Allen-Bradley 22C-B065A103, 22C-B017N103, 22C-B024N103, 22C-B049A103, 22C-B075A103 User Manual
...
User Manual
Original Instructions
PowerFlex 400 Adjustable Frequency AC Drive for Fan
& Pump Applications
Catalog Numbers 22C, Series B
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are
required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may
be impaired.
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.
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 a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Who Should Use This Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 1
Installation/Wiring Opening the Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Frame C Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Frame D Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Frame E Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Frame F Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Frame G Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Frame H Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Maximum Surrounding Air Temperature. . . . . . . . . . . . . . . . . . . . 15
Minimum Mounting Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Debris Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Ungrounded Distribution Systems. . . . . . . . . . . . . . . . . . . . . . . . . . 18
Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ground Fault Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Safety Ground - (PE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Motor Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Shield Termination - SHLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RFI Filter Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Bulletin 140M (Self-Protected Combination Controller)/UL489
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Motor Cable Types Acceptable for 200...600 Volt Installations 23
Reflected Wave Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Output Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
I/O Wiring Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Motor Start/Stop Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 1
Table of Contents
Control Wire Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Maximum Control Wire Recommendations. . . . . . . . . . . . . . . . . 29
I/O Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Typical Multiple Drive Connection Examples . . . . . . . . . . . . . . . 36
Start and Speed Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Accel/Decel Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
RS485 Network Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
On Drive Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
EMC Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Low Voltage Directive (2014/35/EU). . . . . . . . . . . . . . . . . . . . . . . 39
EMC Directive (2014/30/EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Essential Requirements for CE Compliance. . . . . . . . . . . . . . . . . . 40
FCC Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
FCC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Essential Requirements for FCC Compliance . . . . . . . . . . . . . . . . 42
Chapter 2
Start Up Prepare For Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Before Applying Power to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . 45
Applying Power to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Start, Stop, Direction and Speed Control . . . . . . . . . . . . . . . . . . . . 46
Integral Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Operator Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
LED Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
LCD Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Keypad Hand-Off-Auto Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Hand-Off-Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Local/Remote Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Auto/Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
No Function Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Chapter 3
Programming and Parameters About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Parameter Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Basic Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Basic Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Terminal Block Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Communications Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Advanced Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Aux Relay Card Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Advanced Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Parameter Cross Reference by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017
Table of Contents
Chapter 4
Troubleshooting Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
LED Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Manually Clearing Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Auto Restart (Reset/Run) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . 117
Motor does not Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Drive does not Start from Start or Run Inputs wired to the
terminal block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Drive does not Start from Integral Keypad. . . . . . . . . . . . . . . . . . 118
Motor and/or drive will not accelerate to commanded speed.. 119
Motor operation is unstable.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Drive will not reverse motor direction. . . . . . . . . . . . . . . . . . . . . . 119
Drive does not power up.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Appendix A
Supplemental Drive Information Drive, Fuse & Circuit Breaker Ratings . . . . . . . . . . . . . . . . . . . . . . . . . 121
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
PowerFlex 400 Watts Loss (Rated Load, Speed & PWM) . . . . 127
Input Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Appendix B
Accessories and Dimensions Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Appendix C
RJ45 DSI Splitter Cable Connectivity Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
DSI Cable Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Connectivity Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Appendix D
Application Notes Damper Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
PID Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
PID Control Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Exclusive Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Trim Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
PID Reference and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Analog PID Reference Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
PID Deadband . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
PID Preload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
PID Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 3
Table of Contents
PID Gains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Guidelines for Adjusting the PID Gains . . . . . . . . . . . . . . . . . . . . 163
Auxiliary Motor Control Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Appendix E
Modbus RTU Protocol Network Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Supported Modbus Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Writing (06) Logic Command Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Writing (06) Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Reading (03) Logic Status Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Reading (03) Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Reading (03) Drive Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Reading (03) and Writing (06) Drive Parameters . . . . . . . . . . . . . . . 173
Additional Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Appendix F
Metasys N2 Understanding Metasys N2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Metasys N2 Virtual Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Metasys N2 Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Network Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Using Percent (%) for the Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Using Metasys Configurable Objects to Access Parameters. . . . . . . 181
Reading Parameter Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Writing Parameter Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Appendix G
P1 – Floor Level Network (FLN) Understanding P1-FLN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
P1-FLN Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Network Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Using Percent (%) for the Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Using P1 Configurable Points to Access Parameters . . . . . . . . . . . . . 188
Reading Parameter Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Writing Parameter Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
4 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017
Summary of Changes
This manual contains new and updated information as indicated in the
following table.
