Rockwell Automation 23P User Manual

User Manual

PowerFlex Digital DC Drive

PowerFlex DC Drive V1.006…6.002, PowerFlex DC Standalone Regulator V1.006…6.002

Important User Information

IMPORTANT

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.

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).

Allen-Bradley, Connected Components Workbench, DriveExplorer, DriveTools SP, PowerFlex, and Rockwell Automation are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

This manual contains new and updated information.

Summary of Changes

New and Updated Information

This table contains the changes made to this revision.

Top ic Pa ge

Added the Maximum Surrounding Air Temperature Specifications. 18

Updated the frame B drive dimensions to include a different depth dimension for certain catalog
numbers.

Updated the Typical Power Wiring Diagrams to illustrate connections for bother series A and series B
frame D fans.

Updated the Frame D, Series B Heatsink Cooling Fan Specifications to include information on fan air flow
verification after wiring.

Changed the name of parameter 467 from [Max Fld Curr Pct] to [Max Fld Flux Pct].
Note: The parameter name was only incorrect in this manual.

Added new values to the Testpoint Codes and Functions table. 229

Removed the Certifications and Specifications information. 232

20

45

71

Througho ut
manual

Changes to this manual for previous revisions are included in Appendix I History
of Changes on page 381

.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 3

Summary of Changes

4 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014

Table of Contents

Preface

Installation and Wiring

Drive Storage Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Drive Nameplate Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Drive Series Letter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Drive Firmware Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Extra Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Standard Drive Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . 15

Standard Drive Catalog Number Explanation, Cont.. . . . . . . . . . . . . . . . 16

Standalone-Alone Regulator Catalog Numbers . . . . . . . . . . . . . . . . . . . . . 16

Chapter 1

Mount the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Operating Conditions and Temperatures. . . . . . . . . . . . . . . . . . . . . . . 18

Minimum Mounting Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Maximum Surrounding Air Temperature Specifications . . . . . . . . . 18

Approximate Drive Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . 19

Lifting PowerFlex DC Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Mount Frame C and D Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Remove the Drive Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Frame A Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Frame B and C Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Frame D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Isolation Transformers / Line Reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

AC Input Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

DC Output Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Dynamic Brake Resistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

General Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Safety Ground (PE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Power Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Encoder/Resolver Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . 33

Tachometer Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Grounding for Installations in an Ungrounded or High-Impedance,

Neutral Ground, or System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

EMC Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Installation Requirements Related to the Low Voltage Directive. . 40

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 5

Table of Contents

Installation Requirements Related to EN 61800-3 and the EMC

Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Pollution Degree Ratings According to EN 61800-5-1 . . . . . . . . . . 41

Power Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Control Power Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Cable and Wiring Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

AC Input Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

DC Output Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Typical Power Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Armature Converter Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Armature Voltage Feedback Connections. . . . . . . . . . . . . . . . . . . . . . . 53

Field Converter Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Field Current Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Set DIP Switch S14 to the Correct Value . . . . . . . . . . . . . . . . . . . . . . . 60

Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Thermistors and Thermal Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Control Circuit Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Frame C Heatsink Cooling Fan Specifications . . . . . . . . . . . . . . . . . . 69

Frame D, Series B Heatsink Cooling Fan Specifications . . . . . . . . . . 71

Frame C and D Armature Fuse Signal Terminals . . . . . . . . . . . . . . . . 73

DIP Switch and Jumper Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

I/O Signal and Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

I/O Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Digital Encoder Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

DC Analog Tachometer Terminal Block . . . . . . . . . . . . . . . . . . . . . . . 88

Resolver Feedback Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

I/O and Control Wire Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Chapter 2

Drive Start Up

6 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014

Drive Start Up Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Before Applying Power to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Verify all Drive Configuration Settings . . . . . . . . . . . . . . . . . . . . . . . . . 92

Verify the Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Verify the Control and I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Applying Power to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Apply Voltage to the Control Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . 93

Verify the Control Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Load the Default Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Configure the Most Commonly Used Parameters . . . . . . . . . . . . . . . 95

Tune the Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Verify Motor Rotation and Run Feedback Polarity Checks. . . . . . 103

Configure the Speed Feedback Parameters . . . . . . . . . . . . . . . . . . . . . 106

Tune the Speed Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Verify Speed Reference Settings and Drive Operation. . . . . . . . . . . 110

Chapter 3

Table of Contents

Programming and Parameters

Troubleshooting

About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Parameters Table Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

How Parameters are Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

File–Group–Parameter Order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Numbered List View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Cross Reference Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Basic Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Advanced Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Monitor File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Motor Control File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Speed Command File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Dynamic Control File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Applications File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Utility File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Communications File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Input / Output File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Parameter Cross Reference – by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Parameter Cross Reference – by Number. . . . . . . . . . . . . . . . . . . . . . . . . . 209

Chapter 4

Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

HIM Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Clearing Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Alarm Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Common Drive Symptoms and Corrective Actions . . . . . . . . . . . . . . . . 227

Drive will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Drive starts but motor does not turn and no armature current . . 228

