PowerFlex 40 Configured AC Drives
INSTALLATION INSTRUCTIONS
Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application,
Installation and Maintenance of Solid State Controls (Publication SGI-1.1
available from your local Rockwell Automation sales office or online at
www.rockwellautomation.com/literature) describes some important differences
between solid state equipment and hard-wired electromechanical devices.
Because of this difference, and also because of the wide variety of uses for solid
state equipment, all persons responsible for applying this equipment must
satisfy themselves that each intended application of this equipment is
acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect
or consequential damages resulting from the use or application of this
equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Rockwell Automation, Inc. cannot assume responsibility
or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use
of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without
written permission of Rockwell Automation, Inc. is prohibited.
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Throughout this manual, when necessary we use notes to make you aware of
safety considerations.
WARNING: Identifies information about practices or
circumstances that can cause an explosion in a hazardous
!
environment, which may lead to personal injury or death, property
damage, or economic loss.
Important: Identifies information that is critical for successful application and
understanding of the product.
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death, property
!
damage, or economic loss. Attentions help you identify a hazard,
avoid a hazard, and recognize the consequences.
Shock Hazard labels may be located on or inside the equipment
(e.g., drive or motor) to alert people that dangerous voltage may be
present.
Burn Hazard labels may be located on or inside the equipment
(e.g., drive or motor) to alert people that surfaces may be at
dangerous temperatures.
PowerFlex, DriveExplorer, DriveExecutive, DPI, and SCANport are either trademarks or registered trademarks of Rockwell Autom ation, Inc.
Table of Contents
Preface Overview
Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1
What Is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-3
Compliance Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-3
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-4
Chapter 1 PowerFlex 40 Standard Configured Drive Standard Features and Options
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Enclosure Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Power Disconnect Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Operator Device Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Quick Disconnects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
I/O Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Chapter 2 Control Wiring Overview
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Wiring Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Schematic Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Chapter 3 Mechanical Installation
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Layout Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Appendix A Specifications
Appendix B Replacement Parts
Publication 23B-IN001G
2 Table of Contents
Notes:
Publication 23B-IN001G
Overview
Preface
Who Should Use this Manual?
The purpose of this manual is to provide basic information needed to install
PowerFlex
®
40 Adjustable Frequency AC Standard Configured Drives.
User documentation for the PowerFlex 40 Standard Configured Drives
includes these Installation Instructions and the PowerFlex 40 User Manual,
Publication 22B-UM001…. Both manuals are required to properly install
and operate PowerFlex 40 Adjustable Frequency AC Standard Configured
Drives.
For information on … See page …
Who Should Use this Manual?
What Is Not in this Manual P-1
Reference Materials P-2
Manual Conventions P-2
General Precautions P-3
Compliance Certification P-3
Catalog Number Explanation P-4
P-1
This manual is intended for qualified personnel. You must be able to
program and operate Adjustable Frequency AC Drive devices. In addition,
you must have an understanding of the parameter settings and functions.
What Is Not in this Manual
The PowerFlex 40 Adjustable Frequency AC Standard Configured Drives
Installation Instructions is designed to provide only basic installation and
operation information. For this reason, the following topics have not been
included:
• Troubleshooting
• Start-Up
• Programming and Parameters
Please refer to the PowerFlex 40 User Manual for detailed drive
information.
Publication 23B-IN001G
P-2 Overview
Reference Materials
The following manuals are recommended for general drive information:
Title Publication Available Online at …
Wiring and Grounding Guidelines for Pulse
Width Modulated (PWM) AC Drives
Preventive Maintenance of Industrial Control
and Drive System Equipment
Safety Guidelines for the Application,
Installation and Maintenance of Solid State
Control
A Global Reference Guide for Reading
Schematic Diagrams
Guarding Against Electrostatic Damage 8000-4.5.2
DRIVES-IN001…
DRIVES-TD001…
SGI-1.1
0100-2.10
www.rockwellautomation.com/
literature
For detailed PowerFlex 40 information including drive parameters,
programming, start-up, troubleshooting, specifications:
Title Publication Available Online at …
PowerFlex 40 User Manual 22B-UM001…
PowerFlex Reference Manual PFLEX-RM001…
www.rockwellautomation.com/literature
The latest version of this Installation Instructions can be obtained online at …
www.rockwellautomation.com/literature
For Allen-Bradley Drives Technical Support:
Title Online at …
Allen-Bradley Drives Technical Support www.ab.com/support/abdrives
Manual Conventions
• To help differentiate parameter names and LCD display text from other
text, the following conventions will be used:
– Parameter Names will appear in [brackets].
