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Installation Instructions

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1. Frame C P3 Option p 383 3 15 09 P6 Option 364 2 160 457 2 14 34 63 18 00 252 53 n 16 74 7 00 5 75 Tux U U 460 8 Q 18 14 427 2 16 82 406 4 16 00 101 Allen Bradley Y Y 97 a 0 38 058 D do gn 4 pet Publication 23 0010 Mechanical Installation 34 HOFFMAN SEALING PLAIN M6 FLAT NARROW WASHER WASHER STANDARD M6 M6 X 16 PHILLIPS HEAD SPLIT WASHER MACHINE SCREW STANDARD M6 NUT USE LABEL 325708 SIDE MOUNTED DEVICENET eem RECEPTACLE WHEN ORDERED aa DATA NAMEPLATE NOTE 1 1 00 WINDOW oe R5 OPTION Bie EAS WILL BE INSTALLED BY oa NOTE 6 CUSTOMER WHEN NEEDED MOUNT ALL TERMINAL BLOCKS AND FUSE NEXT TO 4 20 88 NOTES 1 MOUNT RH1 SPEED POT IN THE RIGHT MOST AVAILABLE POSITION IN ONE OF SS SWITCHES MAKE SURE TO USE LEGEND PLATE 362657 551 2 APPLY LABEL 156942 AS SHOWN WHEN THERE IS NO NOTE 4 P6 P6T OR P3 P3T OPTIONS IF EITHER P3 P3T OR P6 P6T OPTION IS ORDERED APPLY THE HOT
2. 70 61 10 SUV G0 CONCE66VE NQISNSM ON TERMINAL BLOCK 15 NOlLdO 21901 1OMINOO 6 6e66y2 9 Ov OF Xd3l4M3MOd OIIVWN3HOS TERMINAL BLOCK TB2 RELAY N O 85 RELAY COMMON PARAMETER A055 0 RELAY N C 1 0 TERMINAL BLOCK Publication 23B IN001G Control Wiring Overview 2 7 Figure 2 6 Control Logic Option S4 I O TERMINAL BLOCK STOP 2 WIRE DEVICE START RUN FWD PO36 S WIRE 4 PRESET FREQ DIR RUN REV DIGITAL COMMON AUTO MANUAL 2082 DIGITAL IN1 A051 4 PRESET FREQ 2101 DIGITAL IN2 A052 4 PRESET FREQ DIGITAL INS DIGITAL IN4 OPTO COMMON 24V DC 10V DC 0 10V IN ANALOG COMMON 4 20 IN ANALOG OUTPUT 9261101 Sav 70 82 01 1 NO3 OPTO OUTPUT 2 ak Mm SIE IRD gt gt gt 81818 alele SISIE 85485 DSI SHIELD 90 20 56696 015 5 970934 93157 ON lt TERMINAL BLOCK JAXA YS 4140 21901 1OMINOO OV 314843 OILVNSHOS uoggeuro amy H AA DOU 6 Ce66v 9 RELAY N O RELAY COMMON PARAMETER A055 0 RELAY 1 0 TERMINAL BLOCK Publicat
3. IMT Odd XIIS 3AMQ JAXA OF 4 3 4 OlVW3HOS MO GY NOlLdO 21901 1OMINOO Control Wiring Overview 2 21 Figure 2 20 Control Logic Option R5 with or BULLETIN 100 DEVICENET SYSTEM ACCESSORY V xoo 9 cox 2101 am 2102 oox9 552 INO 2121 DS1 OR IN1 1 IN2 1 15 OR 1 27 INS NEG RCPT 1 4 PIN RECEPTACLE 1 RCPT 3 4 PIN RECEPTACLE REPT 5 4 RECEPTACLE FROM 24 PWR SUPPLY RELAY N O RELAY COMMON PARAMETER 055 0 RELAY I O TERMINAL BLOCK PHOTOELECTRIC V N SENSOR 42EFP2MPBF4 LT OUTPUT COM BLACK OUTPUT PHOTOELECTRIC V SENSOR 2 2 LT OUTPUT COM BL OUTPUT 1 0 TERMINAL BLOCK STOP START RUN FWD P036 2 2 WIRE PO38 4 PRESET FREQ DIR RUN REV DIGITAL COMMON DIGITAL IN1 DIGITAL 2 DIGITAL IN3 DIGITAL 4 OPTO COMMON 24V DC 10V DC 0 10V IN ANALOG COMMON 4 20 ANALOG OUTPUT OPTO OUTPUT 1 OPTO OUTPUT 2 4 RS485 DSI SHIELD lt TERMINAL BLOCK DENOTES JUMPER TO BE REM
4. Reference Materials 1 tivii T Rex S 2 22 eae eee 2 General Precautions 222222225550 ELRS Rey eru era 3 Compliance Certification 3 Catalog Number Explanation 4 PowerFlex 40 Standard Configured Drive Standard Features and Options Chapter iced stk ads dae perve er DUET e PARLE De SUR RI or p 1 1 Standard Features sariti aene dee auct 1 1 Encl sure Options fea aig ea Rer dolere 1 2 Communication 1 3 Power Disconnect Options 1 4 Operator Device Options t atti Eae a 1 9 Quick Disconnects rede ee darn e E 1 13 lea Venn whee 1 14 Control Wiring Overview 2 0 ipn ib uibus du 2 1 Control Wiring Overview 2 1 Schematic Drawings 2 2 Mechanical Installation Chapter Objectives oso
5. ol B amp x 21 mi LI LI a I L o lt P a 13 z a 1 4 RECEPT 4 RECEPTACLE 4 1734 ADNX POINT 1 0 SCANNER SUBNET CONNECTOR 9v 8 zT Figure 2 19 Control Logic Option R4 4 5 SS CONNECTOR 5 PIN CONNECTOR 21 22 25 24 25 Control Wiring Overview 2 20 CUSTOMER 12 24 VDC INPUT MODULE DEVICE NET CUSTOMER SUPPLIED CONNECTION AUTONATION OR T SUBSDARES MAY NOT BE COPIED USED OR DISCLOSED FOR ANY m Allen LEE ET SLM len Bradiey Automation ROCKWELL AUTOMATION ING a SCHEMATIC POWERFLEX 40 AC DRIVE p ARS 05 04 25 08 fars 1052065 12245 04 CONTROL LOGIC OPTION R4 M M REFERENCE ONG PROJECT DRIVE 549952 2 i 2 N m wo QN m Oo m m m m vm m x x ECN NUMBER 51510 349932102 15 N 10 11 12 15 14 15 16 17 18 19 20 22 25 Publication 23 0016 3 rye au alo gt gt 212 alo o 9789101 8529201 NO3 Ea
6. 2042 START RUN FWD PO36 2 2 WIRE POSB 4 PRESET FRE DIR RUN REV DIGITAL COMMON DIGITAL IN1 DIGITAL IN2 DIGITAL IN3 DIGITAL IN4 OPTO COMMON 24 DC 10V DC 0 10 IN ANALOG COMMON 4 20 IN ANALOG OUTPUT sav vo 2z o1 zo LLYVIOL say 0 90 11 vo OPTO OUTPUT 1 YO NOLIVOLOV 40 1 3408 ONIMVSO 18511101 OPTO OUTPUT 2 8952101 0 82 10 so 8 8 8 RS485 DSI SHIELD 3ON3M3 3 11 20 666 6 NQLSNSM ON BLOCK 85 140 21901 1081 JAG OV Or X314H3MOd OIIVW3HOS He Vee DR 0 05667 90 RELAY N O RELAY COMMON PARAMETER 055 0 RELAY N C I O TERMINAL BLOCK Publication 23B IN001G Control Wiring Overview 2 13 Figure 2 12 Control Logic Option S20 I O TERMINAL BLOCK STOP LOCAL CONTROL OFF lt RUN FORWARD 2042 START RUN FWD PO36 2 2 WIRE PO38 4 PRESET FREQ DIR RUN REV DIGITAL COMMON LOCAL REMOTE p 2082 DIGITAL INT COMM PORT xu PARAMETER A051 6 DIGITAL 2 DIGITAL 5 DIGITAL IN4 OPTO COMMON 1 41511101 E 9070934 15 32N3H3434 JAXA OZS 21901 1OMINOO
7. RELAY COMMON PARAMETER A055 0 RELAY Publication 23B IN001G Figure 2 10 Control Logic Option S7 and S8 FORWARD REVERSE 2052 ox 553 EN 86862101 5 0 82 10 so NI C3ZRHOHLAV SV 14 39804804 8 T T gt 5 8 5 ANY 404 03801091 0381 03 409 38 LON AV 8 YO TINO 40 1 340 61 ONIMVHKC STHL NOS 151110 910734 8315 32N3M3334 ON 85 GNV 45 NOlldO 21901 1OMINOO 0 0566 52 JAYA X314M3MOd 25 TERMINAL BLOCK 2 RELAY N O RELAY COMMON PARAMETER A055 0 RELAY N C I O TERMINAL BLOCK Control Wiring Overview 2 11 1 0 TERMINAL BLOCK STOP START RUN FWD PO36 1 3 WIRE PO38 4 PRESET FREQ DIR RUN REV DIGITAL COMMON DIGITAL IN1 DIGITAL IN2 DIGITAL INS DIGITAL IN4 OPTO COMMON 24V DC 10V DC 0 10V IN 4 ANALOG COMMON 4 20 IN ANALOG OUTPUT OPTO OUTPUT 1 OPTO OUTPUT 2 RS485 DSI SHIELD TERMINAL BLOCK Publication 23 0010 2 12 Control Wiring Overview Figure 2 11 Control Logic Option S8 I O TERMINAL BLOCK STOP SNK FORWARD REVERSE SRC
8. ANY 804 059019810 0380 03409 38 LON ANW L YO ONT 40 61 IHL OPTO OUTPUT 2 T 5 8 3 a z 8 8 8 8 aya RS485 DSI SHIELD 44 00 ON lt TERMINAL BLOCK ZZS NOlLdO 21901 1OMINOO OF X3 lJ4M3MOd OIIVW3HOS 2 02866 6 2 TERMINAL BLOCK 2 RELAY N O RELAY COMMON PARAMETER 055 0 RELAY N C I O TERMINAL BLOCK Publication 23B IN001G Figure 2 16 Control Logic Option 522 8 S8 77 OFF HAND AUTO 2022 09 l AUTO RUN REVERSE G hi i xo 9 NO3 T 5 8 3 8 z 8 8 8 8 ET 8 ZZS 21901 TONLNOD JAIXO OF X3lJM3MOd OUVW3HOS C C 66v 9 TERMINAL BLOCK TB2 RELAY N O RELAY COMMON PARAMETER 055 0 RELAY 1 0 TERMINAL BLOCK Control Wiring Overview 2 17 1 0 TERMINAL BLOCK STOP START RUN FWD 036 2 2 WIRE P038 4 PRESET FRE DIR RUN REV DIGITAL COMMON DIGITAL IN1 A051 4 PRESET FREQ DIGITAL IN2 A052 4 PRESET FREQ DIGITAL IN3 DIGI
9. DIGITAL INT COMM PORT PARAMETER A051 6 BULLETIN 100 DEVICENET SYSTEM ACCESSORY DIGITAL IN2 INO DIGITAL INS 051 2151 DIGITAL IN4 1 15 1 27 IN2 OPTO COMMON 24V DC 10V DC o M 8 E 8 T o gt ays S YO NOLVNOLNY 40 1 34084 61 NIMVHO STHL 18 OUTPUT 2 olo nj rye ala ala alo oje Slo gt ala RS485 DSI SHIELD 20 666696 015150 IMC Orid 32N3H3434 81 10 Qvov ON TERMINAL BLOCK TB1 6 6e66y O JAXA TERMINAL BLOCK TB2 RELAY N O RELAY COMMON PARAMETER 055 0 JAXA OF X3lJN3MOd OlvW3HOS RELAY N C MO Y NOlldO 21901 0 1 1 0 TERMINAL BLOCK Publication 23 0010 10 1 12 13 14 15 16 17 18 19 32 33 54 35 36 20 22 23 24 25 26 27 28 29 30 31 37 38 39 40 41 ox o Eat 2 80 55 8325 2 a PORE o Q 2 82 a 5 534 2 a d gt hoa gt 1 N be N T 7 T T pov d NE MM 1 1 1
