The information below summarizes the changes to the PowerFlex 40User Manual since the January 2003 release.Description of New or Updated InformationSee Page(s)Fusing and circuit breaker information updated.1-6Requirements for motor cable types expanded.V/O wring examples clarified.1-16Parameter A136 [PID Diff Rate]default value is 0.00.Minimum resistance values for Dynamic Brake Modules added.B-2Inductance rating for 480 Volt,2.2 kW(3.0 HP)Bulletin 1321-3R SeriesB-3Line Reactor corrected.Dimensions for NEMA Type 1 Bezel kit corrected.B-18Appendix E:Step Logic,Basic Logic and Timer/Counter Functions added E-1Appendix F:PID Setup addedF-1Table of ContentsPrefaceOverviewWho Should Use this Manual?.........P-1Reference Materials.................Manual Conventions.................P-2Drive Frame Sizes...·P-2General Precautions.................P-3Catalog Number Explanation..........P-4Chapter 1Installation/WiringOpening the Cover .................1-1Mounting Considerations.............1-2AC Supply Source Considerations1-3General Grounding Requirements1-5Fuses and Circuit Breakers............1-61-8I/O Wiring Remendations........1-12Start and Speed Reference Control.....1-20EMC Instructions..................1-22Chapter 2Start UpPrepare For Drive Start-Up............2-1Integral Keypad.....................2-3Viewing and Editing Parameters........2-4Remote HIM Menu Structure..........2-5Chapter 3Programming and Parameters3-1Parameter Organization...··3-23-3Basic Program Group................3-9Advanced Program Group............3-14Parameter Cross Reference-by Name..3-42Chapter 4Troubleshooting4-1Fault Descriptions...................4-3Common Symptoms and Corrective Actions..4-5Appendix ASupplemental Drive InformationDrive,Fuse Circuit Breaker Ratings...A-1Appendix BAccessories and DimensionsProduct Selection...................B-1Product Dimensions.................B-7Appendix CRS485 (DSI)ProtocolAppendix DRJ45 DSI Splitter CableAppendix EStep Logic,Basic Logic and Timer/Counter FunctionsAppendix FPID Set UpIndex2Table of ContentsPrefaceOverviewThe purpose of this manual is to provide you with the basic informationneeded to install,start-up and troubleshoot the PowerFlex 40 AdjustableFrequency AC Drive.For information on...Who Should Use this Manual?P-1Reference MaterialsP-1Manual ConventionsP-2Drive Frame SizesGeneral PrecautionsP-3Catalog Number ExplanationWho Should Use this Manual?This manual is intended for qualified personnel.You must be able toprogram and operate Adjustable Frequency AC Drive devices.Inaddition,you must have an understanding of the parameter settings andfunctions.Reference MaterialsThe following manuals are remended for general drive information:TitlePublicationAvailable Online at...Wiring and Groundingwww.ab./manuals/drGuidelines for Pulse WidthModulated(PWM)AC DrivesPreventive Maintenance ofDRIVES-TD001...www.ab./manuals/drIndustrial Control and DriveSystem EquipmentSafety Guidelines for theSG-1.1www.ab./manuals/giApplication.Installation andMaintenance of Solid StateControlA Global Reference Guide for100-2.10www.ab./manuals/giReading Schematic DiagramsGuarding Against Electrostatic8000-4.5.2www.ab./manuals/drDamageOverviewManual ConventionsIn this manual we refer to the PowerFlex 40 Adjustable FrequencyAC Drive as;drive,PowerFlex 40 or PowerFlex 40 Drive.Parameter numbers and names are shown in this format:P031 [Motor NP Volts]NameNumberGroupd=Display GroupP=Basic Program GroupA =Advanced Program GroupThe following words are used throughout the manual to describe anaction:WordMeaningCanPossible,able to do somethingCannotNot possible,not able to do somethingMayPermitted,allowedShallRequired and necessaryShouldRemendedShould NotNot RemendedDrive Frame SizesSimilar PowerFlex 40 drive sizes are grouped into frame sizes tosimplify spare parts ordering,dimensioning,etc.A cross reference ofdrive catalog numbers and their respective frame sizes is provided inAppendix B.OverviewGeneral PrecautionsATTENTION:The drive contains high voltage capacitors which taketime to discharge after removal of mains supply.Before working ondrive,ensure isolation of mains supply from line inputs [R,S,T(L1,L2,L3)].Wait three minutes for capacitors to discharge to safe voltagelevels.Failure to do so may result in personal injury or death.Darkened display LEDs is not an indication that capacitors