Rockwell Automation 23P User Manual

Download

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

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

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

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

Ind. Cont.

Eq. 31KF

Listed

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

Drive

Code Type

20P PowerFlex DC

Motor Operation

Code Type

2 Two Quadrant Operation

4 Four Quadrant Operation

Input Type

Code Type

1 6 Pulse

Enclosure

Code Enclosure Rating

Conform.

Coat

A IP20, NEMA/UL Type Open

Input Voltage

Code Voltage

B 230V AC

D 460V AC

E 600V AC

F 690V AC

Yes

Not available for 230V AC input drives.

Use this code for 400V AC input applications.

7.5

100

125

150

200

250

300

400

500

600

700

800

900

1.5

2.2

3.7

5.5

7.5

18.5

112

149

187

224

298

373

447

552

597

671

4.1

100

129

167

207

250

330

412

495

667

830

996

1162

1238

1494

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

7.5

100

125

150

200

250

300

1.2

1.5

2.2

3.7

5.5

7.5

18.5

112

149

186

224

110

146

180

218

265

360

434

521

700

875

1050

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

100

200

300

400

500

600

800

900

1000

1250

149

224

298

373

447

597

671

746

932

67.5

101.3

135

270

405

540

675

810

1080

1215

1350

1668

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

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

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

Field Supply

Code Type

R Single-Phase Regulated

Packaging/Documentation

Code Shipping Carton User Manual

A Yes Yes

HIM

Code Operator Interface

0 Blank Cover

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

I/O Options

Code Control

None (8 - 24V DC Digital Inputs,

4 Digital Outputs, 3 Analog Inputs,

and 2 Analog Outputs are Standard)

Communication Options

Code Description

N None

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)

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

Chapter 1

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

50 mm

(0.4 in.)

(0.4 in.) (2.0 in.)

10 mm (0.4 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

STS

PORT

MOD

NET A

NET B

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

STS

PORT

MOD

NET A

NET B

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)

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

A1 C

STS

PORT

MOD

NET A

NET B

310.0 (12.2)

155.0 (6.1)

113.0 (4.5)

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

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)

(1.0)

(0.6)

44.5

(1.8)

(2.4)

(1.2)

(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)

(0.4)

44.5 25

(1.8)

(1.0)

(0.6)

146

(5.7)60(2.4)

(1.2)

269.5 (10.6)

454.5 (18.0)

1250

(49.2)

(1.3)

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)

(0.6)

10.5 (0.4)

(0.4)

10.5 (0.4)

127

(5.0)

531

(21.0)

541

(21.3)

(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)

(3.7)

Dimensions are shown in mm and (in.)

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

❏ 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

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)

❏ 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

Installation and Wiring Chapter 1

When operating a drive with firmware version 1.006 in field weakening mode with a DC contactor or inverting fault device that is installed in the armature circuit, see Field Weakening Mode Configuration (v1.006) on page 285

AC Input Contactors

See AC Input Line Reactors and AC Input Contactors on page 254 for a list of recommended AC input contactors.

DC Output Contactors

A DC output contactor can be used to connect the output of the armature circuit to the DC motor. If a DC output contactor is used, an AC input contactor is not needed.

See Dynamic Brake Resistor Kits and DC Output Contactors on page 258 list of recommended DC output contactors.

for a

Dynamic Brake Resistors

See Dynamic Brake Resistor Kits and DC Output Contactors on page 258 for a list of recommended dynamic brake resistor kits.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 31

Chapter 1 Installation and Wiring

PE1/

STS

PORT MOD NET A NET B

Earth

All wires (including motor ground) must be connected inside the motor terminal box.

Transformer Safety Ground

AC Mai ns Supp ly

AC Line Reactor

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 electrical codes. Periodically check the integrity of all ground connections.

For installations within a cabinet, use a safety ground point or ground bus bar connected directly to building steel. Ground all circuits, including the AC input ground conductor, independently and directly to this point/bar.

For installations in distribution systems that have ungrounded or high impedance, neutral connections or systems, see Grounding for Installations in an Ungrounded or High-Impedance, Neutral Ground, or System on page 34

ATTENTION: To comply with the essential requirements of the CE Low Voltage Directive 2006/95/EC, PowerFlex DC drives cannot be powered from a cornerearthed (TN with one phase earthed) supply system. When operating PowerFlex DC drives from an IT or impedance-earthed supply system, only temporary operation is permitted after an earth fault is detected in the power system.

Figure 9 - Typical Grounding

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

Installation and Wiring Chapter 1

Safety Ground (PE)

The safety ground for the drive that is required by code. This point must be connected to adjacent building steel (girder, joist), a floor ground rod, or bus bar (see Figure 9 industrial safety regulations and electrical codes.

on page 32). Ground points must comply with national and local

Power Feeder

Each power feeder from the substation transformer to the drive must be provided with properly sized ground cables. Bond the conduit or cable armor to the substation ground at both ends. Each transformer enclosure or frame must be bonded to ground at a minimum of two locations.

Encoder/Resolver Ground Connections

If used, the encoder or resolver ground connections must be routed in grounded steel conduit. The conduit must be grounded at both ends. The encoder/resolver cable shield must be connected to the shield ground on the drive side. Do not connect the encoder/resolver cable shield to ground on the motor side.

Tachometer Ground Connections

If used, ground connections must be routed in grounded steel conduit. The conduit must be grounded at both ends. Ground the cable shield at the drive end by using only the shield clamps on the grounded metal plate that supports the control board (see Figure 58

on page 81 for shield clamp location).

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 33

Chapter 1 Installation and Wiring

Grounding for Installations in an Ungrounded or HighImpedance, Neutral Ground, or System

The PowerFlex DC drive was designed to work in distribution systems where the isolation transformer Wye neutral is connected to earth ground. PowerFlex DC drives are not designed to work in distribution systems that have ungrounded or high-impedance, neutral connections, or systems that have a phase that is referenced to earth. Symmetrical incoming power is required for correct drive operation.

The use of a grounded Wye neutral is highly recommended to prevent common mode rejection problems with the feedback measurement circuits in the drive. Possible drive damage can occur because of inaccurate feedback measurements of the incoming AC voltage, armature voltage, or field current.

If the PowerFlex DC drive is installed in a system with an ungrounded Wye neutral or with an impedance ground connection, see Ta b l e 8 necessary drive modifications that are required for proper installation.

on page 35 for the

Power Distribution

Figure 10 - Delta/Wye with Grounded Wye Neutral

Rockwell Automation strongly recommends the use of grounded neutral systems for the following reasons:

• Controlled path for common mode noise current

• Consistent line to ground voltage reference, which minimizes insulation

stress

• Accommodation for system-surge protection schemes

Figure 11 - Ungrounded Secondary

Grounding the transformer secondary is essential to the safety of personnel and safe operation of the drive. A floating secondary can allow dangerously high voltages occur between the chassis of the drive and the internal power structure components.

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

Installation and Wiring Chapter 1

T01 T04 T02 T05

T03

T06

T1 T4 T2 T5 T3 T6

78 79 35 36 75 76 U2 V2

TR2 TR1

XSW

XSW1

Note: Remove the front covers from the drive to access the pulse transformer circuit board. See page 27

for instructions.

Figure 12 - High-impedance Ground

Grounding the Wye secondary neutral through a resistor is an acceptable method of grounding. In this case, in a short-circuited secondary condition, none of the output phases to ground will exceed the normal line to line voltage. The resistor is often used to detect ground current by monitoring the associated voltage drop.

Table 8 - Drive Modifications to Support Ungrounded Wye Neutral or Impedance Grounded Connections

Frame Circuit Board Jumper/Connection Figure to see for Details

A Pulse transformer (FIR1-xx-xx) Remove jumper S9 Figure 13

B Pulse transformer (FIR2-xx-xx) Remove jumper S9 Figure 1 4 on page 36

C Pulse transformer (FIR3-xx-xx) Remove jumper S9 Figu re 15 on page 36

Transient noise filter (FIL-31), 200V…500V AC drives

Disconnect the filter board yellow/ green (ground) wire from the PE connection on the drive chassis

Transient noise filter (FIL-57,

Remove jumper S1 Figure 17 on page 37

FIL-69), 575V…690V AC drives

D Pulse transformer (FIR-D-xx-xx) Remove capacitors C121 and C122 Figure 18 on page 38

Overvoltage clipping (CFSF-xxx) Remove jumper S1 Figure 1 9 on page 38

on page 35

Figure 1 6 on page 37

Figure 13 - Frame A Pulse Transformer Circuit Board S9 Jumper Location

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 35

Chapter 1 Installation and Wiring

XCD_IO

XTA

78 79 35 36 75 76 U2 V2

T01

T02

T03

T06

T04

T05

TR1

TR2

Note: Remove the front covers from the drive to access the pulse transformer circuit board. See page 28

for instructions.

XCD_IO

TO5

TO3

TO6

TO2

KGO2

KGO5

KGO3 KGO6

T5 T3

KG2

KG5

KG3

KG6

XCT

PE1

XCD

XUVW

XTA

TR3

XCD_IO

PE1

XCD

Note: The pulse transformer circuit board is behind the control EMI shield, near the top of the drive. See page 28 for instructions on removing the front covers from the drive and page 68

for instructions on moving the control EMI shield.

Figure 14 - Frame B Pulse Transformer Circuit Board S9 Jumper Location

Figure 15 - Frame C Pulse Transformer Circuit Board S9 Jumper Location

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

Installation and Wiring Chapter 1

STS

PORT

MOD

NET A

NET B

Yellow/Green ( ground) wire

Transient noise filter board

Note: Remove the front covers from the drive to access the transient noise filter circuit board. See page 28 for instructions. The transient noise filter board is between terminals C and D below the control EMI shield.

Note: Remove the front covers from the drive to access the transient noise filter circuit board. See page 28 for instructions. The transient noise filter board is on the left side of the control EMI shield.

Figure 16 - Frame C Transient Noise Filter Circuit Board (FIL-31), 200V…500V AC Input Drives, Ground Wire Location

Figure 17 - Frame C Transient Noise Filter Circuit Board (FIL-57, FIL-69), 575V…690V AC Input Drives, S1 Jumper Location

P4 P3

F1 F2 F3

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 37

Chapter 1 Installation and Wiring

Note: The pulse transformer circuit board is behind the top and bottom control panel covers. See page 29 for instructions on removing the covers from the drive.

90°

Note: The overvoltage clipping circuit board is behind the control panel on the upper left side of the drive chassis. See illustration below, left for instructions on opening the control panel.

Overvoltage clipping board location inside drive

1. Disconnect the DPI cable from the HIM (if present).

2. Insert a flathead screwdriver into the holes in the right side of the protective covers on the drive and turn the latch 90° counter-clockwise.

3. Open the control panel to the left.

XP1

XP2

KG1

KG4

KG2

KG5

KG3

KG6

Figure 18 - Frame D Pulse Transformer Circuit Board S1 Jumper Location

XSW1

XSW

TR2

C122 C121

TR1

KG01

T01

KG04

T04

KG02

T02

KG05

T05

KG03

T03

KG06

T06

XTA

XCD_IO

XCD

X4 X5 X6

XCT

XUVW

XUV

C122 C121

XCD_IO

XSPF

XUVW

78 79 35 36 75 76 81 82 U2 V2

Figure 19 - Frame D Overvoltage Clipping Circuit Board S1 Jumper Location

XCD

F31 F21 F11

X1UVW1

XUVW

XCD

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

Installation and Wiring Chapter 1

CE Conformity

Compliance with the Low Voltage Directive and Electromagnetic Compatibility Directive has been demonstrated by using harmonized European Norm (EN) standards, references to which have been published in the Official Journal of the European Communities. PowerFlex DC drives comply with the EN standards listed here when installed according to this User Manual.

EU Declarations of Conformity are available online at:

www.rockwellautomation.com/products/certification/ce/

Low Voltage Directive

• EN 50178 Electronic equipment for use in power installations.

EMC Directive

• EN 61800-3 Adjustable speed electrical power drive systems Part 3: EMC product standard including specific test methods.

General Considerations

• For CE compliance, the drive installation must satisfy requirements that are related to both EN 50178 and EN 61800-3 provided in this document.

