Rockwell Automation PowerFlex 40 Manuale utente

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.

English-2

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

•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

Ambient Operating Temperatures

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.

Mounting Considerations

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.) –

Ambient Temperature Enclosure Rating Minimum Mounting

Clearances

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(1)

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

Use Mounting Option B

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

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.)

Mounting Option A

No clearance required

between drives.

Mounting Option B

See page 16 for mounting dimensions.

General Grounding Requirements

U/T1

V/T2

W/T3

R/L1

S/L2

T/L3

SHLD

Important: The MOV to ground jumper must be

removed if the drive is installed on an ungrounded or

resistive grounded distribution system.

Tighten screw after jumper removal.

Jumper

Location

CE Conformity

English-3

Specifications, Fuses and Circuit Breakers

Drive Ratings

Catalog

Number

Output Ratings Input Ratings Branch Circuit Protection Power

Dissipation

kW (HP) Amps

Voltage

Range kVA Amps Fuses

140M Motor

Protectors(2) Contactors

IP20 Open

Watts

100 - 120V AC (±10%) – 1-Phase Input, 0 - 230V 3-Phase Output

22B-V2P3N104 0.4 (0.5) 2.3 90-132 1.15 9.0 15 140M-C2E-C16 100-C12 40

22B-V5P0N104 0.75 (1.0) 5.0 90-132 2.45 20.3 35 140M-D8E-C20 100-C23 60

22B-V6P0N104 1.1 (1.5) 6.0 90-132 3.0 24.0 40 140M-F8E-C32 100-C37 80

200 - 240V AC (±10%) – 1-Phase(1) Input, 0 - 230V 3-Phase Output

22B-A2P3N104 0.4 (0.5) 2.3 180-264 1.15 6.0 10 140M-C2E-B63 100-C09 40

22B-A5P0N104 0.75 (1.0) 5.0 180-264 2.45 12.0 20 140M-C2E-C16 100-C12 60

22B-A8P0N104 1.5 (2.0) 8.0 180-264 4.0 18.0 30 140M-D8E-C20 100-C23 85

22B-A012N104 2.2 (3.0) 12.0 180-264 5.5 25.0 40 140M-F8E-C32 100-C37 125

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

22B-B2P3N104 0.4 (0.5) 2.3 180-264 1.15 2.5 6 140M-C2E-B40 100-C07 40

22B-B5P0N104 0.75 (1.0) 5.0 180-264 2.45 5.7 10 140M-C2E-C10 100-C09 60

22B-B8P0N104 1.5 (2.0) 8.0 180-264 4.0 9.5 15 140M-C2E-C16 100-C12 85

22B-B012N104 2.2 (3.0) 12.0 180-264 5.5 15.5 25 140M-C2E-C16 100-C23 125

22B-B017N104 3.7 (5.0) 17.5 180-264 8.6 21.0 30 140M-F8E-C25 100-C23 180

22B-B024N104 5.5 (7.5) 24.0 180-264 11.8 26.1 40 140M-F8E-C32 100-C37 235

22B-B033N104 7.5 (10.0) 33.0 180-264 16.3 34.6 60 140M-G8E-C45 100-C60 305

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

22B-D1P4N104 0.4 (0.5) 1.4 342-528 1.4 1.8 3 140M-C2E-B25 100-C07 35

22B-D2P3N104 0.75 (1.0) 2.3 342-528 2.3 3.2 6 140M-C2E-B40 100-C07 50

22B-D4P0N104 1.5 (2.0) 4.0 342-528 4.0 5.7 10 140M-C2E-B63 100-C09 70

22B-D6P0N104 2.2 (3.0) 6.0 342-528 5.9 7.5 15 140M-C2E-C10 100-C09 100

22B-D010N104 4.0 (5.0) 10.5 342-528 10.3 13.0 20 140M-C2E-C16 100-C23 160

22B-D012N104 5.5 (7.5) 12.0 342-528 11.8 14.2 25 140M-D8E-C20 100-C23 175

22B-D017N104 7.5 (10.0) 17.0 342-528 16.8 18.4 30 140M-D8E-C20 100-C23 210

22B-D024N104 11.0 (15.0) 24.0 342-528 23.4 26.0 50 140M-F8E-C32 100-C43 300

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

22B-E1P7N104 0.75 (1.0) 1.7 414-660 2.1 2.3 6 140M-C2E-B25 100-C09 50

22B-E3P0N104 1.5 (2.0) 3.0 414-660 3.65 3.8 6 140M-C2E-B40 100-C09 70

22B-E4P2N104 2.2 (3.0) 4.2 414-660 5.2 5.3 10 140M-C2E-B63 100-C09 100

22B-E6P6N104 4.0 (5.0) 6.6 414-660 8.1 8.3 15 140M-C2E-C10 100-C09 160

22B-E9P9N104 5.5 (7.5) 9.9 414-660 12.1 11.2 20 140M-C2E-C16 100-C16 175

22B-E012N104 7.5 (10.0) 12.2 414-660 14.9 13.7 25 140M-C2E-C16 100-C23 210

22B-E019N104 11.0 (15.0) 19.0 414-660 23.1 24.1 40 140M-D8E-C25 100-C30 300

(1) 200-240V AC - 1-Phase drives are also available with an integral EMC filter. Catalog suffix

changes from N104 to N114.