The motor does not reach commanded speed . . . . . . . . . . . . . . . . . . 228

The motor is turning in the wrong direction . . . . . . . . . . . . . . . . . . 228

The motor reaches maximum speed immediately . . . . . . . . . . . . . . 229

Testpoint Codes and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Supplemental Drive Information

Appendix A

Certifications and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

IP20 NEMA / UL Type Open Watts Loss . . . . . . . . . . . . . . . . . . . . . . . . 232

Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Typical Programmable Controller Configurations . . . . . . . . . . . . . 234

Logic Command/Status Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Drive Power Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Frame A and B Fuse Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Frame C and D Fuse Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Control Power Circuit Protection Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 7

Table of Contents

Switching Power Supply Circuit Board Fuses . . . . . . . . . . . . . . . . . . 249

Frame B Pulse Transformer Circuit Board Fuses . . . . . . . . . . . . . . . 251

Frame C Transient Noise Filter Circuit Board Fuses. . . . . . . . . . . . 252

Frame D Overvoltage Clipping Circuit Board Fuses . . . . . . . . . . . . 253

AC Input Line Reactors and AC Input Contactors. . . . . . . . . . . . . . . . . 254

Isolation Transformers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Dynamic Brake Resistor Kits and DC Output Contactors . . . . . . . . . . 258

DC Contactor Crimp Lug Kit Specifications . . . . . . . . . . . . . . . . . . . . . . 259

Alternate Dynamic Brake Resistor Kits and DC Output Contactors. 260

Alternate EMC Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Terminal Adapter Kits for Frame D Drives . . . . . . . . . . . . . . . . . . . . . . . . 264

Appendix B

HIM Overview

Application Notes

External and Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

LCD Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

ALT Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Using the S.M.A.R.T. List Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

LCD HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Removing/Installing the HIM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Appendix C

Alpha Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Alpha Test Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Analog Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Example 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Example 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Analog Input Signal Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Current / Speed Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

Drive Reference and Feedback Scaling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

Armature Voltage Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

DC Analog Tachometer Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Encoder Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Drive Reference and Feedback Scaling Examples . . . . . . . . . . . . . . . 280

Speed Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Droop Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Field Weakening Mode Configuration (v1.006) . . . . . . . . . . . . . . . . . . . 285

Using a DC Contactor Only (Firmware v1.006 Only) . . . . . . . . . . 286

Using a DC Contactor and a Dynamic Brake (Firmware

v1.006 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

Using an Inverting Fault Device Only (Firmware v1.006 Only). . 286

Using a DC Contactor and an Inverting Fault Device (Firmware

v1.006 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

Using a DC Contactor, a Dynamic Brake and an Inverting Fault

Device (Firmware v1.006 Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

8 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014

Table of Contents

Lifting/Torque Proving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Tuning The Motor For Torque Prove Applications . . . . . . . . . . . . 291

Crane Setup with Encoder/Resolver Feedback . . . . . . . . . . . . . . . . . 291

Crane Setup - Encoderless. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

Manually Tuning the Speed Regulator for Firmware Version 6.xxx . . 301

PID Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Configure a Line Speed Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

Configure the Feedback Signal in the Follower Drive(s) . . . . . . . . 304

Configure the Tension Set Point Signal in the Follower Drive(s) 306

Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

“Auto” Speed Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

“Manual” Speed Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Changing Speed Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Torque Reference Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Auto/Manual Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

Resolver Cable Balance Tuning Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

Performing the Cable Balance Tuning Test . . . . . . . . . . . . . . . . . . . . 309

Resolver Type Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Scale Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Linking Parameters Via the Scale Block Parameters. . . . . . . . . . . . . 312

SCR Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

Open SCR Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

Shorted SCR Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

S-curve Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

S-curve Acceleration Ramp Example: . . . . . . . . . . . . . . . . . . . . . . . . . 316

Speed Regulation Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

Adaptive Speed Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

Speed Up Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

Speed Threshold Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Speed Zero Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

Speed Draw Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Speed / Torque Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

Zero Torque Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

Speed Regulation Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

Torque Regulation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

eed Limited Adjustable Torque (SLAT) Min Mode and SLAT Max

Sp

Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

Sum Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

Start At Powerup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

Fine Tuning the Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

Manually Adjusting the Current Regulator Tune Settings . . . . . . 332

Fine Tuning the Field Current Regulator. . . . . . . . . . . . . . . . . . . . . . 334

Fine Tuning the Speed Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

Fine Tuning the Voltage Regulator in the Field Converter . . . . . . 339

Tuning the Field Current Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 9

Table of Contents

Appendix D

Control Block Diagrams

Installing a Communication Adapter

Optional Analog and Digital I/O
Expansion Circuit Board

Optional 115V AC to 24V DC I/O
Converter Circuit Board

Diagram Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

Appendix E

Communication Adapter Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

What The Communication Adapter Kit Includes . . . . . . . . . . . . . . . . . . 367