• PowerFlex DC drives comply with the EMC requirements of EN 61800-3 when installed according to good EMC practices and the instructions that are provided in this document. However, many factors can influence the EMC compliance of an entire machine or installation, and compliance of the drive itself does not ensure compliance of all applications.

• PowerFlex DC drives are not intended to be used on public low-voltage networks that supply domestic premises. Without additional mitigation, radio frequency interference is expected if used on such a network. The installer is responsible to take measures such as supplementary line filters and enclosures to prevent interference, in addition to the installation requirements of this document.

• PowerFlex DC drives generate notching and harmonic current emissions on the AC supply system. When operated on a public low-voltage network, it is the responsibility of the installer or user to be sure that applicable requirements of the distribution network operator have been met.

ATTENTION: PowerFlex DC drives can produce DC current in the protective earthing conductor, which can reduce the ability of residual current-operated protective devices (RCD) or residual current-operated monitoring devices (RCM), of type A or AC, to provide protection for other equipment in the installation.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 39

Chapter 1 Installation and Wiring

Installation Requirements Related to the Low Voltage Directive

• PowerFlex DC drives are designed to be CE compliant only if they are NOT connected to “corner-earthed” supply systems where one of the three phases of the supply system has been earthed.

• PowerFlex DC drives are compliant with the CE LV Directive when used at altitudes no greater than 2,000 m (6,562 ft).

• PowerFlex DC drives provided in enclosure type IP20 must be installed in a pollution degree 1 or 2 environment to be compliant with the CE LV Directive. Characteristics of the different pollution degree ratings are provided on page 41

• PowerFlex DC drives can produce leakage current in the protective earthing conductor that exceeds 3.5 mA AC or 10 mA DC. The minimum size of the protective earthing (ground) conductor that is used in the application must comply with local safety regulations for high-protective earthing conductor current equipment.

• Frame D PowerFlex DC drives must be installed in a supplementary enclosure that provides protection from electric shock to be compliant with the CE LV Directive.

Drive Frame Catalog Number

Frame A 20Px1Ax4P1… 20Px1Ax129

Frame B 20Px1Ax167… 20Px1Ax412

Frame C 20Px1Ax495… 20Px1Ax667 Frame D 20Px1Ax… 20Px1Ax

Installation Requirements Related to EN 61800-3 and the EMC Directive

• The drive must be earthed (grounded) as described in this User Manual.

• PowerFlex DC drives require the use of an external EMC filter to comply with the EMC Directive and emission limits of EN 61800-3: 2004. PowerFlex DC drives have been tested and verified for compliance to the emission limits of EN 61800-3: 2004 by using only the specific input filters and motor cable lengths that are identified in Ta b l e 9 page 45

Table 9 - Standards and Limits for EMC Input Filters

Standard / Limits (Compliance with any of the limits in the Pollution Degree Ratings According to EN 61 800-5-1 table on page 41 satisfies RF emission requirements for the EMC Directive)

EN61800-3 Category C1 EN61000-6-3 CISPR 11 Group 1 Class B

Compliance may be possible with supplementary mitigation (Consult fac tory)

More Stringent Limits Less St ringent Limits

EN61800-3 Category C2 EN61000-6-4 CISPR11 Group 1 Class A…P <

Compliance may be possible with supplementary mitigation (Consult factory)

RF line filter required 50 m motor cable limit

Compliance may be possible with supplementary mitigation (Consult factory)

for more installation information.

CISPR11 Group 1

20kVA

(1)

Class A…P > 20kVA

RF line filter required 50 m motor cable limit

Compliance may be possible with supplementary mitigation (Consult factory)

. See Typical Power Wiring Diagrams on

EN61800-3 Category C3…I <

100A

(2)

(1)

RF line filter required 50 m motor cable limit

EN61800-3 Category C3…I > 100A

(2)

RF line filter required 50 m motor cable limit

(1)

RF line filter required 50 m motor cable limit

(1)

RF line filter required 50 m motor cable limit

(3)

RF line filter required 50 m motor cable limit

(2)

(1)

(4)

(1) RF 3xxx-MHU EMC filter from Rasmi Electronics Ltd. xxx designates filter current rating. Rasmi EMC filters are manufactured by Rasmi Electronics Ltd. Refer to the manufacturer’s literature for details. (2) RF 3xxx-SIEI EMC filter from Rasmi Electronics Ltd. xxx designates filter current rating. Rasmi EMC filters are manufactured by Rasmi Elec tronics Ltd. Refer to the manufacturer’s literature for details. (3) EPCOS B84143B Type S081 EMC filter from EPCOS AG. EPCOS EMC filters are manufactured by EPCOS AG. Refer to the manufacturer’s literature for details.

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

Installation and Wiring Chapter 1

IMPORTANT

Use of EMC filters other than those listed in Ta bl e 9 on page page 40 must be verified in the application. Additional filters are listed in Alternate EMC Filters on page 261

• Output power wiring to the motor must employ cable with a braided shield providing 75% or greater coverage, or the cables must be housed in metal conduit, or equivalent shielding must be provided. Continuous shielding must be provided from the drive enclosure to the motor enclosure. Both ends of the motor cable shield (or conduit) must terminate with a low-impedance connection to earth.

• At the motor end, the motor cable shield or conduit must terminate in a shielded connector that must be properly installed in an earthed motor wiring box attached to the motor. The motor wiring box cover must be installed and earthed.

• All control (I/O) and signal wiring to the drive must use cable with a braided shield providing 75% or greater coverage, or the cables must be housed in metal conduit, or equivalent shielding must be provided. When shielded cable is used, terminate only the drive end of the cable shield to earth with a low-impedance connection.

• Motor cabling must be separated from control and signal wiring wherever possible.

• Maximum motor cable length must not exceed the maximum length indicated in the table on page 40

for compliance with radio frequency

emission limits for the specific standard and installation environment.

Pollution Degree Ratings According to EN 61800-5-1

Pollution Degree

1 No pollution or only dry, non-conductive pollution occurs. The pollution has no influence.

2 Normally, only non-conductive pollution occurs. Occasionally, however, a temporary conductivity caused

3 Conductive pollution or dry non-conductive pollution occurs, which becomes conductive due to

4 The pollution generates persistent conductivity caused, for example by conduc tive dust or rain or snow.

Description

by condensation is to be expected, when the drive is out of operation.

condensation, which is to be expected.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 41

Chapter 1 Installation and Wiring

Power Circuit Protection

Control Power Circuit Protection

It is recommended that you install frame A and B PowerFlex DC drives with fast acting fuses to protect the armature converter on the AC input and DC output (for four quadrant drives only) sides. Internally mounted fuses for armature converter protection are provided with frame C and D PowerFlex DC drives. See Drive Power Circuit Protection on page 236

for a list of replacement fuses and

general fuse locations.

The 115V / 230V AC control circuit power input terminals U2 and V2 are required to be short circuit protected. This protection can be provided by using standard time delay fuses or a circuit breaker. The time delay fuses or circuit breaker must be selected to survive the short circuit available current of the feeder source for this circuit and the inrush current of the drive’s power supply.

Size the fuses or circuit breaker to primarily protect the wiring from the fuses or circuit breaker connections to terminals U2 and V2, and not nuisance trip or blow from the inrush current.

The table below lists the input current characteristics of the control power.

Table 10 - Control Power Protection

Frame Control Power Supply

Circuit Board ID / Revision Power Rated input current Inrush input current

115V AC 230V AC 115V AC 230V AC

A & D SW1-31 / H & below 60 W 1 A 0.5 A 20 A 10 A

SW1-31 / I & above 80 W 1 A 0.5 A 6 A 10 A

B SW2-32 / H & below 110 W 1.2 A 0.7 A 15 A 7.5 A

SW2-32 / I & above 90 W 1.2 A 0.6 A 6 A 10 A

C SW3-32 / H & below 110 W 1.2 A 0.7 A 15 A 7.5 A

SW3-32 / I & above 90 W 1.2 A 0.6 A 6 A 10 A

Provide a control power input supply from a power source that is stabilized and buffered from the power system transients. The control power of many drives can be fed from a single source, as long as proper distribution protection is provided.

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

Installation and Wiring Chapter 1

Minimum Spacing Between Classes Steel Conduit/Tray

Cable and Wiring Recommendations

Category Wiring

Power 1 AC Power (600V Or

Control 5 115V AC/ DC Logic Relay Lo gic/PLC I/O

Signal (Process)

Signal (Comm. )

Signal Definition Signal Example Cable Type 1 2/3/4 5/6 7/8 9/10/11 See Cable

Class

Greater)

2AC Power (Less Than

600V) 3 DC Power DC Motor Armature 4 DC Power DC Motor Field

115V AC Power Power Supplies,

6 24V AC/DC Logic PLC I/O 7 Analog Signals, DC

Supplies

Digital (Low Speed) TTL 8 Digital (High Sp eed) I/O, Encoder, Resolver,

9 Serial Communication RS-232 (20-COMM-R),

11 Seri al Communication

(Greater Than 20k Baud)

2.3kV 3/ph AC Lines Per NEC & Local

460V 3/ph AC Lines 3/9 in.

Motor Thermostat

Instruments

Reference/Feedback Signal, 5 To 24V DC

Count Pulse Tach

42 2 To Term ina ls /pr in ter s

PLC Remote I/O, PLC Data Highway

Use the following cable and spacing recommendations for all drives sizes:

Minimum Spacing Between Classes - Steel Conduit/Tray

Notes, on

Codes

Shielded Cable – Belden 8735, 8737, 8404

Shielded Cable – Belden 9728, 9730

Shielded Cable – Belden RS-232 – 8735, 8737 RS422 – 9729, 9730

Twi nax ial Cab le – Belden 9463, A-B 1770-CD

03/9 in.

(76/229 mm)

3/9 in.

(76/229 mm)

3/18 in.

(76/457 mm)

03/6 in.

3/6 in.

(76/152 mm)

3/12 in.

(76/305 mm)

See Note 6 1/3 in.

3/9 in.

(76/229 mm)

(76/152 mm)

03/9 in.

3/9 in.

(76/229 mm)

3/18 in.

(76/457 mm)

3/12 in.

(76/305 mm)

(76/229 mm)

01/3 in.

(25/76 mm)

See Note 6 1/2/5

(25/76 mm)

0–

Spacing

page 44

2/3/4/5

Example:

Spacing relationship between 480V AC incoming power leads and 24V DC logic leads:

• 480V AC leads are Class 2; 24V DC leads are Class 6

• For separate steel conduits, the conduits must be 3 inches (76 mm) apart

• In a cable tray, the two groups of leads are to be 6 inches (152 mm) apart

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 43

Chapter 1 Installation and Wiring

Cable Spacing Notes:

1. Both outgoing and return current carrying conductors are to be pulled in same conduit or laid adjacent in tray.

2. Cables of the following classes can be grouped together.

a. Class 1; Equal to or above 601V.

b. Classes 2, 3 and 4 may have their respective circuits pulled in the same conduit or layered in the same tray.

c. Classes 5 and 6 may have their respective circuits pulled in the same conduit or layered in the same tray. Note:

Bundle may not exceed conditions of NEC 310.

d. Classes 7 and 8 may have their respective circuits pulled in the same conduit or layered in the same tray. Note:

Encoder cables run in a bundle may experience some amount of EMI coupling. The circuit application may dictate separate spacing.

e. Classes 9, 10 and 11 may have their respective circuits pulled in the same conduit or layered in the same tray.

Communication cables run in a bundle may experience some amount of EMI coupling and corresponding communication faults. The application may dictate separate spacing.

3. All wires of class 7 through 11 MUST be shielded per the recommendations.

4. In cable trays, steel separators are advisable between the class groupings.

5. If conduit is used, it must be continuous and composed of magnetic steel.

6. Spacing of communication cables classes 2…6 is:

Conduit Spacing: Through Air:

115V – 25 mm (1 in.) 115V – 51 mm (2 in.)

230V – 38 mm (1.5 in.) 230V – 01.5 mm (4 in.)

380/575V – 76 mm (3 in.) 380/575V – 203 mm (8 in.)

575V– proportional to 152 mm (6 in.) per 1000V. 575V – proportional to 305 mm (12 in.) per 1000V.