10. Mounting Considerations Chapter 3 Mechanical Installation This chapter provides information on mounting a PowerFlex 40 Standard Configured Drive For information on See page Mounting Considerations 3 1 Dimensions 3 2 Layout Drawings 3 4 proper installation The Allen Bradley Company cannot assume responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this drive or associated equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation ATTENTION The following information is merely a guide for Environment Before deciding on an installation site verify that the PowerFlex Drive Packages are not installed in an area where the ambient atmosphere contains volatile or corrosive gas vapors or dust The drives are to be installed per the environmental rating they have been designed for Maximum Surrounding Air Temperature PowerFlex 40 Standard Configured Drives are designed to operate at 10 to 40 C 14 to 104 F surrounding air temperature The design of the PowerFlex 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
11. JAXA OF 14 3 4 OIVW3HOS uepewopmy 2 02866 6 2 24N DC 10V DC 0 10 IN ANALOG COMMON 4 20 ANALOG OUTPUT OPTO OUTPUT 1 OPTO OUTPUT 2 RS485 051 SHIELD BLOCK RELAY RELAY COMMON PARAMETER A055 0 RELAY I O TERMINAL BLOCK Publication 23 0010 2 14 Control Wiring Overview Figure 2 13 Control Logic Option S18 I O TERMINAL BLOCK STOP START RUN FWD P036 2 2 WIRE P038 2 0 10 INPUT DIR RUN REV DIGITAL COMMON DIGITAL DIGITAL DIGITAL DIGITAL IN4 OPTO COMMON 24V DC SPEED REFERENCE RH1 10K ANY 404 055019810 0 080 03409 38 LON NI 14393 390440 AVI 6319016916 SL YO NI 40 1 I IHL 114 OUTPUT 2 z amp 85485 DSI SHIELD OWO 00 2666 015156 ON TERMINAL BLOCK 1 C CL OEE 9 815 NOlldO 21901 1OMINOO RELAY N O RELAY COMMON PARAMETER 055 0 x RELAY Publication 23 0016 Figure 2 14 Control Logic Option S21 LOCAL REMOTE a2 2022 2041 552 Edd s s s BEE me e
12. A B 800FP POT6 S18 OPTION ONLY 5 22 10 A B 800FP SM22PX10 S20 OPTION ONLY 828700 MASSA S21 OPTION ONLY A B 800FP SL32PX40 S22 OPTION ONLY A B 800FP SLS2CRPX50 A B 100 DNY42R R3 OPTION 4 184 fe Ao mae R4 OPTION ONLY A B 800FP SL32CRPX50 A B 100 DNY42R 8880 4 2 1 R5 OPTION 8880 4 1 BUSSMANN MDA 3 8429201 90 51 21 150 SLYVd 9 3 193NNOOW3INI Publication 23 0016 81 10 EXTERNAL INTERCONNECT WIRING REQUIREMENTS NO INPUT OPTION NO INPUT OPTION Qqvov P6 P6T OPTION 30A DS P6 P6T OPTION 60A DS OPTION MCP1 B FRAME DRIVE P3 P3T OPTION MCP1 C FRAME DRIVE DRIVE OUTPUT B FRAME DRIVE OUTPUT DRIVE USER MANUAL FOR CABLE RECOMMENDATIONS AND RESTRICTIONS INTERCONNECTION INFORMATION EXPLANATION TERMINAL TERMINAL TORQUE WIRE RANGE DRIVE INPUT 16 19 LB IN 16 10 GA LINE GROUND DRIVE INPUT LINE GROUND INCOMING POWER LINES LINE GROUND INCOMING POWER LINES LINE GROUND MCP1 L1 INCOMING MCP1 L2 POWER LINES MCP1 L3 LINE GROUND 1 11 INCOMING MCP1 L2 POWER LINES MCP1 L3 LINE GROUND DRIVE OUTPUT 16 10 GA MTR GROUND 16 10 GA DRIVE OUTPUT MTR GROUND Chapter Objectives
13. 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 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 ULS08C CUL CAN CSA C22 2 No 14 Please refer to the PowerFlex 40 User Manual publication 22B UMO01 for additional information Publication 23 0016 4 Overview Catalog Number The PowerFlex 40 Adjustable Frequency AC Standard Configured Drives Explanation catalog numbering scheme is shown below Position 1 3 4 5 6 8 9 10 11 12 b f g a e Drive HIM Code Type Code Interface Module 23B PowerFlex 40 1 Fixed Keypad on Drive Fixed Keypad on Drive and LCD b F amp Display with Digital Speed Control HIM on Enclosure Door Voltage Rating 22 25 This option changes the enclosure rating to D 480V ac 3 indooronly SSS f Amp Rating E
14. BY OTHERS WHEN P3 P6 OR P6T LINE PE esu P6 OR P6T OPTIONS OPTIONS LARE NOT ORDERED 777 5515 DEVICENET E22 CONNECTOR E23 OPTIONS COMM OPTION KITS L1 F1 F2 La oy 3 TABLE 2 DEVICENET MODULE POWER TERMINAL BLOCK ETHERNET MODULE PROFIBUS ODULE INTERGAL CONTROLNET MODULE KEYPAD EA1 CUSTOMER DEVICENET ETHERNET PROFIBUS CONTROLNET CONNECTION TO 18 13 19 10 20 13 DEVICENET ONLY TERMINAL BOCK TB1 REFER TO PAGE 2 FOR DETAILED INFORMATION OPTIONAL AUX CONTACTS FOR R3 OR R5 WITH P6 OR P6T OPTION PowerFlex 40 DIGITAL AC DRIVE CATALOG NUMBER TABLE 2 PAGE 2 FOR FURTHER DRIVE INFORMATION REFER TO USER MANUAL PUBLICATION 22B UMOO1C EN E POWER DISCONNECTING OPTION P3 OR OPTIONS mmm m mm FRAME ONLY 11 121 161 5 191 121 8 Pepe ele elg 1 iE als gt gt HE HE 51518 afefe 8 6101 53 v Orid 8315 10 20 66696 015154 o O
15. O Module 4 1734 4 Allen Bradley P6 and P6T option only P3 and P3T option only Option S8 when S7 is not ordered Legend plates are not stocked for general sale A custom quote is required to purchase 1 2 3 R5 option only 4 5 Publication 23 0010 4 Replacement Parts Table B F Miscellaneous Description Designation Voltage HP Part Number Manufacturer Fan FAN Ai 05 50 2410ML 05W B30 B00 Tech Publication 23B IN001G www tockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 350679 P07 Publication 23B INOO1G EN P 2008 Copyright 2007 Rockwell Automation Inc rights reserved Printed in USA Supersedes 23B INOO1F EN P January 2007
16. Rating Wire Size Terminal Wire Amps Size 0 5 3 30 2 5 mm 2 5 8 4 mm 4 0 N m 14 AWG 14 8 AWG 85 Ib in 5 75 30 3 5 mm 2 5 8 4 mm 4 0 N m 12 AWG 14 8 AWG 35 Ib in 10 15 60 4 0 mm 2 5 16 0 mm 4 0 N m 10 AWG 14 4 AWG 85 Ib in 0 Wire is Black Hypalon 0 Maximum minimum sizes that the terminal block will accept these are not recommendations Publication 23 0010 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 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 Unused wires in conduit must be grounded at 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 ATTENTION Do not route signal and control wiring with 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 pu
17. SURFACE pep MOUNT 0 25 FROM DIN RAIL MOUNTED LABEL 0 25 CENTERED ABOVE THE 156940 LABEL HANDLE POSSIBLE 3 FOLLOW ALL MPWS PROCEDURES VENDOR SUPPLIED LITERATURE AND SUPPLIED DOCUMENTATION FOR 5 COMPONENT PLACEMENT AND ASSEMBLY NOTE mA 4 WHEN OPTION IS ORDERED MOUNT L1 L2 L3 LABELS S ON THE BOTTOM AND T1 T2 T3 LABELS ON THE TOP WIRE E zm WTH P3 PST FROM TOP TO THE DRWE A oro WHEN OPTION IS ORDERED MOUNT 111213 ON THE BE TOP AND 71 72 75 THE BOTTOM WIRE FROM BOTTOM TO rc mem THE DRIVE Vr 5 WHEN OPTION P3 IS ORDERED APPLY LABEL 364314 AND TERMINAL ADAPTOR 364364 TO THE TOP AND BOTTOM OF MCP1 RESPECTIVELY WIRE FROM THE TOP 1 72 75 TO THE DRIVE Figure 3 4 PowerFlex 40 Frame B Layout Drawing WHEN OPTION P3T IS ORDERED DO NOT USE THE ABOVE PARTS WIRE FROM BOTTOM OF 1 11 12 13 TO THE DRIVE 6 INDOOR USE ONLY LABEL USE WITH NEMA 4 OR NEMA 4X WITH DOOR MOUNTED HIM ENCLOSURES ONLY T 5 LAYOUT DRAWING PF
18. 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 gt 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 Automation Inc Table of Contents Preface Chapter 1 Chapter 2 Chapter 3 Appendix A Appendix B Overview Who Should Use this What Is Not in this
19. mm 22 12 AWG maximum Hand Off Auto 3 position Hand spring return Off Auto maintained 4 N O Selector Switch contacts Legend Plate 30 x 50 mm Black with white lettering Wiring 0 8 mm 18 AWG Blue Schematic Figure 2 16 on page 2 17 This option is not compatible with Codes R3 R5 51 54 57 520 or 521 Quick Disconnects PowerFlex 40 Standard Configured Drive Standard Features and Options 1 15 Clear Fault Push Button Code S23 This option provides a factory installed 800F Clear Fault push button Component Specifications Bulletin 800F style Internationally rated Devices Meet IP65 IP66 and NEMA UL Type 4 4X 13 UL Listed CSA Certified 10 amp contacts Screw terminals 0 3 3 5 mm 22 12 AWG maximum Clear Fault Push Flush head Black 1 N O contact Button Legend Plate 30 x 50 mm Black with white lettering Wiring 0 8 mm 18 AWG Blue Schematic Figure 2 17 on page 2 18 This option is not compatible with Code 57 DeviceNet Quick Disconnect Bottom Code E22 A Brad Harrison 5 pin bulkhead male receptacle is provided and wired to the drive mounted DeviceNet module The connector is located through the bottom of the enclosure providing a quick disconnect This option is designed to enhance the DeviceNet offering Position 12 Code D and is not compatible with options 4 C E P Position 12 or E23 To review schematic refer to Figure 2 4 on page 2 5 To
