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Rockwell Automation PowerFlex 40 User Manual

Rockwell Automation PowerFlex 40
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Quick Start
PowerFlex 40 Adjustable
Frequency AC Drive
FRN 3.xx
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.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.

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Rockwell Automation PowerFlex 40 Specifications

General IconGeneral
Frequency Range0-400 Hz
Input Voltage200-240V AC, 380-480V AC, 500-600V AC
Output Voltage0 to Input Voltage
Power Rating0.33 to 10 Hp
Control MethodVolts per Hertz
Communication OptionsRS-485
Enclosure TypeIP20 (Open Type)
Operating Temperature-10 to 50 °C (14 to 122 °F)
Protection FeaturesOvercurrent, Overvoltage, Undervoltage, Ground Fault, Short Circuit

Summary

General Safety Precautions

High Voltage Capacitor Discharge Warning

Safety warning regarding high voltage capacitors requiring discharge time after mains removal.

Parameter Misuse Hazard Warning

Warning about potential damage or injury from incorrect use of Auto Rstrt Tries and Start At PowerUp parameters.

Qualified Personnel Requirement

Emphasizes that only qualified personnel should handle installation and maintenance.

Electrostatic Discharge (ESD) Protection

Highlights ESD sensitivity and the need for static control procedures during handling.

Installation and Application Error Risks

Warns about component damage or reduced product life due to wiring or application errors.

Mounting and Environmental Considerations

Drive Mounting and Clearance Requirements

Details upright mounting, screw torque, DIN rail, and minimum clearance requirements for proper installation.

Ambient Temperature and Enclosure Ratings

Lists acceptable ambient temperatures and corresponding enclosure ratings for drive operation.

Grounding and CE Compliance

MOV to Ground Jumper Removal Procedure

Instructions on removing the MOV to ground jumper for specific distribution systems.

CE Conformity Information

Directs users to the User Manual for details on Low Voltage and EMC Directives compliance.

Drive Specifications and Ratings

Catalog Numbers and Technical Specifications

Table detailing catalog numbers, power/input ratings, and branch circuit protection for various drive models.

Input/Output and Protective Features

Output Frequency and Efficiency Ratings

Details the programmable output frequency range and typical drive efficiency.

Control Input/Output Configuration

Describes SRC/SNK modes for digital inputs, analog input impedance, and control output relay ratings.

Recommended Fuses and Circuit Breakers

Specifies recommended fuse types and circuit breakers for drive protection.

Drive Protection and Operational Limits

Drive Protection Mechanisms Overview

Summarizes motor protection, overcurrent, over/undervoltage trips, and ride-through capabilities.

Dynamic Braking Functionality

Mentions the inclusion of an internal brake IGBT for dynamic braking applications.

Power Wiring and Terminal Block Details

Recommended Power Wire Specifications

Lists recommended copper wire types and insulation ratings for power connections.

Power Terminal Block Connections

Illustrates terminal block connections for B and C frame drives, including motor and DC bus connections.

Power Terminal Wire Size and Torque

Provides specifications for maximum/minimum wire sizes and torque for power terminal blocks.

Input Power Conditions and I/O Wiring

Power Quality Conditions and Solutions

Details input power conditions and recommended corrective actions like line reactors or isolation transformers.

Control Wiring Recommendations

Recommends specific wire types, shielding, and insulation for control signal wiring.

I/O Terminal Block Wire Size and Torque

Specifies wire size limits and torque values for control I/O terminal blocks.

Control Terminal Wiring and Configuration

Control Wiring Block Diagram Explained

Visual representation of control terminal connections, including digital inputs, outputs, and analog signals.

Terminal 01 and Enable Jumper Usage

Explains the function of Terminal 01 and the ENBL jumper for start/stop control.

Two-Wire and Three-Wire Control Setup

Details wiring configurations for two-wire and three-wire control methods, including direction changes.

Opto Output Load Handling

Advises on using recovery diodes for opto outputs connected to inductive loads like relays.

Control I/O Terminal Functionality

Relay Output Terminal Assignments

Describes the normally open and normally closed contacts of the output relay (R1, R2, R3).

Analog Output Select and Input Terminals

Explains settings for analog output type and connections for 0-10V and 4-20mA analog inputs.

Digital Input, Output, and Communication Terminals

Details functions of digital inputs, opto outputs, and RS485 communication terminals.

Control Terminal Parameter Mapping

Lists parameters associated with specific control terminal functions and inputs.

Drive Start-Up Preparation and Safety

Pre-Start-Up Safety Precautions

Critical safety warning for qualified personnel regarding live voltages during start-up.