Power Wiring

AC Input Voltages

PowerFlex DC drives are rated for the following AC input voltages @ 50/60 Hz ±5%:

Mains Circuit (Terminals U, V, W)

• 230V ±10%, 3Ph

• 400V ±10%, 3Ph

• 440V ±10%, 3Ph

• 460V ±10%, 3Ph

• 480V ±10%, 3Ph

• 575V ±10%, 3Ph

• 690V ±10%, 3Ph

Field Circuit (Terminals U1, V1)

• 230V ±10%, 1Ph

• 400V ±10%, 1Ph

• 460V ±10%, 1Ph

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

Installation and Wiring Chapter 1

Control Circuit (Terminals U2, V2)

• 115V ±15% or 230V ±15%, 1Ph

Note: For frame B and C drives only, a jumper must be placed between terminals SA-SB on the switching power supply circuit board for the control circuits to work with 115V AC input. See Figure 47 on frame B drives and Figure 48

on page 68 for terminal block location on frame

on page 68 for terminal block location

C drives.

DC Output Voltages

The output voltages below take into account an AC input undervoltage within the stated tolerance limits and a voltage drop of 4% due to an AC input line reactor. It is the same as the rated armature voltage suggested for the connected motor.

Armature Circuit

AC Input Voltage DC Output Armature Voltage (Terminals C & D)

(Terminals U, V, W) Two Quadrant Drive Four Quadrant Drive

230V ±10%, 3Ph 260V 240V

400V ±10%, 3Ph 470V 420V

440V ±10%, 3Ph 530V 460V

460V ±10%, 3Ph 560V 480V

480V ±10%, 3Ph 580V 500V

575V ±10%, 3Ph 680V 600V

690V ±10%, 3Ph 810V 720V

Field Circuit

AC Input Voltage DC Output Field Voltage

(Terminals U1 & V1) Fixed Field Adjustable Field

230V ±10%, 1Ph 200V 200V

400V ±10%, 1Ph 310V 310V

460V ±10%, 1Ph 360V 360V

(1) The max fiel d voltage is equal to 0.85 x AC input line voltage

(1)

(Terminals C1 & D1)

Typical Power Wiring Diagrams

Figure 20 on page 46…Figure 22 on page 48 represent recommended power

wiring configurations for standard PowerFlex DC drive installations. For SAR installations, see Appendix H

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 45

Chapter 1 Installation and Wiring

Aux

PowerFlex DC

Drive

(9)

(4)

(on I/O TB4)

(5)

(+24V on I/O TB2)

(N.O. Relay)

M1 AC Contactor

Control

Board P/S

115V or 230V AC

Input Source

(1, 12)

(9)

13 14

FS2

(6)

FS2

(6)

FS1

(3)

FS1

(3)

FS1

(3)

FU1

FV1

Field Power Terminal Block

Control Power / Relay Outputs

Terminal Block

Armature Volt.

Fdbk. Term. Blk.

(7)

1A1

1A2

Line Reactor

(2)

Isolation

Transformer

(2)

Lockable

Installation

Disconnect

(1)

Safety Ground

AC Input

Voltage

460 VAC

Max. or

230 VAC

Min.

(11)

EMC Filter

(if used)

(14)

Fan Power Terminal Block - Series B ,Frame D Drives Only

(10)

400...460V AC

Input Source

(12)

See footnote

(13)

FUFUFU

U3V3W3

Fan Power Terminal Block - Frame C and Series A, Frame D Drives Only

(10)

230V AC

Input Source

(12)

See footnote

(13)

See Power Wiring Diagrams Notes on page 49 for footnotes.

Figure 20 - Power Wiring with AC Input Contactor

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

Aux

See Power Wiring Diagrams Notes on page 49 for footnotes.

Installation and Wiring Chapter 1

Figure 21 - Power Wiring with DC Output Contactor

(6)

FS2

13 14

(6)

FS2

(14)

(10)

(on I/O TB4)

(4)

(+24V on I/O TB2)

(5)

PowerFlex DC

(3)

FS1

(2)

Line Reactor

(N.O. Relay)

M1 DC

Drive

(3)

FS1

FU1

FV1

AC Input

Voltage

Control

Board P/S

Control Power / Relay Outputs

Terminal Block

(9)

(1)

(9)

(14)

Fan Power Terminal Block - Frame C and Series A, Frame D Drives Only

(13)

Fan Power Terminal Block - Series B ,Frame D Drives Only

U3V3W3

FUFUFU

(13)

Contactor

1A1

Armature Volt.

1A2

Fdbk. Term. Blk.

Field Power Terminal Block

460 VAC

(3)

Max. or

(11)

Min.

230 VAC

FS1

EMC Filter

(2)

Isolation

Lockable

Installation

(if used)

Transformer

Disconnect

See footnote

(1, 12)

115V or 230V AC

Safety Ground

3 Phas e

AC l ine

Input Source

(12)

230V AC

Input Source

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 47

See footnote

400...460V AC

(12)

Input Source

Chapter 1 Installation and Wiring

PowerFlex DC

Drive

(9)

(4)

(on I/O TB4)

(5)

(+24V - on I/O TB2)

Control

Board P/ S

(9)

FS1

(3)

FS1

(3)

FU1

FV1

Field Power Terminal Block

Control Power / Relay Ouputs

Terminal Block

Armature Volt.

Fdbk. Term. Blk.

1A1

1A2

Line Reactor

(2)

(1)

Aux

(N.O. Relay)

M1 DC Cntctr

13 14

FS2

(6)

FS2

(6)

Res.

(8)

FS1

(3)

Isolation

Transformer

(2)

Safety Ground

AC Input

Voltage

460 VAC

Max. or

230 VAC

Min.

(11)

3 Phas e

AC line

Lockable

Installation

Disconnect

115V or 230V AC

Input Source

(1, 12)

EMC Filter

(if used)

(14)

Fan Power Terminal Block - Series B ,Frame D Drives Only

(10)

400...460V AC

Input Source

(12)

See footnote

(13)

FUFUFU

U3V3W3

Fan Power Terminal Block - Frame C and Series A, Frame D Drives Only

(10)

230V AC

Input Source

(12)

See footnote

(13)

See Power Wiring Diagrams Notes on page 49 for footnotes.

Figure 22 - Power Wiring with DC Output/Dynamic Braking Contactor and a Dynamic Brake

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

Installation and Wiring Chapter 1

Power Wiring Diagrams Notes

1. For frame B and C drives only, a jumper is required between terminals SA and SB for 115V AC control input power. See Control Circuit Input Power on page Control Circuit Input Power for more information.

2. An Isolation Transformer and/or 3…5% impedance Line Reactor is required. If the Isolation Transformer provides the required 3…5% impedance, a Line Reactor is not required. See AC Input Line Reactors and AC Input Contactors on page 254

for recommendations. It is recommended that the isolation

256

transformer has a grounded Wye secondary neutral. If the PowerFlex DC drive is installed in a system with an ungrounded Wye neutral or with an impedance ground connection, see Grounding for Installations in an Ungrounded or High-Impedance, Neutral Ground, or System on page 34 for more information.

3. AC input fuses for the armature converter are customer supplied for frame A and B drives and are internally mounted on frame C and D drives. See Drive Power Circuit Protection on page 236

4. Par 140 [Digital In8 Sel] set to 31 “Contactor.”

and Isolation Transformers on page

for fuse recommendations.

5. If the +24V internal power supply is used, terminal 18 (24V common) must be jumpered to terminal 35 (digital input common).

6. Customer supplied armature output fuses are required on four quadrant and are recommended on two quadrant Frame A and B drives. See Drive Power Circuit Protection on page 236

for fuse recommendations.

7. Optional armature voltage feedback sensing not required with AC contactor.

8. The “Enable” input must be removed to perform a dynamic braking stop.

9. Par 1391 [ContactorControl] = 1 “AC Cntctr” and Par 1392 [Relay Out

1 Sel] = 25 “Contactor”. Important: Terminal 35 and 36 are on the Control Power / Relay Outputs Terminal block, NOT the I/O terminal blocks. See Figure 37

on page 63…Figure 41 on page 65.

10. Only frame C and D drives require an external power supply for the heatsink cooling fan(s). See Frame C Heatsink Cooling Fan Specifications on page 69 page 71

11. See Field Converter Connections on page 56

and Frame D, Series B Heatsink Cooling Fan Specifications on

for more information.

12. If sourced from the main 3 phase AC input, the connections must be taken from the primary side of the isolation transformer or line reactor (clean power).

13. Fuses or a circuit breaker. See Frame C Heatsink Cooling Fan Specifications on page 69 Specifications on page 71

and Frame D, Series B Heatsink Cooling Fan for detailed information.

14. For frames B, C, and D drives, a pilot relay is required for the contactor coil.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 49

Chapter 1 Installation and Wiring

IMPORTANT

UCV DWPE

Front View

ATTENTION: Do not operate the drive with the power terminal cover removed.

Operating the drive with the power terminal cover removed may result in a hazardous condition that could cause personal injury and/or equipment damage.

Note: Front view of drive shown with bottom protective and power terminal covers removed. See Remove the Drive Covers on page 27

for information on removing the drive covers.

Armature Converter Connections

Terminals Description

U, V, W Three phase AC input to the armature converter

C, D DC output to the motor armature

PE Safety ground

Table 11 - Armature and Safety Ground (PE) Terminal Specifications

Drive Current Rating Code

230V 460V 575 690

Frame

A 7P0…055 4P1…052 – – U, V, W, C, D, PE

073…110 073…129 – – Terminal Block 12 (106)

B All All All – U, V, W, C, D 10 25 (221)

C All All All All U, V, W, C, D 10 25 (221)

D All All All All U, V, W, C, D, PE 12 45 (398.2)

(1)

Terminals Wire Size and Type Terminal Bolt

See Cable and Wiring

PE 8 15 (132.75)

Recommendations on

page 43

Size (mm)

5 6 (53)

Tightening Tor que

N•m (lb•in)

(1) Se e Standard Drive Catalog Number Explanation on page 15, positions 8, 9 and 10 for corresponding drive HP rating, armature amp rating and

field amp rating.

Certain frame D drives require the use of a terminal adapter kit(s) for terminals U, V, W, C and D. See Terminal Adapter Kits for Frame D Drives on page 264 details.

Figure 23 - Frame A Armature Converter Terminal Locations

for

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

Figure 24 - Frame B Armature Converter Terminal Locations

UCVDW

Bottom View

Front View

Figure 25 - Frame C Armature Converter Terminal Locations

Installation and Wiring Chapter 1

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 51

Chapter 1 Installation and Wiring

Top of Dr ive

UV W

Bottom of Drive PE C D

Important: Certain frame D drives require the use of a terminal adapter kit(s) for terminals

U, V, W, C and D. See Terminal Adapter Kits for Frame D Drives on page 264

for details.

Figure 26 - Frame D Armature Converter Terminal Locations

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

Installation and Wiring Chapter 1

IMPORTANT

Armature Voltage Feedback Connections

When a DC output contactor or inverting fault breaker or fuse is used with the drive, the Armature Voltage Feedback terminals can be used to monitor the armature voltage at the motor regardless of the state of the contactor or inverting fault device. When this terminal block is not connected to the motor armature terminals, the terminals must be jumpered (as described in the Ta b l e 1 2 armature voltage feedback is monitored internally within the drive. In this case, when a DC contactor is used with the drive, a speed feedback device is not used, and the contactor opens, the drive will no longer receive the armature voltage feedback signal.

By default, these terminals are jumpered - 1A1 to A1 and 1A2 to A2. If these terminals are not wired to the motor terminals, the jumpers must be installed.

Note that this terminal block is not present on drives shipped from the factory prior to those with version 3.001 firmware installed. However, new pulse transformer circuit boards shipped as replacement parts from the factory contain this terminal block and can be used with any firmware version.

) and the

Table 12 - Armature Voltage Feedback Terminal Jumper Positions

Terminals Description

1A1 Jumpered to A1 when internal armature voltage feedback is used.

Not used when A1 is connected to motor terminal A1.

A1 Voltage feedback from motor terminal A1.

1A2 Jumpered to A2 when internal armature voltage feedback is used.

Not used when A2 is connected to motor terminal A2.