20. review layout refer to Figure 3 4 on page 3 4 For NEMA UL Type 4 or less stringent environments the outer connector construction 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 compatible with options 4 C E P Position 12 or E22 To review schematic refer to Figure 2 4 on page 2 5 To review layout refer to Figure 3 4 on page 3 4 For NEMA UL Type 4 or less stringent environments the outer connector construction is made of plastic designed to withstand washdown conditions Publication 23 0010 1 16 PowerFlex 40 Standard Configured Drive Standard Features and Options Options Publication 23B IN001G DeviceNet I O 4 In 2 Out w Spring Return HOA and Power Disconnect Aux Contact Position 16 Code R3 This option provides a factory installed 800F door mounted operator device a 100 DNY42R and a power disconnect auxiliary contact mounted internal to the cabinet The Hand Off Auto selector switch will start the drive while held in the Hand mode and stop it in the Off mode The default speed reference comes from parameter P038 option 4 Preset Freq The
21. the drive This area must be kept clear of all control and power wiring Publication 23 0010 3 2 Mechanical Installation Figure 3 1 Minimum Mounting Clearances Dimensions are in millimeters and inches Drive or other device Allen Bradley Dimensions Figure 3 2 Frame B Dimensions Dimensions are in millimeters and inches 459 15 98 77 8011 17 05 r 88 336 6 1778 69 3 m 13 25 7 00 707 23 j D 355 1 13 98 Y 2 6 35 025 lilies lle etl Optional mounting bracket orientation amp Publication 23B IN001G Figure 3 3 Frame Dimensions Dimensions are in millimeters and inches Mechanical Installation 3 3
22. 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 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 inte
23. 0010 2 4 Control Wiring Overview Figure 2 3 Control Logic Options 4 C D E amp P 8 S 8 5 5 8 ole amp of ofS NN AN NN EJ E 111 alallala 2 2 2 2 alo 21021019 CLAS a N23 OMT Ord 31H 19370 d 3 SNOl1dO 21901 1OMINOO JANG OV OF X314M3MOd OIIVW3HOS Publication 23B IN001G AV ONY 821010189018 YO NOLLVNOLAY 40 I ONIMVHO IHL TERMINAL BLOCK 782 RELAY N O RELAY COMMON PARAMETER A055 0 RELAY N C T I O TERMINAL BLOCK 1 0 TERMINAL BLOCK STOP START RUN FWD P056 5 COMM PORT P038 5 COMM PORT DIR RUN REV DIGITAL COMMON DIGITAL IN1 DIGITAL IN2 DIGITAL INS DIGITAL IN4 OPTO COMMON 24V DC 10V DC 0 10V IN ANALOG COMMON 4 20mA IN ANALOG OUTPUT OPTO OUTPUT 1 amp OPTO OUTPUT 2 RS485 DSI SHIELD lt TERMINAL BLOCK NO3 Figure 2 4 Control Logic Option 51 HAND AUTO E 2022 x00 AUTO RUN E 24070934 43157 S 0 lo 51 Sja gt ala alo E elo SIS PII SIS oo 193nrOHd LS NOWdO 21901 10
24. 12 PowerFlex 40 Standard Configured Drive Standard Features and Options Publication 23B IN001G Local Speed Potentiometer Code 518 This option provides a factory installed 800F door mounted one turn potentiometer for speed control The device provides the speed source when no digital inputs are active When this option is provided it becomes the speed source for the Hand mode of the Hand Off Auto selector switch Option 51 and the Manual mode of the Auto Manual selector switch Option S4 Component Specifications Bulletin 800F IEC style Internationally rated Devices Meet IP65 IP66 and NEMA UL Type 4 4X 13 UL Listed CSA Certified Screw terminals 0 3 3 5 mm 22 12 AWG maximum Speed Potentiometer 1 turn 10k 2 25W 500V Legend Plate 30 x 50 mm Black with white lettering Wiring 0 8 mm 18 AWG Blue Schematic Figure 2 13 on page 2 14 This option is not compatible with Codes R3 R5 Local Control Off Run Forward and Local Remote Selector Switches Code S20 This option provides two factory installed 800F door mounted selector switches The Local Remote selector switch determines the source of the start stop speed and direction commands In Local mode the factory default setting for parameter P038 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 s
25. 22B D1P4F104 Allen Bradley 1 0 22B D2P3F104 Allen Bradley 2 0 22B D4POF104 Allen Bradley 3 0 22B D6PO0F 104 Allen Bradley 5 0 22B D010F 104 Allen Bradley 75 22B D012F104 Allen Bradley 10 22B D017F104 Allen Bradley 15 22B D024F104 Allen Bradley Drive Module EA1 480V AC 0 5 22B D1P4H204 Allen Bradley Plate Drive 1 0 22B D2P3H204 Allen Bradley 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 Table Communication Options Description Designation Voltage HP Part Number Manufacturer ControlNet 1 22 Allen Bradley DeviceNet EA1 All All 22 COMM D Allen Bradley EtherNet EA1 All All 22 COMM E Allen Bradley PROFIBUS EA1 All All 22 COMM P Allen Bradley Adaptor Frame B 1 0 5 5 0 22 Allen Bradley Frame C EA1 All 7 5 15 22B CCC Allen Bradley Table B C Quick Disconnect Options Description Designation Voltage HP Part Number Manufacturer DeviceNet Bottom E22 All All 41358N Brad Harrison DeviceNet L Side E23 All All 41358N Brad Harrison Table B D HIM Options Description Door Mounted IP 66 NEMA UL Type Designation Voltage HP Part Number Manufacturer Allen Bradley Table Operator Devices Control Options Replacement Parts B 3 Option Description Designation Voltage HP Part Number Manu
26. 40 AC DRIVE NEMA 4 4x 12 0 5 5 HP 3PH 4BOV 09 15 05 Layout Drawings Publication 23B IN001G 3 5 Mechanical Installation Figure 3 5 PowerFlex 40 Frame C Layout Drawing SIDE MOUNTED DEVICENET RECEPTACLE WHEN ORDERED B3 18 000 HANDLE FOR P3 OPTION WITH C FRAME ENCLOSURE BOTTOM MOUNTED DEVICENET RECEPTACLE WHEN ORDERED ist BOTTOM MOUNTED R5 RECEPTACLES amp e C 89 NOTES oo E C MOUNT RH SPEED POT IN THE RIGHT MOST ILABLE POSITION IN ONE OF SS SWITCHES 5 2 APPLY LABEL 156942 AS SHOWN WHEN THERE NO OR 6 6 OPTIONS IF EITHER P6 P6T OR P3 P3T OPTION IS ORDERED APPLY THE HOT SURFACE LABEL 0 25 CENTERED ABOVE THE 156942 LABEL 3 FOLLOW ALL MPWS PROCEDURES VENDOR SUPPLIED LITERATURE AND SUPPLIED DOCUMENTATION FOR COMPONENT PLACEMENT ND ASSEMBLY 4 WHEN OPTION P6 IS ORDERED MOUNT 114245 LABELS 2 15 LABELS ON THE TOP WIRE WHEN OPTION IS ORDERED MOUNT 11 215 ON THE TOP A
27. 520 S21 or S22 The drive mounted DeviceNet and the 100 DNY42R will appear as separate nodes on the communication system PowerFlex 40 Standard Configured Drive Standard Features and Options 1 17 DeviceNet Point I O w IB4 4 Inputs Position 16 Code R4 This option provides a factory installed 1734 ADNX Point I O Scanner combination with a 1734 IB4 4 input four point 24V DC sink input The drive DeviceNet is prewired to the subnet connector of the 1734 ADNX The customer is required to make the DeviceNet connection directly to the 1734 ADNX network connector The 1734 IB4 is connected via a backplane offering four available inputs for customer use The Point I O Scanner allows data to be gathered from the drive mounted DeviceNet and the 1734 4 4 input appear as one node on the communication system Refer to publication 1734 13051 for more detail on the 1734 4 Component Specifications 1734 ADNX Devices style Internationally rated Meet IP65 IP66 and NEMA UL Type 4 4 13 UL Listed CSA Certified 10 amp contacts Screw terminals 0 3 3 5 mm 22 12 AWG maximum 1734 IB4 Devices Refer to publication 1734 051 Schematic Figure 2 19 on page 2 20 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 Note Customer is required to supply external 24 DC AC to power 1734 ADNX scanner Pu