For example: [DC Bus Voltage].
– Display Text will appear in “quotes.” For example: “Enabled.”
• The following words are used throughout the manual to describe an
action:
Word Me aning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Must Unavoidable, you must do this
Shall Required and necessary
Should Recommended
Should Not Not recommended
Publication 23B-IN001G
General Precautions
Overview P-3
ATTENTION: This drive contains ESD (Electrostatic
Discharge) sensitive parts and assemblies. Static control
!
precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with
static control procedures, reference A-B publication 8000-4.5.2,
“Guarding Against Electrostatic Damage” or any other applicable
ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can
result in component damage or a reduction in product life. Wiring
!
or application errors, such as, undersizing the motor, incorrect or
inadequate AC supply, or excessive ambient temperatures may
result in malfunction of the system.
ATTENTION: Only qualified personnel familiar with adjustable
frequency AC drives and associated machinery should plan or
!
implement the installation, start-up and subsequent maintenance
of the system. Failure to comply may result in personal injury
and/or equipment damage.
Compliance Certification
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged before performing
!
any work on the drive. Measure the voltage at the drive (Refer to
the PowerFlex 40 User Manual for test point locations). The
voltage must be zero.
Certifications are applicable to approved program defined options.
U.S./Canada UL: UL508C
CUL: CAN/CSA-C22.2 No. 14
Please refer to the PowerFlex 40 User Manual, publication 22B-UM001,
for additional information.
Publication 23B-IN001G
P-4 Overview
Catalog Number Explanation
1-3 4 56-8 9 10111213141516+
23B –
D 4P0 D 1 0 4 N N – P6
The PowerFlex 40 Adjustable Frequency AC Standard Configured Drives
catalog numbering scheme is shown below.
Position
abcdefghi j
a
Drive
Code Type
23B PowerFlex 40
b
Voltage Rating
Code Voltage Ph.
D 480V ac 3
c
Amp Rating
480V 60Hz Input
Code Amps kW (Hp)
1P4 1.4 0.4 (0.5)
2P3 2.3 0.75 (1.0)
4P0 4.0 1.5 (2.0)
6P0 6.0 2.2 (3.0)
010 10.5 4.0 (5.0)
012 12 5.5 (7.5)
017 17 7.5 (10)
024 24 11 (15)
d
Enclosure
Code Enclosure
C NEMA/UL Type 4X ‡
D NEMA/UL Type 4 ‡
‡ The design of the PowerFlex 40 Standard
Configured Drive supports indoor and outdoor
applications that are not in direct sunlight.
Code Interface Module
1 Fixed Keypad on Drive
Display with Digital Speed Control
F
This option changes the enclosure rating to
indoor only.
Code Rating
0 Not Filtered
Code Version
4 RS485 (Standard)
C ControlNet
D DeviceNet
E EtherNet/IP
P PROFIBUS DP
Code Rating
N Reserved
Code Rating
N Reserved
e
HIM
Fixed Keypad on Drive and LCD
HIM on Enclosure Door
(22-HIM-C2S)
f
Emission Class
g
Version
h
i
j
Options
Code Description
-E22
-E23
-P3 Motor Circuit Protector
-P3T
-P6 Disconnect Switch - Fused
-P6T
-R3
-R4 DeviceNet Point I/O w/IB4 (4 Inputs)
-R5
-S1
-S4 Auto/Manual S.S. (Speed Ref.)
-S7 Start and Stop P.B.
-S8 Forward/Reverse S.S.
-S18
-S20
-S21
-S22
-S23 Clear Fault P.B.