A2 Voltage feedback from motor terminal A2.

Table 13 - Armature Voltage Feedback Circuit Wire Sizes and Terminal Specifications

Frame Terminals Wire Size and Type

A, B & C 1A1, A1, 1A2, A2 24…10 AWG/kcmils 0.5…0.6 (4.4…5.3)

D 22…8 AWG/kcmils 0.8…1.6 (7.1…14.2)

(1) Wire with an insulation rating of 600V or greater is recommended. See Cable and Wiring

Recommendations on page 43

for cable spacing information.

(1)

Tightening Torque N•m (lb•in)

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 53

Chapter 1 Installation and Wiring

Bottom of View of Drives

Shown with terminals jumpered for internal armature voltage feedback.

Drive with no fan

Drive with fan

Top of Drive

Shown with terminals jumpered for internal armature voltage feedback.

Figure 27 - Frame A Armature Voltage Feedback Circuit Terminal Block Location

Figure 28 - Frame B Armature Voltage Feedback Circuit Terminal Block Location

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

Installation and Wiring Chapter 1

1A1

(C)

A1 1A2

(D)

1A1

(C)

A1 1A2

(D)

1A1

(C)

A1 1A2

(D)

1A1

(C)

A1 1A2

(D)

Bottom of Drive

Bottom of Drive, Left Side

Shown with terminals jumpered for internal armature voltage feedback.

Figure 29 - Frame C Armature Voltage Feedback Circuit Terminal Block Location

Figure 30 - Frame D Armature Voltage Feedback Circuit Terminal Block Location

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 55

Chapter 1 Installation and Wiring

Field Converter Connections

For 575V and 690V AC input drives only, a step down transformer with either a 230 VAC secondary, for a 150V motor field, or 460 VAC, for a 300V motor field, is required before the input to the field control circuit (terminals U1, V1).

Also, If the rated voltage of the DC motor field is not compatible with the field DC output voltage of the drive, an external field control transformer must be used. Refer to the following example for transformer selection information.

Example: 10 Hp, 240V Armature, 17.2A, 240V Field, 2.0 A motor

a. The field control transformer must have a 230V primary, a 460V

secondary, and be single-phase, 60 Hz

b. kVA = 2 A x 460VAC x 1.5 = 1.38 kVA (1.5 kVA is closest)

In addition, the following configuration must be completed in the PowerFlex DC drive:

c. Control board DIP switch S14 must be set to select a value of 2 A. d. Parameter 374 [Drv Fld Brdg Cur] must be programmed to match DIP

switch S14 = “2.”

e. Parameter 280 [Nom Mtr Fld Amps] must be programmed to the rated

motor nameplate field current “2.”

Field Converter Terminal Designations

Terminals Description

U1, V1 Single phase AC input to the field circuit

C1, D1 DC output to the motor field

Table 14 - Frames A…C Field Circuit Wire Sizes and Terminal Specifications

(1)

Terminals Wire Size and Type

U1, V1, C1, D1 24…10 AWG/kcmils 0.5…0.8 (4.4…7.1)

(1) See Cable and Wiring Recommendations on page 43 for more information.

Tightening Torque N•m (lb•in)

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

Installation and Wiring Chapter 1

Bottom of Drive

Table 15 - Frame D Field Circuit Wire Sizes and Terminal Specifications

Drive Current Rating Code

(1)

Terminals Wire Size

230V 460V 575V 690V

875 830 810 678

1K0 996 1K0 791

–– 1K2904

–– 1K31K0

–– 1K6–

U1, V1, C1, D1

– 1K1 – 1K1

– 1K3 – 1K2

– 1K4 – 1K4

–––1K5

(1) See Standard Drive Catalog Number Explanation on page 15, positions 8, 9 and 10 for corresponding drive HP rating, armature amp

rating and field amp rating.

(2) See Cable and Wiring Recommendations on page 43 for more information on wire types.

(2)

6 AWG

2 AWG

Tightening Torque N•m (lb•in)

4.0 (35.4)

Figure 31 - Frame A Field Circuit Terminal Block Location

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 57

Chapter 1 Installation and Wiring

Top of Dr ive

V1U1C1D1

Front of Drive

Figure 32 - Frame B Field Circuit Terminal Block Location

Figure 33 - 230V/460V AC Input Frame C Field Circuit Terminal Block Location

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

Installation and Wiring Chapter 1

Top, Left Side of Drive

Bottom of Drive, Left SideTop of Drive Shown with control cover removed.

Remove control cover to a ccess terminals.

AC input for field is at top of fuse holder (marked FU1, FV1)

C1 D1

Wire r outing hole

Cable clamp

Figure 34 - 575V/690V AC Input Frame C Field Circuit Terminal Block Location

Figure 35 - Frame D Field Circuit Terminal Block Location

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 59

Chapter 1 Installation and Wiring

Note: This illustration is an example configuration for a drive with a field supply amp rating of 20 A and a motor with a rated field current less than or equal to 17 A.

Field Current Configuration

DIP switch S14 on the drive’s control circuit board is factory set to the minimum field current rating based on the drive size (see DIP Switch and Jumper Settings on page 75

for S14 location). The configuration of this switch must be changed to be greater than or equal to the rated field current specified on the motor nameplate (unless a permanent magnet motor is being used) or possible motor damage may result. In addition, the value selected with switch S14 must be entered in parameter 374 drive is commissioned (see Drive Start Up on page 91

[Drv Fld Brdg Cur] in the control software when the

ATTENTION: DIP switch S14 must be set to a value that is greater than or equal to the rated field current specified on the motor nameplate or possible motor damage may result.

Set DIP Switch S14 to the Correct Value

Complete the following steps to set switch S14 to the correct field current value.

1. Locate and record the frame size and field supply amp rating listed on the drive data nameplate (see Drive Nameplate Data on page 12

for location).

2. Locate and record the rated field current value listed on the motor data nameplate.

3. For frame A, B, and C drives:

• Use Ta b l e 1 6

on page 61 to set switch S14 to be the equivalent or next

higher value as compared to the motor’s rated field current.

For frame D drives:

• Use Ta b l e 1 7

or Ta b l e 1 8 on page 61 to set switch S14 to be the equivalent or next higher value as compared to motor’s rated field current.

Figure 36 - Example DIP Switch S14 Configuration

3 4

DIP

Note : The configuration of switch S14 is not required if the motor’s field control is provided via an external source (for example, a permanent magnet motor), however, it is recommended that the switch settings be completed as described above.

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

Installation and Wiring Chapter 1

Table 16 - DIP Switch S14 Field Current Configuration Settings Frames A, B and C Drives

Switch ohms > 168.5 333.3 182 36.4 845 1668 3333 – Equivalent

Field Current Scale S14-1 S14-2 S14-3 S14-4 S14-5 S14-6 S14-7 S14-8 Ohms

1 A OFF OFF OFF OFF OFF ON

2 A OFF OFF OFF OFF ON OFF 845

3 A OFF OFF OFF OFF ON ON 560.9

5 A OFF ON OFF OFF OFF OFF 333.3

10 A ON OFF OFF OFF OFF OFF 168.5

13 A ON OFF OFF OFF ON ON 129.6

17 A OFF ON ON OFF ON ON 97.3

20 A ON OFF ON OFF OFF ON 83.1

Not used

(OFF)

Resistance

1668

Table 17 - DIP Switch S14 Field Current Configuration Settings for Frame D Drives and Standalone Regulators with a Rated Field Supply of 40 A

Switch ohms > 168.5 333.3 182 36.4 845 1668 3333 – Equivalent

Field Current Scale S14-1 S14-2 S14-3 S14-4 S14-5 S14-6 S14-7 S14-8 Ohm

1 A OFF OFF OFF OFF OFF OFF ON

2 A OFF OFF OFF OFF OFF ON OFF 1668

4 A OFF OFF OFF OFF ON OFF OFF 845

6 A OFF OFF OFF OFF ON ON OFF 560.9

10 A OFF ON OFF OFF OFF OFF OFF 333.3

20 A ON OFF OFF OFF OFF OFF OFF 168.5

30 A ON ON OFF OFF OFF OFF OFF 111.9

40 A ON OFF ON OFF OFF ON OFF 83.1

Resistance

3333

Not

used

(OFF)

Table 18 - DIP Switch S14 Field Current Configuration Settings for Frame D Drives and Standalone Regulators with a Rated Field Supply of 70 A

Switch ohms > 168.5 333.3 182 36.4 845 1668 3333 – Equivalent

Field Current Scale S14-1 S14-2 S14-3 S14-4 S14-5 S14-6 S14-7 S14-8 Ohm

1 A OFF OFF OFF OFF OFF ON OFF

5 A OFF ON OFF OFF OFF OFF OFF 333.3

10 A ON OFF OFF OFF OFF OFF OFF 168.5

20 A ON OFF ON OFF OFF ON OFF 83.1

50 A OFF ON OFF ON OFF OFF OFF 32.8

70 A ONONONONOFFOFFOFF 23.9

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 61

Resistance

1668

Not

used

(OFF)

Chapter 1 Installation and Wiring

Relay Outputs

Terminals 35 and 36 and 75 and 76 are N.O. relay outputs. The relay output between terminals 35 and 36 is configured with parameter 1392 [Relay Out 1 Sel]. The relay output between terminals 75 and 76 is configured with parameter 629

[Relay Out 2 Sel]. See Contactors on page 30 for more

information.

Terminals Description Maximum

Voltag e

35, 36 Normally open contact. Configured with parameter 1392 [Relay Out 1

Sel], set to 25 “Contactor” by default.

250V AC 1 A75, 76 Normally open contact. Configured with parameter 629 [Relay Out 2

Sel], set to 5 “Ready” by default.

78, 79 Motor thermistor (PTC) or thermal switch connections

Maximum Current

Note: If external contactor coil current ratings are greater than 1 amp, use an interposing relay between the drive relay 1 or relay 2 output and the contactor coil.

Thermistors and Thermal Switches

To detect motor overheating and protect the motor from overloading, an external, user-supplied thermistor (PTC) or thermal switch must be connected to terminals 78 and 79. The drive’s response to a motor over temperature fault is configured in parameter 365 switch is not used, a 1 k 79 (installed at the factory). Follow the appropriate instructions below when installing a thermal sensor.

[OverTemp Flt Cfg]. If a thermistor or thermal

Ω resistor must be connected between terminals 78 and

Thermistors (PTC)

PTC thermistors fitted in the motor can be connected directly to the drive via terminals 78 and 79. In this case the 1 k terminals 78 and 79.

Thermal Switches (Klixon®) in the Motor Windings

“Klixon” type temperature-dependent contacts can disconnect the drive from the motor via an external control or can be configured as an external fault by using a digital input on drive. They can also be connected to terminals 78 and 79 to indicate a drive “Motor Over Temp” fault (F16), though this is not recommended due to the noise sensitivity of the current threshold circuitry. If a thermal switch is used a 1 k and one of the terminals.

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

Ω resistor must be placed in series between the switch

Ω resistor is not required between

Installation and Wiring Chapter 1

78 79 35 36 75 76

Note: Terminals 78 and 79 shown with 1 kΩ resistor in place of temperature sensor.

78 79 35 36 75 76

Table 19 - Relay Outputs and Thermistor/Thermal Switch Wire Sizes and Specifications

Signal Type Terminals Wire Size and Type

Flexible (mm2)

Relay Outputs 35 & 36, 75 & 76

Thermistor and Thermal Switches

(1) See Cable and Wiring Recommendations on page 43 for more information.

78 & 79

0.140…1.500 0.140…1.500 26…14 0.5 (4.4)

(1)

Multi-core (mm2)

AWG

Tightening Tor que

N•m (lb•in)

Figure 37 - Frame A Relay and Thermistor/Thermal Switch Terminal Block Locations

Figure 38 - Frame B Relay and Thermistor/Thermal Switch Terminal Block Locations

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 63

Chapter 1 Installation and Wiring

35 36 75 76 78 79

Lower, right side of the control pan.

78 79 35 36 75 76

Figure 39 - 230V/460C AC Input Frame C Relay and Thermistor/Thermal Switch Terminal Block Locations

Figure 40 - 575V/690C AC Input Frame C Relay and Thermistor/Thermal Switch Terminal Block Locations

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

Installation and Wiring Chapter 1

Control pan, to the left of the HIM cradle.