Tools That You Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

Installing the Communication Adapter Module in the Drive. . . . . . . . 368

Frame A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

Frames B and C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370

Frame D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371

Appendix F

What This Option Board Provides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

I/O Expansion Board Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

Appendix G

What This Option Board Provides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

I/O Converter Board Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376

PowerFlex DC Standalone Regulator
Installation

History of Changes

Index

Appendix H

Installation and Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

Appendix I

20P-UM001J-EN-P, February 2014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381

20P-UM001I-EN-P, February 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382

20P-UM001H-EN-P, April 2011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383

20P-UM001G-EN-P, October 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

20P-UM001F-EN-P, June 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385

10 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014

Preface

Top ic Pa ge

Drive Storage Conditions 11
Drive Nameplate Data 12
Drive Specifications 12
Extra Resources 13
Technical Support 13
Convent ions 13
General Precautions 14
Standard Drive Catalog Number Explanation 15
Standalone-Alone Regulator Catalog Numbers 16

The purpose of this manual is to provide you with the basic information required
to install, start-up, and troubleshoot the PowerFlex DC drive. This manual is
intended for qualified personnel. You must be able to program and operate DC
drives. In addition, you must have an understanding of the parameter settings and
functions that are detailed in this manual.

Drive Storage Conditions

If it is necessary to store the drive for any length of time before installation, follow
these storage guidelines to provide satisfactory start-up operation and retain
warranty coverage:

• After receipt and inspection, repack the drive in its original shipping
container and store in a clean, dry place.

• Place where the ambient temperatures do not exceed -25°C (-13°F) or
55°C (131°F)

• Place where the range of relative air humidity does not exceed 5…95%.

• At an altitude of less than 3,000 meters (10,000 ft.) above sea level.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 11

Preface

Note: Certification

Marks Location.

See the data
nameplate label on
your drive for actual
agency certifications.

Drive frame size
Drive serial number

Drive series letter

Drive Nameplate Data

The PowerFlex DC drive contains a data nameplate label on the side of each
drive. This nameplate identifies the specific model number, applicable AC input
power, and DC output power data. Include this information when
communicating with Rockwell Automation personnel about this product.

Cat No.

20P41AD4P1RA0NNN

UL Type OPEN/IP20

Input: 460VAC 50/60 Hz 3.3A 3 Phase

Output: 500VDC 4.1A REGEN 2.0HP

1 Min Overload Amps

3 Sec Overload Amps
DC Field:

Input: 460VAC 50/60 Hz 10A max. 1 Phase

Output: 360VDC 10A max.

Regulator Power: 115/230VAC 50/60 Hz 1.0/0.5A 1 Phase

MFD. in 2XXX on MMM DD

Made in Italy

6.2

8.2

EXAMPLE ONLY

Series: A

I/O: 24VDC (Standard)
Original Firmware V. 1.001

N223

Frame: A

Serial Number: A23E0042

C

Ind. Cont.

Eq. 31KF

Listed

R

US

Drive Series Letter

Drive Specifications

Series B drives are identified as such on the data nameplate label. The drive series
letter is on the top, right side of the label.

Drive Frame Sizes

Similar PowerFlex DC drive ratings are grouped into frame sizes to make
ordering spare parts and drive dimensions simpler. The drive frame size is listed
just above the serial number on the data nameplate label. See the Standard Drive
Catalog Number Explanation on page 15

for a list of drive catalog numbers and

their respective frame sizes.

Drive Firmware Version

The original firmware version of the drive as shipped from the factory appears on
the data nameplate label just above the certifications. If the firmware version has
been upgraded since the drive was shipped, you can view the current version on
the HIM (if installed). See Diagnostics Menu on page 269

For drive specification information, see the PowerFlex Digital DC Drive,
Technical Data, 20P-TD001

.

for details.

12 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014

Preface

Extra Resources

These documents contain more information on related products from Rockwell
Automation.

Resource Description

Preventive Maintenance of Industrial Control and Drive
System Equipment, DRIVES-TD001

Safety Guidelines for the Application, Installation, and
Maintenance of Solid State Control, SGI-1.1

A Global Reference Guide for Reading Schematic Diagrams,
100-2.10

Guarding Against Electrostatic Damage, 8000-4.5.2 Provides common practices that can help guard against

Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1

Product Certifications website, http://ab.com

Provides a checklist for performing preventive
maintenance.

Provides general guidelines for the application,
installation, and maintenance of solid-state control in the
form of individual devices or packaged assemblies that
incorporate solid-state components.

Provides a simple cross-reference of common schematic/
wiring diagram symbols that are used throughout various
parts of the world.

ESD.
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/literature

. To order paper copies of
technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.

Technical Support

Conventions

For Allen-Bradley Drives Technical Support:

Title Online at. . .

Allen-Bradley Drives Technical Support www.ab.com/support/abdrives

• To help differentiate parameter names and LCD display text from other
text, the following conventions are used:

– Parameter names appear in [brackets].

For example: [Armature Voltage].

