The group menu letter will flash Press the Up Arrow or Down Arrow to scroll through the group menu d P and A Press Enter or Sel to enter a group The right digit of the last viewed parameter in that group will flash Press the Up Arrow or Down Arrow to scroll through the parameters that are in the group Press Enter or Sel to view the value of a parameter If you do not want to edit the value press Esc to return to the parameter number Press Enter or Sel to enter program mode to edit the param
13. B gt gt gt Quick Start PowerFlex 40 Adjustable Frequency AC Drive This Quick Start guide summarizes the basic steps needed to install start up and program the PowerFlex 40 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 40 information including EMC instructions application considerations and related precautions refer to the PowerFlex 40 User Manual Publication 22B UM001 on the CD supplied with the drive or at www ab com manuals dr 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
14. JBAB C Frame 22 JBAC 4 UL_NS 4 lt 108 7 4 28 lt 92 2 3 63 lt 775 3 05 lt 69 2 2 72 gt 28 5 50 0 1 97 gt 45 7 1 80 1 12 22 5 0 89 22 2 0 87 222 2 en pel 7 0 87 B Frame C Frame Option Drive Drive CH O C O A Comm Cover 25 0 98 25 0 98 C OH B EMC Line Filter 50 1 97 O 179 8 134 3 7 08 C EMC Line Filter 229 9 02 6 28 OOO we D IP30 NEMA 1 UL 133 1 30 60 2 36 O 105 3 Tess Type 1 4 15 0 Es a IP30 NEMA 1 UL 64 2 52 60 2 36 76 3 Ss 4 32 Type 1 for Comm M RY f 3 00 AWOL Cover i WS 4 WQS IT LI O O Y 1 C Frame 22 JBCC used with Comm Cover B Frame 22 JBCB used with Comm Cover Not available at print U S Allen Bradley Drives Technical Support Tel 1 262 512 8176 Fax 1 262 512 2222 Email support drives ra rockwell com Online www ab com support abdrives Rockwell Publication 22B QS001A EN P October 2002 Automation Copyright 2002 Rockwell Automation Inc All rights reserved Printed in Taiwan
15. Not Used 13 10V In Ctrl 4 1 0 Terminal 05 1 Acc amp Dec 2 14 20mA In Ctrl A052 Digital In2 Sel 2 Jog 15 PID Disable 4 I O Terminal 06 3 Aux Fault 16 MOP Up A053 Digital In3 Sel 4 Preset Freq 17 MOP Down 5 1 0 Terminal 07 5 Local 18 Timer Start A054 Digital In4 Sel 6 Comm Port 19 Counter In 11 I O Terminal 08 7 Clear Fault 20 Reset Timer 8 RampStop CF 21 Reset Countr 9 CoastStop CF 22 Rset Tim amp Cnt 10 DCInjStop CF 23 Logic In1 11 Jog Forward 24 Logic In2 12 Jog Reverse 25 Current Lmt2 A055 Relay Out Sel 0 20 0 Ready Fault 11 Logic In 1 0 1 At Frequency 12 Logic In 2 2 MotorRunning 13 Logic 1 amp 2 3 Reverse 14 Logic 1 or 2 4 Motor Overld 15 StpLogic Out 5 Ramp Reg 16 Timer Out 6 Above Freq 17 Counter Out 7 Above Cur 18 Above PF Ang 8 Above DCVolt 19 Anlg In Loss 9 Retries Exst 20 ParamControl 10 Above Anlg V A056 Relay Out Level 0 0 9999 0 1 0 0 A058 Opto Out Sel 0 20 0 Ready Fault 11 Logic In 1 2 A061 Opto Out2 Sel 1 At Frequency 12 Logic In 2 1 2 MotorRunning 13 Logic 1 amp 2 3 Reverse 14 Logic 1 or 2
16. Sel 400 FFFF 1 Hex 400 A103 Comm Data Rate 0 5 0 1200 3 9600 3 Power to drive must be cycled before any I 2400 4 19 2K changes will affect drive operation 2 4800 5 38 4K A104 Comm Node Addr 11 247 1 100 Power to drive must be cycled before any changes will affect drive operation A105 Comm Loss Action 0 3 0 Fault 2 Stop 0 1 Coast Stop 3 Continu Last A106 Comm Loss Time 0 1 60 0 Secs 0 1 5 0 A107 Comm Format 0 2 0 RTU 8 N 1 1 RTU 8 E 1 0 Power to drive must be cycled before any 2 RTU 8 0 1 changes will affect drive operation A108 Language 1 10 1 English 6 Reserved 1 2 Fran ais 7 Portugu s 3 Espa ol 8 Reserved 4 Italiano 9 Reserved 5 Deutsch 10 Nederlands A110 Anlg In 0 10V Lo _ 0 0 100 0 0 1 0 0 A111 Anlg In 0 10V Hi _ 0 0 100 0 0 1 100 0 A112 Anlg In4 20mA Lo 0 0 100 0 0 1 0 0 A113 Anlg In4 20mA Hi 0 0 100 0 0 1 100 0 A114 Slip Hertz FLA 0 0 10 0 Hz 0 1 Hz 2 0 Hz A118 Current Limit 2 0 1 Drive Amps x 1 8 0 1 Amps Amps x 1 5 A119 Skip Frequency 0 400 Hz 1Hz 0 Hz A120 Skip Freq Band 0 0 30 0 Hz 0 1 Hz 0 0 Hz A121 Stall Fault Time 0 5 0 60 Seconds 3 360 Seconds 0 1 120 Seconds 4 480 Seconds 2 240 Seconds 5 Fit Disabled A122 Analog In Loss 0 6 0 Disabled