DeviceNet Quick Disconnect
(Bottom)
DeviceNet Quick Disconnect (Left
Side)
Motor Circuit Protector (Customer
wiring into top of device)
Disconnect Switch - Fused
(Customer wiring into top of device)
DeviceNet I/O (4 In/2 Out) w/Spring
Return HOA and Power Disconnect
Aux. Contact
-R3 plus 4 I/O Quick Disconnects
and (1) 24V DC Receptacle
Hand/Off/Auto S.S.
(Start/Stop/Speed Ref.)
Door Mounted Local Speed Pot (1-
Tur n )
Local/Remote and Local Control
Off/Run Forward Selector Switches
Local/Off/Remote with 1 N.O.
Interposing Relay
Spring Return Hand/Off Auto S.S.
(Start/Stop/Speed Ref.)
Publication 23B-IN001G
Chapter 1
PowerFlex 40 Standard Configured Drive Standard Features and Options
Chapter Objectives
Standard Features
This chapter describes the standard features and operation for PowerFlex 40
Standard Configured Drives and associated options.
For information on … See page …
Standard Features
Enclosure Options 1-2
Communication Options 1-3
Power Disconnect Options 1-4
Operator Device Options 1-9
Quick Disconnects 1-15
I/O Options 1-16
This package integrates the Standard PowerFlex 40 drive. The PowerFlex
40 drive can be used for Volts per hertz or Sensorless Vector applications
and offers an Autotune feature allowing the drive to adapt to individual
motor characteristics.
The PowerFlex 40 is assembled in an enclosure which includes the
following features…
• NEMA/UL Type 4/4X - indoor and outdoor applications other than
direct sunlight.
• Flange mount drive/external heatsink reducing overall enclosure size.
(1)
1-1
• Mounting feet - orientation is adjustable per customer requirements.
If required, the drive can be removed from the front of the enclosure for
ease of assembly or repair.
Low cost, highly configurable I/O inputs and/or 0-10V/4-20 mA outputs
that are not used by program standard features and options are available for
customer use.
(1)
The enclosure does not normally protect electrical equipment from
condensation, corrosion or contamination, which may occur within the
enclosure or enter via the conduit or unsealed openings. Users must
make adequate provisions to safeguard against such conditions, and
satisfy themselves that the equipment is properly protected. For further
information on criteria associated with NEMA enclosure ratings, refer to
NEMA standards Publication No. 250-1991. When optional Door
Mounted HIM is supplied, enclosure is rated indoor only. See enclosure
options for specific enclosure style quoted.
Publication 23B-IN001G
1-2 PowerFlex 40 Standard Configured Drive Standard Features and Options
Enclosure Options
NEMA/UL Type 4 (Position 9, Code D)
The enclosure provided is a NEMA/UL Type 4, painted mild steel, which
supports both NEMA/UL Type 4 and NEMA/UL Type 12 applications.
Type 4 enclosures are intended for indoor or outdoor use primarily to
provide a degree of protection against windblown dust and rain, splashing
water, and hose directed water, and to be undamaged by the formation of ice
on the enclosure. They are designed to meet hose-down, dust, and external
icing and rust resistance design tests. Doors and openings will be gasket
sealed. There are no ventilation openings within the enclosure to allow for
free exchange of inside and outside air.
Note: If optional Door Mounted HIM is not supplied, the design of the
PowerFlex 40 Standard Configured Drive supports indoor and outdoor
applications that are not in direct sunlight.
NEMA/UL Type 4X (Position 9, Code C)
The enclosure provided is a NEMA/UL Type 4X. The material is type 304
stainless steel. Type 4X enclosures are intended for indoor or outdoor use
primarily to provide a degree of protection against corrosion, windblown
dust and rain, splashing water, and hose directed water, and to be
undamaged by the formation of ice on the enclosure. They are designed to
meet hose-down, dust, and external icing and rust resistance design tests.
Doors and openings will be gasket sealed. There are no ventilation openings
within the enclosure to allow for free exchange of inside and outside air.
Note: If optional Door Mounted HIM is not supplied, the design of the
PowerFlex 40 Standard Configured Drive supports indoor and outdoor
applications that are not in direct sunlight.