– Display text appears in “quotes.” For example: “Enabled.”

• 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

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 13

Preface

General Precautions

AT TE NT IO N: This drive contains ESD (Electrostatic Discharge) sensitive parts and

assemblies. Static control precautions are required when you install, test, service,
or repair this assembly. If ESD control procedures are not followed, component
damage can result. If you are not familiar with static control procedures, see
publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other
applicable ESD protection handbook.

AT TE NT IO N: An incorrectly applied or installed drive can result in component
damage or a reduction in product life. Installation or application errors, such as,
an undersized motor, incorrect or inadequate AC supply, or excessive surrounding
air temperatures can result in malfunction of the system.

AT TE NT IO N: Allow only qualified personnel, familiar with DC drives and
associated machinery, to plan or implement the installation, start-up and
subsequent maintenance of the system. Failure to comply can result in personal
injury and equipment damage.

AT TE NT IO N: An incorrectly applied or installed bypass system can result in
component damage or reduction in product life. The most common causes are:

• An AC line connection to the drive output or control terminals.

• Improper bypass or output circuits that are not Allen-Bradley approved.

• Output circuits that do not connect directly to the motor.

Contact Allen-Bradley for assistance with your application or installation.

14 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014

Standard Drive Catalog

Position

1-3 4 5 6 7 8-10 11 12 13 14 15 16

20P 4 1 A D 4P1 R A 0 N N N

abcdef gh i jkl

a

Drive

Code Type

20P PowerFlex DC

b

Motor Operation

Code Type

2 Two Quadrant Operation

4 Four Quadrant Operation

c

Input Type

Code Type

1 6 Pulse

d

Enclosure

Code Enclosure Rating

Conform.

Coat

A IP20, NEMA/UL Type Open

e

Input Voltage

Code Voltage

B 230V AC

D 460V AC

E 600V AC

F 690V AC

f1

f2

Yes

Not available for 230V AC input drives.

Use this code for 400V AC input applications.

f3

f4

2

3

5

7.5

10

15

20

25

30

40

50

60

75

100

125

150

200

250

300

400

500

600

700

800

900

1.5

2.2

3.7

5.5

7.5

11

15

18.5

22

30

37

45

56

75

93

112

149

187

224

298

373

447

552

597

671

4.1

6

10

14

19

27

35

45

52

73

86

100

129

167

207

250

330

412

495

667

830

996

1162

1238

1494

A

A

A

A

A

A

A

A

A

A

A

A

A

B

B

B

B

B

C

C

D

D

D

D

D

10

10

10

10

10

10

10

10

10

14

14

14

14

20

20

20

20

20

20

20

40

40

70

70

70

Hp

Armature

Amps

Frame

Field

Amps

Code kW

460V, 60 Hz Input

4P1

6P0

010

014

019

027

035

045

052

073

086

100

129

167

207

250

330

412

495

667

830

996

1K1

1K3

1K4

1.5

2

3

5

7.5

10

15

20

25

30

40

50

60

75

100

125

150

200

250

300

1.2

1.5

2.2

3.7

5.5

7.5

11

15

18.5

22

30

37

45

56

75

93

112

149

186

224

7

9

12

20

29

38

55

73

93

110

146

180

218

265

360

434

521

700

875

1050

A

A

A

A

A

A

A

A

A

A

B

B

B

B

B

B

C

C

D

D

10

10

10

10

10

10

10

14

14

14

20

20

20

20

20

20

20

20

40

40

Hp

Armature

Amps

Frame

Field

Amps

Code kW

230V, 60 Hz Input

7P0

9P0

012

020

029

038

055

073

093

110

146

180

218

265

360

434

521

700

875

1K0

50

75

100

200

300

400

500

600

800

900

1000

1250

37

56

75

149

224

298

373

447

597

671

746

932

67.5

101.3

135

270

405

540

675

810

1080

1215

1350

1668

B

B

B

B

B

C

C

D

D

D

D

D

20

20

20

20

20

20

20

40

40

40

40

40

Hp

Armature

Amps

Frame

Field

Amps

Code kW

575V, 60 Hz Input

067

101

135

270

405

540

675

810

1K0

1K2

1K3

1K6

298

373

447

552

597

671

746

820

932

1044

Hp

Armature

Amps

Frame

Field

Amps

Code kW

690V, 60 Hz Input

452

565

678

791

904

1K0

1K1

1K2

1K4

1K5

400

500

600

700

800

900

1000

1100

1250

1400

452

565

678

791

904

1017

1130

1243

1413

1582

C

C

D

D

D

D

D

D

D

D

20

20

40

40

40

40

70

70

70

70

Number Explanation

Preface

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 15

Preface

Position

1-3 4 5 6 7 8-10 11 12 13 14 15 16

20P 4 1 A D 4P1 R A 0 N N N

abcdefghi jkl

g

Field Supply

Code Type

R Single-Phase Regulated

h

Packaging/Documentation

Code Shipping Carton User Manual

A Yes Yes

i

HIM

Code Operator Interface

0 Blank Cover

Standard - for user installed options, see
Human Interface and Wireless Interface
Modules on page 9.

j

I/O Options

Code Control

N

None (8 - 24V DC Digital Inputs,

4 Digital Outputs, 3 Analog Inputs,

and 2 Analog Outputs are Standard)

k

Communication Options

Code Description

N None

l

Cabinet Options

Code Type

N None

Standard - for user installed options, see
Communication Option Kits on page 10.

