Allen Bradley PowerFlex 400

218 Pages·2014·5.57 MB·English

by  Rockwell Automation

Adjustable
Frequency
AC Drive for
Fan & Pump
Applications
FRN 1.xx - 7.xx
User Manual
www.abpowerflex.com
Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application, Installation
and Maintenance of Solid State Controls (Publication SGI-1.1 available from your
local Rockwell Automation sales office or online at
http://www.rockwellautomation.com/literature) describes some important
differences between solid state equipment and hard-wired electromechanical
devices. Because of this difference, and also because of the wide variety of uses for
solid state equipment, all persons responsible for applying this equipment must
satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. 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 diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of
information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety
considerations.
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 loss.
Important: Identifies information that is critical for successful application and
understanding of the product.
ATTENTION: Identifies information about practices or circumstances
that can lead to personal injury or death, property damage, or economic
loss. Attentions help you:
• identify a hazard
• avoid the hazard
• recognize the consequences
Shock Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that surfaces may be at dangerous
temperatures.
PowerFlex is a registered trademark of Rockwell Automation, Inc.
DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.
PLC is a registered trademark of Rockwell Automation, Inc.
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Summary of Changes
Manual Updates
The information below summarizes the changes to the PowerFlex 400
User Manual since the June 2013 release.
Description of New or Updated Information See Page(s)
Maximum Surrounding Air Temperature table updated. 1-5
Frames G & H Mounting Clearances diagram updated. 1-7
Multiple Digital Input Connections example updated. 1-27
New parameters listed in the table below added to Parameter 3-2
Organization table.
Parameter T055 [Relay Out1 Sel]: Option 24 “Fault” added. 3-14
Parameter T060 [Relay Out2 Sel]: Option 24 “Fault” added. 3-16
Parameter T065 [Opto Out Sel]: Option 24 “Fault” added. 3-18
Parameter T077 [Sleep-Wake Sel] description updated. 3-23
Parameter T077 [Sleep-Wake Sel]: Option 4 “Ind Slp Wake” added.
Parameter T082 [Analog Out1 Sel]: Settings 24...29 added. 3-25
Parameter T085 [Analog Out2 Sel]: Settings 24...29 added. 3-27
Parameter A153 [PID Feedback Sel]: Options 3...8 added. 3-38
Parameter R221...R236 [Relay Outx Sel]: Option 24 “Fault” added. 3-55
Parameter d328 [PID Fdbk Disply]: Minimum value updated from “0.0%” 3-65
to “-200.0%”. Maximum value updated from “120.0%” to “200.0%”
New parameters listed in the table below added to Parameter 3-71
Cross-Reference table.
Internal DC Bus Choke specification for 380-480V AC Input updated A-4
from “11-160 kW (15-250 HP)” to “18.5-160 kW (25-250 HP)”.
Table D.B Parameter A153 [PID Feedback Sel] Options 3...8 added. D-5
Writing (06) Logic Command Data description updated. E-3
Writing (06) Reference description updated. E-4
New Parameters
The following parameters have been added with the release of Firmware
Release Number (FRN) 7.xx.
Parameter Number Page Parameter Number Page
[Sleep Sel] T090 3-29 [ACT1 Minimum] A206 3-53
[Wake Sel] T091 3-29 [ACT1 Maximum] A207 3-53
[Wake Deviation] A203 3-52 [ACT2 Minimum] A208 3-53
[ACT1 Input] A204 3-52 [ACT2 Maximum] A209 3-53
[ACT2 Input] A205 3-52 [Wake PID Preload] A210 3-54
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22C-UM001I-EN-P
soc-2
Manual Updates
The information below summarizes the changes to the PowerFlex 400
User Manual since the September 2009 release.
Description of New or Updated Information See Page(s)
Minimum Enclosure Volume column and new footnotes added. 1-13, A-2
Drive, Fuse & Circuit Breaker Ratings topic updated. A-1
Electronic Motor Overload Protection description updated. A-3, A-4
Manual Updates
The information below summarizes the changes to the PowerFlex 400
User Manual since the October 2006 release.
Description of New or Updated Information See Page(s)
Note on placement of wiring for Frame E 240V, 30-37kW (40-50HP) and 1-17
480V, 55-75 kW (75-100HP) drives added.
Parameter T072 [Analog In 1 Loss]: Description revised, and Option 7 3-21
‘Hold Last’ added
Parameter T076 [Analog In 2 Loss]: Description revised, and Option 7 3-23
‘Hold Last’ added
Fault F003 (Power Loss) description changed. 4-3
Fault F004 (UnderVoltage) description changed. 4-3
Fault F017 (Input Phase Loss) description added. 4-4
Fault F032 (Fan Fdbck Loss) description added. 4-4
Altitude derating specification revised. A-3
Internal DC Bus Choke specification corrected. A-4
New Parameters
The following parameters have been added with the release of Firmware
Release Number (FRN) 6.xx.