(2) 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

Input/Output Ratings Approvals

Output Frequency: 0-400 Hz (Programmable)

Efficiency: 97.5% (Typical)

Digital Control Inputs (Input Current = 6mA) Analog Control Inputs

SRC (Source) Mode:

18-24V = ON

0-6V = OFF

SNK (Sink) Mode:

0-6V = ON

18-24V = OFF

4-20mA Analog: 250 ohm input impedance

0-10V DC Analog: 100k ohm input impedance

External Pot: 1-10k ohms, 2 Watt minimum

Control Output

Programmable Output (form C relay)

Resistive Rating: 3.0A at 30V DC, 3.0A at 125V AC, 3.0A at 240V AC

Inductive Rating: 0.5A at 30V DC, 0.5A at 125V AC, 0.5A at 240V AC

Opto Outputs

30V DC, 50mA

Non-inductive

Analog Outputs (10 bit)

0-10V, 1k ohm Min.

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: I2t 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 occurs 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)

460-600V AC Input – Trip occurs at 1005V DC bus voltage (equivalent to 711V AC incoming line)

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)

460-600V AC Input – If P042 = 3 “High Voltage” trip occurs at 487V DC bus voltage (344V AC incoming line);

If P042 = 2 “Low Voltage” trip occurs at 390V DC bus voltage (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 except No Brake versions. Refer to Appendix B of the PowerFlex 40 User Manual

on CD for DB resistor ordering information.

UL508C

CSA 22.2

EMC Directive 89/336

LV: EN 50178, EN 60204

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

English-5

Power Terminal Block

Power Terminal Block Specifications

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

Anixter OLF-7xxxxx,

Belden 29501-29507 or

equivalent

Shielded Tray rated 600V, 75°C or 90°C (167°F or 194°F)

RHH/RHW-2

Anixter 7V-7xxxx-3G

Shawflex 2ACD/3ACD or

equivalent

Terminal (1) Description

R/L1, S/L2 1-Phase Input

R/L1, S/L2, T/L3 3-Phase Input

U/T1 To Motor U/T1

Switch any two motor

leads to change

forward direction.

V/T2 To Motor V/T2

W/T3 To Motor W/T3

P2, P1

DC Bus Inductor Connection (C Frame drives only.)

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.

Frame Maximum Wire Size (2) Minimum Wire Size (2) To rq ue

B 5.3 mm2(10 AWG) 1.3 mm2(16 AWG) 1.7-2.2 N-m (16-19 lb.-in.)

C 8.4 mm2(8 AWG) 1.3 mm2(16 AWG) 2.9-3.7 N-m (26-33 lb.-in.)

(2) Maximum/minimum sizes that the terminal block will accept - these are not

recommendations.

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

English-6

Input Power Conditions

I/O Terminal Block Specifications

Refer to the PowerFlex 40 User Manual on CD for maximum power and

control cable length recommendations.

Input Power Condition Corrective Action

Low Line Impedance (less than 1% line reactance) •Install Line Reactor(1)

•or Isolation Transformer

•or Bus Inductor – 5.5-11 kW

(7.5-15 HP) drives only

(1) Refer to Appendix B of the PowerFlex 40 User Manual on CD for accessory ordering

information.

Greater than 120 kVA supply transformer

Line has power factor correction capacitors •Install Line Reactor

•or Isolation Transformer

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.

•or Install Isolation Transformer

with grounded secondary if

necessary.

Ungrounded distribution system

240V open delta configuration (stinger leg) •Install Line Reactor

I/O Wiring Recommendations (2)

Wire Type(s)(3) Description Minimum Insulation

Rating

Belden 8760/9460

(or equiv.)

0.8 mm2(18 AWG), twisted pair, 100% shield

with drain. 300V

60 degrees C

(140 degrees F)

Belden 8770

(or equiv.)

0.8 mm2(18AWG), 3 conductor, shielded for

remote pot only.

(2) If the 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.

(3) Standed or solid wire.

Frame Maximum Wire Size (4) Minimum Wire Size (4) Torque

B & C 1.3 mm2(16 AWG) 0.13 mm2(26 AWG) 0.5-0.8 N-m (4.4-7 lb.-in.)

(4) Maximum / minimum that the terminal block will accept - these are not

recommendations.

English-7

Control Wiring Block Diagram

(1) Important: I/O Terminal 01 is always a coast to stop

input except when P036 [Start Source] is set to

“3-Wire” or “Momt FWD/REV” control. In three wire

control, I/O Terminal 01 is controlled by P037 [Stop

Mode]. All other stop 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 I/O Terminal 01 as a stop or enable input.