Publication 23B-IN001G
PowerFlex 40 Standard Configured Drive Standard Features and Options 1-3
Communication Options
DeviceNet (Position 12, Code D)
The DeviceNet option is drive mounted and consists of the DeviceNet
communication adaptor (22-COMM-D) and adaptor cover (22B-CCB for
frame B drives or 22B-CCC for frame C drives). When DeviceNet is
present, no other communication option is available other than the HIM.
When used as a slave, the HIM will have limited functionality. For details
related to the DeviceNet option, refer to the PowerFlex DeviceNet Adapter
User Manual, publication 22COMM-UM003….
To review this schematic see
Figure 2.1 on page 2-2 and Figure 2.3 on page 2-4.
EtherNet/IP (Position 12, Code E)
The EtherNet/IP option is drive mounted and consists of the EtherNet/IP
communication adaptor (22-COMM-E) and adaptor cover (22B-CCB for
frame B drives or 22B-CCC for frame C drives). When EtherNet/IP is
present, no other communications option is available other than the HIM.
When used as a slave, the HIM will have limited functionality. For details
related to the EtherNet/IP option, refer to the PowerFlex EtherNet/IP
Adapter User Manual, publication 22COMM-UM004….
To review this schematic see
Figure 2.1 on page 2-2 and Figure 2.3 on page 2-4.
PROFIBUS (Position 12, Code P)
The PROFIBUS option is drive mounted and consists of the PROFIBUS
communication adaptor (22-COMM-P) and adaptor cover (22B-CCB for
frame B drives or 22B-CCC for frame C drives). When PROFIBUS is
present, no other communication option is available other than the HIM.
When used as a slave, the HIM will have limited functionality. For details
related to PROFIBUS option, refer to the PowerFlex PROFIBUS Adapter
User Manual, publication 22COMM-UM005….
To review this schematic see
Figure 2.1 on page 2-2 and Figure 2.3 on page 2-4.
ControlNet (Position 12, Code C)
The ControlNet option is drive mounted and consists of the ControlNet
communication adaptor (22-COMM-C) and adaptor cover (22B-CCB for
frame B drives or 22B-CCC for frame C drives). When ControlNet is
present, no other communication option is available other than the HIM.
When used as a slave, the HIM will have limited functionality. For details
related to ControlNet option, refer to the PowerFlex ControlNet Adapter
User Manual, publication 22COMM-UM006….
To review this schematic see
Figure 2.1 on page 2-2 and Figure 2.3 on page 2-4.
Publication 23B-IN001G
1-4 PowerFlex 40 Standard Configured Drive Standard Features and Options
Power Disconnect Options
Drive Motor Circuit Protector (Position 16+, Code -P3)
The Drive Motor Circuit Protector option is factory installed and provides a
manual means of disconnecting input power to the drive. The Allen-Bradley
Bulletin 140M switch is designed to meet short circuit requirements for
branch circuit protection. The rotary style handle is padlockable in On or
Off position. This option has a 65 kA short circuit withstand rating. Over
load protection is supplied by the drive not the motor circuit protector.
Incoming customer supplied power cables terminate at terminals R, S, T
(L1, L2, L3) located on the bottom of the device.
Component Specifications
Switch A-B Bulletin 140M, 480V, 65 kA short circuit withstand rating
3-pole, Rod operated
UL listed, CE Approved, CSA Certified
Handle Rotary style handle through the door, Door interlocked
Padlockable in On or Off position, Defeatable in the On position
IP66 (Type 3R, 3, 12, 4, 4X)
Drive Motor Circuit Protector (Position 16+, Code -P3T)
The Drive Motor Circuit Protector option is factory installed and provides a
manual means of disconnecting input power to the drive. The Allen-Bradley
Bulletin 140M switch is designed to meet short circuit requirements for
branch circuit protection. The rotary style handle is padlockable in On or
Off position. This option has a 65 kA short circuit withstand rating. Over
load protection is supplied by the drive not the motor circuit protector.
Incoming customer supplied power cables terminate at terminals R, S, T
(L1, L2, L3) located on the top of the device.