17. coming line potential To avoid electric shock hazard or damage to equipment only qualified service personnel should perform the following procedure Thoroughly read and understand the procedure before beginning If an event does not occur while performing this procedure Do Not Proceed Remove All Power including user supplied control voltages User supplied voltages may exist even when main AC power is not applied to the drive Correct the malfunction before continuing Before Applying Power to the Drive 1 Confirm that all inputs are connected to the correct terminals and are secure 2 Verify that AC line power at the disconnect device is within the rated value of the drive 3 Verify that any digital control power is 24 volts 4 Verify that the Sink SNK Source SRC Setup DIP Switch is set to match your control wiring scheme See page 7 for location Important The default control scheme is Source SRC The Stop terminal is jumpered I O Terminals 01 and 11 to allow starting from the keypad If the control scheme is changed to Sink SNK the jumper must be removed from I O Terminals 01 and 11 and installed between I O Terminals 01 and 04 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 Applying Power to the Drive 6 Apply AC power and control voltages to the drive 7 Familiarize yours
18. el Time 1 Decel Time 1 0 1 0 Preset Freq 2 Accel Time 2 Decel Time 2 1 1 0 Preset Freq 3 Accel Time 2 Decel Time 2 0 0 1 Preset Freq 4 Accel Time 1 Decel Time 1 1 0 1 Preset Freq 5 Accel Time 1 Decel Time 1 0 1 1 Preset Freq 6 Accel Time 2 Decel Time 2 1 1 1 Preset Freq 7 Accel Time 2 Decel Time 2 2 When a Digital Input is set to Accel 2 amp Decel 2 and the input is active that input overrides the settings in this table A078 Jog Frequency 0 0 Maximum Freq 0 1 Hz 10 0 Hz A079 Jog Accel Decel 0 1 600 0 Secs 0 1 Secs 10 0 Secs A080 DC Brake Time 0 0 99 9 Secs 0 1 Secs 0 0 Secs A setting of 99 9 Secs Continuous A081 DC Brake Level 0 0 Drive Amps x 1 8 0 1 Amps Amps x 0 05 A082 DB Resistor Sel 0 99 0 Disabled 2 NoProtection 0 1 Normal RA Res 3 99 of Duty Cycle A083 S Curve 0 100 1 0 Disabled A084 Boost Select 0 14 Settings in of base voltage 8 Only active when A125 Torque Perf Mode is 0 Custom V Hz 7 or amp 10 set to 0 V Hz Variable Torque Constant Torque rives 1 30 0 VT 5 0 0 no IR 10 10 0 CT 2 35 0 VT 6 0 0 11 12 5 CT 3 40 0 VT 7 2 5 CT 12 15 0 CT 4 45 0 VT 8 5 0 CT 13 17 5 CT 9 7 5 CT 14 20 0 CT A085 Start Boost 0 0 25 0 0 1 2 5 Only active when A084 Boost Select and A125 Torque Pe
19. elf with the integral keypad features see next page before setting any Program Group parameters Start Stop Direction and Speed Control Factory default parameter values allow the drive to be controlled from the integral keypad No programming is required to start stop change direction and control speed directly from the integral keypad Important To disable reverse operation see A095 Reverse Disable If a fault appears on power up refer to page 15 for an explanation of the fault code For complete troubleshooting information refer to the PowerFlex 40 User Manual on the CD supplied with the drive See the PowerFlex 40 User Manual on CD for