Top ic Pag e
CE Conformity updated 39
Programming options updated 55
UL and CE certification updated 123
Internal DC Bus Choke specification for 380-480V AC Input updated
from "18.5-160 kW (25-250 HP)" to "11-160 kW (15-250 HP)".
Connected Components Workbench and DriveExecutive software
compatibility updated
New Parameters
No new parameters have been added with the release of Firmware Release
Number (FRN) 8.xx.
124
134
Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 5
Summary of Changes
Notes:
6 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017
Preface
Overview
Who Should Use This Manual?
Additional Resources
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.
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.
These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
Wiring and Grounding Guidelines for Pulse Width
Modulated (PWM) AC Drives, publication DRIVES-IN001
Preventive Maintenance of Industrial Control and Drive
System Equipment, publication DRIVES-TD001
Safety Guidelines for the Application, Installation, and
Maintenance of Solid-State Control, publication SGI-1.1
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Product Certifications website, http://
www.rockwellautomation.com/global/certification/
overview.page
Provides basic information to install, protect, wire,
and ground pulse width modulated (PWM) AC drives.
Provides a checklist as a guide in performing
preventive maintenance.
Provide general guidelines for the application,
installation, and maintenance of solid-state control in
the form of individual devices or packaged assemblies
incorporating solid-state components.
Provides general guidelines for installing a Rockwell
Automation industrial system.
Provides declarations of conformity, certificates, and
other certification details.
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page.
To order paper copies of technical documentation, contact your local
Allen-Bradley distributor or Rockwell Automation sales representative.
Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 7
Preface
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 Mean ing
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
8 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017
.
Preface
General Precautions
ATT EN TI ON : To avoid an electric shock hazard, verify that the voltage on the
bus capacitors has discharged before performing any work on the drive.
Measure the DC bus voltage at the –DC and +DC terminals or at the –DC and
P2 terminals on the Power Terminal Block (refer to Chapter 1
Power Terminal
descriptions). The voltage must be zero.
A darkened LCD display and LEDs is not an indication that capacitors have
discharged to safe voltage levels.
ATT EN TI ON : 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.
ATT EN TI ON : 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.
ATT EN TI ON : 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.
ATT EN TI ON : The bus regulator function is extremely useful for preventing
nuisance overvoltage faults resulting from aggressive decelerations,
overhauling loads, and eccentric loads. However, it can also cause either of
the following two conditions to occur.
1. Fast positive changes in input voltage or imbalanced input voltages can cause
uncommanded positive speed changes;
2. Actual deceleration times can be longer than commanded deceleration times
However, a “Stall Fault” is generated if the drive remains in this state for 1
minute. If this condition is unacceptable, the bus regulator must be disabled
(see parameter A187
).
Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 9
Preface
1-3 4 5 6-8 9 10 11 12
22C – D 038 A 1 0 3
Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Comm Slot
Code Drive
22C PowerFlex 400
Code Voltage Ph.
B 240V AC 3
D 480V AC 3
Output Current @ 200...240V 60Hz Input Output Current @ 380...480V Input
Code Amps kW HP Frame Code Amps kW HP Frame
012 12 2.2 3.0 C 6P0 6.0 2.2 3.0 C
017 17.5 3.7 5.0 C 010 10.5 4.0 5.0 C
024 24 5.5 7.5 C 012 12 5.5 7.5 C
033 33 7.5 10 C 017 17 7.5 10 C
04949 1115D 02222 1115C
06565 1520D 03030 1520C
075 75 18.5 25 D 038 38 18.5 25 D
09090 2230D 04545.5 2230D
120 120 30 40 E 060 60 30 40 D
145 145 37 50 E 072 72 37 50 E
088 88 45 60 E
105 105 55 75 E
142 142 75 100 E
170 170 90 125 F
208 208 110 150 F
260 260 132 200 G
310 310 160 250 G
370 370 200 300 H
460 460 250 350 H
Code Enclosure
N Panel Mount - IP20/UL Open-Type
(1)
A Panel Mount - IP30/NEMA 1/UL Type 1
(2)
F Flange Mount - IP20/UL Open Type
(3)
Code Interface Module
1 Fixed Keypad
Code Rating
0 Not Filtered
Code Versi on
3RS485
(1) Frame C drives only available with IP20/UL Open-Type enclosure. Field installed conversion kit available to achieve IP30/NEMA 1/UL Type 1 rating.