havedischarged to safe voltage levels.ATTENTION:Only qualified personnel familiar with adjustablefrequency AC drives and associated machinery should plan orimplement the installation,start-up and subsequent maintenance of thesystem.Failure to ply may result in personal injury and/orequipment damage.ATTENTION:This drive contains ESD (Electrostatic Discharge)sensitive parts and assemblies.Static control precautions are requiredwhen installing,testing,servicing or repairing this assembly.Component damage may result if ESD control procedures are notfollowed.If you are not familiar with static control procedures,reference A-B publication 8000-4.5.2,"Guarding Against ElectrostaticDamage"or any other applicable ESD protection handbook.ATTENTION:An incorrectly applied or installed drive can result inponent damage or a reduction in product life.Wiring or applicationerrors,such as,undersizing the motor,incorrect or inadequate ACsupply,or excessive ambient temperatures may result in malfunction ofthe system.P-4OverviewCatalog Number Explanation4568910131422BA1P5114AADriveDash Voltage RatingRatingEnclosure HIM Emission Class TypeOptionalCode22BPowerFlex 404StandardCode Rating0Not FilteredCode VoltagePh.1Filtered120V AC1A240V AC13Code Interface ModuleCode PurposeB240V ACFixed KeypadAAReserved for480V ACthrucustom firmwareE600V AC77Code EnclosureNPanel Mount-IP 20 (NEMA Type Open)FFlange Mount-IP 20(NEMA Type Open)Replacement Plate Drive-IP 20(NEMA Type Open)Output Current@100-120V InputOutput Current@200-240V InputCodeAmpskW (HP)Code Amps kW (HP)2P32.30.40.5)2P32.30.4(0.55P05.00.75(1.0)5P05.00.751.0)6P06.01.1(1.5)8P08.001201717.53.7(5.0024245.5(7.5)033337.5(10)Output Current@380-480V InputOutput Current@500-600V InputCode AmpskW (HP)Code Amps1P41.40.40.51P71.70.751.02P32.30.75(1.0)3P03.01.5(2.0)4P04.04P22.2(3.0)6P06.02.23.0)6P66.64.0(5.0)01010.54.05.0)9P99.95.5(7.5)012125.57.501212.27.5(10)0177.5(10)0191911(15)0242411(15)Position 12 of the Catalog Number now indicates drive type.All PowerFlex 40drives are equipped with RS485 munication.Additional accessories,options and adapters are available.See Appendix B for details.Chapter 1Installation/WiringThis chapter provides information on mounting and wiring thePowerFlex 40 Drive.For information on...See pageFor information on...See page11Fuses and Circuit Breakers1-6Mounting Considerations12Power Wiring1-8AC Supply Source Considerations 1-3RemendationsGeneral Grounding Requirements 1-5EMC Instructions122Most start-up difficulties are the result of incorrect wiring.Everyprecaution must be taken to assure that the wiring is done as instructed.All items must be read and understood before the actual installationbegins.ATTENTION:The following information is merely a guide for properinstallation.Rockwell Automation,Inc.cannot assume responsibilityfor the pliance or the nonpliance to any code,national,local orotherwise for the proper installation of this drive or associatedequipment.A hazard of personal injury and/or equipment damageexists if codes are ignored during installation.Opening the Cover1.Press and hold in the tabs on each side of the cover.2.Pull the cover out and up to release.0Installation/WiringMounting ConsiderationsMount the drive upright on a flat,vertical and level surface.FrameScrew SizeScrew TorqueDIN RailBM4(#8-3235mmM5(#10-24)2.45-2.94N-m22-26lb.-in.)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 ClearancesRefer to Appendix B for mounting dimensions.25 mmW120mm120mm(4.7 in.)(4.7nMounting Option AodoboNo clearance requiredodobobetween drives.Mounting Option B120mm120mm(4.7 in.)(4.7inAmbient Operating TemperaturesTable 1.A Enclosure and Clearance RequirementsAmbient TemperatureEnclosure RatingMinimum MountingMinimumMaximumClearancesIP 20/Open TypeUse Mounting Option A40℃(104F)-10℃(14℉)IP 30/NEMA 1/UL Type 1(1)Use Mounting Option B50C (122F)IP 20/Open TypeUse Mounting Option BRating requires installation of the PowerFlex 40 IP 30/NEMA 1/UL Type 1 option kit.Debris ProtectionA plastic top panel is included with the drive.Install the panel to preventdebris from falling through the vents of the drive housing duringinstallation.Remove the panel for IP 20/Open Type applications.Storage.Store within an ambient temperature range of-40 to +85C..Store within a relative humidity range of 0%to 95%,non-condensing.Do not expose to a corrosive atmosphere.