Component Specifications
Switch A-B Bulletin 140M, 480V, 65 kA short circuit withstand rating
3-pole, Rod operated
UL listed, CE Approved, CSA Certified
Handle Rotary style handle through the door, Door interlocked
Padlockable in On or Off position, Defeatable in the On position
IP66 (Type 3R, 3, 12, 4, 4X)
Publication 23B-IN001G
PowerFlex 40 Standard Configured Drive Standard Features and Options 1-5
Drive Input Fused Disconnect Switch (Position 16+, Code -P6)
The Drive Input Fused Disconnect Switch option is factory installed and
provides a manual means of disconnecting input power to the drive. The
Allen-Bradley Bulletin 194R switch is designed to meet disconnect switch
requirements for branch circuit protection. The rotary style handle is
padlockable in On or Off position. This option has a 100 kA short circuit
withstand rating. Class J fuses are supplied with the disconnect switch.
Incoming customer supplied power cables terminate at terminals R, S, T
(L1, L2, L3) located on the bottom of the device.
Component Specifications
Switch A-B Bulletin 194R, 600V, 100 kA short circuit withstand rating
Integral class J fuses, Captive terminal clamps
3-pole, Rod operated
UL listed, CE Approved, CSA, ASTA, and LOVAG Certified
Handle Rotary style handle through the door, Door interlocked
Padlockable in On or Off position, Defeatable in the On position
True switch status indication
IP66 (Type 3R, 3, 12, 4, 4X)
Drive Input Fused Disconnect Switch (Position 16+, Code -P6T)
The Drive Input Fused Disconnect Switch option is factory installed and
provides a manual means of disconnecting input power to the drive. The
Allen-Bradley Bulletin 194R switch is designed to meet disconnect switch
requirements for branch circuit protection. The rotary style handle is
padlockable in On or Off position. This option has a 100 kA short circuit
withstand rating. Class J fuses are supplied with the disconnect switch.
Incoming customer supplied power cables terminate at terminals R, S, T
(L1, L2, L3) located on the top of the device.
Component Specifications
Switch A-B Bulletin 194R, 600V, 100 kA short circuit withstand rating
Integral class J fuses, Captive terminal clamps
3-pole, Rod operated
UL listed, CE Approved, CSA, ASTA, and LOVAG Certified
Handle Rotary style handle through the door, Door interlocked
Padlockable in On or Off position, Defeatable in the On position
True switch status indication
IP66 (Type 3R, 3, 12, 4, 4X)
Publication 23B-IN001G
1-6 PowerFlex 40 Standard Configured Drive Standard Features and Options
Main Fuses (F1-F3)
ATTENTION: Most codes require that upstream branch circuit
protection be provided to protect input power wiring. Install the
!
fuses recommended in Table 1.A
Failure to observe this precaution could result in damage to, or
destruction of, the equipment.
Input line branch circuit protection fuses must be used to protect the input
power lines. If input fuses are not provided with your drive, recommended
fuse values are shown in Table 1.A
1.A are applicable for one drive per branch circuit. No other load may be
applied to that fused circuit.
The recommended fuse type for all PowerFlex 40 Standard Configured
Drives is UL Class J.
Table 1.A Branch Fusing
Voltage Rating Drive Rating HP Fuse Rating Amps
480V AC 0.5 3
1.0 6
2.0 10
3.0 15
5.0 20
7.5 25
10 30
15 50
. Do not exceed the fuse ratings.
. The input fuse ratings listed in Tabl e
Publication 23B-IN001G
PowerFlex 40 Standard Configured Drive Standard Features and Options 1-7
Input Power Wiring
Refer to the PowerFlex 40 User Manual for additional detailed information
about input power wiring recommendations and selection.
ATTENTION: Protect the contents of the options cabinet from
metal chips and other debris while drilling the conduit openings.
!
Failure to observe this precaution could result in damage to, or
destruction of, the equipment.
ATTENTION: Do not route signal and control wiring with
power wiring in the same conduit. This can cause interference
!
with drive operation. Failure to observe this precaution could
result in damage to, or destruction of, the equipment.
To connect AC input power to the drive package:
❏ 1. Select the proper wire size according to NEC and all applicable local
codes and standards. Note that you must punch openings in the Option
Cabinet of the desired conduit size, following NEC and all applicable
local codes and standards. Power terminal block specifications are listed
in Table 1.B
.