(2) Frame D, E, F, G and H drives only available with IP30/NEMA 1/UL Type 1 enclosure.
(3) Frame C drives only.
Additional accessories, options and adapters are available. See Appendix B for details.
Catalog Number Explanation
10 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017
Installation/Wiring
This chapter provides information on mounting and wiring the
PowerFlex 400 Drive.
For information on... See page
Opening the Cover 12
Mounting Considerations 15
AC Supply Source Considerations 18
General Grounding Requirements 19
Fuses a nd Circuit Breakers 21
Power Wiring 22
I/O Wiring Recommendations 28
Start and Speed Reference Control 37
RS485 Network Wiring 38
EMC Instructions 39
FCC Instructions 42
Chapter 1
Most start-up difficulties are the result of incorrect wiring. Every precaution
must be taken to assure that the wiring is done as instructed. All items must be
read and understood before the actual installation begins.
ATT EN TI ON : The following information is merely a guide for proper
installation. Rockwell Automation, Inc. cannot assume responsibility for the
compliance or the noncompliance to any code, national, local or otherwise
for the proper installation of this drive or associated equipment. A hazard of
personal injury and/or equipment damage exists if codes are ignored during
installation.
Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 11
Chapter 1 Installation/Wiring
Opening the Cover
Frame C Drives
1. Press and hold in the tabs on each side of the cover.
2. Pull the cover out and up to release.
Frame D Drives
1. Loosen the two captive cover screws.
2. Pull the bottom of the cover out and up to release.
12 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017
Frame E Drives
1. Loosen the four captive cover screws.
2. Pull the bottom of the cover out and up to release.
Installation/Wiring Chapter 1
Frame F Drives
1. Turn the latch counterclockwise.
2. Pull on the latch to swing the door open.
Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 13
Chapter 1 Installation/Wiring
Frame G Drives
1. 1. Loosen the four captive cover screws.
2. Pull the bottom of the cover out and up to release.
Frame H Drives
1. Loosen the four captive cover screws.
2. Pull the bottom of the cover out and up to release.
14 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017
Installation/Wiring Chapter 1
Mounting Considerations
• Mount the drive upright on a flat, vertical and level surface.
Frame Screw Size Screw Torque
C M5 (#10-24) 2.45-2.94 N-m (22-26 lb.-in.)
D M8 (5/16 in.) 6.0-7.4 N-m (53.2-65.0 lb.-in.)
E M8 (5/16 in.) 8.8-10.8 N-m (78.0-95.3 lb.-in.)
F M10 (3/8 in.) 19.6-23.5 N-m (173.6-208.3 lb.-in.)
G M12 (1/2 in.) 33.5-41.0 N-m (296.5-362.9 lb.-in.)
H M12 (1/2 in.) 33.5-41.0 N-m (296.5-362.9 lb.-in.)
• Protect the cooling fan by avoiding dust or metallic particles.
• Do not expose to a corrosive atmosphere.
• Protect from moisture and direct sunlight.
Maximum Surrounding Air Temperature
Frame Enclosure Rating Temperature Range Minimum Mounting Clearances
C IP 20/UL Open-Type -10° to 45°C
(14° to 113°F)
IP 30/NEMA 1/UL Type 1
IP 20/UL Open-Type -10° to 50°C
D IP 30/NEMA 1/UL Type 1 -10° to 45°C
E
FSee Figure 3
GSee Fi gure 4
H
(1) Frame C drives require installation of the PowerFlex 400 IP 30/NEMA 1/UL Type 1 option kit to achieve this rating.
(1)
-10° to 45°C
(14° to 113°F)
(14° to 122°F)
(14° to 113°F)
See Figure 1
See Figure 1, Mounting Option B
See Figure 1, Mounting Option B
See Figure 2
, Mounting Option A
Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 15
Chapter 1 Installation/Wiring
120 mm
(4.7 in.)