All I/O Options are purchased separately and
are user installed. See I/O Options on page 9.

Standard Drive Catalog Number Explanation, Cont.

Standalone-Alone Regulator Catalog Numbers

Conformally coated circuit boards are provided with the following catalog
numbers.

230V / 460V AC Input Regulators 575V / 690V AC Input Regulators Field Amps

Cat. No. Cat. No.

23PMD4 23PMF4 40

23PMD7 23PMF7 70

(1)

23PAMP

(1) Gate Amplifier - used with all voltage classes of the Stand-Alone Regulator. Note: The Stand-Alone Re gulator and Gate Amplifier are

currently sold through Rockwell Automation Drive Systems only. Consult the factory for availability.

23PAMP

(1)

(1)

16 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014

Chapter 1

IMPORTANT

IMPORTANT

Installation and Wiring

Topic Page Topic Page

Mount the Drive 18 CE Conformity 39

Approximate Drive Dimensions and
Wei ght s

Lifting PowerFlex DC Drives 25 Co ntrol Power Circ uit Protection 42

Remove the Drive Covers 27 Cable and Wiring Recommendations 43

Isolation Transformers / Line Reactors 29 Power Wiring 44

Contac tors 30 DIP Switch and Jumper Settings 75

General Grounding Requirements 32 I/O Wiring 80

19 Power Circuit Protection 42

This chapter provides information on how to mount and wire the PowerFlex DC
drive.

Most start-up difficulties are the result of incorrect wire connections. Take all
precautions to assure that wire connections are done as instructed. All items must
be read and understood before the actual installation begins.

For PowerFlex DC Stand-Alone Regulator (SAR) installations, see Appendix H
for important installation and configuration information. A 23PMDx catalog
number on the data nameplate on the drive identifies a SAR. (see Drive
Nameplate Data on page 12

for location).

The PowerFlex DC drive is not designed for use with multiple motor
applications or resistive loads. Contact your Local Solution Center for multiple
motor applications. See Local Solution Centers, publication

DSDC-BR001

, for more information.

The recommended drive to motor horsepower ratio is 2:1.

AT TE NT IO N: The following information is merely a guide for proper installation.
Rockwell Automation 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. If codes are ignored during
installation, a hazard of personal injury and equipment damage exists.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 17

Chapter 1 Installation and Wiring

10 mm

10 mm

50 mm

(0.4 in.)

(0.4 in.) (2.0 in.)

10 mm
(0.4 in.)

150 mm (6.0 in.)

150 mm (6.0 in.)

150 mm (6.0 in.)

STS

PORT

MOD

NET A

NET B

STS

PORT

MOD

NET A

NET B

Airflow through the drive
must not be impeded.

Mount the Drive

Operating Conditions and Temperatures

PowerFlex DC drives are designed to operate at 0…50 °C (32…122 °F)
surrounding air temperature without derating. The drive must be mounted in a
clean, dry location. Contaminants such as oils, corrosive vapors, and abrasive
debris must be kept out of the enclosure. NEMA / UL Type Open, IP20
enclosures are intended for indoor use primarily to provide a degree of protection
against contact with enclosed equipment. These enclosures offer no protection
against airborne contaminants.

Minimum Mounting Clearances

Minimum clearance requirements are intended to be from drive to drive. Other
objects can occupy this space; however, reduced airflow can cause protection
circuits to fault the drive. The drive must be mounted in a vertical orientation as
shown in Figure 1
vertical. Intake air temperature must not exceed the product specification.

Figure 1 - Drive Enclosure Minimum Mounting Clearances

and must not be mounted at an angle greater than 30° from

Maximum Surrounding Air Temperature Specifications

• 0…50 °C (32…122 °F), typical

• De-rate 1.25% for every 1 °C (°F) over 50 °C (122 °F), to 55 °C (131 °F)

• Additional cooling is required for temperatures above 55 °C (131 °F)

18 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014

Installation and Wiring Chapter 1

A

B

A2

B1

C

STS

PORT

MOD

NET A

NET B

A1

Approximate Drive Dimensions and Weights

The PowerFlex DC drive is available in a NEMA / UL Type Open, IP20
enclosure only. Follow all mounting clearances to provide proper drive operation.

ATTENTION: Remove all loose packing materials, including the containers of
desiccants (if any), from the drive enclosure before you mount and energize the
drive.

