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Rockwell PowerFlex 40 User Manual

Rockwell PowerFlex 40
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Quick Start
PowerFlex 40 Adjustable
Frequency AC Drive
FRN 5.xx - 6.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… 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.
Aotewell Ltd
www.aotewell.com
Industry Automation
HongKong|UK|China
sales@aotewell.com
+86-755-8660-6182
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Rockwell PowerFlex 40 Specifications

General IconGeneral
BrandRockwell
ModelPowerFlex 40
CategoryController
LanguageEnglish

Summary

General Precautions

High Voltage Capacitor Discharge Warning

Warning about high voltage capacitors taking time to discharge after mains supply removal.

Parameter Application Warning

Warning about potential damage/injury from misapplied parameters A092/A094.

Qualified Personnel Warning

Warning that only qualified personnel should plan/implement installation and maintenance.

ESD Sensitive Parts Warning

Warning about ESD sensitive parts and required static control precautions.

Incorrect Application/Installation Warning

Warning that incorrect application or installation can cause damage or malfunction.

Mounting Considerations

Minimum Mounting Clearances

Specifies required clearances for proper drive cooling and air flow based on mounting options.

Ambient Operating Temperatures

Lists acceptable ambient operating temperature ranges and corresponding enclosure ratings.

Typical Grounding

Disconnecting MOVs

Jumper Location

Shows the location of the jumper to be removed for disconnecting MOVs.

Phase to Ground MOV Removal

Details the procedure for removing the MOV jumper for phase to ground connections.

CE Conformity

Specifications, Fuses and Circuit Breakers

Protective Features

Motor Protection

Details 12t overload protection for motor thermal management and class 10 protection.

Overcurrent Protection

Specifies hardware and instantaneous limits for overcurrent faults.

Over Voltage Protection

Lists trip voltages for overvoltage conditions across different input voltage ranges.

Under Voltage Protection

Lists trip voltages for undervoltage conditions across different input voltage ranges.

Control Ride Through

Specifies minimum and typical ride-through duration for control signals.

Faultless Power Ride Through

States the ride-through time for faultless power conditions.

Dynamic Braking

Notes the inclusion of an internal brake IGBT and reference for DB resistor ordering.

Power Wiring

Power Wire Rating

Specifies acceptable wire types and ratings for power connections.

Recommended Copper Wire

Lists recommended copper wire types for power connections.

Power Terminal Block

B Frame Terminal Block

Diagram and description of the terminal block for the B Frame.

C Frame Terminal Block

Diagram and description of the terminal block for the C Frame.

Input Power Conditions

Corrective Actions for Input Power

Lists corrective actions for various input power conditions like low impedance or noise.

I/O Wiring Recommendations

Recommended Wire Types for I/O

Specifies recommended wire types for I/O connections and their insulation ratings.

I/O Terminal Block Specifications

Control Terminal Block

Control Wiring Block Diagram

Illustrates the wiring connections for the control terminal block.

Control Terminal Designations

Lists and describes the function of each terminal in the control block.

Important Terminal Notes

Provides critical notes and important information regarding terminal connections and jumpers.

Control I/O Terminal Designations

Prepare For Drive Start-Up

Before Applying Power to the Drive

Details checks and confirmations required before powering the drive.

Applying Power to the Drive

Instructions for applying AC power and control voltages to the drive.

Start, Stop, Direction and Speed Control

Changing Speed Reference (IP66/4X)

How to adjust speed reference on IP66/4X drives via keypad or parameter.

Speed Reference Tips

Tips for setting the speed reference using internal frequency parameter A069.

Integral Keypad

Integral Keypad Menu Functions

Describes the different menu groups (Display, Basic Program, Advanced Program, Fault Designator).

Integral Keypad LED Indicators

Explains the meaning of each LED state on the integral keypad.

Integral Keypad Key Functions

Details the function of each key on the integral keypad for navigation and control.

Viewing and Editing Parameters

Parameter Viewing and Editing Steps

Detailed steps for navigating menus, selecting parameters, and changing values.

Display Group Parameters

Smart Start-Up with Basic Program Group Parameters

Motor Nameplate Parameters

Parameters P031, P032, P033 related to motor nameplate voltage, frequency, and current.

Frequency Control Parameters

Parameters P034, P035 for setting minimum and maximum output frequencies.

Start Control Scheme

Parameter P036 for selecting the drive's start control method.

Stop Mode Parameter

Speed Reference Parameter

Acceleration and Deceleration Time Parameters

Drive Reset and Voltage Class Parameters

Advanced Group Parameters

Digital Input Selection Parameters

Parameters A051-A054 to configure functions for digital inputs.

Relay Output Configuration

Parameters A055 and A056 for configuring relay output selection and level.

Opto Output Configuration

Parameters A058, A059, A061, A062, A064 for configuring opto outputs.

Analog Output Configuration

Second Acceleration/Deceleration & Internal Frequency

Preset and Jog Frequency Parameters

DC Brake and S-Curve Parameters

Boost and Voltage Control Parameters

Motor Protection and Start Parameters

Fault and Communication Parameters

Analog Input and Output Setup

Advanced Process and Logic Parameters

Advanced Input and Tuning Parameters

Advanced Logic and Timing Parameters

Advanced Brake and Communication Logic

Fault Codes

Auxiliary Input and Voltage Faults

Details faults related to auxiliary input, DC bus ripple, under/over voltage.

Motor and Thermal Faults

Covers faults for motor stall, overload, and heatsink over-temperature.

Current, Ground and Input Faults

Explains faults for HW overcurrent, ground fault, and analog input loss.

Wiring and Configuration Faults

Addresses faults related to phase shorts, parameter defaults, SW overcurrent, and I/O board failure.

Communication and Unit Faults

Details faults for net loss, SVC autotune, comm loss, and power unit errors.

Drive Dimensions

Frame Dimensions and Weights

Details dimensions (mm/in) and weights (kg/lbs) for B and C frames.

IP20 Frame Dimensions

Specific dimensional drawings for the IP20 NEMA/UL Type Open frames.

Option Kit Dimensions

Dimensions for communication and RFI filter option kits for B and C frames.

IP66, NEMA/UL Type 4X Dimensions

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