more information on parameters English 9 Integral Keypad Menu Description ne im La ey Display Group View Only nes P u J Henz a gd Consists of commonly viewed drive operating PROGRAM FAULT 4 O OLDO Bo conditions Basic Program Group Consists of most commonly used programmable functions Advanced Consists 0 Program Group remaining programmable functions Fault Designator Consists of list of codes for specific fault conditions Displayed only when fault is present E No LED LED State Description o Run Direction Steady Red Indicates drive is running and commanded motor direction Status Flashing Red Drive has been commanded to chan
20. eter value The right digit will flash and the Program LED will illuminate if the parameter can be edited Press the Up Arrow or Down Arrow to change the parameter value If desired press Sel to move from digit to digit or bit to bit The digit or bit that you can change will flash 10 Press Esc to cancel a change The digit will stop flashing the previous value is restored and the Program LED will turn off Or Press Enter to save a change The digit will stop flashing and the Program LED will turn off Press Esc to return to the parameter list Continue to press Esc to back out of the programming menu If pressing Esc does not change the display then d001 Output Frequency is displayed Press Enter or Sel to enter the group menu Key s Example Displays nn uw PROGRAM O FAULT O a A dud dog CA or CV PROGRAM FAULT ora P i PROGRAM y War wl PJA PROGRAM S rwd PIF Woly PROGRAM FAl a 5 ecu PROGRAM UI O PUD 4 PROGRAM O FAULT O See the PowerFlex 40 User Manual on CD for more information on parameters o VOLTS o AMPS HERTZ om o VOLTS o AMPS o HERTZ o VOLTS o AMPS o HERTZ o VOLTS o AMPS o HERTZ e VOLTS o AMPS o HERTZ e VOLTS o AMPS o HERTZ e VOLTS o AMPS o HERTZ o VOLTS o AMPS o HERTZ See the PowerFlex 40 User Manual on CD for
21. ge direction Indicates actual motor direction while decelerating to zero Alphanumeric Steady Red Indicates parameter number parameter value or fault code Display Flashing Red Single digit flashing indicates that digit can be edited All digits flashing indicates a fault condition Displayed Units Steady Red Indicates the units of the parameter value being displayed Program Status Steady Red Indicates parameter value can be changed Fault Status Flashing Red Indicates drive is faulted Pot Status Steady Green Indicates potentiometer on Integral Keypad is active Start Key Status Steady Green Indicates Start key on Integral Keypad is active The Reverse key is also active unless disabled by A095 Reverse Disable No Key Name Description Escape Back one step in programming menu 9 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 A CV Down Arrow Increase decrease the value of a flashing digit Enter Advance one step in programming menu lt Save a change to a parameter value RS Potentiometer Used to control speed of drive Default is active Controlled by parameter P038 X AT Start Used to start the drive Default is active CL Controlled by parameter P036 Reverse Used to reverse direction of the drive Default is active A Controlled by parameters P0