28. 81 3AMG OF X314M3MOd 5 RELAY N O RELAY COMMON PARAMETER A055 0 RELAY N C Control Wiring Overview 2 5 1 0 TERMINAL BLOCK STOP START RUN FWD P036 2 2 WIRE 038 4 PRESET FRE DIR RUN REV DIGITAL COMMON DIGITAL IN1 A051 4 PRESET FREQ DIGITAL IN2 A052 4 PRESET FREQ DIGITAL INS DIGITAL IN4 OPTO COMMON 24 DC 10V DC 0 10V IN 4 ANALOG COMMON 4 20 ANALOG OUTPUT OPTO OUTPUT 1 OPTO OUTPUT 2 RS485 DSI SHIELD lt TERMINAL BLOCK Publication 23 0010 2 6 Control Wiring Overview Figure 2 5 Control Logic Option S1 amp S8 2022 5 SNK 009 FORWARD REVERSE SRC F HAND 1 0 TERMINAL BLOCK AUTO RUN ART RUN START RUN FWD PO36 2 2 PO38 4 PRESET FREQ DIR RUN REV DIGITAL COMMON DIGITAL IN1 A051 4 PRESET FREQ DIGITAL IN2 A052 4 PRESET FREQ DIGITAL IN3 DIGITAL IN4 OPTO COMMON 24V DC o 4 20 ava sv 90 21 11 ANALOG OUTPUT OPTO OUTPUT 1 6291101 2 o 215 0 915 81814 SIS a o N T o gt o N 1 RS485 DSI SHIELD
29. 82101 81 410 Qvov 80 20 2 6696 NQISNSM 8S NOlLdO 21901 1ONINOO JAG OF 14 3 4 OlVW3HOS 6 6 66y9 I TERMINAL BLOCK TB2 RELAY N O RELAY COMMON PARAMETER 055 0 RELAY I O TERMINAL BLOCK I O TERMINAL BLOCK STOP START RUN FWD P036 2 2 WIRE PO38 4 PRESET FREQ DIR RUN REV DIGITAL COMMON DIGITAL IN1 A051 4 PRESET FREQ DIGITAL 2 A052 4 PRESET FREQ DIGITAL IN DIGITAL IN4 OPTO COMMON 24V DC 10V DC 0 10V IN ANALOG COMMON 4 20 IN ANALOG OUTPUT OPTO OUTPUT 1 OPTO OUTPUT 2 85485 DSI SHIELD lt TERMINAL BLOCK Publication 23 0010 2 10 Control Wiring Overview Figure 2 9 Control Logic Option S7 I O TERMINAL BLOCK STOP START RUN FWD PO36 1 3 WIRE 038 4 PRESET FREQ DIR RUN REV DIGITAL COMMON DIGITAL IN1 DIGITAL IN2 DIGITAL INS DIGITAL IN4 OPTO COMMON 24V DC 10V DC sav 70 20 01 9261101 suv 70 82 01 18 OUTPUT 2 84862101 5 50 82 10 z Hi b RS485 DSI SHIELD 60 20 6666 6 11558 WISV ON BLOCK ZS 21901 7103105 RELAY N O
30. AL HOLE P6 P6T OPTIONS 2 Q Q Q Aux CONTACTS WHEN DRIVE C FRAME P3 P3T OPTIONS 42 Aux CONTACTS WHEN ORDERED DRIVE AUTO HAND MANUAL AUTO START STOP 1 mo m Nm S4 OPTION 57 OPTION REVERSE FORWARD REVERSE FORWARD REMOTE LOCAL RUN 555 E S8 WHEN ORDERED WITH S7 OPTION S8 OPTION LOCAL CONTROL OFF FF 9 REMOTE 7 LOCAL 3 521 HAND CLEAR FAULT 525 OPTION R3 amp R5 OPTIONS CR1 Prog 4 PE IYPICAL CONTROL RELAY MACH 125775 CRI 4 1784 RH1 m 1734 ADNX CW SL CCW d NETWORK B R R4 OPTION 7 5 518 BOTTOM WIRE COVER CAN BE REMOVED AND DISCARDED IF PRESENT POWER TERMINAL BLOCK B FRAME WITH COVER REMOVED DEVICENET PORT RS485 HIM PORT aj X yv yn DEVICENET PORT BOTTOM WIRE COVER BE REMOVED AND DISCARDED PRESENT C FRAME WITH COVER REMOVED REMOTE HIM RS485 PORT TB1 POWER TERMINAL BLOCK R5 OPT
31. ASE DRIVE RATINGS FUSE RATINGS P6 OPTION P6 P6T OPTIONS OPTIONS P3 OPTION CATALOG NO FRAME HP VOLTAGE FLA TYPE AMP VOLT CATALOG NO CATALOG NO KIT NO 22B D1P4F104 542 528 E LPJ AJT 5 600V 1948 4030 3 140 2 40 363326 22B D2P3F104 342 528 LPJ AJT 6 600V 194R NJO30P3 140 2 65 363333 22B D4POF104 542 528 LPJ AJT 10 600V 194R NJO30P3 140M D8E C10 365537 22B D6POF104 342 528 K LPJ AJT 15 600V 194R NJO30P3 140M D8E C16 363341 22B D010F104 342 528 5 LPJ AJT 20 600 194R NJO30P3 140M D8E C25 363345 22B D012F104 7 542 528 LPJ AJT 25 600V 194R NJO3OP3 140 25 365349 22B D017F104 342 528 LPJ AJT 30 600V 1948 4030 3 140 32 363353 22B D024F104 5 542 528 LPJ 50 600V 194R NJO60P3 140 45 363357 m m m m m m I I I L L 1 L 1 I 1 I 1 1 1 1 1 1 1 NOLLVWOLAIV NI CHZIHOHLUV Ld39X3 3804804 E ANV 804 055019610 0 0380 031402 38 LON ANN SLI YO TANNOY JO SI ONIMVHC IHL 6646001 7 81 10 ON ENN SONILV JAYA DILVW3HOS 3AlJQ JAG NININA uogyeulo any jjesp o Publication 23
32. FP SM32 Allen Bradley Anti Rotation Switch SS2 800F ALC1 Allen Bradley Mounting Latch 552 800F ALP Allen Bradley Contact Block 2 N O SS2 800F X10 Allen Bradley Legend Plate 552 354769 Allen Bradley MOV CR1 V130LA10A Harris Relay CR1 700 HA 32A1 Allen Bradley Relay Socket Base CR1 700 HN125 Allen Bradley Relay Retainer Clip CR1 700HN159 Allen Bradley Option S22 Selector Switch 552 800FP SL32 Allen Bradley Mounting Latch 552 800F ALP Allen Bradley Contact Block 1 N O SS2 800F X10 Allen Bradley Legend Plate 552 354614 Allen Bradley Option S23 Push Button Black 1 All 800FP F2 Allen Bradley Mounting Latch 1 800F ALP Allen Bradley Contact Block 1 N O PB1 800F X10 Allen Bradley Legend Plate PB1 382966 Allen Bradley Option R3 R5 Selector Switch 552 All All 800FP SL32CR Allen Bradley Aux Contact Adapter 051 194 Allen Bradley Aux Contact DS1 195 GA11 Allen Bradley Aux Contact MCP1 140M C ASA11 Allen Bradley Contact Block 5 N O SS2 800F X10 Allen Bradley Legend Plate 552 354614 Allen Bradley 10 Module EA4 100 DNY42R Allen Bradley Quick Disconnect 1 4 8880 4 2 1 Allen Bradley Quick Disconnegt RCPT5 888D M4AE1 1 Allen Bradley Terminal Black TB4 1492 WTF3 Allen Bradley Fuse Block F6 1492 H6 Allen Bradley Fuse F6 MDA 3 Bussmann Option R4 DeviceNet Adaptor 4 All 1734 ADNX Allen Bradley Point Terminal Base EA4 1734 TB3SQ10 Allen Bradley Input I
33. ION 3053 6016 9 9 20 1 5011 2 5 COMMUNICATION CARD OUTPUT SIDE JUMPER TERMINALS 1 2 5 AND 4 ON THE INPUT SIDE USING 18GA BLUE WIRE 103819 JUMPER TERMINALS 5 6 AND 7 ON THE INPUT SIDE USING 16 GA BLUE WITH WHITE TRACER 16GA 144183 USE THE OUTPU OF RECPTACLE 1 AND RECEPTACLE 2 ONLY CONNECT ONLY 1 WIRE TO THE OUTPUT SIDE OF TERMINALS 1 2 GOING TO EA4 SIDE OF TERMINAL 3 TO CONNECT BROWN WIRES AND CONNECT ONLY 1 WIRE TO THE OUTPUT SIDE OF TERMINALS 5 AND 6 BLUE WIRES FROM RECEPTACLES 5 AND 4 RESPECTIVELY ACAD 07 15 04 07 15 04 1026255 85925 es 1025655 usa 1923519 err e LAYOUT DRAWING PF40 AC DRIVE NEMA 4 4X 12 0 5 15 HP 3PH 480V Publication 23B IN001G Appendix A Specifications Table Standard Configured Drive Products Input Output Ratings Output Frequency 0 400 Hz Programmable Efficiency 97 596 Typical Approvals Gr usc 0 22 2 No 14 Disconnecting Means 140M Motor Circuit Protector Provides branch circuit protection 65 kA short circuit withstand 194R Fused Disconnect Provides branch circuit protection 100 kA short circuit withstand Class J fuses Protective Features Over Voltage 480V AC Input Trip occurs at 810V DC bu
34. N 216 IHS L 5133 5 40 501415 vo izo 80 80 50 so 90 o 500 80 50900 66 9 92 NOILdO NOILNGINLSIG 3MOd OV X314M3MOd OIIVW3HOS Publication 23B IN001G AUX CONTACTS FOR R3 OR R5 WITH P6 OR P6T OPTION MOTOR DATA HP VOLTS _ 5 REFER TO MOTOR NAMEPLATE FOR DATA AC MOTOR GENERAL NOTES 1 BUILDING GROUND TO GROUNDED BY CUSTOMER ae NV SIGNAL COMMON WW POWER EQUIPMENT GROUND 7 CHASSIS CONNECTION INDICATES COMPONENTS SUPPLIED BY OTHERS INDICATES WIRE SUPPLIED BY OTHERS INDICATES 4 TERMINAL BLOCK INDICATES TERMINAL ON INDIVIDUAL 2 COMPONENTS 4 COIL AND CONTACT CROSS REFERENCING NUMBERS ADJACENT TO COIL AND UNDER CONTACT INDICATE SHEET AND LINE NUMBERS 1 3 SURGE SUPPRESSOR 1 3 4 INDICATES LINE NO 3 2 18 INDICATES SHEET NO 1 UNDERSCORED TEXT LINE INDICATES A NORMALLY CLOSED CONTACT CROSS REFERENCING NUMBERS ADJACENT TO SOURCE AND DESTINATION SYMBOLS INDICATE SHEET AND LINE NUMBERS TO 1 24 FROM 17244 2 INDICATES LINE NO 24 INDICATES SHEET NO 1 Control Wiring Overview 2 3 Figure 2 2 Drive Ratings TABI 2 ge S A 255550527255 750 075232022205 3 PH