78 79 35 36 75 76

Figure 41 - Frame D Relay and Thermistor/Thermal Switch Terminal Block Locations

Control Circuit Input Power

The control circuit must be powered by a clean, external 230V AC or 115V AC single phase power supply. For frame B and C drives only between terminals SA and SB for 115V AC control input power. For frame B drive SA-SB terminal block location, see Figure 47 SA-SB terminal block location, see Figure 47

on page 68.

Note: If the SA-SB terminal block is not configured for the correct input voltage, “No Fault” (F0) displays on the HIM, if installed.

Terminals Description

U2, V2 Single phase AC power for the control circuits

PE Safety ground (on frame C drive terminal blocks only)

Table 20 - Control Circuit Wire Sizes and Terminal Specifications

Terminals Wire Size and Type

Flexible

)

(mm

U2, V2 0.14…1.5 0.14…2.5 26…14 0.5 (4.4)

PE 2.5…10 2.5…10 12…8 2.0 (18.0)

(1) See Cable and Wiring Recommendations on page 43 for more information.

(1)

Multi-core (mm2)

AWG

Tightening Torque N•m (lb•in)

, a jumper is required

on page 68. For frame C drive

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 65

Chapter 1 Installation and Wiring

U2 V2

U2 V2 PE

Figure 42 - Frame A Control Circuit Terminal Block Location

Figure 43 - Frame B Control Circuit Terminal Block Location

Figure 44 - 230V/460V AC Input Frame C Control Circuit Terminal Block Location

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

Installation and Wiring Chapter 1

Lower, right side of the control pan.

U2 V2

Figure 45 - 575V/690V AC Input Frame C Control Circuit Terminal Block Location

Figure 46 - Frame D Control Circuit Terminal Block Location

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 67

Chapter 1 Installation and Wiring

Front of Drive

Top, right side of drive.

Switching power supply board SA-SB terminals Back of control board EMI shield

The SA-SB terminal block is on the switching power supply circuit board on the back of the control board EMI shield.

1. Remove the top protective cover from the drive.

3. Loosen captive screws.

2. Disconnect cables XFCD and XR.

4. Lower control board EMI shield and disconnect cable XSW from switching power supply board (see above).

XSW connector

To access the SA-SB terminal block:

3. Loosen captive screws.

Figure 47 - SA-SB Terminal Block Location on Frame B Drives

Figure 48 - SA-SB Terminal Block Location on Frame C Drives

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

Installation and Wiring Chapter 1

Frame C Heatsink Cooling Fan Specifications

Frame C drives require an external 230V AC power supply for the heatsink cooling fans. If sourced from the main 3 phase AC input, the power supply connections must be taken from the primary side of the installed Isolation Transformer or Line Reactor (clean power).

In addition, the fan power input terminals U3 and V3 are required to be short circuit protected. This protection can be provided by using a circuit breaker or fuses.

• If a circuit breaker is used, it must be rated for the short circuit available current of the feeder source for this circuit and the inrush current of the fan. Size the circuit breaker to primarily protect the wiring from the circuit breaker connections to terminals U3 and V3, and not nuisance trip or blow from the inrush current.

• If fuses are used, they must be rated for either 230V AC, 2.0 Amps (slow blow).

Table 21 - Frame C Heatsink Cooling Fans Terminal Designations

Terminal Description Maximum Voltage Maximum Current

Single-phase AC input power for cooling fans. 230V AC 1 A

Table 22 - Frame C Heatsink Cooling Fans Wire Sizes and Terminal Specifications

Terminals Wire Size and Type

Flexible (mm2)

U3, V3 0.14…1.5 0.14…2.5 26…16 0.4 (3.5)

(1) See Cable and Wiring Recommendations on page 43 for more information.

(1)

Multi-core (mm2)

AWG

Tightening Torque N•m (lb•in)

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 69

Chapter 1 Installation and Wiring

U3 V3

Lower, right side of the control pan.

U3 V3

Figure 49 - 230V/460V AC Input Frame C Heatsink Cooling Fan Terminal Block Location

Figure 50 - 575V/690V AC Input Frame C Heatsink Cooling Fan Terminal Block Location

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

Installation and Wiring Chapter 1

IMPORTANT

Airflow Direction

Frame D, Series B Heatsink Cooling Fan Specifications

The Frame D, series B drive cooling fan requires three phase (50/60 Hz), 400…460V AC input power. If sourced from the main 3 phase AC input, the power supply connections must be taken from the primary side of the installed isolation transformer or line reactor (clean power).

When connecting the fan power wiring, verify that the airflow exits through the top of the drive. If the airflow is incorrect, switch the leads on terminals U3 and V3.

The cooling fan power input terminals U3, V3 and W3 are required to be short circuit protected. This protection can be provided by using a circuit breaker or fuses.

• If a circuit breaker is used, it must be rated for the short circuit available current of the feeder source for this circuit and the inrush current of the fan. Size the circuit breaker to primarily protect the wiring from the circuit breaker connections to terminals U3, V3, and W3, and not nuisance trip or blow from the inrush current.

• If fuses are used, they must be rated for either 400V AC, 2.5 Amps (slow blow), or 460V AC, 3.15 Amps (slow blow).

A normally closed (N.C.) contact wired to terminals 31 and 32 of the fan terminal block can be connected to an external device to provide indication of a fan supply failure or can be wired to drive digital input terminals configured for 14 “Aux Fault” (via Pars 133…144).

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 71

Chapter 1 Installation and Wiring

Top View

of Drive

Series B terminal block shown

Table 23 - Frame D, Series B Heatsink Cooling Fan Terminal Designations

Terminal Block Terminal Description AC Voltage Max Current

U3 Three-phase AC input

power connections

400…460V AC (50/60 Hz)

1.5 A

PE Safety ground – –

31 Normally clo sed contact 250V AC 1 A

Table 24 - Frame D Heatsink Cooling Fan Signal Wire Sizes and Terminal Specifications

Terminals Wire Size and Type

Flexible (mm2) Multi-core (mm2)AWG

U3, V3, W3, 31, 32, PE 0.14…1.5 0.14…2.5 28…12 0.5…0.6 (4.4…5.3)

(1) See Cable and Wiring Recommendations on page 43 for more information.

(1)

Tightening Torque N•m (lb•in)

Figure 51 - Frame D Heatsink Cooling Fan Terminal Block Location

U3 V3 W3 PE 31 32

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

Installation and Wiring Chapter 1

81 82

Frame C and D Armature Fuse Signal Terminals

Terminals 81 and 82 on frame C and D drives are connected to the indicating switch mounted on each of the internal armature circuit protection fuses. These terminals can be connected to an external device to provide indication that the fuses have opened. Alternatively, terminals 81 and 82 can be wired to drive digital input terminals configured for 64 “Invert Flt” (via Pars 133…144).

Table 25 - Armature Fuse Signal Terminal Designations

Terminal Description Maximum Voltage Maximum Current

Table 26 - Armature Fuse Signal Wire Size and Terminal Specifications

Terminals Wire Size and Type

81, 82 0.14…1.5 0.14…2.5 26…16 0.4 (3.5)

Internal armature fuse intervention signal. 250V AC 1 A

Flexible

(mm

)

(1)

Multi-core (mm2)

AWG

Tightening Torque N•m (lb•in)

(1) See Cable and Wiring Recommendations on page 43 for more information.

Figure 52 - 230V/460V AC Input Frame C Internal Armature Fuse Signal Terminal Block Location

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 73

Chapter 1 Installation and Wiring

Lower, right side of the control pan.

81 82

Figure 53 - 575V/690V AC Input Frame C Internal Armature Fuse Signal Terminal Block Location

Figure 54 - Frame D Internal Armature Fuse Signal Terminal Block Location

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

Installation and Wiring Chapter 1

See Tab le 27 on page 76 for descriptions corresponding to the ID numbers shown here.

Do not use - for

engineering use only.

DIP Switch and Jumper Settings

DIP switches and jumpers on the control circuit board are used to configure the drive for flashing firmware to the control board EEPROM, the appropriate speed feedback device settings, analog input signals and minimum field current.

Figure 55 - Control Circuit Board DIP Switch and Jumper Locations

S15

1 2 3 4 5 6 7 8

RST

ACT RUN

PWR

S18

S12

DEBUG

- A B C +

1 2 3 4 5 6 7 8

S21

ENC_5 ENC_12

S14

S20

A+ A- B+ B- Z+ Z- COM +V

S11

S10

21 22 23 24 25 26 27 28 29 30

1 2 3 4 5 6 7 8 9 10

31 32 33 34 35 36 37 38 39 40

11 12 13 14 15 16 17 18 19 20

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 75

Chapter 1 Installation and Wiring

= ON

= OFF

= ON

= OFF

= 12-15V

= 5V

ENC_5 ENC_12

Table 27 - Control Circuit Board Jumper and DIP Switch Settings

ID Jumper/

Function Factory Default Example

Switch

S0 For factory boot flashing only. Leave set to the factory setting. Jumper Off

Jumper On Firmware boot

Jumper Off Normal function

S1 For factory boot flashing only. Leave set to the factory setting. Jumper Off

Jumper On Write firmware boot code

Jumper Off Boot code on flash is protected

S2 Not used. Leave set to the factory setting. Jumper Off

S3 For factory boot flashing only. Leave set to the factory setting. Jumper Off

Jumper On Reset

Jumper Off Normal function

S4 Configures the input voltage of the DC analog tachometer.

See Tab le 2 8

on page 77 for configuration.

90V –

S9 Configures the input signal of Analog Input 1 (terminals 1 and 2): On

Off Position 0…20 mA / 4…20 mA

On Position 0…10V / ±10V

Note: The input signal type must also be programmed accordingly in Par 71 [Anlg In1 Config].

S10 Configures the input signal of Analog Input 2 (terminal 3 and 4): On

Off Position 0…20 mA / 4…20 mA

On Position 0…10V / ±10V

Note: The input signal type must also be programmed accordingly in Par 76 [Anlg In2 Config].

S11 Configures the input signal of Analog Input 3 (terminals 5 and 6): On

Off Position 0…20 mA / 4…20 mA

On Position 0…10V / ±10V

Note: The input signal type must also be programmed accordingly in Par 81 [Anlg In3 Config].

S12 Not used. Leave set to the factory setting. Off –

= ON

= OFF

=OFF

S14 Field current resistors setting, see Field Current Configuration on page 60

The value selected with switch S14 must be entered in Par 374 [Drv Fld Brdg Cur] when the drive is commissioned. For permanent magnet motor applications, leave set to the factory default settings.

S15 Configuration of the control circuit board to the appropriate drive size. Leave set to the factory setting, unless the

control board has been supplied as a spare part. See DIP Switch S15 Settings on page 77 based on drive current rating code.

S18 Not used. Leave set to the factory setting. Off –

S20 Monitoring of the Z channel of the Digital Encoder on connector XE2: On

Off Position Z channel monitored

On Position Z channel not monitored

The S20 setting must match the value selected in Par 652 [Encoder Err Chk]. For example, if S20 = “Off”, then Par 652 = 1 “Enabled”.

S21 Encoder power supply voltage and input selection:

This switch setting determines both the power supply (input) and feedback level (output) voltage of the connected encoder. Note: When control power is supplied to the drive, the appropriate LED lights to indicate the selection of the switch.

ENC_5 +5 V encoder (+2.5…5.4V input range)

ENC_12 +12…15 V encoder (+5.4V…15.2V input range)

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

for switch configuration

Minimum field current rating based on drive size.

Armature current based on drive size.

12…5 V

–

Installation and Wiring Chapter 1

Note: The illustration depicts the DIP switch settings for 90V (factory default).

3 4

DIP

Note: Illustration for example only.

DIP Switch S4 Settings

ATTENTION: The drive can overspeed if DIP switch S4 is set incorrectly or the tachometer is wired incorrectly. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

DIP switch S4 must be configured to be greater than or equal to the maximum DC input voltage. Maximum DC Input Voltage = (Tach Volts/1000 rpm) x Par 45 [Max Ref Speed] x 1.1. See Drive Reference and Feedback Scaling on page

for details on programming speed feedback values.