120 mm
(4.7 in.)
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.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
Closest object that may
restrict air flow
through the drive heat
sink and chassis.
Mounting Option A
No clearance required
between drives.
Mounting Option B
150 mm
(6.0 in.)
150 mm
(6.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.)
Minimum Mounting Clearances
Refer to Appendix B for mounting dimensions.
Figure 1 - Frame C Mounting Clearances
Figure 2 - Frames D & E Mounting Clearances
16 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017
Figure 3 - Frame F Mounting Clearances
300 mm
(11.8 in.)
300 mm
(11.8 in.)
200 mm
(1)
(7.9 in.)
200 mm
(1)
(7.9 in.)
(1)
(1) If the drive is installed with a side gap of 200 mm, it has to be removed from the shelf to change the fan. If the drive
is installed with a side gap of 300 mm, it does not need to be removed from the shelf to change the fan.
Installation/Wiring Chapter 1
250 mm
(9.8 in.)
50 mm
(2.0 in.)
Figure 4 - Frames G & H Mounting Clearances
50 mm
(2.0 in.)
150 mm
(6.0 in.)
Debris Protection
Frame C Drives – A plastic top panel is included with the drive. Install the
panel to prevent debris from falling through the vents of the drive housing
during installation. Remove the panel for IP 20/Open Type applications.
Frame D, E, F, G and H Drives – These drives have built-in debris protection.
Installation of a protective panel is not required.
Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 17
Chapter 1 Installation/Wiring
Frame C Frame E and F (Typical)
Important:
Tighten screw after jumper removal.
Storage
• Store within an ambient temperature range of -40° to +85°C.
• Store within a relative humidity range of 0% to 95%,non-condensing.
• Do not expose to a corrosive atmosphere.
AC Supply Source Considerations
Ungrounded Distribution Systems
ATT EN TI ON : PowerFlex 400 drive frames contain protective MOVs that are
referenced to ground. These devices must be disconnected if the drive is
installed on an ungrounded or resistive grounded distribution system.
Disconnecting MOVs (Drive Frames C, E and F only.)
To prevent drive damage, the MOVs connected to ground shall be
disconnected if the drive is installed on an ungrounded distribution system
where the line-to-ground voltages on any phase could exceed 125% of the
nominal line-to-line voltage. To disconnect these devices, remove the jumper
shown in Figure 6
Figure 5 - Phase to Ground MOV Removal
.
Three-Phase
AC Input
R/L1
S/L2
T/L3
Jumper
123
4
18 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017
Figure 6 - MOV Jumper Location
Installation/Wiring Chapter 1
SHLD
U/T1
V/T2
W/T3
R/L1
S/L2
T/L3
Note: Frame D, G and H drives do not contain a MOV to ground connection
and are suitable for operation in both grounded and ungrounded distribution
systems without modification.
Input Power Conditioning
The drive is suitable for direct connection to input power within the rated
voltage of the drive (see Appendix A
conditions which may cause component damage or reduction in product life. If
any of the conditions exist, as described in Ta b l e 1
listed under the heading Corrective Action on the line side of the drive.
IMPORTANT Only one device per branch circuit is required. The device should be mounted
closest to the branch and sized to handle the total current of the branch
circuit.
Table 1 - Input Power Conditions
Input Power Condition Corrective Action
Low Line Impedance (less than 1% line reactance) • Install Line Reactor
Line has power factor correction capacitors • Install Line Reactor
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
Ungrounded distribution system
(1) Refer to Appendix B for accessory ordering information.
). Listed in Ta b l e 1 are certain input power
, install one of the devices
(1)
• or Isolation Transformer
(1)
• or Isolation Transformer
• Remove MOV jumper to ground (Frame C, E and F
drives only)
• or Install Isolation Transformer with grounded
secondary if necessary
General Grounding Requirements
The drive Safety Ground - (PE) must be connected to system ground.
Ground impedance must conform to the requirements of national and local
industrial safety regulations and/or electrical codes. The integrity of all ground
connections should be periodically checked.