Figure 2 - Frame A Drive Dimensions

A B C A1A2B1

mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)

267 (10.5) 359 (14.0) 287 (11.3) 7 (0.3) 250 (9.8) 275 (10.8)

Table 1 - Frame A Weights

Drive Current Rating Code Drive Weight Drive and Packaging

230V 460V kg (lb) kg (lb)‘

7P0 4P1

9P0 6P0

012 010

020 014

–019

029 027

8.4 (18.5) 10.5 (23.2)

038 035

–052

073 073

093 086

8.8 (19.4) 11 (24.3)055 045

10.8 (23.8) 13 (28.7)

110 100

–129

Weig ht

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 19

Chapter 1 Installation and Wiring

A

A1

B1

C1

B

A2

STS

PORT

MOD

NET A

NET B

A3

45.2 (1.8)

98.5 (3.9)

53.1 (2.1)

48.5 (1.9)

147.0 (5.8) 53.1 (2.1)

48.5 (1.9)

200.1 (7.9)

248.6 (9.8)

C2

Terminal Details Dimensions in mm (in.)

Figure 3 - Frame B Drive Dimensions

A A1A2A3B B1C1C2

mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)

311 (12.2) 275 (10.8) 16.5 (0.65) 7 (0.3) 388 (15.3) 375 (14.8) 350 (13.8) 380 (15.0)

(1) Only frame B drive catalog numbers 20P21AD330, 20P21AD412, 20P21AE405, 20P41AB36 0, 20P41AB434, 20P41AD330,

20P41AD412, 20P41AE405.

(1)

Table 2 - Frame B Weights

Drive w/ND Rating Code Drive Weight Drive and Packaging Weight

230V 460V 575V kg (lb) kg (lb)

146 167 067

25.5 (56.2) 27.5 (60.6)180 207 101

218 – 135

265 250 270 29.5 (65.0) 31.5 (69.5)

360 330 405

434 412 –

32 (70.5) 34 (75)

20 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014

Installation and Wiring Chapter 1

B1

B2

B3

A

A1 C

B

B4

STS

PORT

MOD

NET A

NET B

B5

310.0 (12.2)

155.0 (6.1)

113.0
(4.5)

28.0

(1.1)

28.0
(1.1)

28.0
(1.1)

35.5 (1.4)

Terminal Details Dimensions in mm (in.)

Figure 4 - Frame C Drive Dimensions

A A1 B B1 B2 B3 B4 B5 C

mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)

521 (20.5) 499 (19.7) 511 (20.1) 400 (15.7) 200 (7.9) 55 (2.2) 56 (2.2) 10.5 (0.4) 416 (16.4)

Table 3 - Frame C Weights

Drive w/ND Rating Code Weight - Regenerative Drives Weight - Non-regenerative Drives

230V 460V 575V 690V kg (lb) kg (lb) kg (lb) kg (lb)

– 495 – 61 (134.5) 83 (183.0) 57 (125.7) 79 (174.2)

521 667 –

700 – –

– – 540 452

– – 675 565

Drive Drive and Packaging Drive Drive and Packaging

65 (143.3) 87 (191.8) 62 (136.7) 84 (185.2)

72 (158.7) 94 (207.2) 68 (150.0) 90 (198.4)

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 21

Chapter 1 Installation and Wiring

Dimensions of terminals U, V, and W are the same.

Dimensions are shown in mm and (in.)

Lifting flange

Note: 134 mm (5.3 in.) C and D terminals are installed on 460V AC input, 800 and 900 Hp, 575V AC input, 1000 Hp, and 690V AC input,

1100, 1200, 1250, and 1400 Hp drives only. All other frame D ratings have 100 mm (4.0 in.) C and D terminals.

PE C D

PE C D

80.5
(3.2)

Figure 5 - Frame D Dimensions - Right Side and Front Views

544

(21.4)

359

(14.1)

436.5
(17.2)

174
(6.9)

704

(27.7)

25

(1.0)

15

(0.6)

44.5

(1.8)

60

(2.4)

30

(1.2)

42

(1.7)

792

(31.2)

208
(8.2)

144

(5.7)

157.5
(6.2)

252.5
(10.0)

437.5

(17.2)

134

(5.3)

22.6
(0.9)

44.5
(1.8)

134
(5.3)

44.5

(1.8)

10.5
(0.4)

10

(0.4)

44.5
25

(1.8)

15

(1.0)

(0.6)

146

(5.7)60(2.4)

(1.2)

269.5
(10.6)

454.5
(18.0)

1250

(49.2)

32

(1.3)

30

44.5

27.8
(1.1)

(1.8)

100

(4.0)

100
(4.0)

22 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014

215.225
(8.5)

103.25
(4.1)

1435 MAX

(56.5)

129

(5.1)

129
(5.1)

227.5
(9.0)

157.5
(6.2)

1230

(48.4)

16

(0.6)

10.5
(0.4)

10

(0.4)

10.5
(0.4)

127

(5.0)

531

(21.0)

541

(21.3)

94

(3.7)

127

(5.0)

127

(5.0)

127

(5.0)

Ø 23
(0.9)

127

(5.0)

127

(5.0)

127

(5.0)

127

(5.0)

94

(3.7)

94

(3.7)

94

(3.7)

Dimensions are shown in mm and (in.)