279

Figure 56 - DC Analog Tachometer DIP Switch S4 Example

3 4

DIP

Table 28 - DC Analog Tachometer DIP Switch S4 Configuration

Maximum DC Input Voltage

22V ON ON ON ON

45V ONONONOFF

90V ON ON OFF OFF

180V ON OFF OFF OFF

300V OFF OFF OFF OFF

S4-1 S4-8

S4-2 S4-7

S4-3 S4-6

S4-4 S4-5

DIP Switch S15 Settings

DIP Switch S15 is configured for the appropriate drive size at the factory. Do not change the settings unless you are installing a replacement control board.

Figure 57 - Drive Size DIP Switch S15 Example

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 77

Chapter 1 Installation and Wiring

Table 29 - Drives with 230V Input - DIP Switch S15 Configuration

Frame Drive Current

A 7P0 ON OFF OFF OFF OFF OFF OFF OFF

B 146 ON ON OFF ON OFF OFF OFF OF F

C 521 ON OFF OFF OFF ON OFF OFF OFF

Rating Code

9P0 OFF ON OFF OFF OFF OFF OFF OFF

012 ON ON OFF OFF OFF OFF OFF OFF

020 OFF OFF ON OFF OFF OFF OFF OFF

029 ON OFF ON OFF OFF OFF OFF OF F

038 OFF ON ON OFF OFF OFF OFF OFF

055 ON ON ON OFF OFF OFF OFF OFF

073 OFF OFF OFF ON OFF OFF OFF OFF

093 ON OFF OFF ON OFF OFF OFF OFF

110 OFF ON OFF ON OFF OFF OFF OFF

180 OFF OFF ON ON OFF OFF OFF OFF

218 ON OFF ON ON OFF OFF OFF OFF

265 OFF ON ON ON OFF OFF OFF OFF

360 ON ON ON ON OFF OFF OFF OFF

434 OFF OFF OFF OFF ON OFF OFF OFF

700 OFF ON OFF OFF ON OFF OFF OFF

875 ON ON OFF OFF ON OFF OFF OFF

1K0 OFF OFF ON OFF ON OFF OFF OFF

S15-1 S15-2 S15-3 S15-4 S15-5 S15-6 S15-7 S15-8

Table 30 - Drives with 460V Input - DIP Switch S15 Configuration

Frame Drive Current

Rating Code

4P1 OFF OFF OFF OFF OFF OFF ON OFF

6P0 ON OFF OFF OFF OFF OFF ON OFF

010 OFF ON OFF OFF OFF OFF ON OFF

014 ON ON OFF OFF OF F OFF ON OFF

019 OFF OFF ON OFF OFF OFF ON OFF

027 ON OFF ON OFF OFF OFF ON OFF

035 OFF ON ON OFF OFF OFF ON OFF

045 ON ON ON OFF OFF OFF ON OFF

052 OFF OFF OFF ON OFF OFF ON OFF

073 ON OFF OFF ON OFF OFF ON OFF

086 OFF ON OFF ON OFF OFF ON OFF

100 ON ON OFF ON OFF OFF ON OFF

129 OFF OFF ON ON OF F OFF ON OFF

S15-1 S15-2 S15-3 S15-4 S15-5 S15-6 S15-7 S15-8

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

Installation and Wiring Chapter 1

Frame Drive Current

B 167 ON OFF ON ON OFF OFF ON OFF

C 495 OFF ON OFF OFF ON OFF ON OFF

Rating Code

207 OFF ON ON ON OFF OFF ON OFF

250 ONON ON ONOFFOFFONOFF

330 OFF OFF OFF OFF ON OFF ON OFF

412 ON OFF OFF OFF ON OFF ON OFF

667 ON ON OFF OFF ON OFF ON OFF

830 OFF OFF ON OFF ON OFF ON OFF

996 ON OFF ON OFF ON OFF ON OFF

1K1 OFF ON ON OFF ON OFF ON OFF

1K3 ON ON ON OFF ON OFF ON OFF

1K4 OFF OFF OFF ON ON OFF ON OFF

S15-1 S15-2 S15-3 S15-4 S15-5 S15-6 S15-7 S15-8

Table 31 - Drives with 575V Input - DIP Switch S15 Configuration

Fram e

Drive Current

Rating Code

C 540 ON OFF ON OFF OFF OFF OFF ON

D 810 ON ON ON OFF OFF OFF OFF ON

067 OFF OFF OFF OFF OFF OFF OFF ON

101 ON OFF OFF OFF OFF OFF OFF ON

135 OFF ON OFF OFF OFF OFF OFF ON

270 ON O N OFF OFF OFF OFF OFF ON

405 OFF OFF ON OFF OFF OFF OFF ON

675 OFF ON ON OF F OFF OFF OFF ON

1K0 OFF OFF OFF ON OFF OFF OFF ON

1K2 ON OFF OFF ON OFF OFF OFF ON

1K3 OFF ON OFF ON OFF OFF OFF ON

1K6 ON ON OFF ON OFF OFF OFF ON

S15-1 S15-2 S15-3 S15-4 S15-5 S15-6 S15-7 S15-8

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 79

Chapter 1 Installation and Wiring

IMPORTANT

Table 32 - Drives with 690V Input - DIP Switch S15 Configuration

I/O Wiring

Frame Drive Current

Rating Code

C 452 OFF OFF OFF OFF OFF OFF ON ON

565 ON OFF OFF OFF OFF OFF ON ON

D 678 OFF ON OFF OFF OFF OFF ON ON

791 ON ON OFF OFF OFF OFF ON ON

904 ON OFF ON OFF OFF OFF ON ON

1K0 OFF ON ON OFF OFF OFF ON ON

1K1 ON ON ON OFF OFF OFF ON ON

1K2 OFF OFF OFF ON OFF OFF ON ON

1K4 OFF ON OFF ON OFF OFF ON ON

1K5 ON ON OFF ON OFF OFF ON ON

S15-1 S15-2 S15-3 S15-4 S15-5 S15-6 S15-7 S15-8

Observe the following points when installing I/O wiring:

• Use copper wire only.

• Wire with an insulation rating of 600V or greater is recommended.

I/O terminals labeled “(–)” or “Common” are not referenced to earth ground and are designed to greatly reduce common mode interference. Grounding these terminals can cause signal noise.

ATTENTION: Configuring an analog input for current operation and driving it from a voltage source could cause component damage. Verify proper switch configuration prior to applying input signals. See DIP Switch and Jumper Settings on page 75

ATTENTION: Hazard of personal injury or equipment damage exists when bipolar input sources are used. Noise and drift in sensitive input circuits can cause unpredictable changes in motor speed and direction. Use speed command parameters to help reduce input source sensitivity.

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

Installation and Wiring Chapter 1

Terminal Block 3

Ter mina l Bl ock 1

Ter minal Bloc k 4

Terminal Block 2

I/O Signal and Control Wiring

Eight (8) digital inputs, four (4) digital outputs, three (3) analog inputs, and two (2) analog outputs are available on the standard I/O terminal blocks provided with the drive. One digital input (1…8) must be configured for “Enable” (digital input 4 by default = “Enable”). See I/O and Control Wire Routing on page 89 for information on routing I/O signal and control wires.

Additional digital and analog I/O is available when the optional I/O expansion circuit board is installed. See Appendix F

for more information. Also, you can use the optional 115V AC Converter circuit board to convert 115V AC digital input signals to 24V DC digital inputs signals to interface with the digital inputs on the standard I/O terminal blocks. See Appendix G

Table 33 - Analog I/O, Digital I/O and DC Analog Tachometer Wire Sizes and Terminal Specifications

Signal Type Terminal Block

(Terminals)

Analog and Digital I/O TB1…4 (1…40) DC Analog Tach M3 (+ and –)

Wire Size and Type Flexible (mm

0.140…1.500 0.140…1.500 26…16 0.4 (3.5)

for more information.

(1)

)Multi-core

(mm2)

AWG

Tightening Tor que

N•m (lb•in)

(1) See Cable and Wiring Recommendations on page 43 for more information.

Figure 58 - I/O Terminal Block Locations

Table 34 - I/O Terminal Block 1 Designations

No. Signal Description Factory Default Config. Parameter

1 Analog Input 1 (+) Isolated 2 Analog Input 1 (–) 3 Analog Input 2 (+) 0 “Off” 75 [Anlg In2 Sel] 4 Analog Input 2 (–) 5 Analog Input 3 (+) 0 “Off” 80 [Anlg In3 Sel] 6 Analog Input 3 (–)

7 +10V Pot Reference 2…5 kΩ load. Max ±10V, 10 mA. – – 8 –10V Pot Reference 9 Pot Common For (+) and (–) 10V pot references. – – 10 PE ground PE ground to drive chassis. – –

(1)

, bipolar, differential

±10V / 0…20 mA or 4…20 mA. Important: 0…20 mA or 4…20 mA operation

requires that switch S9, S10, and S11 on the control board be in the “Off” position. Drive damage may occur if the switch is not in the correct position based on the type of input signal. See Ta bl e 2 7

on page 54.

Max ±10V, Max 0.25 mA.

1 “Speed Ref A” 70 [Anlg In1 Sel]

(1) D ifferential Isolation - External source must be maintained at less than 160V with respect to PE. Input provides high common mode immunity.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 81

Chapter 1 Installation and Wiring

Table 35 - I/O Terminal Block 2 Designations

No. Signal Description Factory Default Config. Parameter

11 Internal 0V (Gnd) – – 12 Digital Input 1 Max +30V, 15V/3.2 mA, 24V/5 mA, 13 Digital Input 2 3 “Start” 134 [Digital In2 Sel] 14 Digital Input 3 11 “Jog” 135 [Digital In3 Sel] 15 Digital Input 4 1 “Enable” 136 [Digital In4 Sel]

and 30V/6.4 mA. A digital input (1…8) must be configured for

“Enable”.

16 Digital Input Common Important: When the internal +24V DC supply

2 “Stop/CF” 133 [Digital In1 Sel]

–– (terminal 19) is used for digital inputs 1…4, you must connect the digital input common (terminal

16) to the +24V supply common (terminal 18).

17 Not Used – – 18 24V Supply Common Common for the internal power supply. – – 19 Internal +24V DC Supply Drive supplied +24V DC I/O power.

–– Max. +20…30V, 200 mA Note: The total current draw is the sum of encoder

power, digital outputs and any other loads connected to terminal 19.

20 PE ground PE ground to drive chassis. – –

Table 36 - I/O Terminal Block 3 Designations

No. Signal Description Factory

Default

21 Analog Output 1 (+) Max. ±10V, 5 mA. 12 “Motor Speed” 66 [Anlg Out1 Sel] 22 Analog Output 1 (–) 23 Analog Output 2 (+) 13 “Motor Curr” 67 [Anlg Out2 Sel] 24 Analog Output 2 (–) 25 Digital Output Common – – 26 Digital Output 1 Max. +30V, 50 mA 5 “Ready” 145 [Digital Out1 Sel] 27 Digital Output 2 9 “Fault” 146 [Digital Out2 Sel] 28 Digital Output 3 2 “Spd Thresh” 147 [Digital Out3 Sel] 29 Digital Output 4 4 “CurrentLimit” 148 [Digital Out4 Sel] 30 Digital Output +24V DC Source Tie point for the internal supply or customer

–– supplied voltage for the digital outputs. See the I/O Wiring Examples for sourcing digital outputs on page85

for more information.

Max. +30V DC, 80 mA.

Important: When the internal +24V DC supply (terminal 19) is used for digital outputs 1…4, you must connect terminal 19 to terminal 30 and the digital output common (terminal 25) to the +24V supply common (terminal 18).

Config. Parameter

Table 37 - I/O Terminal Block 4 Designations

No. Signal Description Factory Default Config. Parameter

31 Digital Input 5 Max +30V, 15V/3.2 mA, 24V/5 mA, 32 Digital Input 6 18 “Speed Sel 2” 138 [Digital In6 Sel] 33 Digital Input 7 19 “Speed Sel 3” 139 [Digital In7 Sel] 34 Digital Input 8 31 “Contactor” 140 [Digital In8 Sel]

and 30V/6.4 mA. A digital input (1…8) must be configured for

“Enable”.