22. high or other causes of excess current F13 Ground Fault Check the motor and external wiring to the drive output terminals for a grounded condition F29 Analog In Loss An analog input is configured to fault on signal loss A signal loss has occurred F33 Auto Rstrt Tries Correct the cause of the fault and manually clear F38 Phase U to Gnd Check the wiring between the drive and motor Check motor for grounded phase F39 PhaseVtoGnd Replace drive if fault cannot be cleared F40 Phase W to Gnd F41 Phase UV Short Check the motor and drive output terminal wiring for a shorted condition F42 Phase UW Short Replace drive if fault cannot be cleared F43 Phase VW Short F48 Params Defaulted The drive was commanded to write default values to EEPROM Clear the fault or cycle power to the drive Program the drive parameters as needed F63 SW OverCurrent Check load requirements and A098 SW Current Trip setting F64 Drive Overload Reduce load or extend Accel Time F70 Power Unit Cycle power Replace drive if fault cannot be cleared F80 Autotune Failure The autotune function was either cancelled by the user of failed F81 Comm Loss If adapter was not intentionally disconnected check wiring to the port Replace wiring port expander adapters or complete drive as required Check connection An adapter was intentionally disconnected Turn off using A105 Comm Loss Action F100 Parameter Checksum Restore factory defaults F122 I O B
23. mally closed contact for output relay A055 Analog Output Select 0 10V Sets analog output to either voltage or current Setting must match DIP Switch A065 Analog Out Sel Sink Source Source SRC Inputs can be wired as Sink SNK or Source SRC via DIP Switch DIP Switch setting 01 Stop 1 Coast The factory installed jumper or a normally closed Poge input must be present for the drive to start 02 Start Run FWD Not Active Command comes from the integral keypad by default P036 P037 03 Direction Run REV Not Active To disable reverse operation see A095 Reverse P036 P037 Disable A095 04 Digital Common For digital inputs Electronically isolated with digital inputs from analog I O and opto outputs 05 Digital Input 1 Preset Freq Program with A051 Digital In1 Sel A051 06 Digital Input 2 Preset Freq Program with A052 Digital In2 Sel A052 07 Digital Input 3 Local Program with A053 Digital In3 Sel A053 08 Digital Input 4 Jog Forward Program with A054 Digital In4 Sel A054 09 Opto Common For opto coupled outputs Electronically isolated with opto outputs from analog I O and digital inputs 11 24V DC Referenced to Digital Common Drive supplied power for digital inputs Maximum output current is 100mA 12 10V DC Referenced to Analog Common P038 Drive supplied power for 0 10V external potentiometer Maximum output current is 15mA 13 10V In
24. minal 03 RS485 port except as noted below 3 DCBrkAuto CF Important I O Terminal 01 is always a coast to 4 Ramp stop input except when P036 Start Source is set 3 Coast for 3 Wire control When in three wire control I O 8 DC Brake Terminal 01 is controlled by P037 Stop Mode 7 DC BrakeAuto 1 Stop input also clears active fault English 12 Stop drive before changing this parameter No Parameter Min Max Display Options Default P038 Speed Reference 0 6 0 Drive Pot 0 1 InternalFreq Free a source of the speed reference to the 2 0 10V Input Important When A051 or A052 Digital Inx Sel is 3 aane pi set to option 2 4 5 6 13 or 14 and the digital 4 Preset Bori input is active A051 A052 A053 or A054 will 5 somm Port override the speed reference commanded by this 8 Stp Logic parameter Refer to Chapter 1 of the PowerFlex 40 User Manual on CD for details P039 Accel Time 1 0 0 600 0 Secs 0 1 Secs 10 0 Secs Sets the rate of accel for all speed increases P040 Decel Time 1 0 1 600 0 Secs 0 1 Secs 10 0 Secs Sets the rate of decel for all speed decreases Reset To Defalts o1 Ready ldle 0 Resets all parameter values to factory defaults 1 Factory Rset Advanced Group Parameters No Parameter Min Max Display Options Default A051 Digital Int Sel 0 25 0
