Rockwell Automation PowerFlex 40 User manual

INSTALLATION INSTRUCTIONS

PowerFlex 40 Configured AC Drives

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 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.

Important: Identifies information that is critical for successful application and

understanding of the product.

PowerFlex, DriveExplorer, DriveExecutive, DPI, and SCANport are either trademarks or registered trademarks of Rockwell Automation, Inc.

!WARNING: Identifies information about practices or

circumstances that can cause an explosion in a hazardous

environment, which may lead to personal injury or death, property

damage, or economic loss.

!ATTENTION: Identifies information about practices or

circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you identify a hazard,

avoid a hazard, and recognize the 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.

Publication 23B-IN001G

Table of Contents

Preface Overview

Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1

What Is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1

Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-3

Compliance Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-3

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-4

Chapter 1 PowerFlex 40 Standard Configured Drive Standard Features and Options

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Enclosure Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Power Disconnect Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Operator Device Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Quick Disconnects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

I/O Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Chapter 2 Control Wiring Overview

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Control Wiring Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Schematic Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Chapter 3 Mechanical Installation

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Layout Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Appendix A Specifications

Appendix B Replacement Parts

Publication 23B-IN001G

2Table 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-UM001…. Both manuals are required to properly install

and operate PowerFlex 40 Adjustable Frequency AC Standard Configured

Drives.

Who Should Use this

Manual?

This manual is intended for qualified personnel. You must be able to

program and operate Adjustable Frequency AC Drive devices. In addition,

you must have an understanding of the parameter settings and functions.

What Is Not in this Manual The PowerFlex 40 Adjustable Frequency AC Standard Configured Drives

Installation Instructions is designed to provide only basic installation and

operation information. For this reason, the following topics have not been

included:

•Troubleshooting

•Start-Up

•Programming and Parameters

Please refer to the PowerFlex 40 User Manual for detailed drive

information.

For information on … See page …

Who Should Use this Manual? P-1

What Is Not in this Manual P-1

Reference Materials P-2

Manual Conventions P-2

General Precautions P-3

Compliance Certification P-3

Catalog Number Explanation P-4

Publication 23B-IN001G

P-2 Overview

Reference Materials The following manuals are recommended for general drive information:

For detailed PowerFlex 40 information including drive parameters,

programming, start-up, troubleshooting, specifications:

The latest version of this Installation Instructions can be obtained online at …

www.rockwellautomation.com/literature

For Allen-Bradley Drives Technical Support:

Manual Conventions •To help differentiate parameter names and LCD display text from other

text, the following conventions will be used:

–Parameter Names will appear in [brackets].

For example: [DC Bus Voltage].

–Display Text will appear in “quotes.” For example: “Enabled.”

•The following words are used throughout the manual to describe an

action:

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 Diagrams

0100-2.10

Guarding Against Electrostatic Damage 8000-4.5.2

Title Publication Available Online at …

PowerFlex 40 User Manual 22B-UM001… www.rockwellautomation.com/literature

PowerFlex Reference Manual PFLEX-RM001…

Title Online at …

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

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

Overview P-3

General Precautions

Compliance Certification Certifications are applicable to approved program defined options.

U.S./Canada UL: UL508C

CUL: CAN/CSA-C22.2 No. 14

Please refer to the PowerFlex 40 User Manual, publication 22B-UM001,

for additional information.

!ATTENTION: This drive contains ESD (Electrostatic

Discharge) sensitive parts and assemblies. Static control

precautions are required when installing, testing, servicing or

repairing this assembly. Component damage may result if ESD

control procedures are not followed. If you are not familiar with

static control procedures, reference A-B publication 8000-4.5.2,

“Guarding Against Electrostatic Damage” or any other applicable

ESD protection handbook.

!ATTENTION: An incorrectly applied or installed drive can

result in component damage or a reduction in product life. Wiring

or application errors, such as, undersizing the motor, incorrect or

inadequate AC supply, or excessive ambient temperatures may

result in malfunction of the system.

!ATTENTION: Only qualified personnel familiar with adjustable

frequency AC drives and associated machinery should plan or

implement the installation, start-up and subsequent maintenance

of the system. Failure to comply may result in personal injury

and/or equipment damage.

!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.

Publication 23B-IN001G

P-4 Overview

Catalog Number

Explanation

The PowerFlex 40 Adjustable Frequency AC Standard Configured Drives

catalog numbering scheme is shown below.

Position

1-3 4 56-89 10111213141516+

23B – D 4P0 D 1 0 4 N N – P6

abcdefghi j

Drive

Code Type

23B PowerFlex 40

Voltage Rating

Code Voltage Ph.