Mounting holes

Mounting holes

Lifting flange

Installation and Wiring Chapter 1

Figure 6 - Frame D Dimensions - Left Side and Back Views

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 23

Chapter 1 Installation and Wiring

Table 4 - Frame D - 230V AC Input Drive Weights

Drive w/ND
Rating Code

875

1K0

Weight - Regenerative Drives Weight - Non-regenerative Drives

Drive Drive and Packaging Drive Drive and Packaging

kg (lb) kg (lb) kg (lb) kg (lb)

203 (447.5) 281 (619.5) 152 (335.1) 230 (507.1)

Table 5 - Frame D - 460V AC Input Drive Weights

Drive w/ND
Rating Code

830

996

1K1

1K4

Weight - Regenerative Drives Weight - Non-regenerative Drives

Drive Drive and Packaging Drive Drive and Packaging

kg (lb) kg (lb) kg (lb) kg (lb)

202 (445.3) 280 (617.3) 152 (335.1) 230 (507.1)

215 (474.0) 293 (646.0) 165 (363.8) 243 (535.7)1K3

Table 6 - Frame D - 575V AC Input Drive Weights

Drive w/ND
Rating Code

810

1K0

1K2 215 (474.0) 293 (646.0) 165 (363.8) 243 (535.7)

1K3 222 (489.4) 300 (661.4) 172 (379.2) 250 (551.2)

1K6 241 (531.3) 319 (703.3) 191 (421.1) 269 (593.0)

Weight - Regenerative Drives Weight - Non-regenerative Drives

Drive Drive and Packaging Drive Drive and Packaging

kg (lb) kg (lb) kg (lb) kg (lb)

198 (436.5) 276 (608.5) 148 (326.3) 226 (498.2)

Table 7 - Frame D - 690V AC Input Drive Weights

Drive w/ND
Rating Code

678

791

904 200 (440.9) 278 (612.9) 150 (330.7) 228 (502.7)

1K0 202 (445.3) 280 (617.3)

1K1

1K2 165 (363.8) 243 (535.7)

1K4

1K5 191 (421.1) 269 (593.0)

24 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014

Weight - Regenerative Drives Weight - Non-regenerative Drives

Drive Drive and Packaging D rive Drive and Packaging

kg (lb) kg (lb) kg (lb) kg (lb)

198 (436.5) 276 (608.5) 148 (326.3) 226 (498.2)

215 (474.0) 293 (646.0)

241 (531.3) 319 (703.3)

152 (335.1) 230 (507.1)

172 (379.2) 250 (551.2)

Installation and Wiring Chapter 1

IMPORTANT

Lifting PowerFlex DC Drives

The dimensions and weights that are specified in Ta b l e 3 on page 21 and

Ta b l e 4

the proper equipment to lift and hold the weight of the drive while mounting.

…Ta b l e 7 on page 24 must be considered when mounting the device. Use

ATTENTION: To guard against possible personal injury or equipment damage...

• Inspect all lifting hardware for proper attachment before lifting the drive.

• Do Not let any part of the drive or lift mechanism to contact electrically charged

conductors or components.

• Do Not subject the drive to high rates of acceleration or deceleration while
transporting to the mounting location or when lifting.

• Do Not let personnel or their limbs be directly underneath the drive when it is
being lifted and mounted.

Mount Frame C and D Drives

All lifting equipment and components (hooks, bolts, lifts, slings, and chains)
must have a minimum

lifting capacity of 453.6 kg (1,000 lb).

Verify that all mounting screws are properly tightened before and after drive
operation.

1. Verify the hole pattern on the panel on which you intend to mount the
drive. See Figure 4

2. Install the mounting hardware:

❏ For frame C drives, insert, but do not tighten, a bolt in one of the top

holes in the panel. The bolt must be fully threaded into the panel
before hanging the drive.

❏ For Frame D drives, insert, but do not tighten, the six bolts for the top

mounting flange on the drive into the panel. The bolts must be fully
threaded into the panel before hanging the drive.

3. To limit the pull in forces on the drive, the lifting devices that are
connected to the hooks must be long enough to make the angle between
the chain or cable and a vertical line that extends up from the flange center
less than 45° angle as illustrated in Figure 7

26

.