25. more information on parameters English 11 Display Group Parameters No Parameter Min Max Display Options d001 Output Freq 0 0 Maximum Freq 0 1 Hz d002 Commanded Freq _ 0 0 Maximum Freq 0 1 Hz d003 Output Current 0 00 Drive Amps x 2 0 01 Amps d004 Output Voltage 0 Drive Rated Volts 1 VAC d005 DC Bus Voltage Based on Drive Rating 1 VDC d006 Drive Status 0 1 1 Condition True Bit3 Bit 2 Bit 1 Bit 0 Decelerating Accelerating Forward Running d007 Fault x Code F2 F122 Fi d009 d010 Process Display 0 00 9999 0 01 1 d012 Control Source 0 9 Bit 1 Speed Command Bit 0 Start Command See P038 9 Jog Freq See P036 9 Jog d013_ Contrl In Status 0 1 1 Input Present Bit3 Bit2 Bit1 Bito Dynamic Brake Stop Input Dir Run REV Start Run FWD d014 Dig In Status 0 1 1 Input Present Bit3 Bit 2 Bit1 Bit 0 Digital In4 Sel Digital In3 Sel Digital In2 Sel Digital In1 Sel d015 Comm Status 0 1 1 Condition True Bit3 Bit 2 Bit 1 Bit 0 Fault Occurred RS485 Option Transmitting Receiving d016 Control SW Ver 1 00 99 99 0 01 d017 Drive Type 1001 9999 1 d018 Elapsed Run Time 0 9999 Hrs 1 10Hrs d019 Testpoint Data O FFFF 1 Hex d020 Analog In 0 10V 0 0 100 0 0 1 d021 Analog In 4 20mA _ 0 0 100 0 0 1 d022 Output Power 0 00 Drive Po
26. oard Fail Cycle power Replace drive if fault cannot be cleared 1 Auto Reset Run type faul It Configure with parameters A092 and A093 English 16 Drive Dimensions PowerFlex 40 Frames Ratings are in kW and HP 480V AC 3 Phase E 0 4 0 5 22 3 0 04 05 2 2 3 0 i 0 75 1 0 4 0 5 0 j 1 5 2 1 5 2 0 C 2 2 3 0 5 5 7 5 5 5 7 5 7 5 10 0 7 5 10 0 PowerFlex 40 AC Drive 2 A 5 i c gt Dimensions are in millimeters and inches f D ae Weights are in kilograms and pounds c 130 260 180 116 246 4 3 5 1 10 2 7 1 4 57 9 7 9 5 ib Qil ii fl fit a l k 5 5 0 22 Communication RFI Filter IP 30 NEMA 1 UL Type 1 Option Kits B 79 1 3 11 j 107 0 4 21 28 5 64 1 2 52 lt 66 0 2 60 gt 1 12 ry 7 40 6 1 60 24 0 0 94 ope 25 6 1 01 a li S Pa ain OBE RS AL O O Al OOO ii 4 33 D AR o SL om ER No 111 2 pen ey S Te ES B Frame 22
27. owerflex Powerflex o o o o 120mm gt Mae 120mm 4 7 in vv v 4 7 in e Alt Sa e Ambient Operating Temperatures Protect the cooling fan by avoiding dust or metallic particles Ambient Temperature Enclosure Rating Minimum Mounting Minimum Maximum Clearances 40 C 104 F IP 20 Open Type Use Mounting Option A 10 C 14 F IP 30 NEMA 1 UL Type 1 Use Mounting Option B 50 C 122 F IP 20 Open Type Use Mounting Option B 1 Rating requires installation of the PowerFlex 40 IP 30 NEMA 1 UL Type 1 option kit General Grounding Requirements Important Remove the MOV to ground jumper if the drive is installed on an ungrounded distribution system Tighten screw after jumper removal Jumper Location Refer to the PowerFlex 40 User Manual on the CD supplied with the drive for details on how to comply with the Low Voltage LV and Electromagnetic Compatibility EMC Directives English 3 Specifications Fuses and Circuit Breakers Catalog Output Ratings Input Ratings Branch Circuit Protection Diosipati on Number Voltage 140M Moiog IP20 Open kW HP Amps Range kVA Amps Fuses _ Protectors Contactors Watts 100 120V AC 1 Phase Input 0 230V 3 Phase Output 22B V2P3N104 0 4 0 5 2 3 90 126 1 15 9 0 15 140M xxE C16 100 C12 30 22B V5PON104