Essential Pre-Power Application Checks

Step-by-step checklist to confirm input connections, AC line power, digital control power, and DIP switch settings.

Initial Power Application and Keypad Familiarization

Instructions for applying AC power and getting familiar with the integral keypad before parameter configuration.

Default Control Scheme Operation

Explains that default settings allow control via the integral keypad without programming.

Integral Keypad Operation and Indicators

Keypad Display and Menu Structure

Describes the alphanumeric display, status LEDs, and available menu groups (Display, Basic Program, Advanced Program, Fault).

Understanding Keypad LED Status Lights

Explains the meaning of different LED states (Steady/Flashing Red/Green) for run, program, and fault status.

Keypad Navigation and Control Functions

Details the function of each keypad key (Escape, Select, Arrows, Enter, Potentiometer, Start, Reverse, Stop) for navigation and control.

Viewing and Editing Drive Parameters

Parameter Navigation and Group Selection

Steps to view parameter numbers, enter group menus, and scroll through parameters.

Editing Parameter Values Procedure

Process for entering program mode, flashing digits, changing values, and saving or canceling edits.

Exiting Parameter Editing Mode

Instructions on how to exit parameter editing mode and return to the parameter list or main display.

Parameter Reference: Display Group

Display Group Parameter List (d001-d029)

Table detailing display group parameters, their min/max values, and options.

Smart Start-Up with Basic Program Parameters

Motor and Frequency Setup Parameters (P031-P033)

Parameters for setting motor nameplate voltage, frequency, and overload current for basic setup.

Speed and Start Control Setup Parameters (P034-P036)

Parameters for setting minimum/maximum frequency, speed reference source, and start control scheme.

Basic Program Group Parameter Configuration

Stop Mode and Speed Reference Source Settings (P037-P038)

Parameters for setting the drive stop mode and the source of the speed reference.

Accel/Decel and Reset Parameter Settings (P039-P043)

Parameters for accel/decel times, resetting defaults, voltage class, and motor overload retention.

Advanced Group Parameter Reference

Digital Input Function Selection (A051-A054)

Parameters for configuring the function of digital inputs (I/O Terminals 05-08).

Relay Output Function Selection (A055-A056)

Parameters for configuring the function and level of the output relays.

Advanced Group Parameter Configuration Details

Opto Output and Analog Output Configuration

Parameters for opto output levels and analog output selection and scaling.

Accel/Decel and Preset Frequency Settings

Parameters for secondary accel/decel times and preset frequency selections.

Jog Frequency and Input Logic Table

Configuration for jog frequency and a table detailing input states for preset frequency selection.

Advanced Parameter Settings for Operation

Boost, Current Limit, and Motor Protection

Parameters for voltage boost, current limit, and motor overload selection.

Auto Restart and Reverse Operation Control

Parameters for configuring auto-restart attempts, delay, start-at-power-up, and reverse disable.

Flying Start, Compensation, and Current Trip

Parameters for flying start enable, compensation types, and software current trip settings.

Fault Clear, Program Lock, and Comm Settings

Parameters for clearing faults, locking programs, and configuring communication node addresses and data rates.

Advanced Parameter Configuration Options

Analog Input Scaling and PID Control Setup

Parameters for scaling analog inputs and configuring PID loop gains, times, and deadband.

Slip Frequency and Stall Fault Configuration

Parameters for slip frequency, stall fault time, and analog input loss behavior.

Torque Performance and Autotune Setup

Parameters for selecting torque performance mode, bipolar input enable, and autotune functions.

Brake Control and Speed Reference Trim

Parameters for electromagnetic brake delay, MOP reset, and dynamic braking threshold.

Drive Fault Code Reference and Resolution

Common Drive Fault Code Descriptions

Lists various fault codes (F2-F81) and their descriptions, indicating potential causes like input voltage, motor issues, or communication.

Specific Fault Causes and Troubleshooting

Details fault causes for specific codes such as Auxiliary Input, Overvoltage, Motor Stalled, and Heatsink Overtemp.

Fault Clearing Procedures

Instructions on how to clear faults by pressing Stop, cycling power, or using the Fault Clear parameter.

Drive Dimensions and Mounting Options

PowerFlex 40 Frame Size and Rating Guide

Table showing frame sizes (B, C) and corresponding kW/HP ratings for different voltage/phase configurations.

Physical Dimensions and Weight Information

Diagram and table detailing the physical dimensions (A, B, C, D, E, F) and ship weights for drive frames.

Optional Communication and Filter Kit Dimensions

Details dimensions and mounting for optional communication covers and EMC filters for B and C frames.

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