❏ 2. Connect the three-phase AC input power leads (three-wire VAC) to the
appropriate terminals. Connect the AC input power leads to terminals
L1, L2, L3 on the fused disconnect switch or motor circuit protector.
Note: Drive Input Fused Disconnect Switch (-P6) and Drive Motor
Circuit Protector (-P3) options are bottom fed. Drive Input Fused
Disconnect Switch (-P6T) and Drive Motor Circuit Protector (-P3T)
options are top fed.
❏ 3. Tighten the AC input terminal power terminals to the proper torque
according to drive type as shown in Table 1.B
Table 1.B Component Current Ratings and Wire Sizing
PowerFlex 40 SPD Drive Rating - 480V
HP Continuous
Current Rating
Amps
0.5-3 30 2.5 mm
5-7.5 30 3.5 mm
10-15 60 4.0 mm
(1)
Wire is Black Hypalon.
(2)
Maximum/minimum sizes that the terminal block will accept - these are not recommendations.
Factory Power
Wire Size
(14 AWG)
(12 AWG)
(10 AWG)
(1)(2)
2
2
2
.
Customer
Terminal Wire
Size
2.5-8.4 mm
(14-8 AWG)
2.5-8.4 mm
(14-8 AWG)
2.5-16.0 mm
(14-4 AWG)
2
2
2
Operating Torque
4.0 N-m
(35 lb.-in.)
4.0 N-m
(35 lb.-in.)
4.0 N-m
(35 lb.-in.)
Publication 23B-IN001G
1-8 PowerFlex 40 Standard Configured Drive Standard Features and Options
Output Power Wiring
Refer to the PowerFlex 40 User Manual for additional detailed information
about output power wiring recommendations and selection.
ATTENTION: Unused wires in conduit must be grounded at
both ends to avoid a possible shock hazard caused by induced
!
voltages. Also, if a drive sharing a conduit is being serviced or
installed, all drives using this conduit should be disabled to
eliminate the possible shock hazard from cross-coupled motor
leads. Failure to observe these precautions could result in bodily
injury.
ATTENTION: Do not route signal and control wiring with
power wiring in the same conduit. This can cause interference
!
with drive operation. Failure to observe this precaution could
result in damage to, or destruction of, the equipment.
To connect AC output power wiring from the drive to the motor:
❏ 1. Wire the three-phase AC output power motor leads by routing them
according to the drive option type. Note that you must punch openings in
the option cabinet of the desired conduit size, following NEC and all
applicable local codes and standards. Power terminal block
specifications are listed in Table 1.C
.
Do not route more than three sets of motor leads through a single
conduit. This will minimize cross-talk that could reduce the effectiveness
of noise reduction methods. If more than three drive/motor connections
per conduit are required, shielded cable must be used. If possible, each
conduit should contain only one set of motor leads.
❏ 2. Connect the three-phase AC output power motor leads to terminals
U, V, W (T1, T2, T3) on the power terminal block located on the drive.
❏ 3. Tighten the three-phase AC output power terminals to the proper torque
according to drive type as shown in Table 1.C
Table 1.C AC Output Power Terminal Block Specifications
Frame Maximum Wire Size
2
B 5.3 mm
C 8.4 mm
(1)
Maximum/minimum sizes that the terminal block will accept - these are not recommendations.
(10 AWG) 1.3 mm2 (16 AWG) 1.7-2.2 N-m (16-19 lb.-in.)
2
(8 AWG) 1.3 mm2 (16 AWG) 2.9-3.7 N-m (26-33 lb.-in.)
(1)
Minimum Wire Size Recommended Torque
.
Publication 23B-IN001G
PowerFlex 40 Standard Configured Drive Standard Features and Options 1-9
Operator Device Options
Hand/Off/Auto Selector Switch (Position 16+, Code S1)
This 800F door mounted operator device is factory installed and provides a
Hand/Off/Auto selector switch.
The Hand/Off/Auto selector switch will start the drive in Hand mode and
stop the drive in Off mode. In Auto mode the drive will be stopped and
started from remote contact closures. In all cases, the Stop input to the drive
must be present before the drive will start.