28. rf Mode are set to 0 English 14 No Parameter Min Max Display Options Default A086 Break Voltage 0 0 100 0 0 1 25 0 Only active when A084 Boost Select and A125 Torque Perf Mode are set to 0 A087 Break Frequency 0 0 400 0 Hz 0 1 Hz 15 0 Hz Only active when A084 Boost Select and A125 Torque Perf Mode are set to 0 A088 Maximum Voltage 20 Rated Volts 1 VAC Rated Volts A089 Current Limit 1 0 1 Drive Amps x 1 8 0 1 Amps Amps x 1 5 A090 Motor OL Select 0 2 0 No Derate 1 Min Derate 0 2 Max Derate A091 PWM Frequency 2 0 16 0 kHz 0 1 kHz 4 0 kHz A092 _ Auto Rstrt Tries 0 9 1 0 A093 Auto Rstrt Delay 0 0 300 0 Secs 0 1 Secs 1 0 Secs A094 Start At PowerUp 10 1 0 Disabled 1 Enabled 0 A095 Reverse Disable 0 1 0 Rev Enabled 1 Rev Disabled 0 A096 Flying Start En 0 1 0 Disabled 1 Enabled 0 A097 Compensation 0 3 0 Disabled 2 Mechanical 1 1 Electrical 3 Both A098 SW Current Trip 0 0 Drive Amps x 2 0 1 Amps 0 0 Disabled A099 Process Factor 0 1 999 9 0 1 30 0 A100 Fault Clear 0 2 0 Ready Idle 1 Reset Fault 0 2 Clear Buffer A101 Program Lock 0 9999 0 Unlocked 1 Locked 0 A102 Testpoint
29. rs 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 22B D017N104 7 5 10 0 Input Output Ratings Output Frequency 0 400 Hz Programmable Efficiency 97 5 Typical Under Voltage 100 120V AC Input Trip occurs at 210V DC bus voltage equivalent to 75V 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 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 0 75 kW 1 HP and larger Refer to Appendix B of the PowerFlex 40 User Manual on CD for DB resistor ordering information 1 200 240V AC 1 Phase drives are also available with an integral EMC filter Catalog suffix changes from N104 to N114 Refer to the Bulletin 140M Motor Protectors Selection Guide publication 140M SG001 to determine the frame and breaking capacity required for your application English 4 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 Ani
30. wer x 2 0 01 kW d023 Output Powr Fctr 0 0 180 0 deg 0 1 deg d024 Drive Temp 0 120 degC 1 degC d025 Counter Status 0 9999 1 d026 Timer Status 0 0 9999 0 1 Secs d028 Stp Logic Status 0 7 1 Smart Start Up with Basic Program Group Parameters The PowerFlex 40 is designed so that start up is simple and efficient The Program Group contains the most commonly used parameters Stop drive before changing this parameter No Parameter Min Max Display Options Default P031 Motor NP Volts 20 Drive Rated Volts 1 VAC Based on Drive Rating Set to the motor nameplate rated volts P032 Motor NP Hertz 15 400 Hz 1Hz 60 Hz Set to the motor nameplate rated frequency P033 Motor OL Current 0 0 Drive Rated Ampsx2 0 1 Amps Based on Drive Rating Set to the maximum allowable motor current P034_ Minimum Freq 0 0 400 0 Hz 0 1 Hz 0 0 Hz Sets the lowest frequency the drive will output continuously P035 Maximum Freq 0 400 Hz 1Hz 60 Hz Sets the highest frequency the drive will output P036 Start Source 0 5 0 Keypad 0 Sets the control scheme used to start the drive Hu Ea 1 When active the Reverse key is also active 3 2 W Lvl Sens unless disabled by A095 Reverse Disable 4 2 W Hi Speed 5 Comm Port P037 Stop Mode 0 7 0 Ramp CF 0 Active stop mode for all stop sources e g keypad Coast ort a run forward I O Terminal 02 run reverse I O 2 DC Brake CF 1 Ter
31. xter OLF Tua Re equivalent R Anixter 7V 7xxxx 3G 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 B Frame C Frame R L S L2 T L3 UTI V T2 WIT3 RILI S L2 T L3 UMI V T2 WT3 P2 P1 SHH HIE IOS Sd ES Ba Oe DSO DC DC BR BR DC DC BR BR Terminal Description R L1 S L2 1 Phase Input R L1 S L2 T L3 3 Phase Input cll To Motor Urti Q Switch any two motor V T2 To Motor VT2 T 16 leads to change WT3 To Motor W T3 R forward direction DC Bus Inductor Connection The drive is shipped with a jumper between Terminals P2 P2 P1 and P1 Remove this jumper only when a DC Bus Inductor V U 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 0 75 kW 1 HP ratings and higher 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 Power Terminal Block Specifications Frame Maximum Wire Size Minimum Wire Size Torque B 5 3 mm 10 AWG 1 3mm 16 AWG
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