❏ For frame C drives, insert the properly sized and rated lifting hooks

into the holes on the lifting flanges at the top of the drive. See Figure 7
on page 26

❏ For frame D drives, insert the properly sized lifting rod into the holes

on the lifting flanges at the top of the drive. See Figure 8

on page 21 or 22 on page 22.

on page 26 or Figure 8 on page

.

on page 26.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 25

Chapter 1 Installation and Wiring

Lifting flanges

Must be less
than 45° angle

Must be less
than 45° angle

Figure 7 - Lift Frame C Drives

Figure 8 - Lift Frame D Drives

4. Lift the drive into place onto the bolts that are installed in the panel.

5. Install the remaining bolts into the panel. Tighten M8 bolts to a minimum

torque of 15 N
N

•m (221.2 lb•in).

26 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014

•m (132.7 lb•in) and M10 bolts to a minimum torque of 25

Installation and Wiring Chapter 1

Remove the Drive Covers

Some protective covers must be removed to provide access to the power and I/O
terminals on the drive. Remove the upper cover only to install an optional
communication adapter or service the drive. See Installing a Communication
Adapter on page 367

for information.

Frame A Drives

You must remove both the lower protective cover and the power terminal cover
on frame A drives to access the power terminals.

Remove the Power Terminal Cover

• Remove the two screws as shown here and slide the cover down and off the
chassis.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 27

Chapter 1 Installation and Wiring

STS

PORT

MOD

NET A

NET B

Frame B Shown

Remove the Lower Protective Cover

• Remove the two screws as shown here and, while gently lifting along the
top edge, slide the cover down and off the chassis.

Frame B and C Drives

1. Loosen, but do not remove, the two screws that secure the bottom cover.

2. Slide the cover down until the screw heads align with the key holes and lift

the cover off the chassis.

28 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014

Installation and Wiring Chapter 1

Frame D

1. For any protective cover, loosen, but do not remove, the hexalobular head
screws that secure the cover to the drive frame.

2. Slide the cover up until the screw heads align with the key holes and lift the
cover off the chassis. The top and bottom most covers are also secured with
screws at the top and bottom of the drive, respectively.

Isolation Transformers / Line Reactors

When connecting the drive directly to the main distribution system, an isolation
transformer or 3…5% impedance AC line reactor must be used to guard against
system disturbance. If the isolation transformer provides the required 3…5%
impedance, a line reactor is not required.

See Isolation Transformers on page 256
transformers.

See AC Input Line Reactors and AC Input Contactors on page 254
recommended AC line reactors. The type of line reactor that is used depends
upon the following:

• Current absorbed by the AC input

• AC input voltage

• Relative short circuit voltage

• AC input frequency

for a list of recommended isolation

for a list of

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 29

Chapter 1 Installation and Wiring

Contactors

When an AC input contactor is used, the IEC AC1 rating of the contactor must
be equal to the rated thermal (RMS) current value at the main input of the drive.

Drive configurations for AC or DC contactors, with or without a dynamic brake
(DB), are as follows (see Typical Power Wiring Diagrams on page 45

for

examples):

• When only an AC contactor is used:

❏ Set parameter 1391

(1)

value)

[ContactorControl] to 1 “AC Cntctr” (default

❏ Set one [Relay Out x Sel] parameter and one [Digital Inx Sel]

parameter to “Contactor” (default value for parameters 1392
Out 1 Sel] and 140

[Digital In8 Sel])

[Relay

• When only a DC contactor is used:

❏ Set parameter 1391

[ContactorControl] to 3 “DC Cntctr”

(1)

❏ Set one [Relay Out x Sel] parameter and one [Digital Inx Sel] to

“Contactor” (default value for parameters 1392

[Digital In8 Sel])

140

[Relay Out 1 Sel] and

• When an AC contactor and dynamic brake contactor are used:

❏ Set parameter 1391

[ContactorControl] to “AC Cntctr+DB”

❏ Set one [Relay Out x Sel] parameter (1392 [Relay Out 1 Sel] or 629

[Relay Out 2 Sel]) to “Contactor” and the other relay output to
“ContactorDB”

❏ Set one [Digital Inx Sel] parameter to “Contactor” (default value for

parameter 140

[Digital In8 Sel])

• When a DC contactor and dynamic brake contactor are used:

❏ Set parameter 1391

[ContactorControl] to “DC Cntctr+DB”

❏ Set one [Relay Out x Sel] parameter (1392 [Relay Out 1 Sel] or 629

[Relay Out 2 Sel]) to “Contactor” and the other relay output to
“ContactorDB”

❏ Set one [Digital Inx Sel] parameter to “Contactor” (default value for

parameter 140

[Digital In8 Sel])

• When a contactor is NOT used:

❏ Set parameter 1391

[ContactorControl] to “None”

(1)

❏ Do NOT set either [Relay Out x Sel] parameter to “Contactor” or

“ContactorDB”

(1)

(1)

❏ Do NOT set any [Digital Inx Sel] parameter to “Contactor”

(1) Par 1391 [ContactorControl] is contained in the “Advanced” parameter configuration group. See How Parameters are Organized on

page 115

for more information.

30 Rockwell Automation Publication 20P-UM001K-EN-P - July 2014