35. ND T1 12 T3 ON THE BOTTOM WIRE FROM BOTTOM TO THE DRIVE 5 WHEN OPTION P3 IS ORDERED APPLY LABEL 364314 AND TERMINAL ADAPTOR 364364 TO THE TOP AND BOTTOM WCP RESPECTIVELY WIRE FROM THE TOP T1 12 13 TO THE DRIVE EAS WILL BE INSTALLED BY WHEN OPTION P3T IS ORDERED 00 NOT USE THE ABOVE CUSTOMER WHEN NEEDED MOUNT PARTS WIRE FROM BOTTOM OF 1 1 12 15 TO THE ALL TERMINAL BLOCKS AND FUSE DRNE NEXT TO EM 6 INDOOR USE ONLY LABEL USE WITH 4 OR 4X WITH DOOR MOUNTED HIM ENCLOSURES ONLY ie CE d Cr en Bradi ARS LAYOUT DRAWING PF40 DRIVE 12 15 04 NEMA 4 4X 12 7 5 15 HP 3PH 480V 28 1025655 emer Los 1023519 weree rion 549932 5 Ei Publication 23 0010 Mechanical Installation 6 3 Figure 3 6 PowerFlex 40 General Option Layout Drawing DS1 aer ron cor MCP1 SISIS s n 868 MCP1 33 33 T 34 s FS 34 41 ron coe Aux CONCI WHEN ORDERED B FRAME NOI RUN 2 POWER WRES FROM ONE TERMIN
36. OVED FOR USE AS CONTACT OUTPUT amp DENOTES CONNECTION FROM 24V COM THAT CAN BE REMOVED Publication 23 0010 2 22 90 62 60 80 NO3 3 o T 8 8 5 8 8 S 469600 8 0010266 01515 ON 6 C 66v 9 Control Wiring Overview SS1 552 552 552 552 4 4 4 552 4 DRIVE UNIT FUSES DISCONNECT MTR CIRCUIT PROT HIM DEVICENET MOD ETHERNET MOD PROFIBUS MOD CONTORLNET MOD AUTO MAN SS H O A SEL SW FOR REV SS CLE R FAULT START PB STOP PB RELAY FAN SPEED POT OPRATOR LOC REM SS OFF RUN FWD SS LCL OFF REM SS RELAY H O A SEL SW H O A SEL SW DEVNET 1 0 REL PLC 1 0 MOD DEVICENET ADAPTER H O A SEL SW DEVNET 1 0 REL 1 4 RECEPTACLE MICRO FEMALE 5 F6 RECEPTACLE 24VDC FUSE Figure 2 21 Interconnect Wire amp Parts List REFER TO 349932 12 FOR CAT NO REFER TO TABLE 2 PAGE 2 5 FOR FUSE SIZE AND MANUFACTURER A B 194R NJO3OP3 OR 194R NJOGOP3 REFER TO TABLE 2 PAGE 2 3 FOR SIZE REFER TO TABLE 2 PAGE 2 3 FOR KIT NUMBER OR PART NUMBERS 22 25 22 0 22 22 22 5 22 11 5 32 40 5 22 11 A B 800FP F2PX10 A B 800FP F3PX10 A B BOOEP FAPXO1 700 2 1 TECH 2410ML 05W B30
37. P1 480V 0 5 5 194R NX12 Allen Bradley Option P3 or P3T 7 5 15 140 0 Allen Bradley Operator Terminal MCP1 480V AC 0 5 5 0 46006 086 010 Allen Bradley Markings 140M C TE Allen Bradley 7 5 15 46006 091 01 0 Allen Bradley 140M F TE Allen Bradley Disconnect Switch DS1 480V 0 5 10 194R NJO30P3 Allen Bradley Option P6 or PeT 15 194R NJ060P3 Allen Bradley Operator Handle 051 480V AC 0 5 15 194R HS4 Allen Bradley Option or 6 Operator Shaft 051 480V 0 5 15 194R R1 Allen Bradley Option P6 or P6T Main Fuses F1 F2 F3 480VAC 105 LPJ 3SP Bussman Option P6 or P6T AJT 3 Ferraz Shawmut 1 0 LPJ 6SP Bussman 2 0 LPJ 10 Bussman LPJ 10SP Bussman AJT 10 Ferraz Shawmut 3 0 LPJ 15 Bussman LPJ 15SP Bussman 5 0 LPJ 20 Bussman LPJ 20SP Bussman AJT 20 Ferraz Shawmut 75 LPJ 25 Bussman LPJ 25SP Bussman AJT 25 Ferraz Shawmut 10 LPJ 30 Bussman LPJ 30SP Bussman AJT 30 Ferraz Shawmut 15 LPJ 50 Bussman LPJ 50SP Bussman 1 Replacement Kit includes Motor Circuit Protector and top and bottom terminal labels instructions Does not include handle adaptor or connection rod 2 Part of Motor Circuit Protector Replacement Kit Publication 23B IN001G 2 Replacement Parts Publication 23B IN001G Table B A Components Continued Description Designation Voltage Part Number Manufacturer Drive Module 1 480V 0 5
38. PowerFlex 40 Configured AC Drives INSTALLATION INSTRUCTIONS ALLEN BRADLEY ROCKWELL SOFTWARE Automation 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 http 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
39. TAL IN4 OPTO COMMON 24V DC 10V DC 4 20 IN ANALOG OUTPUT OPTO OUTPUT 1 OPTO OUTPUT 2 RS485 DSI SHIELD lt BLOCK Publication 23 0010 2 18 Control Wiring Overview Figure 2 17 Control Logic Option S23 I O TERMINAL BLOCK STOP START RUN FWD 036 5 COMM PORT P038 5 COMM PORT DIR RUN REV DIGITAL COMMON DIGITAL IN1 A051 4 PRESET FREQ DIGITAL IN2 DIGITAL IN3 CLEAR FAULT 2131 2132 9 DIGITAL 144 1 054 7 CLEAR FAULT OPTO COMMON 24V DC 10V DC 4 20 IN ANALOG OUTPUT OPTO OUTPUT 1 81 YO ON NOLLVIOLO V TENDIQOH 40 1 3404 61 IHL OPTO OUTPUT 2 T 5 8 3 a z 8 8 8 8 aya RS485 DSI SHIELD 44 00 ON lt TERMINAL BLOCK EZS NOWdO 21901 1OMINOO OV OF X314M3MOd OIIVW3HOS C ELOGE TERMINAL BLOCK TB2 RELAY N O RELAY COMMON PARAMETER 055 0 RELAY N C I O TERMINAL BLOCK Publication 23B IN001G Control Wiring Overview 2 19 Figure 2 18 Control Logic Option R3 with P3 P3T or I O TERMINAL BLOCK STOP START RUN FWD P036 2 2 WIRE PO38 4 PRESET FREQ DIR RUN REV DIGITAL COMMON
40. al Block TB1 and Relay Terminal Block TB2 located on the drive Main Control Board provide terminals for interfacing customer supplied control inputs and outputs analog and discrete control wiring will be made at these terminals To connect control and signal wiring to the drive package 1 Wire the control and signal 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 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 the drive 3 Tighten the I O terminals to the proper torque according to drive type as shown in Table 2 A Table 2 A I O Terminal Block Specifications Voltage Rating Maximum Wire Size Minimum Wire Size Torque 208 460V AC 1 3 mm 16 AWG 0 13 mm 26 AWG 0 5 0 8 N m 4 4 7 Ib in 00 Maximum minimum sizes that the terminal block will accept these are not recommendations Publication 23B IN001G 2 2 Control Wiring Overview Schematic Drawings o L1 Figure 2 1 Power Distribution Option 480 VOLTS 12 DISCONNECTING MEANS AND SHORT CIRCUIT PROTECTION POWER DISCONNECTING OPTION 3PH 50 60H LINES L3 PROVIDED
41. blication 23 0010 1 18 PowerFlex 40 Standard Configured Drive Standard Features and Options Publication 23B IN001G DeviceNet I O 4 In 2 Out w Spring Return HOA Power Disconnect Aux Contact and 4 I O Quick Disconnects Position 16 Code R5 This option provides a factory installed 800F door mounted operator device a 100 DNY42R mounted internal to the cabinet a power disconnect auxiliary contact four I O quick disconnects and a 24V DC male receptacle The Hand Off Auto selector switch will start the drive while held in the Hand mode and stop it in the Off mode The default speed reference comes from parameter P038 option 4 Preset Freq The selector switch has a spring return disallowing the operator to remain in Hand When in Auto the default speed reference is derived parameter A051 option 4 Preset Freq The 100 DNY42R is powered by DeviceNet and provides control based on customer control parameters The inputs and outputs are powered by customer supplied 24V DC This options is prewired with an auto contact from the Hand Off Auto selector switch between the I O and INO terminals The main power disconnect auxiliary contact is wired between the I O V and 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 Bulletin 800F IEC style I
42. cel times Each time may be programmed from 0 600 seconds in 0 1 second increments Intermittent Overload 150 Overload capability for up to 1 minute 200 Overload capability for up to 3 seconds Electronic Motor Overload Protection Class 10 protection with speed sensitive response Stop Modes Accel Decel Publication 23 0010 2 Specifications Notes Publication 23B IN001G Replacement Parts Table Components Appendix B Description Designation Voltage HP Part Number Manufacturer Circuit MCP1 480V AC 05 140 02 84077 Allen Bradley rotector 1 0 140M C2E B637 Allen Bradle Option P3 or PST 20 140 08 109 3 0 140 08 0160 Allen Bradley 5 0 140M D8E C25 J Allen Bradley 75 140M F8E C25 Allen Bradley 10 140M F8E C32 Allen Bradley 15 140M F8E C45 Allen Bradley Replacement Kit 7 1 480V AC 05 363326 Allen Bradley Option P3 1 0 363333 Allen Bradley 2 0 363337 Allen Bradley 3 0 363341 Allen Bradley 5 0 363345 Allen Bradley 7 5 363349 Allen Bradley 10 363353 Allen Bradley 15 363357 Allen Bradley Operator Handle 480V 0 5 5 190 54 Allen Bradley Option P3 or P3T 7 5 15 140 66 Allen Bradley Operator Handle 480V 0 5 15 140M D HA Allen Bradley Adaptor Option P3 or Operator Shaft MC
