Rockwell Automation PowerFlex 40 Installation Instructions Manual Download | Manualshive

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INSTALLATION INSTRUCTIONS

PowerFlex 40 Configured AC Drives

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Summary of Contents for PowerFlex 40

Page 1: ...INSTALLATION INSTRUCTIONS PowerFlex 40 Configured AC Drives ...

Page 2: ...e 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 I...

Page 3: ...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 Consid...

Page 4: ...Publication 23B IN001G 2 Table of Contents Notes ...

Page 5: ...e 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 incl...

Page 6: ... action Title Publication Available Online at Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives DRIVES IN001 www rockwellautomation com literature 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 D...

Page 7: ... 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 fre...

Page 8: ...eserved i Code Rating N Reserved e HIM Code Interface Module 1 Fixed Keypad on Drive F Fixed Keypad on Drive and LCD Display with Digital Speed Control HIM on Enclosure Door 22 HIM C2S This option changes the enclosure rating to indoor only j Options Code Description E22 DeviceNet Quick Disconnect Bottom E23 DeviceNet Quick Disconnect Left Side P3 Motor Circuit Protector P3T Motor Circuit Protecto...

Page 9: ...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 For information on See page Standard Features 1 1 Enclosure Options 1 2 Communication Options 1 3 Power Disconnect Options 1 4 Operator Device Options 1 9 Qu...

Page 10: ...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 agai...

Page 11: ...t 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 ...

Page 12: ...lled 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 custom...

Page 13: ...ulletin 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 Specifi...

Page 14: ...e 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 ATTENTION Most codes require that upstream branch circuit protection be provided to protect input power wiring Install the fuses recommended in Table 1 A Do not exceed the fuse ratings Failure to observe this precaut...

Page 15: ...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 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...

Page 16: ...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 ATTENTION Unused wires in conduit must be grounded at both ends to avoid a possible shock hazard caused by i...

Page 17: ...pecifications This option is not compatible with Codes R3 R5 S4 S7 S20 S21 or S22 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 Commun...

Page 18: ...d 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 1 4 Preset Freq 6 Comm Port 4 Preset Freq Speed Pot Door Preset Speed 4 Preset Freq 4 Preset Freq 13 10V In Ctrl Analog Input 4 20mA ...

Page 19: ...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 This option is not compatible with Codes R3 R5 S20 or S21 Bulletin 800F Devices IEC style Internationally rated Meet IP65 IP66 and NEMA UL Type 4 4X 13 UL List...

Page 20: ...38 Speed Reference 4 Preset Freq In Remote mode the factory default setting for parameter A051 Digital In1 Sel 6 Comm Port The Off Run Forward selector switch allows the drive to be started and stopped when in Local Control Component Specifications This option is not compatible with Codes R3 R5 S1 S4 S7 S8 S21 or S22 Bulletin 800F Devices IEC style Internationally rated Meet IP65 IP66 and NEMA UL ...

Page 21: ...stomer supplied and protected 120V AC source In all cases the Stop input to the drive must be present before the drive will start In both Local and Remote modes the speed source is parameter A070 Preset Freq 0 Component Specifications This option is not compatible with Codes R3 R5 S1 S4 S7 S8 S20 or S22 Bulletin 800F Devices IEC style Internationally rated Meet IP65 IP66 and NEMA UL Type 4 4X 13 U...

Page 22: ...2 Component Specifications This option is not compatible with Codes R3 R5 S1 S4 S7 S20 or S21 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...

Page 23: ...ction is made of plastic designed to withstand washdown conditions DeviceNet Quick Disconnect Left Side Code E23 A Brad Harrison 5 pin bulkhead male receptacle is provided and wired to the drive mounted DeviceNet module The connector is located through the left side of the enclosure providing a quick disconnect This option is designed to enhance the DeviceNet offering Position 12 Code D and is not...

Page 24: ...he I O V and IN0 terminals The main power disconnect auxiliary contact is wired between the I O V and IN1 terminals indicating if the disconnect is on or off Two inputs and two outputs are available for customer use Component Specifications This option must be used with the drive mounted DeviceNet option D Position 12 and is not compatible with options R4 R5 S1 S4 S7 S8 S20 S21 or S22 The drive mo...