Parameter Number Page Parameter Number Page
[PID Invert Error] A201 3-52 [Fault 5 Time-hr] d339 3-68
[MOP Reset Sel] A202 3-52 [Fault 5 Time-min] d340 3-68
[PID Fdbk Display] d328 3-65 [Fault 6 Time-hr] d341 3-68
[DC Bus Ripple V] d329 3-65 [Fault 6 Time-min] d342 3-68
[Fault 4 Code] d330 3-66 [Fault 7 Time-hr] d343 3-69
[Fault 5 Code] d331 3-66 [Fault 7 Time-min] d344 3-69
[Fault 6 Code] d332 3-66 [Fault 8 Time-hr] d345 3-69
[Fault 7 Code] d333 3-66 [Fault 8 Time-min] d346 3-69
[Fault 8 Code] d334 3-67 [Fault 9 Time-hr] d347 3-69
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22C-UM001I-EN-P
soc-3
Parameter Number Page Parameter Number Page
[Fault 9 Code] d335 3-67 [Fault 9 Time-min] d348 3-70
[Fault 10 Code] d336 3-67 [Fault10 Time-hr] d349 3-70
[Fault 4 Time-hr] d337 3-67 [Fault10 Time-min] d350 3-70
[Fault 4 Time-min] d338 3-68
Manual Updates
The information below summarizes the changes to the PowerFlex 400
User Manual since the November 2005 release.
Description of New or Updated Information See Page(s)
Information for Frames G and H added Throughout
Frame C mounting requirements clarified 1-6
Analog Output DIP switch setting corrected 1-25
Parameter T072 [Analog In 1 Loss]: Option 6 renamed “Preset Freq0” 3-21
Parameters T082 and T085 [Analog Outx Sel]: Settings 18, 19 and 20 3-25
added
Parameter C107 [Comm Write Mode] description clarified. 3-32
Parameter A170 [Boost Select]: Options added for Frames G and H 3-43
Parameters R221-R236 [Relay Outx Sel]: Default changed from option 3-55
0 to option 23
Current rating for Single Phase operation corrected to 35% A-4
EMC Line Filters added for Frames G and H B-5, B-19, B-20
New Parameter
The following parameter has been added with the release of Firmware
Release Number (FRN) 5.xx.
Parameter Number Page
[Analog In Filter] T089 3-28
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22C-UM001I-EN-P
soc-4
Notes:
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22C-UM001I-EN-P
Table of Contents
Preface Overview
Who Should Use this Manual? . . . . . . . . . P-1
Reference Materials . . . . . . . . . . . . . . . . . P-1
Manual Conventions. . . . . . . . . . . . . . . . . P-2
Drive Frame Sizes. . . . . . . . . . . . . . . . . . . P-2
General Precautions . . . . . . . . . . . . . . . . . P-3
Catalog Number Explanation . . . . . . . . . . P-4
Chapter 1 Installation/Wiring
Opening the Cover . . . . . . . . . . . . . . . . . . 1-1
Mounting Considerations . . . . . . . . . . . . . 1-5
AC Supply Source Considerations . . . . . . 1-9
General Grounding Requirements . . . . . 1-11
Fuses and Circuit Breakers . . . . . . . . . . . 1-12
Power Wiring . . . . . . . . . . . . . . . . . . . . . 1-14
I/O Wiring Recommendations . . . . . . . . 1-19
Start and Speed Reference Control. . . . . 1-28
RS485 Network Wiring. . . . . . . . . . . . . . 1-30
EMC Instructions . . . . . . . . . . . . . . . . . . 1-31
FCC Instructions. . . . . . . . . . . . . . . . . . . 1-34
Chapter 2 Start Up
Prepare For Drive Start-Up. . . . . . . . . . . . 2-1
Integral Keypad. . . . . . . . . . . . . . . . . . . . . 2-3
Viewing and Editing Parameters. . . . . . . . 2-5
Keypad Hand-Off-Auto Functions . . . . . . 2-6
Chapter 3 Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . 3-1
Parameter Organization. . . . . . . . . . . . . . . 3-2
Basic Display Group. . . . . . . . . . . . . . . . . 3-4
Basic Program Group . . . . . . . . . . . . . . . . 3-7
Terminal Block Group. . . . . . . . . . . . . . . 3-12
Communications Group . . . . . . . . . . . . . 3-31
Advanced Program Group. . . . . . . . . . . . 3-35
Aux Relay Card Group. . . . . . . . . . . . . . 3-55
Advanced Display Group . . . . . . . . . . . . 3-60
Parameter Cross-Reference – by Name . 3-71
Chapter 4 Troubleshooting
Drive Status. . . . . . . . . . . . . . . . . . . . . . . . 4-1
Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fault Descriptions. . . . . . . . . . . . . . . . . . . 4-3
Common Symptoms and Corrective Actions . .