Figure 7 - Typical Grounding
Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 19
Chapter 1 Installation/Wiring
Ground Fault Monitoring
If a system ground fault monitor (RCD) is to be used, only Type B (adjustable)
devices should be used to avoid nuisance tripping.
Safety Ground - (PE)
This is the safety ground for the drive that is required by code. One of these
points must be connected to adjacent building steel (girder, joist), a floor
ground rod or bus bar. Grounding points must comply with national and local
industrial safety regulations and/or electrical codes.
Motor Ground
The motor ground must be connected to one of the ground terminals on the
drive.
Shield Termination - SHLD
Either of the safety ground terminals located on the power terminal block
provides a grounding point for the motor cable shield. The motor cable shield
connected to one of these terminals (drive end) should also be connected to
the motor frame (motor end). Use a shield terminating or EMI clamp to
connect the shield to the safety ground terminal. The conduit box may be used
with a cable clamp for a grounding point for the cable shield.
When shielded cable is used for control and signal wiring, the shield should
be grounded at the source end only, not at the drive end.
RFI Filter Grounding
Using an external filter with any drive rating, may result in relatively high
ground leakage currents. Therefore, the filter must only be used in
installations with grounded AC supply systems and be permanently
installed and solidly grounded (bonded) to the building power distribution
ground. Ensure that the incoming supply neutral is solidly connected (bonded)
to the same building power distribution ground. Grounding must not rely on
flexible cables and should not include any form of plug or socket that would
permit inadvertent disconnection. Some local codes may require redundant
ground connections. The integrity of all connections should be periodically
checked.
20 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017
Installation/Wiring Chapter 1
Fuses and Circuit Breakers
The PowerFlex 400 does not provide branch short circuit protection. This
product should be installed with either input fuses or an input circuit breaker.
National and local industrial safety regulations and/or electrical codes may
determine additional requirements for these installations.
Fusing
The ratings in the table that follows are the recommended values for use with
each drive rating. The devices listed in this table are provided to serve as a
guide.
Bulletin 140M (Self-Protected Combination Controller)/UL489 Circuit Breakers
When using Bulletin 140M or UL489 rated circuit breakers, the guidelines
listed below must be followed in order to meet the NEC requirements for
branch circuit protection.
• Bulletin 140M can be used in single and group motor applications.
• Bulletin 140M can be used up stream from the drive without the need
for fuses.
Table 2 - Recommended Branch Circuit Protective Devices
Volt age
Rating
200-240V AC
– 3-Phase
Drive Rating
kW (HP)
2.2 (3.0) 20 140M-F8E-C16 100-C23 5098
3.7 (5.0) 30 140M-F8E-C25 100-C37 5098
5.5 (7.5) 35 140M-F8E-C32 100-C37 5098
7.5 (10) 45 140M-F8E-C45 100-C45 5098
11 (15) 70 — 100-C60 —
15 (20) 90 — 100-C85 —
18.5 (25) 100 — 100-D95 —
22 (30) 125 — 100-D110 —
30 (40) 175 — 100-D180 —
37 (50) 200 — 100-D180 —
Fuse Rating
Amps
(1)
140M Motor
Protectors
Catalog No.
(2)(3)
Recommended
MCS Contactors
Catalo g No.
Min. Enclosure
(4)
Volume
3
Inches
Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 21
Chapter 1 Installation/Wiring
Table 2 - Recommended Branch Circuit Protective Devices
Volt age
Rating
380-480V AC
–
3-Phase
(1) Recommended Fuse Class: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.
(2) The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary.
See Bulletin 140M Motor Protection Circuit Breakers Application Ratings.
(3) Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 208 Wye or Delta, 240 Wye or Delta, 480Y/277 or
600Y/347. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground systems.
(4) When using a Manual Self-Protected (Type E) Combination Motor Controller, the drive must be installed in a ventilated or non-
ventilated enclosure with the minimum volume specified in this column. Application specific thermal considerations may
require a larger enclo sure.