43. ces Meet IP65 IP66 and NEMA UL Type 4 4 13 UL Listed CSA Certified 10 amp contacts Screw terminals 0 3 3 5 mm 22 12 AWG maximum Local Off Remote position Maintained 2 contacts Selector Switch Interposing Control 1 relay 10 amp 120V AC coil Octal base Relay Legend Plate 30 x 50 mm Black with white lettering Wiring 0 8 mm 18 AWG Blue Schematic Figure 2 14 on page 2 15 This option is not compatible with Codes R3 5 51 54 57 58 520 522 Publication 23 0010 1 14 PowerFlex 40 Standard Configured Drive Standard Features and Options Spring Return Hand Off Auto Selector Switch Code 522 This 800F door mounted operator device is factory installed and provides a Hand Off Auto selector switch The Hand position is equipped with a spring return The Hand Off Auto selector switch will start the drive while held in Hand mode and stop the drive in Off mode The selector switch has a spring return disallowing the operator to remain in Hand 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 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 poten
44. e Rafa gt gt gt 81318 fefe 8 81816 z 5 ON 66 8 92 315 LZS 0 21901 1OMINOO 8429201 s y 90 51 21 5 OV Oy X314M43MOd CUSTOMER PLC OUTPUT CUSTOMER SUPPLIED AND PROTECTED 120 RELAY N O RELAY COMMON PARAMETER 055 0 RELAY Control Wiring Overview 2 15 I O TERMINAL BLOCK STOP START RUN FWD PO36 2 2 WIRE 4 PRESET FREQ DIR RUN REV DIGITAL COMMON DIGITAL IN1 DIGITAL IN2 DIGITAL 5 DIGITAL IN4 OPTO COMMON 24V DC 10V DC 0 10V IN ANALOG COMMON 4 20Ma IN ANALOG OUTPUT OPTO OUTPUT 1 OPTO OUTPUT 2 RS485 DSI SHIELD TERMINAL BLOCK TB Publication 23 0010 2 16 Control Wiring Overview Figure 2 15 Control Logic Option S22 7 HAND AUTO I O TERMINAL BLOCK 2021 2022 STOP x00 AUTO RUN T START RUN FWD PO36 2 2 WIRE 4 PRESET FREQ DIR RUN REV DIGITAL COMMON DIGITAL IN1 A051 4 PRESET FREQ DIGITAL IN2 A052 4 PRESET FREQ DIGITAL 5 DIGITAL IN4 OPTO COMMON 24V DC 10V DC 0 10 IN 4 ANALOG COMMON 4 20 IN ANALOG OUTPUT OPTO OUTPUT 1
45. eaker or equivalent Protective Features Motor Protection Pt overload protection 15096 for 60 Secs 20096 for 3 Secs Provides Class 10 protection Overcurrent 20096 hardware limit 30096 instantaneous fault Control Ride Through Minimum ride through is 0 5 Secs typical value 2 Secs Faultless Power Ride Through 100 milliseconds Dynamic Braking Internal brake IGBT included with all ratings Environment Altitude 1000 m 3300 ft max without derating Storage Temperature 40 to 85 degrees 40 to 185 degrees Control Atmosphere Important Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas vapors or dust If the drive is not going to be installed for a period of time it must be stored in an area where it will not be exposed to a corrosive atmosphere Relative Humidity to 95 non condensing Shock operating 156 peak for 11ms duration 1 0ms Vibration operating 1G peak 5 to 2000 Hz Frequency Accuracy Digital Input Within 0 05 of set output frequency Analog Input Within 0 5 of maximum output frequency Analog Output 2 of full scale 10 bit resolution Speed Regulation Open Loop with Slip Compensation 2 of base speed across a 40 1 speed range 1 of base speed across a 60 1 speed range Multiple programmable stop modes including Ramp Coast DC Brake Ramp to Hold and S Curve Two independently programmable accel and de
46. ensation 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 23 0010 1 2 PowerFlex 40 Standard Configured Drive Standard Features and Options Enclosure Options Publication 23B IN001G 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 applicati
47. ent 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 UMO006 To review this schematic see Figure 2 1 on page 2 2 and Figure 2 3 on page 2 4 Publication 23 0010 1 4 PowerFlex 40 Standard Configured Drive Standard Features and Options Power Disconnect Options Publication 23B IN001G 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 P
48. et Freq 6 Comm Port 13 10V In Ctrl HIM Door Preset Speed 4 Preset Freq 4 Preset Freq 6 Comm Port Analog Input 0 10V 4 Preset Freq 13 10V In 6 Comm Port Analog Input 4 20mA 4 Preset Freq 14 20mA In Ctrl 6 Comm Port 0 Communication port will have both logic and reference control Component Specifications Bulletin 800F IEC style Internationally rated Devices Meet IP65 IP66 and NEMA UL Type 4 4X 13 UL Listed CSA Certified 10 amp contacts Screw terminals 0 3 3 5 mm 22 12 AWG maximum Hand Off Auto 3 position Maintained Selector Switch 4 contacts Legend Plate 30 x 50 mm Black with white lettering Wiring 0 8 mm 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 57 S20 S21 or 522 Publication 23 0010 1 10 PowerFlex 40 Standard Configured Drive Standard Features and Options Auto Manual Selector Switch Position 16 Code 54 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 518 is supplied and i
49. facturer Option 51 Selector Switch 552 800FP SM32 Allen Bradley Mounting Latch 552 800F ALP Allen Bradley Contact Block 4 N O SS2 800F X10 Allen Bradley Legend Plate 552 354614 Allen Bradley Option S4 Selector Switch 551 800FP SM22 Mounting Latch 551 800F ALP Allen Bradley Contact Block 1 N O 551 800 10 Allen Bradley Contact Block 1 N C 551 800 01 Allen Bradley Legend Plate 551 354650 Allen Bradley Option S7 Push Button Green PB2 All All 800FP F3 Allen Bradley Push Button Red PB3 800FP E4 Allen Bradley Mounting Latch PB2 PB3 800F ALP Allen Bradley Contact Block 1 PB2 800F X10 Allen Bradley Contact Block 1 N C PB3 800F X01 Allen Bradley Legend Plate PB2 354666 Allen Bradley Legend Plate PB3 354859 Allen Bradley Option S8 Selector Switch 553 All All 800FP SM22 Allen Bradley Mounting Latch 553 800F ALP Allen Bradley Contact Block 1 N O SS3 800F X10 Allen Bradley Contact Block 1 N C 553 800 019 Allen Bradley Legend Plate 553 354662 Allen Bradley Option 18 Potentiometer Operator RH1 All All 800F POT6 Allen Bradley Legend Plate RH1 362657 Allen Bradley Option S20 Selector Switch 551 552 800FP SM22 Mounting Latch 551 552 800F ALP Allen Bradley Contact Block 1 N O 551 552 800 10 Allen Bradley Legend Plate 551 354702 Allen Bradley Legend Plate 552 354786 Allen Bradley Option S21 Selector Switch 552 All All 800
50. igure 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 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 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 PowerFlex PROFIBUS Adapter User Manual publication 22 1 005 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 pres
51. ings Failure to observe this precaution could result in damage to or destruction of the equipment ATTENTION Protect the contents of the options cabinet from 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 ATTENTION Do not route signal and control wiring with 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 Table 1 B Component Current Ratings and Wire Sizing PowerFlex 40 SPD Drive Rating 480V HP Continuous Factory Power Customer Operating Torque Current
52. ion 23 0010 2 8 Control Wiring Overview Figure 2 7 Control Logic Option 54 amp S7 I O TERMINAL BLOCK STOP SNK SRC START RUN FWD PO36 1 3 038 4 PRESET FRE DIR RUN REV DIGITAL COMMON AUTO MANUAL 2082 DIGITAL IN1 XO A051 4 PRESET FREQ Lp 2101 DIGITAL IN2 o9 A052 4 PRESET FREQ SS1 DIGITAL 5 DIGITAL IN4 OPTO COMMON 24V DC 10V DC 0 10V IN ANALOG COMMON 4 20 ANALOG OUTPUT o S S N o R gt a a OPTO OUTPUT 1 OPTO OUTPUT 2 suv so ez 10 vo lt lt 9 lt 201 s v 90 62 60 85485 DSI SHIELD ON lt BLOCK INXA LOarOdd LS 5 21901 1041509 JAXA OV OF X3lJM3MOd OLLWNSHOS RELAY N O RELAY COMMON PARAMETER 055 0 RELAY Publication 23 0016 Control Wiring Overview 2 9 Figure 2 8 Control Logic Option S4 with S8 FORWARD REVERSE 2042 AUTO MANUAL 2082 2101 o9 9 551 1 1 1 sele 11 BEE gt gt 81313 alele SEP S 5 8 51515151238 BEBEL 5 HE 884 88 ii B i NO3 4611101 89