(2) 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 for I/O Terminal 03 to change direction.

(3) 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.

(4) 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.

Control Terminal Block

Digital Common

Digital Input 1

Digital Input 2

Digital Input 3

Stop (1)(4)

Start/Run FWD (2)

Direction/Run REV

Digital Input 4

Opto Common

Relay N.O.

Relay Common

Relay N.C.

+24V DC

+10V DC

0-10V (or ±10V) Input

Analog Common

4-20mA Input

Analog Output

Opto Output 1

Opto Output 2

RS485 Shield

+24V

+10V

Typical

SNK Wiring

Typical

SRC Wiring

RS485

(DSI)

R1 R2 R3 SNK

SRC

0-10V

0-20mA 01 02 03 04 05

11 12 13 14 15

06 07 08 09

16 17 18 19

(1)

Enable (4)

Jumper

30V DC

50mA

Non-inductive

Common

24V

ENBL Enable (4)

Jumper

(3)

Pot must be

1-10k ohm

2 Watt Min.

0-10V

0/4-20mA

Analog Output Select

SRCSNK

30V DC 125V AC 240V AC

Resistive 3.0A 3.0A 3.0A

Inductive 0.5A 0.5A 0.5A

P036 [Start Source] Stop I/O Terminal 01 Stop

Keypad Per P037 Coast

3-Wire Per P037 Per P037

2-Wire Per P037 Coast

RS485 Port Per P037 Coast

English-8

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 Normally closed contact for output relay. A055

Analog Output Select

DIP Switch

0-10V Sets analog output to either voltage or current. Setting must match

A065 [Analog Out Sel].

Sink/Source

DIP Switch

Source (SRC) Inputs can be wired as Sink (SNK) or Source (SRC) via DIP Switch

setting.

01 Stop (1) Coast The factory installed jumper or a normally closed

input must be present for the drive to start.

P036 (1)

02 Start/Run FWD Not Active Command comes from the integral keypad by default.

To disable reverse operation, see A095 [Reverse

Disable].

P036, P037

03 Direction/Run REV Not Active P036, P037,

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.

Drive supplied power for 0-10V external

potentiometer.

Maximum output current is 15mA.

P038

13 ±10V In (2) Not Active For external 0-10V (unipolar) or ±10V (bipolar) input

supply (input impedance = 100k ohm) or

potentiometer wiper.

P038,

A051-A054,

A123, A132

14 Analog Common – 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 (2) Not Active For external 4-20mA input supply

(input impedance = 250 ohm).

P038,

A051-A054,

A132

16 Analog Output OutFreq 0-10 The default analog output is 0-10V. To covert to a

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)

A065, A066

17 Opto Output 1 MotorRunning Program with A058 [Opto Out1 Sel] A058, A059,

A064

18 Opto Output 2 At Frequency Program with A061 [Opto Out2 Sel] A061, A062,

A064

19 RS485 (DSI) Shield – Terminal should be connected to safety ground - PE

when using the RS485 (DSI) communications port.

(1) See Footnotes (1) and (4) on page 7.

(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.

English-9

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 yourself 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 17 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.

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

incoming 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.

English-10

Integral Keypad

No. LED LED State Description

➊Run/Direction

Status

Steady Red Indicates drive is running and commanded motor direction.

Flashing Red Drive has been commanded to change direction. Indicates

actual motor direction while decelerating to zero.

➋Alphanumeric

Display

Steady Red Indicates parameter number, parameter value, or fault code.

Flashing Red Single digit flashing indicates that digit can be edited.

All digits flashing indicates a fault condition.

➌Displayed Units Steady Red Indicates the units of the parameter value being displayed.

➍Program Status Steady Red Indicates parameter value can be changed.

➎Fault Status Flashing Red Indicates drive is faulted.

➏Pot Status Steady Green Indicates potentiometer on Integral Keypad is active.

➐Start 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

➑Escape Back one step in programming menu.

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

Down Arrow

Scroll through groups and parameters.

Increase/decrease the value of a flashing digit.

Enter Advance one step in programming menu.

Save a change to a parameter value.

➒Potentiometer Used to control speed of drive. Default is active.

Controlled by parameter P038.

Start Used to start the drive. Default is active.

Controlled by parameter P036.

Reverse Used to reverse direction of the drive. Default is active.

Controlled by parameters P036 and A095.

Stop Used to stop the drive or clear a fault.

This key is always active.

Controlled by parameter P037.

FAULT

VOLTS

AMPS

HERTZ

RUN

FWD

REV

PROGRAM

➊➋

➍

➏

➒

➎

Menu Description

Display Group (View Only)

Consists of commonly viewed drive operating

conditions.

Basic Program Group

Consists of most commonly used

programmable functions.

Advanced Program Group

Consists of remaining programmable functions.

Fault Designator

Consists of list of codes for specific fault

conditions. Displayed only when fault is present.

➌

➑

➐

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