Drive Rating
kW (HP)
2.2 (3.0) 10 140M-D8E-C10 100-C09 5098
4.0 (5.0) 20 140M-D8E-C16 100-C16 5098
5.5 (7.5) 20 140M-D8E-C16 100-C23 5098
7.5 (10) 25 140M-D8E-C20 100-C23 5098
11 (15) 30 140M-F8E-C32 100-C30 5098
15 (20) 40 140M-F8E-C32 100-C37 5098
18.5 (25) 50 140M-F8E-C45 100-C60 9086
22 (30) 60 — 100-C60 —
30 (40) 80 — 100-C85 —
37 (50) 100 — 100-C85 —
45 (60) 125 — 100-D110 —
55 (75) 150 — 100-D140 —
75 (100) 200 — 100-D180 —
90 (125) 250 — 100-D210 —
110 (150) 250 — 100-D250 —
132 (200) 300 — 100-D300 —
160 (250) 400 — 100-D420 —
200 (300) 500 — 100-D420 —
250 (350) 600 — 100-D630 —
Fuse Rating
Amps
(1)
140M Motor
Protectors
Catalog No.
(2)(3)
Recommended
MCS Contactors
Catalo g No.
Min. Enclosure
(4)
Volume
3
Inches
Power Wiring
ATT EN TI ON : National Codes and standards (NEC, VDE, BSI, etc.) and local
codes outline provisions for safely installing electrical equipment.
Installation must comply with specifications regarding wire types, conductor
sizes, branch circuit protection and disconnect devices. Failure to do so may
result in personal injury and/or equipment damage.
ATT EN TI ON : To avoid a possible shock hazard caused by induced voltages,
unused wires in the conduit must be grounded at both ends. For the same
reason, if a drive sharing a conduit is being serviced or installed, all drives
using this conduit should be disabled. This will help minimize the possible
shock hazard from “cross coupled” power leads.
22 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017
Installation/Wiring Chapter 1
Motor Cable Types Acceptable for 200...600 Volt Installations
A variety of cable types are acceptable for drive installations. For many
installations, unshielded cable is adequate, provided it can be separated from
sensitive circuits. As an approximate guide, allow a spacing of 0.3 meters (1
foot) for every 10 meters (32.8 feet) of length. In all cases, long parallel runs
must be avoided. Do not use cable with an insulation thickness less than 15
mils (0.4 mm/0.015 in.). Do not route more than three sets of motor leads in a
single conduit to minimize “cross talk”. If more than three drive/motor
connections per conduit are required, shielded cable must be used.
UL installations must use 600V, 75°C or 90°C wire.
Use copper wire only.
Unshielded
THHN, THWN or similar wire is acceptable for drive installation in dry
environments provided adequate free air space and/or conduit fill rates limits
are provided. Do not use THHN or similarly coated wire in wet areas. Any
wire chosen must have a minimum insulation thickness of 15 mils and should
not have large variations in insulation concentricity.
Shielded/Armored Cable
Shielded cable contains all of the general benefits of multi-conductor cable
with the added benefit of a copper braided shield that can contain much of the
noise generated by a typical AC Drive. Strong consideration for shielded cable
should be given in installations with sensitive equipment such as weigh scales,
capacitive proximity switches and other devices that may be affected by
electrical noise in the distribution system. Applications with large numbers of
drives in a similar location, imposed EMC regulations or a high degree of
communications /networking are also good candidates for shielded cable.
Shielded cable may also help reduce shaft voltage and induced bearing currents
for some applications. In addition, the increased impedance of shielded cable
may help extend the distance that the motor can be located from the drive
without the addition of motor protective devices such as terminator networks.
Refer to Reflected Wave in “Wiring and Grounding Guidelines for PWM AC
Drives,” publication DRIVES-IN001A-EN-P
Consideration should be given to all of the general specifications dictated by
the environment of the installation, including temperature, flexibility, moisture
characteristics and chemical resistance. In addition, a braided shield should be
included and be specified by the cable manufacturer as having coverage of at
least 75%. An additional foil shield can greatly improve noise containment.
.
A good example of recommended cable is Belden® 295xx (xx determines
gauge). This cable has four (4) XLPE insulated conductors with a 100%
coverage foil and an 85% coverage copper braided shield (with drain wire)
surrounded by a PVC jacket.
Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 23
Chapter 1 Installation/Wiring
Other types of shielded cable are available, but the selection of these types may
limit the allowable cable length. Particularly, some of the newer cables twist 4
conductors of THHN wire and wrap them tightly with a foil shield. This
construction can greatly increase the cable charging current required and
reduce the overall drive performance. Unless specified in the individual
distance tables as tested with the drive, these cables are not recommended and
their performance against the lead length limits supplied is not known.
Table 3 - Recommended Shielded Wire
Location Rating/Type Description
Standard
(Option 1)
Standard
(Option 2)
Class I & II;
Division I & II
600V, 90°C (194°F)
XHHW2/RHW-2
Anixter B209500-B209507,
Belden 29501-29507,
or equivalent
Tray rated 600V, 90°C
(194°F) RHH/RHW-2
Anixter OLF-7xxxxx
or equivalent
Tray rated 600V, 90°C
(194°F) RHH/RHW-2
Anixter 7V-7xxxx-3G
or equivalent
• Four tinned copper conductors with XLPE
insulation.
• Copper braid/aluminum foil combination shield
and tinned copper drain wire.
•PVC jacket.
• Three tinned copper conductors with XLPE
insulation.
• 5 mil single helical copper tape (25% overlap min.)
with three bare copper grounds in contact with
shield.
•PVC jacket.
• Three bare copper conductors with XLPE insulation
and impervious corrugated continuously welded
aluminum armor.
• Black sunlight resistant PVC jacket overall.
• Three copper grounds on #10 AWG and smaller.
Reflected Wave Protection
The drive should be installed as close to the motor as possible. Installations
with long motor cables may require the addition of external devices to limit
voltage reflections at the motor (reflected wave phenomena). See Ta b l e 4
for
recommendations.
The reflected wave data applies to all frequencies 2 to 10 kHz.
For 240V ratings, reflected wave effects do not need to be considered.
Table 4 - Maximum Cable Length Recommendations
Reflected Wave
380...480V Ratings Motor Insulation Rating Motor Cable Only
1000 Vp-p 7.6 meters (25 feet)
1200 Vp-p 22.9 meters (75 feet)
1600 Vp-p 152.4 meters (500 feet)
(1) Longer cable lengths can be achieved by installing devices on the output of the drive. Consult factory for recommendations.
(1)
Output Disconnect
The drive is intended to be commanded by control input signals that will start
and stop the motor. A device that routinely disconnects then reapplies output
power to the motor for the purpose of starting and stopping the motor should
24 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017
Installation/Wiring Chapter 1
Frame D
R/L1
S/L2
T/L3
P1
P2
DC–
U/T1
V/T2
W/T3
Frame C
R/L1 S/L2 T/L3
U/T1 V/T2
W/T3
P2 P1
BR–BR+DC+DC–
not be used. If it is necessary to disconnect power to the motor with the drive
outputting power, an auxiliary contact should be used to simultaneously
disable drive control run commands.
Power Terminal Block
Frame C, D, F, G and H drives utilize a finger guard over the power wiring
terminals. Replace the finger guard when wiring is complete.
Figure 8 - Power Terminal Blocks (Frames C through D)
Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 25
Chapter 1 Installation/Wiring
Bottom view of terminal block and wire
Jumper
Wire
Wire
Jumper
Correc t Incor rect
Figure 9 - Power Terminal Blocks (Frames E through H)
R/L1
S/L2
R/L1
R/L1
S/L2
T/L3
S/L2
T/L3
T/L3
P1
P1
P2
DC–
P1
P2
DC–
U/T1
V/T2
P2
DC–
U/T1
V/T2
W/T3
U/T1
V/T2
W/T3
W/T3
Frame E:
480V
37-45 kW
(50-60 HP)
Frame E:
240V 480V
30-37 kW 55-75 kW
(40-50 HP) (75-100 HP)
See note at the bottom
of this page.
Frame F
Frame G
R/L1
S/L2
T/L3
P2
U/T1
W/T3
DC–
V/T2
P1
Frame H
R/L1
S/L2
T/L3
DC+
DC–
U/T1
V/T2
W/T3
IMPORTANT For Frame E, 240V 30...37 kW (40...50 HP) and 480V 55...75 kW (75...100 HP)
drives, take care to place the wire beneath the jumper and not above it when
connecting to terminals P1 and P2.