Page 25: ... customer use The Point I O Scanner allows data to be gathered from the drive mounted DeviceNet and the 1734 IB4 4 input appear as one node on the communication system Refer to publication 1734 IN051 for more detail on the 1734 IB4 Component Specifications This option must be used with the drive mounted DeviceNet option D Position 12 and is not compatible with options 4 C E P Position 12 R3 or R5 ...

Page 26: ...isconnect auxiliary contact is wired between the I O V and IN1 terminals indicating if the disconnect is on or off The four I O quick disconnects allow the customer to quickly connect to the remaining two inputs and outputs that are available for customer use Component Specifications This option must be used with the drive mounted DeviceNet option D Position 12 and is not compatible with options R...

Page 27: ...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 I O terminal block specifications are listed in Table 2 A Control and signal wires should be separated from power wires by at least 0 3 meters 1 foot 2 Connect the control and signal wiring to the I O terminals located on ...

Page 28: ...Publication 23B IN001G 2 2 Control Wiring Overview Schematic Drawings Figure 2 1 Power Distribution Option ...

Page 29: ...Publication 23B IN001G Control Wiring Overview 2 3 Figure 2 2 Drive Ratings ...

Page 30: ...Publication 23B IN001G 2 4 Control Wiring Overview Figure 2 3 Control Logic Options 4 C D E P ...

Page 31: ...Publication 23B IN001G Control Wiring Overview 2 5 Figure 2 4 Control Logic Option S1 ...

Page 32: ...Publication 23B IN001G 2 6 Control Wiring Overview Figure 2 5 Control Logic Option S1 S8 ...

Page 33: ...Publication 23B IN001G Control Wiring Overview 2 7 Figure 2 6 Control Logic Option S4 ...

Page 34: ...Publication 23B IN001G 2 8 Control Wiring Overview Figure 2 7 Control Logic Option S4 S7 ...

Page 35: ...Publication 23B IN001G Control Wiring Overview 2 9 Figure 2 8 Control Logic Option S4 with S8 ...

Page 36: ...Publication 23B IN001G 2 10 Control Wiring Overview Figure 2 9 Control Logic Option S7 ...

Page 37: ...Publication 23B IN001G Control Wiring Overview 2 11 Figure 2 10 Control Logic Option S7 and S8 ...

Page 38: ...Publication 23B IN001G 2 12 Control Wiring Overview Figure 2 11 Control Logic Option S8 ...

Page 39: ...Publication 23B IN001G Control Wiring Overview 2 13 Figure 2 12 Control Logic Option S20 ...

Page 40: ...Publication 23B IN001G 2 14 Control Wiring Overview Figure 2 13 Control Logic Option S18 ...

Page 41: ...Publication 23B IN001G Control Wiring Overview 2 15 Figure 2 14 Control Logic Option S21 ...

Page 42: ...Publication 23B IN001G 2 16 Control Wiring Overview Figure 2 15 Control Logic Option S22 ...

Page 43: ...Publication 23B IN001G Control Wiring Overview 2 17 Figure 2 16 Control Logic Option S22 S8 ...

Page 44: ...Publication 23B IN001G 2 18 Control Wiring Overview Figure 2 17 Control Logic Option S23 ...

Page 45: ...Publication 23B IN001G Control Wiring Overview 2 19 Figure 2 18 Control Logic Option R3 with P3 P3T or P6 P6T ...

Page 46: ...Publication 23B IN001G 2 20 Control Wiring Overview Figure 2 19 Control Logic Option R4 ...

Page 47: ...Publication 23B IN001G Control Wiring Overview 2 21 Figure 2 20 Control Logic Option R5 with P3 P3T or P6 P6T ...

Page 48: ...Publication 23B IN001G 2 22 Control Wiring Overview Figure 2 21 Interconnect Wire Parts List ...

Page 49: ...ex Standard Configured Drive supports indoor and outdoor applications that are not in direct sunlight Minimum Mounting Clearances Be sure there is adequate clearance for air circulation around the drive For best air movement do not mount drives directly above each other Note that no devices are to be mounted behind the drive This area must be kept clear of all control and power wiring For informat...