53. itch 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 518 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 228 07 001 for other options Hand Off Auto Selector Switch Code S1 Speed Reference Parameter Settings Hand Mode Auto Mode P038 Speed Reference 051 Digital In1 Sel 052 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 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 4 Preset Freq 14 20 In Ctrl 13 10V In Ctrl Communication 4 Pres
54. ition 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 1s 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 57 with S8 the selector switch only changes direction The drive is started and stopped via the Start and Stop push buttons Code 57 Component Specifications Bulletin 800F style Internationally rated Devices Meet IP65 IP66 and NEMA UL Type 4 4 13 UL Listed CSA Certified 10 amp contacts Screw terminals 0 3 3 5 mm 22 12 AWG maximum Forward Reverse 2 2 position Maintained 1 amp 1 contacts Selector Switch 3 2 position Maintained 1 N C contact Legend Plate 30 x 50 mm Black with white lettering Wiring 0 8 mm 18 AWG Blue Schematics 2 Wire Control Figure 2 5 on page 2 6 Figure 2 8 on page 2 9 Figure 2 11 on page 2 12 3 Wire Control Figure 2 10 on page 2 11 This option is not compatible with Codes R3 R5 520 or S21 Publication 23 0010 1
55. lation Instructions is designed to provide only basic installation and operation information For this reason the following topics have not been included e Troubleshooting e Start Up e Programming and Parameters Please refer to the PowerFlex 40 User Manual for detailed drive information Publication 23 0010 2 Overview Reference Materials The following manuals are recommended for general drive information Title Publication Available Online at Wiring and Grounding Guidelines for Pulse DRIVES INOO Width Modulated PWM AC Drives Preventive Maintenance of Industrial Control DRIVES TD001 and Drive System Equipment Safety Guidelines for the Application SGI 1 1 www rockwellautomation com Installation and Maintenance of Solid State literature Control A Global Reference Guide for Reading 0100 2 10 Schematic Diagrams Guarding Against Electrostatic Damage 8000 4 5 2 For detailed PowerFlex 40 information including drive parameters programming start up troubleshooting specifications Publication Available Online at PowerFlex 40 User Manual 22 0 001 PowerFlex Reference Manual 001 WWW rockwellautomation comiliterature The latest version of this Installation Instructions be obtained online www rockwellautomation com literature For Allen Bradley Drives Technical Support Title Online Allen Bradley Drives Technical Support
56. mission Class 480V 60Hz Input Code Rating Code Amps kW Hp 0 Not Filtered 1P4 1 4 0 4 0 5 2 23 0 75 1 0 9 4 4 0 1 5 2 0 Version 6 6 0 2 2 3 0 Code Version 010 10 5 4 0 5 0 4 RS485 Standard 012 12 5 5 7 5 ControlNet 017 17 7 5 10 D DeviceNet 024 24 11 15 EtherNet IP B PROFIBUS DP d Enclosure h Code Enclosure Code Rating NEMA UL Type 4X N Reserved D NEMA UL Type 4 t The design of the PowerFlex 40 Standard i Configured Drive supports indoor and outdoor applications that are not in direct sunlight Code Rating N Reserved Publication 23B IN001G 13 14 15 16 Options Code Description 22 DeviceNet Quick Disconnect Bottom DeviceNet Quick Disconnect Left E23 Side P3 Motor Circuit Protector Motor Circuit Protector Customer 22224 wiring into top of device P6 Disconnect Switch Fused Per Disconnect Switch Fused Customer wiring into top of device DeviceNet I O 4 In 2 Out w Spring R3 Return HOA and Power Disconnect Aux Contact R4 DeviceNet Point I O w IB4 4 Inputs R5 R3 plus 4 Quick Disconnects and 1 24V DC Receptacle S1 Hand Off Auto S S Start Stop Speed Ref S4 Auto Manual S S Speed Ref S7 Start and Stop P B S8 Forward Reverse S S Door Mounted Local Speed Pot 1 S18 Turn S20 Local Remote and Local Control Off Run Forward Selector Switches Local Off Remote with 1 N O S21 Interposing Relay 22 Spring Ret
57. nch 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 Output Power Terminal Block Specifications Maximum Wire Size Minimum Wire Size Recommended Torque B 5 3 mm 10 AWG 1 3 16 AWG 17 22 N m 16 19 Ibin C 8 4 mm 8 AWG 1 3 mm 16 AWG 2 9 3 7 N m 26 33 00 Maximum minimum sizes that the terminal block will accept these are not recommendations Publication 23B IN001G Operator Device Options PowerFlex 40 Standard Configured Drive Standard Features and Options 1 9 Hand Off Auto Selector Switch Position 16 Code 51 This 800F door mounted operator device is factory installed and provides a Hand Off Auto selector switch The Hand Off Auto selector sw
58. nternationally rated Devices Meet IP65 IP66 and NEMA UL Type 4 4 13 UL Listed CSA Certified 10 amp contacts Screw terminals 0 3 3 5 mm 22 12 AWG maximum Hand Off Auto 3 position Hand spring return Off Auto maintained Selector Switch 3 amp 3 contacts Legend Plate 30 x 50 mm Black with white lettering Wiring 0 8 mm 18 AWG Blue 100 DNY42R cULus Listed CSA DeviceLogix Rotary address switches 24V DC or 120V AC inputs High Capacity transistor or Relay outputs ODVA Compliance v2 0 Tested Power Disconnect Auxiliary Contact 1 N O amp 1 N C Side mounted contacts Receptacle Shell Black anodized machined aluminum Connector Insert Nylon Contacts Machined brass with gold over nickel plating Schematic Figure 2 20 on page 2 21 This option must be used with the drive mounted DeviceNet option D Position 12 and is not compatible with options R3 R4 51 54 57 S8 520 S21 S22 The drive mounted DeviceNet and the 100 DNYR42 will appear as separate nodes on the communication system Chapter Objectives Control Wiring Overview Chapter 2 Control Wiring Overview This chapter describes the control and signal wiring connection options For information on Control Wiring Overview 2 1 Schematic Drawings 2 2 Refer to the PowerFlex 40 User Manual for additional detailed information about control and signal wiring The Control I O Termin
59. ons that are not in direct sunlight NEMA UL Type 4X Position 9 Code C The enclosure provided is 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 Communication Options PowerFlex 40 Standard Configured Drive Standard Features and Options 1 3 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 UMO03 To review this schematic see F
60. rlocked 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 Publication 23B IN001G Main Fuses F1 F3 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 precaution could result in damage to or destruction of the equipment ATTENTION Most codes require that upstream branch circuit 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 The input fuse ratings listed in Table 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 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 metal chips and other debris while drilling the conduit open
61. rotector Position 16 Code 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 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
62. s oe be pum d 3 1 Mounting Considerations 3 1 Dimensions os btu ities ans EE HH Ene einn adir ber ane 3 2 Layout DrawI1ngsz 5 2 oe ee og Rede tnn enm loeo ere Rue a ds 3 4 Specifications Replacement Parts Publication 23B IN001G 2 Table of Contents Notes Publication 23B IN001G Preface Overview 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 UMO01 Both manuals are required to properly install and operate PowerFlex 40 Adjustable Frequency AC Standard Configured Drives For information See page Who Should Use this Manual P 1 What Is Not in this Manual P 1 Reference Materials 2 Manual Conventions P 2 General Precautions P 3 Compliance Certification 3 Catalog Number Explanation 4 Who Should Use this This manual is intended for qualified personnel You must be able to Manual 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 Instal