35 Digital Input Common Important: When the internal +24V DC supply

(terminal 19) is used for digital inputs 5…8, you must connect the digital input common (terminal

35) to the +24V supply common (terminal 18).

Not Used – –

… 40

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

17 “Speed Sel 1” 137 [Digital In5 Sel]

––

Installation and Wiring Chapter 1

1 2

4 5 6 7

I/O Wiring Examples

Input/Output Connection Example Required Parameter Changes Potentiometer Unipolar Speed

Reference

10kΩ Pot. Recommended (2kΩ Minimum)

• Adjust Scaling:

72 [Anlg In1 Scale] and

73 [Anlg1 Tune Scale]

• View Signal Value:

1404 [Analog In1 Value]

5 6

• Vi ew Sign al Output: 385 [Speed Ref Out]

Note: Ver ify that DI P switch S9 is set to “On” (0…10V). See Tab le 27

page 54.

Joystick Bipolar Speed Reference

±10V Input

Important: See the Attention statement on page 80

for important

bipolar wiring information.

Analog Input Bipolar Speed Reference

±10V Input

Important: See the Attention statement on page 80 for important bipolar wiring information.

Analog Input Unipolar Speed Reference

0…+10V Input or 0…20 mA or 4…20 mA

Common

• Set Direction Mode: 1322 [Direction Mode] = 1 “Bipolar”

• Adjust Scaling: 72 [Anlg In1 Scale] and 73 [Anlg1 Tune Scale]

• View Signal Value: 1404 [Analog In1 Value]

• Vi ew Sign al Output: 385 [Speed Ref Out]

Note: Ver ify that DI P switch S9 is set to “On” (0…10V). See Tab le 27

page 54.

1 2

4 5 6 7

• Set Direction Mode: 1322 [Direction Mode] = 1 “Bipolar”

• Adjust Scaling: 72 [Anlg In1 Scale] and 73 [Anlg1 Tune Scale]

• View Signal Value: 1404 [Analog In1 Value]

• Vi ew Sign al Output: 385 [Speed Ref Out]

Note: Ver ify that DI P switch S9 is set to “On” (0…10V). See Tab le 27

page 54.

1 2

4 5 6 7

• Configure for Voltage or Current: 71 [Anlg In1 Config]

• Adjust Scaling: 72 [Anlg In1 Scale] and 73 [Anlg1 Tune Scale]

• View Signal Value: 1404 [Analog In1 Value]

• Vi ew Sign al Output: 385 [Speed Ref Out]

Note: Ver ify that DI P switch S9 is set to “On” for 0…10V operation, or “Off” for 0…20 mA or 4…20 mA operation. See Tab l e 27

on page 54.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 83

Chapter 1 Installation and Wiring

21 22 23 24 25 26 27 28 29 30

+–

11 12 13 14 15 16 17 18 19 20

Stop

Start

Input/Output Connection Example Required Parameter Changes Analog Output Bipolar Signal

±10V Bipolar (based on the signal of the assigned input source - for example Analog Input 1)

• Select Source Value: 66 [Anlg Out1 Sel]

• Adjust Scaling: 62 [Anlg Out1 Scale]

or 0…10V Unipolar (shown)

Enable Input

24V DC internal supply

2-Wire Control Non-Reversing

24V DC internal supply

Important: Programming inputs for 2-wire control deactivates the HIM Start and Jog buttons.

2-Wire Control Reversing

24V DC external supply

Important: Programming inputs for 2-wire control deactivates the HIM Start and Jog buttons.

+24V

Stop-Run

Run Fwd.

Run Rev.

Neutral/

Common

• No Changes Required.

Note: If the digital input used for “Enable” is changed from the default setting of digital input 4, the wiring must be changed accordingly.

• Disable Digital Input 1:

11 12 13 14 15 16 17 18 19 20

133 [Digital In1 Sel] = 0 “Not Used”

• Set Digital Input 2: 134 [Digital In2 Sel] = 5 “Run”

• Set Digital Input 1: 133 [Digital In1 Sel] = 6 “Run Forward”

• Set Digital Input 2: 134 [Digital In2 Sel] = 7 “Run Reverse”

3-Wire Control

24V DC internal supply

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

• No Changes Required.

Installation and Wiring Chapter 1

11 12 13 14 15 16 17 18 19 20

Stop

Start

+24V

Neutral/

Common

21 22 23 24 25 26 27 28 29 30

Ready

Fault

External

+24V DC

External Neutral/

Common

Spd Thresh

Input/Output Connection Example Required Parameter Changes 3-Wire Control

• No Changes Required

24V DC external supply Requires 3-wire functions only ([Digital In1 Sel]). configuring 2-wire selections will cause a type 2 alarm (see page 224

Sourcing Digital O utputs

Internal 24V DC supply

Sourcing Digital O utputs

External 24V DC supply

Ready

Fault

Spd Thresh

• No Changes Required

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

• No Changes Required

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 85

Chapter 1 Installation and Wiring

Digital Encoder terminal block

Control board

EMI shield

Wire s hield g round

Digital Encoder Terminal Block

Always connect the encoder connection cables directly to the terminals on the encoder terminal block. The encoder cable must be made up of twisted pairs with the shield connected to the shield ground on the drive side. Do not connect the shield to ground on the motor side. In some cases (for example, cable lengths that exceed 100 meters), it may be necessary to ground the shield of each twisted pair on the power supply. See the PowerFlex Digital DC Drive Technical Data, publication 20P-TD001

Figure 59 - Digital Encoder Terminal Block Location

, for digital encoder specifications.

Table 38 - Digital Encoder Terminal Designations

Terminal Block Label Signal

A+ Encoder A Single channel A or dual channel

A+

A-

B+

B-

Z+

Z-

COM

(1) S electable via switch S21 on the control board. See Tabl e 2 7 on page 76. (2) S electable via switch S20 on the control board. See Tabl e 2 7 on page 76.

A- Encoder A (NOT)

B+ Encoder B Single channel B or dual channel

B- Encoder B (NOT)

Z+ Encoder Z Pulse, marker or registration input

Z- Encoder Z (N OT)

(1)

COM +5/12…15V

+V +5/12…15V

DC Return Internal power common

(1)

DC Power

Description

quadrature A input

quadrature B input

(2)

Internal power source 200 mA

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

Figure 60 - Sample Encoder Power Wiring

Common

+5/12-15V DC (200 mA)

A+

A-

B+

B-

Z+

Z-

COM

to Shield

(1)

B NOT

A NOT

Z NOT

Supply Common

A+

A-

B+

B-

Z+

Z-

COM

to Shield

(1)

Power Source Connection Example Internal Drive Power

+5/12…15V DC, 200 mA

(1)

Installation and Wiring Chapter 1

External Power Source

COM

Z-

Z+

B-

B+

External

Power

Supply

Common

A-

A+

(1) Shield connec tion is on drive control board EMI shield. See Figure 59 on page 86.

Figure 61 - Sample Encoder Signal Wiring

Encoder Signal Connection Example Single-Ended, Dual Channel

Shield

(1)

Differential, Dual Channel

COM

to Shield

Z NOT Z B NOT B A NOT A

(1)

Z-

Z+

B-

B+

A-

A+

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 87

Chapter 1 Installation and Wiring

Analog Tachometer

terminal block

−

DC Analog Tachometer Terminal Block

Figure 62 - Analog Tachometer Terminal Block Location

See the PowerFlex Digital DC Drive Technical Data, publication 20P-TD001, for DC analog tachometer specifications.

ATTENTION: The drive can overspeed if DIP switch S4 is set incorrectly, or the tachometer is wired incorrectly. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

Table 39 - DC Analog Tachometer Terminal Designations

Label Signal Description

– Negative input – A

(Not Used)B C + Positive input

See Verify Motor Rotation and Run Feedback

Polarity Checks on page 103

on determining feedback polarity.

(1) Max imum voltage depends on the configuration of DIP switch S4. See DC Analog Tachometer DIP Switch S4 Example on page 77.

for informati on

22.7 / 45.4 / 90.7 / 181.6 / 302.9V max voltage

8 mA max. current

(1)

Resolver Feedback Module

The resolver feedback module (catalog number 20P-RES-A0), which provides a drive interface to a selection of compatible resolvers, must be ordered and purchased separately from the drive. The resolver option module includes the PowerFlex DC Drive Resolver Feedback Module Installation Instructions, publication 20P-IN071 Resolver Type Selection on page 310 resolvers.

, which provides installation and wiring information. See

for more information on compatible

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

Installation and Wiring Chapter 1

Frame A Shown

I/O and Control Wire Routing

Frames A…C

Route all I/O and control wires from through the bottom of the drive, between the bottom front protective cover and the terminal cover (frame A) or plastic covers (frames B and C).

Frame D

Route the field power input cables through the opening at the top left side of the control panel.

Route control and I/O cables through the opening at the bottom left side of the control panel.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 89

Chapter 1 Installation and Wiring

Notes:

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

Chapter 2

IMPORTANT

Drive Start Up

This chapter describes how to start up the PowerFlex DC drive. If using the LCD HIM (Human Interface Module) to commission the drive, it is recommended that you read Appendix B

ATTENTION: Power must be applied to the drive to perform the following startup procedure. Some of the voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, allow only qualified service personnel to perform the following procedure. Thoroughly read and understand the procedure before beginning. If an event does not occur while performing this procedure, Do Not Proceed. Remove Power including user supplied control voltages. Correct the malfunction before continuing.

- HIM Overview before performing these procedures.

Drive Start Up Checklist

It is recommended that you uncouple the motor from all loads at this time, until otherwise directed.

This checklist contains the major steps required to complete the drive commissioning procedure.

❏ Verify all Drive Configuration Settings - page 92

❏ Verify the Power Wiring - page 92

❏ Verify the Control and I/O Wiring - page 92

❏ Apply Voltage to the Control Circuits - page 93

❏ Verify the Control Voltages - page 95

❏ Load the Default Settings - page 95

❏ Configure the Most Commonly Used Parameters - page 95

❏ Tun e th e Cur ren t R eg ul at or - page 101

❏ Verify Motor Rotation and Run Feedback Polarity Checks - page 103

❏ Configure the Speed Feedback Parameters - page 106

❏ Tune the Speed Regulator - page 108

❏ Verify Speed Reference Settings and Drive Operation - page 110

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 91

Chapter 2 Drive Start Up

Before Applying Power to the Drive

Verify all Drive Configuration Settings

1. With the bottom cover removed from the drive (see Remove the Drive Covers on page 27 the rated field current specified on the motor nameplate. See Ta b l e 1 6 on page 61

2. Verify all switch settings (S9, S10, and S11) for the analog inputs. See

Ta b l e 2 7

3. Verify all DIP switch and jumper settings for the digital encoder or analog tachometer feedback device. See Ta b l e 2 7

Figure 56

on page 76.

on page 77.

ATTENTION: The Drive can overspeed if DIP switch S4 is set incorrectly, or the tachometer is wired incorrectly. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

), verify that DIP switch S14 is set correctly to be ≥

on page 76 and

Verify the Power Wiring

• Verify that the AC line power at the disconnect device is within the rated value of the drive and that all power wiring is correct. See Power Wiring on page 44

for further information.

ATTENTION: Do not connect any external power to the armature output terminals, personal injury and/or equipment damage can occur.

Verify the Control and I/O Wiring

1. Verify that control power and I/O wiring is correct. A digital input (1…8 only) must be wired and configured as a drive enable. See Control Circuit Input Power on page 65 information.

2. If you are using a PTC thermistor or thermal switch to protect the motor from overloading, remove the 1 k and 79. See Thermistors and Thermal Switches on page 62

and I/O Wiring on page 80 for further

Ω resistor between terminals 78

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

Drive Start Up Chapter 2

IMPORTANT

Applying Power to the Drive

The remainder of the “Drive Start Up” procedure in this manual uses a HIM to configure and autotune the drive. If you prefer, you can use the DriveExplorer™, DriveTools™ SP, or Connected Components Workbench™ software to program drive parameters or use the drive “Start Up” wizard (basic application configuration only) available with both software packages. You must use DriveExplorer v5.02 or higher or DriveTools SP v4.01 or higher with a PowerFlex DC drive specific software patch. The patch can be downloaded from http://

www.ab.com/support/abdrives/webupdate/.