Page 50: ...s Figure 3 2 Frame B Dimensions Dimensions are in millimeters and inches ON F F O 152 4 6 00 152 4 6 00 152 4 6 00 152 4 6 00 Drive or other device ON F F O 355 6 14 00 9 4 0 37 393 2 15 48 405 9 15 98 336 6 13 25 287 5 11 32 177 8 7 00 69 3 2 73 355 1 13 98 342 4 13 48 304 8 12 00 285 8 11 25 Optional mounting bracket orientation 6 35 0 25 ...

Page 51: ... 3 Frame C Dimensions Dimensions are in millimeters and inches ON F F O 19 1 0 75 19 1 0 75 12 7 0 50 177 8 7 00 Detail 146 1 5 75 460 8 18 14 406 4 16 00 427 2 16 82 16 0 0 63 425 2 16 74 457 2 18 00 Frame C 9 7 0 38 P3 Option 383 3 15 09 P6 Option 364 2 14 34 ...

Page 52: ...Publication 23B IN001G 3 4 Mechanical Installation Layout Drawings Figure 3 4 PowerFlex 40 Frame B Layout Drawing ...

Page 53: ...Publication 23B IN001G Mechanical Installation 3 5 Figure 3 5 PowerFlex 40 Frame C Layout Drawing ...

Page 54: ...Publication 23B IN001G 3 6 Mechanical Installation Figure 3 6 PowerFlex 40 General Option Layout Drawing ...

Page 55: ...nd Circuit Breakers Recommended Fuse Type UL Class J CC T or Type BS88 600V 550V or equivalent Recommended Circuit Breakers HMCP circuit breaker or equivalent Protective Features Motor Protection I2t overload protection 150 for 60 Secs 200 for 3 Secs Provides Class 10 protection Overcurrent 200 hardware limit 300 instantaneous fault Control Ride Through Minimum ride through is 0 5 Secs typical val...

Page 56: ...Publication 23B IN001G A 2 Specifications Notes ...

Page 57: ...n P3 or P3T MCP1 480V AC 0 5 5 7 5 15 190 HS4 140M C DN66 Allen Bradley Allen Bradley Operator Handle Adaptor Option P3 or P3T MCP1 480V AC 0 5 15 140M D HA Allen Bradley Operator Shaft Option P3 or P3T MCP1 480V AC 0 5 5 7 5 15 194R NX12 140M C DS Allen Bradley Allen Bradley Operator Terminal Markings MCP1 480V AC 0 5 5 0 A46006 086 01 2 140M C TE 2 Allen Bradley Allen Bradley 7 5 15 A46006 091 0...

Page 58: ...2 0 22B D4P0H204 Allen Bradley 3 0 22B D6P0H204 Allen Bradley 5 0 22B D010H204 Allen Bradley 7 5 22B D012H104 Allen Bradley 10 22B D017H104 Allen Bradley 15 22B D024H104 Allen Bradley Description Designation Voltage HP Part Number Manufacturer ControlNet EA1 All All 22 COMM C Allen Bradley DeviceNet EA1 All All 22 COMM D Allen Bradley EtherNet EA1 All All 22 COMM E Allen Bradley PROFIBUS EA1 All A...

Page 59: ... Contact Block 1 N O Legend Plate Legend Plate SS1 SS2 SS1 SS2 SS1 SS2 SS1 SS2 All All 800FP SM22 800F ALP 800F X10 354702 354786 Allen Bradley Allen Bradley Allen Bradley Allen Bradley 5 Allen Bradley 5 Option S21 Selector Switch Anti Rotation Switch Mounting Latch Contact Block 2 N O Legend Plate MOV Relay Relay Socket Base Relay Retainer Clip SS2 SS2 SS2 SS2 SS2 CR1 CR1 CR1 CR1 All All 800FP SM...

Page 60: ...Publication 23B IN001G B 4 Replacement Parts Table B F Miscellaneous Description Designation Voltage HP Part Number Manufacturer Fan FAN All 0 5 5 0 2410ML 05W B30 B00 NMB Tech ...

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Page 62: ... Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Power Control and Information Solutions Headquarters Publication 23B IN001G EN P May 2008 350679 P07 Supersedes 23B IN001F EN P January 2007 Copyright 2007 Rockwell Automation Inc All rights reserved Pr...

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