4-5
Appendix A Supplemental Drive Information
Drive, Fuse & Circuit Breaker Ratings. . . A-1
Specifications . . . . . . . . . . . . . . . . . . . . . . A-2
Input Power Connections . . . . . . . . . . . . . A-7
Appendix B Accessories and Dimensions
Product Selection . . . . . . . . . . . . . . . . . . . B-1
Product Dimensions . . . . . . . . . . . . . . . . . B-8
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22C-UM001I-EN-P
2 Table of Contents
Appendix C RJ45 DSI Splitter Cable
Appendix D Application Notes
Damper Control Setup. . . . . . . . . . . . . . . . D-1
PID Setup. . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Auxiliary Motor Control Setup . . . . . . . . D-12
Appendix E Modbus RTU Protocol
Network Wiring. . . . . . . . . . . . . . . . . . . . . E-1
Parameter Configuration . . . . . . . . . . . . . . E-2
Supported Modbus Function Codes . . . . . E-2
Writing (06) Logic Command Data. . . . . . E-3
Writing (06) Reference . . . . . . . . . . . . . . . E-4
Reading (03) Logic Status Data. . . . . . . . . E-4
Reading (03) Feedback . . . . . . . . . . . . . . . E-4
Reading (03) Drive Error Codes . . . . . . . . E-5
Reading (03) and Writing (06) Drive
Parameters . . . . . . . . . . . . . . . . . . . . . . . E-5
Additional Information . . . . . . . . . . . . . . . E-5
Appendix F Metasys N2
Understanding Metasys N2. . . . . . . . . . . . F-1
Network Points . . . . . . . . . . . . . . . . . . . . . F-3
Using Percent (%) for the Reference. . . . . F-5
Using Metasys Configurable Objects to Access
Parameters . . . . . . . . . . . . . . . . . . . . . . . F-6
Appendix G P1 – Floor Level Network (FLN)
Understanding P1-FLN . . . . . . . . . . . . . . . G-1
Network Points . . . . . . . . . . . . . . . . . . . . . G-2
Using Percent (%) for the Reference. . . . . G-6
Using P1 Configurable Points to Access
Parameters . . . . . . . . . . . . . . . . . . . . . . . G-7
Index
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22C-UM001I-EN-P
Preface
Overview
The purpose of this manual is to provide you with the basic information
needed to install, start-up and troubleshoot the PowerFlex 400
Adjustable Frequency AC Drive.
For information on… See page…
Who Should Use this Manual? P-1
Reference Materials P-1
Manual Conventions P-2
Drive Frame Sizes P-2
General Precautions P-3
Catalog Number Explanation P-4
Who Should Use this Manual?
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
functions.
Reference Materials
The following manuals are recommended for general drive information:
Title Publication Available Online at …
Wiring and Grounding DRIVES-IN001…
Guidelines for Pulse Width
Modulated (PWM) AC Drives
Preventive Maintenance of DRIVES-TD001…
Industrial Control and Drive
System Equipment www.rockwellautomation.com/
Safety Guidelines for the SGI-1.1 literature
Application, Installation and
Maintenance of Solid State
Control
A Global Reference Guide for 100-2.10
Reading Schematic Diagrams
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22C-UM001I-EN-P
P-2 Overview
Manual Conventions
• In this manual we refer to the PowerFlex 400 Adjustable Frequency
AC Drive as; drive, PowerFlex 400 or PowerFlex 400 Drive.
• Parameter numbers and names are shown in this format:
P031[Motor NP Volts]
Name
Number
Group
b = Basic Display Group
P = Basic Program Group
T = Terminal Block Group
C = Communications Group
A = Advanced Program Group
R = Aux Relay Card Group
d = Advanced Display Group
• The following words are used throughout the manual to describe an
action:
Word Meaning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Must Unavoidable, you must do this
Shall Required and necessary
Should Recommended
Should Not Not Recommended
Drive Frame Sizes
Similar PowerFlex 400 drive sizes are grouped into frame sizes to
simplify spare parts ordering, dimensioning, etc. A cross reference of
drive catalog numbers and their respective frame sizes is provided in
Appendix B.
PowerFlex 400 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22C-UM001I-EN-P