If an operator interface is not available, use a remote device to start up the drive. For information on using the HIM, see the HIM Overview on page 265

When power is first applied, the HIM may require approximately 5 seconds until commands are recognized (including the Stop key).

Apply Voltage to the Control Circuits

1. Apply power to the control circuits (terminals U2 and V2) of the drive.

2. If any of the digital inputs are configured to “Stop/CF” (CF = Clear

Fault), “Enable” or “Aux Fault,” verify that signals are present or reconfigure [Digital Inx Sel]. If a fault code displays, see Chapter 4 Troubleshooting on page 215

3. If the STS LED is not flashing green at this point, see “Drive Status Indicators” below.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 93

Chapter 2 Drive Start Up

Figure 63 - Drive Status Indicators

PORT MOD NET A NET B

STS

# Name Color State Description

1 STS

(Status)

Green Flashing Drive ready, but not running and no faults are present.

Steady Drive running, no faults are present.

Yellow Flashing, Drive

Stopped Flashing, Drive

Running

A condition exists that is preventing the drive from starting. Check parameters 1403 [Start Inhibits] and/or 1380 [Drive Alarm 1].

An intermittent type 1 alarm condition is occurring. Check parameter 1380 [Drive Alarm 1]. See Fault Descriptions on page 218

and/or Alarm

Descriptions on page 224.

Steady, Drive Running

A continuous type 1 alarm condition exists. Check parameter 1380 [Drive Alarm 1]. See Fault Descriptions on page 218

and/or Alarm Descriptions

on page 224.

Red Flashing A fault has occurred. Check [Fault x Code] or view the Fault Queue on the

HIM. See Fault Descriptions on page 218

Steady A non-resettable, non-configurable fault has occurred. Check [Fault x

Code] or view the Fault Queue on the HIM. See Fault Descriptions on page

218

2 PORT Refer to the Communication

MOD Status of communications module (when installed).

Adapter User Manu al.

Status of DPI port internal communications (if present).

NET A Status of network (if connected). NET B Status of secondary network (if connected).

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

Drive Start Up Chapter 2

IMPORTANT

Verify the Control Voltages

• Verify that the following voltages are present at I/O terminal block 1 and

2. See I/O Signal and Control Wiring on page 81

Terminal Number… Voltage to Terminal Number…

7 +10V 9 8-10V 9

19 +24 - 30V 18

Load the Default Settings

It is recommended that you reset the drive to the default settings. By resetting the drive to the default settings, any previous parameter modifications you have made will be overwritten.

1. On the HIM, from the “Main” menu scroll to the “Memory Storage” menu.

2. Press Enter.

3. Scroll to “Reset To Defaults” and press Enter.\

A message displays to verify that you want to reset the drive to the factory settings.

4. Press Enter. Note: A “Params Defaulted” (F48) entry will be made in the drive’s Fault

Queue to indicate the change.

Configure the Most Commonly Used Parameters

If your application only requires basic drive parameter set up, you can use the S.M.A.R.T. list screen available on the HIM to program the drive. See Using the S.M.A.R.T. List Screen on page 267

To access all parameters in this procedure you must set the Parameter View option to “Advanced”.

for more information.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 95

Chapter 2 Drive Start Up

1. At the Main menu, scroll to the Parameter option.

2. Press ALT and then Sel.

3. Scroll to the Numbered List option.

4. Press Enter.

5. Type 211.

6. Press Enter.

7. Press Sel.

8. Typ e 1 .

9. Press Enter.

10. Press Esc.

11. Press ALT and then Sel.

12. Scroll to the File-Group-Par option.

13. Press Enter.

14. Scroll to the “Motor Control” file.

15. Press Enter.

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

Drive Start Up Chapter 2

16. With the “Motor Data” group selected, press Enter.

17. Configure the following parameters:

Note: Parameters 45 [Max Ref Speed] and 162 [Max Feedback Spd] are typically set to the motor nameplate base speed. However, if a speed feedback device is used (encoder or tachometer), see Drive Reference and Feedback Scaling on page 279

for details on setting these

parameters.

❏ 45 [Max Ref Speed] - Enter the motor nameplate base speed.

❏ 162 [Max Feedback Spd] - Enter the motor nameplate base speed.

❏ 175 [Rated Motor Volt] - Enter the rated motor nameplate

armature voltage. This value is the measured armature voltage when the motor is running at base speed with rated field current and represents 100% of the rated armature voltage when field weakening is not used. If field weakening is used, set this value to 90% of the rated armature voltage to prevent a possible overvoltage condition when the drive transitions to the field weakening mode.

❏ 179 [Nom Mtr Arm Amps] - Enter the rated motor nameplate

armature current. Note: To prevent current scaling/resolution issues, the drive size (as set by DIP switch S15 and shown in Par 465 [Drive Size]) can not exceed the motor size (as set by Par 179) by more than three times.

❏ 374 [Drv Fld Brdg Cur] - Enter the rated current of the field bridge

regulator to match the value set using the DIP switch S14. See Field Current Configuration on page 60

❏ 280 [Nom Mtr Fld Amps] - Enter the rated motor nameplate field

current. If using a permanent magnet motor, leave this parameter set to the default value.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 97

Chapter 2 Drive Start Up

IMPORTANT

18. Access the “Field Config” group.

19. Configure the following parameters:

❏ If the motor field power is supplied by an external source, set Par

497 [Field Reg Enable] = 0 “Disabled”. Otherwise, verify that this parameter is set to 1 “Enabled” (default). Leave set to the default value if using a permanent magnet motor.

❏ If you are utilizing field economy when the drive is stopped or at

zero speed, set Par 1407 [Field Econ Delay] to the desired amount of time to elapse after the drive stops or reaches zero speed before field economy becomes active (the value set in Par 468 [Min Fld Curr Pct]). The default value is 300 seconds. Leave set to the default value if using a permanent magnet motor.

❏ Par 469 [Field Mode Sel] - select the desired field mode (default = 0

“Base Speed”, constant field current):

• 1 “Field Weaken”, field weakening mode

• 2 “External”, power to the field is supplied externally

• 3 “PM External”, external field is created by a permanent magnet (PM) motor

❏ If you are utilizing field economy at zero speed, set 468 [Min Fld

Curr Pct] to the desired minimum field current for field economy (default = 30%). Leave set to the default value if using a permanent magnet motor.

❏ If you are operating the drive in field weakening mode, set Par 456

[Fld Weaken Ratio] = Motor nameplate base speed / Par 45 [Max Ref Speed] x 100. Leave set to the default value if using a permanent magnet motor.

When operating the drive in field weakening mode, it is necessary to refer to the CEMF value or to the crossover data. If the maximum field current is not within 10% of the maximum value of the internal field converter, configure the current feedback using DIP switch S14. See Field Current Configuration on page

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

Drive Start Up Chapter 2

20. Access the “Utility” file.

21. Press Enter.

22. Access the “Alarms” group.

23. Configure the following parameters:

❏ Par 481 [UnderVolt Thresh] - Enter the value at which an AC under

voltage condition will be detected by the drive (default = 200V on a 240V AC line and 400V on a 480V AC line). Typically, this value is approximately 85% of the nominal AC line voltage.

❏ Par 584 [OverCurrent Thr] - Enter the value at which a drive over

current condition will be detected (default = 175%). Set the threshold level at least 10% above the selected operating current limit (Par 7 [Current Limit]).

❏ Par 585 [OverSpeed Val] - Enter a value that is 10% above the

maximum speed that the motor will achieve. Typically 10% above Par 162 [Max Feedback Spd].

24. Access the “Input & Output” file.

25. Press Enter.

26. Access the “Analog Inputs” group.

27. Configure the following:

❏ If you have connected a potentiometer to analog input 1 for a speed

reference:

• Verify that Par 70 [Anlg In1 Sel] is set to 1 “Speed Ref A” (default).

• Verify that switch S9 and Par 71 [Anlg In1 Config] are configured to match (voltage versus a current signal). See DIP Switch and Jumper Settings on page 75

• Set Par 72 [Anlg In1 Scale] and Par 74 [Anlg In1 Offset] appropriately.

❏ If you are using the HIM on the drive cover (Port 1) for the speed

reference, set Par 70 [Anlg In1 Sel] to 0 “Off ”.

Rockwell Automation Publication 20P-UM001K-EN-P - July 2014 99

Chapter 2 Drive Start Up

28. Access the “Digital Inputs” group.

29. Configure the following parameters:

❏ Par 1391 [ContactorControl] - Select the type of contactor(s) used

with the drive: 1 “Contactor” (default, AC input or DC output contactor), 2 “Contactor+DB” (AC input or DC output contactor and dynamic brake contactor), or 0 “None”.

Note : If you select 0 “None” for Par 1391 [ContactorControl], a “CntactrCflct” alarm will display. The alarm will be resolved and automatically clear when you complete the Digital Output configuration below.

Note : If Par 1391 [ContactorControl] is set to 1 or 2, an Auxiliary Status contactor must be wired to a digital input (default for digital input 8).

❏ Par 140 [Digital In8 Sel] - If a contactor is NOT used, set to other

than 31 “Contactor” (for example, 0 “Not Used”).

❏ If an auxiliary status contactor is wired to a digital input, set the

appropriate [Digital Inx Sel] parameter to 31 “Contactor”.

30. Access the “Digital Outputs” group.

31. Configure the following parameters:

❏ If a contactor and a dynamic brake resistor are used:

• Par 629 [Relay Out 2 Sel] = 24 “ContactorDB”.

❏ If a neither a contactor nor a dynamic brake resistor are used:

• Par 629 [Relay Out 2 Sel] = Set to other than 24 “ContactorDB” or 25 “Contactor” (for example, 0 “Not Used”).

• Par 1392 [Relay Out 1 Sel] = Set to other than 24 “ContactorDB” or 25 “Contactor” (for example, 0 “Not Used”).

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

Rockwell Automation 23P User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Summary of Changes

New and Updated Information

Table of Contents

Preface

Drive Storage Conditions

Drive series letter

Drive Nameplate Data

Drive Specifications

Drive Frame Sizes

Drive Firmware Version

Extra Resources

Technical Support

Conventions

General Precautions

Standard Drive Catalog Number Explanation, Cont.

Standalone-Alone Regulator Catalog Numbers

Mount the Drive

Operating Conditions and Temperatures

Minimum Mounting Clearances

Maximum Surrounding Air Temperature Specifications

Approximate Drive Dimensions and Weights

Lifting PowerFlex DC Drives

Mount Frame C and D Drives

Remove the Drive Covers

Frame A Drives

Frame B and C Drives

Frame D

Isolation Transformers / Line Reactors

Contactors

AC Input Contactors

DC Output Contactors

Dynamic Brake Resistors

General Grounding Requirements

Safety Ground (PE)

Power Feeder

Encoder/Resolver Ground Connections

Tachometer Ground Connections

Power Distribution

CE Conformity

Low Voltage Directive

EMC Directive

General Considerations

Installation Requirements Related to the Low Voltage Directive

Installation Requirements Related to EN 61800-3 and the EMC Directive

Pollution Degree Ratings According to EN 61800-5-1

Power Circuit Protection

Control Power Circuit Protection

Cable and Wiring Recommendations

Power Wiring

AC Input Voltages

DC Output Voltages

Typical Power Wiring Diagrams

Armature Converter Connections

Armature Voltage Feedback Connections

Field Converter Connections

Field Current Configuration

Set DIP Switch S14 to the Correct Value

Relay Outputs

Thermistors and Thermal Switches

Control Circuit Input Power

Frame C Heatsink Cooling Fan Specifications

Frame D, Series B Heatsink Cooling Fan Specifications

Frame C and D Armature Fuse Signal Terminals

DIP Switch and Jumper Settings

I/O Wiring

I/O Signal and Control Wiring

I/O Wiring Examples

Digital Encoder terminal block

DC Analog Tachometer Terminal Block

Resolver Feedback Module

I/O and Control Wire Routing

Drive Start Up Checklist

Before Applying Power to the Drive

Verify all Drive Configuration Settings

Verify the Power Wiring

Verify the Control and I/O Wiring