63. s voltage equivalent to 575V AC incoming line Under Voltage 480 AC Input Trip occurs at 390V DC bus voltage equivalent to 275V AC incoming line Environment Ambient Operating Temperature NEMA 4 12 IP66 10 to 40 degrees C 14 to 104 degrees 1 Cooling Method Fan All drive ratings Control Carrier Frequency 2 4 kHz Drive rating and heat calculations are based on 4 kHz 1 The design of the PowerFlex 40 Standard Configured Drive NEMA 4 12 and 4X packages support indoor and outdoor applications that are not in direct sunlight When optional Door Mounted HIM is supplied enclosure is rated for indoor use only Table Standard PowerFlex 40 Drives SRC Source Mode 18 24 Volts ON 0 6 Volts OFF Digital Control Inputs Input Current 6 mA SNK Sink Mode 0 6 Volts ON 18 24 Volts OFF Analog Control Inputs 4 20 Analog 250 ohm input impedance 0 10V DC Analog 100 ohm input impedance External Pot 1 10k ohms 2 Watt minimum Control Output Programmable Output form C relay Resistive Rating 3 0A at 30V DC 3 0A at 125V AC 3 0A at 240V 30V DC 50 mA Inductive Rating 0 5A at 30V DC at 125V AC 0 5A at 240V AC Non inductive Opto Outputs Analog Output 10 bit 0 10V 1k ohm Min Fuses and Circuit Breakers Recommended Fuse Type UL Class J CC T or Type BS88 600V 550V or equivalent Recommended Circuit Breakers HMCP circuit br
64. selector switch has a spring return disallowing the operator to remain in Hand When in Auto the default speed reference is derived parameter A051 option 4 Preset Freq The 100 DNY42R is powered by DeviceNet and provides control based on customer control parameters This option is prewired with an auto contact from the Hand Off Auto selector switch between the I O and INO terminals The main power disconnect auxiliary contact is wired between the I O V and terminals indicating if the disconnect is on or off Two inputs and two outputs are available for customer use Component Specifications Bulletin 800F style Internationally rated Devices Meet IP65 IP66 and NEMA UL Type 4 4 13 UL Listed CSA Certified 10 amp contacts Screw terminals 0 3 3 5 mm 22 12 AWG maximum Hand Off Auto 3 position Hand spring return Off Auto maintained Selector Switch 3 N O amp 3 N C contacts Legend Plate 30 x 50 mm Black with white lettering Wiring 0 8 mm 18 AWG Blue 100 DNY42R cULus Listed CSA DeviceLogix Rotary address switches 24V DC or 120V AC inputs High Capacity transistor or Relay outputs ODVA Compliance v2 0 Tested Power Disconnect Auxiliary Contact 1 N O amp 1 N C Side mounted contacts Schematic Figure 2 18 on page 2 19 This option must be used with the drive mounted DeviceNet option D Position 12 and is not compatible with options R4 R5 51 S4 57 S8
65. sted CSA Certified 10 amp contacts Screw terminals 0 3 3 5 mm 22 12 AWG maximum Auto Manual 2 position Maintained Selector Switch 1 N C contact Legend Plate 30 x 50 mm Black with white lettering Wiring 0 8 mm 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 520 521 or S22 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 IEC style Internationally rated Devices Meet IP65 IP66 and NEMA UL Type 4 4X 13 UL Listed CSA Certified 10 amp contacts Screw terminals 0 3 3 5 mm 22 12 AWG maximum Start Push Button Flush head Green 1 contact Stop Push Button Extended head Red 1 contact Legend Plate 30 x 50 mm Black with white lettering Wiring 0 8 mm 18 AWG Blue Schematics Figure 2 7 on page 2 8 Figure 2 9 on page 2 10 Figure 2 10 on page 2 11 This option is not compatible with Codes R3 R5 S1 520 521 522 or 523 Forward Reverse Selector Switch Pos
66. t 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 228 07 001 for other options Auto Manual Selector Switch Code S4 Speed Reference Parameter Settings Manual Mode Auto Mode P038 Speed Reference 051 Digital In1 Sel 052 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 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 4 Preset Freq 14 20mA In Ctrl 13 10V In Ctrl Communication 4 Preset Freq 6 Comm Port 13 10V In HIM Door Preset Speed 4 Preset Freq 4 Preset Freq 6 Comm Port Analog Input 0 10 4 Preset Freq 13 10V In Ctrl 6 Comm Port Analog Input 4 20mA 4 Preset Freq 14 20mA In Ctrl 6 Comm Port Communication port will have both logic and reference control Publication 23B IN001G Component Specifications Bulletin 800F style Internationally rated Devices Meet IP65 IP66 and NEMA UL Type 4 4X 13 UL Li
67. tarted and stopped when in Local Control Component Specifications Bulletin 800F Devices style Internationally rated Meet IP65 IP66 and NEMA UL Type 4 4 13 UL Listed CSA Certified 10 amp contacts Screw terminals 0 3 3 5 mm 22 12 AWG maximum Local Control Off Run 2 position Maintained 1 contact Forward Selector Switch Local Remote 2 position Maintained 1 N O contact Selector Switch Legend Plate 30 x 50 mm Black with white lettering Wiring 0 8 mm 18 AWG Blue Schematic Figure 2 12 on page 2 13 This option is not compatible with Codes R3 5 51 54 57 58 521 or 522 PowerFlex 40 Standard Configured Drive Standard Features and Options 1 13 Local Off Remote Selector Switch With One Normally Open Interposing Relay Code S21 This 800F door mounted operator device and interposing relay option is factory installed and provides a Local Off Remote selector switch The Local Off Remote selector switch will start the drive in Local mode and stop it in Off mode In Remote mode the drive will be stopped and started from the factory installed CR1 contact which is energized by a customer 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 Bulletin 800F IEC style Internationally rated Devi
68. tiometer Option 518 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 Spring Return HOA Selector Switch Code 522 Speed Reference Parameter Settings Hand Mode Auto Mode P038 Speed Reference 051 Digital In1 Sel 052 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 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 4 Preset Freq 14 20mA In Ctrl 13 10V In Ctrl Communication Port 4 Preset Freq 6 Comm Port 13 10V In 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 Publication 23B IN001G Component Specifications Bulletin 800F IEC style Internationally rated Devices Meet IP65 IP66 and NEMA UL Type 4 4X 13 UL Listed CSA Certified 10 amp contacts Screw terminals 0 3 3 5
69. urn Hand Off Auto S S Start Stop Speed Ref 523 Clear Fault Chapter Objectives Standard Features Chapter 1 PowerFlex 40 Standard Configured Drive Standard Features and Options This chapter describes the standard features and operation for PowerFlex 40 Standard Configured Drives and associated options 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 uick Disconnects 1 15 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 D e Flange mount drive external heatsink reducing overall enclosure size e 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 The enclosure does not normally protect electrical equipment from cond
70. www ab com support abdrives Manual Conventions e 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 e The following words are used throughout the manual to describe an action Word Meaning 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 Compliance Certification 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

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