The Hand/Off/Auto selector switch also determines the source of the
actual drive speed reference. In Hand mode, speed source is parameter
A072 [Preset Freq 2]. In Auto mode, speed source is parameter A071
[Preset Freq 1].
If the door mounted speed potentiometer (Option S18) is supplied and it is
intended to be the speed reference in Hand mode, set parameter A052
[Digital In2 Sel] to option 13 “10V In Ctrl”. Refer to the table below and the
PowerFlex 40 User Manual, publication 22B-UM001, for other options.
Hand/Off/Auto Selector Switch (Code S1)
Speed Reference Parameter Settings
Hand Mode Auto Mode P038 [Speed Reference] A051 [Digital In1 Sel] A052 [Digital In2 Sel]
Preset Speed Preset Speed 4 “Preset Freq” 4 “Preset Freq” 4 “Preset Freq”
Analog Input (0-10V) 4 “Preset Freq” 13 “10V In Ctrl” 4 “Preset Freq”
Analog Input (4-20mA) 4 “Preset Freq” 14 “20mA In Ctrl” 4 “Preset Freq”
Communication Port
Speed Pot (Door) Preset Speed 4 “Preset Freq” 4 “Preset Freq” 13 “10V In Ctrl”
Analog Input (4-20mA) 4 “Preset Freq” 14 “20mA In Ctrl” 13 “10V In Ctrl”
Communication Port
HIM (Door) Preset Speed 4 “Preset Freq” 4 “Preset Freq” 6 “Comm Port”
Analog Input (0-10V) 4 “Preset Freq” 13 “10V In Ctrl” 6 “Comm Port”
Analog Input (4-20mA) 4 “Preset Freq” 14 “20mA In Ctrl” 6 “Comm Port”
(1)
Communication port will have both logic and reference control.
(1)
4 “Preset Freq” 6 “Comm Port” 4 “Preset Freq”
(1)
4 “Preset Freq” 6 “Comm Port” 13 “10V In Ctrl”
Component Specifications
Bulletin 800F
Devices
IEC style, Internationally rated
Meet IP65/IP66 and NEMA/UL Type 4/4X/13
UL Listed, CSA Certified
10 amp contacts
2
(22–12 AWG) maximum
Hand/Off/Auto
Selector Switch
Screw terminals, 0.3–3.5 mm
3 position, Maintained
4 N.O. contacts
Legend Plate 30 x 50 mm, Black with white lettering
Wiring 0.8 mm
2
(18 AWG), Blue
Schematics Figure 2.4 on page 2-5
Figure 2.5 on page 2-6
This option is not compatible with Codes R3, R5, S4, S7, S20, S21 or S22.
Publication 23B-IN001G
1-10 PowerFlex 40 Standard Configured Drive Standard Features and Options
Auto/Manual Selector Switch (Position 16+, Code S4)
This 800F door mounted operator device is factory installed and provides an
Auto/Manual selector switch.
The Auto/Manual selector switch determines the source of the actual drive
speed reference. Using 2-wire control in Auto mode, speed source is
parameter A071 [Preset Freq 1]. In Manual mode, the speed source is
parameter A072 [Preset Freq 2].
If the door mounted speed potentiometer (Option S18) is supplied and it is
intended to be the speed reference in Manual mode, set parameter P052
[Digital In2 Sel] to option 13 “10V In Ctrl”. Refer to the table below and the
PowerFlex 40 User Manual, publication 22B-UM001, for other options.
Auto/Manual Selector Switch (Code S4)
Speed Reference Parameter Settings
Manual Mode Auto Mode P038 [Speed Reference] A051 [Digital In1 Sel] A052 [Digital In2 Sel]
Preset Speed Preset Speed 4 “Preset Freq” 4 “Preset Freq” 4 “Preset Freq”
Analog Input (0-10V) 4 “Preset Freq” 13 “10V In Ctrl” 4 “Preset Freq”
Analog Input (4-20mA) 4 “Preset Freq” 14 “20mA In Ctrl” 4 “Preset Freq”
Communication Port
Speed Pot (Door) Preset Speed 4 “Preset Freq” 4 “Preset Freq” 13 “10V In Ctrl”
Analog Input (4-20mA) 4 “Preset Freq” 14 “20mA In Ctrl” 13 “10V In Ctrl”
Communication Port
HIM (Door) Preset Speed 4 “Preset Freq” 4 “Preset Freq” 6 “Comm Port”
Analog Input (0-10V) 4 “Preset Freq” 13 “10V In Ctrl” 6 “Comm Port”
Analog Input (4-20mA) 4 “Preset Freq” 14 “20mA In Ctrl” 6 “Comm Port”
(1)
Communication port will have both logic and reference control.