P1 P2 DC- P1 P2 DC-
26 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017
Installation/Wiring Chapter 1
Table 5 - Power Terminal Descriptions
(1)
Ter min al
R/L1, S/L2, T/L3 3-Phase Input
U/T1 To Motor U/T1
V/T2 To Motor V/T2 =
W/T3 To Motor W/T3
P2, P1 DC Bus Inductor Connection
DC–, DC+ DC Bus Connection (Frame C and H Drives)
P2, DC– DC Bus Connection (Frame D, E, F and G Drives)
BR+, BR– Not Used
(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.
Description
Switch any two
motor leads to change
forward direction.
Drives are 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.
Safety Ground - PE
Table 6 - Power Terminal Block Specifications
Frame Maximum Wire Size
C8.4 mm
2
(8 AWG) 1.3 mm2 (16 AWG) 2.9 N-m (26 lb-in)
(1)
Minimum Wire Size
D 33.6 mm2 (2 AWG) 8.4 mm2 (8 AWG) 5.1 N-m (45 lb-in)
E480V
33.6 mm2 (2 AWG) 3.5 mm2 (12 AWG) 5.6 N-m (49.5 lb-in)
37...45 kW
(50...60 HP)
E240V
107.2 mm
2
(4/0 AWG) 53.5 mm2 (1/0 AWG) 19.5 N-m (173 lb-in)
30-37 kW
(40...50 HP)
480V
55...75 kW
(75...100 HP)
F 152.0 mm2 (300 MCM) 85.0 mm2 (3/0 AWG) 19.5 N-m (173 lb-in)
2
G 152.0 mm
(300 MCM) 107.2 mm2 (4/0 AWG) 29.4 N-m (260 lb-in)
H 253.0 mm2 (500 MCM) 152.0 mm2 (300 MCM) 40.0 N-m (354 lb-in)
(1) Maximum/minimum sizes that the terminal block will accept – these are not recommendations. If national or local codes
require sizes outside this range, lugs may be used. Some ratings will require a pair of wires.
(1)
Recommended Torque
Rockwell Automation Publication 22C-UM001J-EN-E - January 2017 27
Chapter 1 Installation/Wiring
I/O Wiring Recommendations
Motor Start/Stop Precautions
ATT EN TI ON : A contactor or other device that routinely disconnects and
reapplies the AC line to the drive to start and stop the motor can cause drive
hardware damage. The drive is designed to use control input signals that will
start and stop the motor. If used, the input device must not exceed one
operation per minute or drive damage can occur.
ATT EN TI ON : The drive start/stop control circuitry includes solid-state
components. If hazards due to accidental contact with moving machinery or
unintentional flow of liquid, gas or solids exist, an additional hardwired stop
circuit may b e require d to remove the AC line to the drive. When the AC line is
removed, there will be a loss of any inherent regenerative braking effect that
might be present - the motor will coast to a stop. An auxiliary braking
method may be required.
Important points to remember about I/O wiring:
• Always use copper wire.
• Wire with an insulation rating of 600V or greater is recommended.
• Control and signal wires should be separated from power wires by at
least 0.3 meters (1 foot).
•
ATT EN TI ON : Driving the 4-20 mA analog input from a voltage source could
cause component damage. Verify proper configuration prior to applying
input signals.
Control Wire Types
Table 7 - Recommended Control and Signal Wire
Wire Type(s) Description Minimum Insulation Rating
Belden 8760/9460
or equivalent
Belden 8770
or equivalent
(1) 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.
2
0.8 mm
(18 AWG), twisted pair,
100% shield with drain
0.8 mm2 (18 AWG), 3 conductor,
shielded for remote pot only.
(1)
300V
60 °C
(140 °F)
I/O Terminal Block
Table 8 - I/O Terminal Block Specifications
Frame Maximum Wire Size
All 1.3 mm
(1) Maximum/minimum sizes that the terminal block will accept - these are not recommendations.
2
(16 AWG) 0.13 mm2 (26 AWG) 0.5...0.8 N-m (4.4...7 lb-in)
(1)
Minimum Wire Size
(1)
Tor que
28 Rockwell Automation Publication 22C-UM001J-EN-E - January 2017
Loading...