D 480V ac 3

Amp Rating

480V 60Hz Input

Code Amps kW (Hp)

1P4 1.4 0.4 (0.5)

2P3 2.3 0.75 (1.0)

4P0 4.0 1.5 (2.0)

6P0 6.0 2.2 (3.0)

010 10.5 4.0 (5.0)

012 12 5.5 (7.5)

017 17 7.5 (10)

024 24 11 (15)

Enclosure

Code Enclosure

C NEMA/UL Type 4X ‡

D NEMA/UL Type 4 ‡

‡ The design of the PowerFlex 40 Standard

Configured Drive supports indoor and outdoor

applications that are not in direct sunlight.

Emission Class

Code Rating

0 Not Filtered

Version

Code Version

4 RS485 (Standard)

C ControlNet

D DeviceNet

E EtherNet/IP

P PROFIBUS DP

Code Rating

N Reserved

Code Rating

N Reserved

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.

Options

Code Description

-E22 DeviceNet Quick Disconnect

(Bottom)

-E23 DeviceNet Quick Disconnect (Left

Side)

-P3 Motor Circuit Protector

-P3T Motor Circuit Protector (Customer

wiring into top of device)

-P6 Disconnect Switch - Fused

-P6T Disconnect Switch - Fused

(Customer wiring into top of device)

-R3

DeviceNet I/O (4 In/2 Out) w/Spring

Return HOA and Power Disconnect

Aux. Contact

-R4 DeviceNet Point I/O w/IB4 (4 Inputs)

-R5 -R3 plus 4 I/O 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.

-S18 Door Mounted Local Speed Pot (1-

Tur n)

-S20 Local/Remote and Local Control

Off/Run Forward Selector Switches

-S21 Local/Off/Remote with 1 N.O.

Interposing Relay

-S22 Spring Return Hand/Off Auto S.S.

(Start/Stop/Speed Ref.)

-S23 Clear Fault P.B.

Publication 23B-IN001G

Chapter 1

PowerFlex 40 Standard Configured Drive

Standard Features and Options

Chapter Objectives This chapter describes the standard features and operation for PowerFlex 40

Standard Configured Drives and associated options.

Standard Features 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. (1)

•Flange mount drive/external heatsink reducing overall enclosure size.

•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.

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

Quick Disconnects 1-15

I/O Options 1-16

(1) The enclosure does not normally protect electrical equipment from

condensation, corrosion or contamination, which may occur within the

enclosure or enter via the conduit or unsealed openings. Users must

make adequate provisions to safeguard against such conditions, and

satisfy themselves that the equipment is properly protected. For further

information on criteria associated with NEMA enclosure ratings, refer to

NEMA standards Publication No. 250-1991. When optional Door

Mounted HIM is supplied, enclosure is rated indoor only. See enclosure

options for specific enclosure style quoted.

1-2 PowerFlex 40 Standard Configured Drive Standard Features and Options

Publication 23B-IN001G

Enclosure Options NEMA/UL Type 4 (Position 9, Code D)

The enclosure provided is a NEMA/UL Type 4, painted mild steel, which

supports both NEMA/UL Type 4 and NEMA/UL Type 12 applications.

Type 4 enclosures are intended for indoor or outdoor use primarily to

provide a degree of protection against windblown dust and rain, splashing

water, and hose directed water, and to be undamaged by the formation of ice

on the enclosure. They are designed to meet hose-down, dust, and external

icing and rust resistance design tests. Doors and openings will be gasket

sealed. There are no ventilation openings within the enclosure to allow for

free exchange of inside and outside air.

Note: If optional Door Mounted HIM is not supplied, the design of the

PowerFlex 40 Standard Configured Drive supports indoor and outdoor

applications that are not in direct sunlight.

NEMA/UL Type 4X (Position 9, Code C)

The enclosure provided is a NEMA/UL Type 4X. The material is type 304

stainless steel. Type 4X enclosures are intended for indoor or outdoor use

primarily to provide a degree of protection against corrosion, windblown

dust and rain, splashing water, and hose directed water, and to be

undamaged by the formation of ice on the enclosure. They are designed to

meet hose-down, dust, and external icing and rust resistance design tests.

Doors and openings will be gasket sealed. There are no ventilation openings

within the enclosure to allow for free exchange of inside and outside air.

Note: If optional Door Mounted HIM is not supplied, the design of the

PowerFlex 40 Standard Configured Drive supports indoor and outdoor

applications that are not in direct sunlight.

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