(1)
4 “Preset Freq” 6 “Comm Port” 4 “Preset Freq”
(1)
4 “Preset Freq” 6 “Comm Port” 13 “10V In Ctrl”
Component Specifications
Bulletin 800F
Devices
IEC style, Internationally rated
Meet IP65/IP66 and NEMA/UL Type 4/4X/13
UL Listed, CSA Certified
10 amp contacts
2
(22–12 AWG) maximum
Auto/Manual
Selector Switch
Screw terminals, 0.3–3.5 mm
2 position, Maintained
1 N.C. contact
Legend Plate 30 x 50 mm, Black with white lettering
Wiring 0.8 mm
2
(18 AWG), Blue
Schematics Figure 2.6 on page 2-7
Figure 2.7 on page 2-8
Figure 2.8 on page 2-9
This option is not compatible with Codes R3, R5, S1, S20, S21 or S22.
Publication 23B-IN001G
PowerFlex 40 Standard Configured Drive Standard Features and Options 1-11
Start and Stop Push Buttons (Position 16+, Code S7)
This option provides factory installed 800F Start and Stop push buttons.
In all cases, the Stop input to the drive must be present before the drive will
start. Using 3-wire control, speed source is parameter A070 [Preset Freq 0].
The Stop push button may also be used as a fault reset.
Component Specifications
Bulletin 800F
Devices
Start Push Button Flush head, Green, 1 N.O. contact
Stop Push Button Extended head, Red, 1 N.C. contact
Legend Plate 30 x 50 mm, Black with white lettering
Wiring 0.8 mm
Schematics Figure 2.7 on page 2-8
This option is not compatible with Codes R3, R5, S1, S20, S21, S22 or S23.
IEC style, Internationally rated
Meet IP65/IP66 and NEMA/UL Type 4/4X/13
UL Listed, CSA Certified
10 amp contacts
Screw terminals, 0.3–3.5 mm
2
(18 AWG), Blue
Figure 2.9 on page 2-10
Figure 2.10 on page 2-11
2
(22–12 AWG) maximum
Forward/Reverse Selector Switch (Position 16+, Code S8)
This 800F door mounted operator device is factory installed and provides a
Forward/Reverse selector switch.
When configured for 2-wire control, the drive will start when the selector
switch is set to Forward. When the selector switch is set to Reverse, the
drive will run in reverse. If the selector switch is operated while the drive is
running, a change of direction command will occur. If the drive is stopped
and the selector switch is operated, a change of direction command will
occur. The speed source is parameter P070 [Preset Freq 0].
When configured for 3-wire control (Code S7 with S8), the selector switch
only changes direction. The drive is started and stopped via the Start and
Stop push buttons (Code S7).
Component Specifications
Bulletin 800F
Devices
Forward/Reverse
Selector Switch
Legend Plate 30 x 50 mm, Black with white lettering
Wiring 0.8 mm
Schematics 2-Wire Control: Figure 2.5 on page 2-6
IEC style, Internationally rated
Meet IP65/IP66 and NEMA/UL Type 4/4X/13
UL Listed, CSA Certified
10 amp contacts
Screw terminals, 0.3–3.5 mm
2-Wire: 2 position, Maintained, 1 N.O. & 1 N.C. contacts
3-Wire: 2 position, Maintained, 1 N.C. contact
2
(18 AWG), Blue
Figure 2.11 on page 2-12
3-Wire Control: Figure 2.10 on page 2-11
2
(22–12 AWG) maximum
, Figure 2.8 on page 2-9,
This option is not compatible with Codes R3, R5, S20 or S21.
Publication 23B-IN001G
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