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PowerFlex Digital DC DrivePowerFlex DC Drive V1.0066.001, PowerFlex DC Standalone Regulator V1.0066.001

User Manual

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Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, andoperation of this equipment before you install, configure, operate, or maintain this product. Users are required tofamiliarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are requiredto be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may beimpaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from theuse or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables andrequirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility orliability 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, orsoftware 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.

Labels may also be on or inside the equipment to provide specific precautions.

Allen-Bradley, Connected Components Workbench, DriveExplorer, DriveTools SP, PowerFlex, and Rockwell Automation are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,

which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous

voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may

reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to

potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

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Rockwell Automation Publication 20P-UM001J-EN-P - February 2014 3

Summary of Changes

This manual contains new and updated information.

New and Updated

Information

This table contains the changes made to this revision.

Topic Page

Added the Drive Series Lettersection to the Preface to provide additional drive identification information. 12

Updated theTypical Power Wiring Diagrams to reflect installations using an EMC input filter and Frame D,series B drive fan cooling systems.

45

AddedFigure 34575V/690V AC Input Frame C Field Circuit Terminal Block Location. 59

AddedFigure 40575V/690C AC Input Frame C Relay and Thermistor/Thermal Switch Terminal BlockLocations.

64

AddedFigure 45575V/690V AC Input Frame C Control Circuit Terminal Block Location. 67

Updated the Frame C Heatsink Cooling Fan Specifications section to include information for protectingthe fan using fuses.

69

AddedFigure 50575V/690V AC Input Frame C Heatsink Cooling Fan Terminal Block Location. 70

Updated the Frame D, Series B Heatsink Cooling Fan Specificationswith information for the new series Bcooling fan.

71

AddedFigure 53575V/690V AC Input Frame C Internal Armature Fuse Signal Terminal Block Location. 73

Added the following new parameters for firmware version 6.001: 111

Moved parameters 493 [Arm Volt Kp], 494 [Arm Volt Ki], 495 [Arm Volt Kp Base], a nd496 [Arm Volt Ki Base] from the Speed Command file / Speed Regulator group to the Motor Control file /Field Config group.

129

Moved parameters 93 [Spd Reg Kp Base] and 94 [Spd Reg Ki Base] from the Speed Command file / SpeedRegulator group to the Motor Control file / Autotune group.

138

Changed the units from % to none for parameters 87 [Spd Reg Kp], 99 [Spd Reg Kp Outpt], and 459[SpdReg Kp Bypass].

144, 144,148

Changed the units from % to sec-1 for parameters 88 [Spd Reg Ki], 100 [SpdReg Ki Outpt], and 460[SpdReg Ki Bypass].

144, 145,148

Changed the default value of [Droop Filter] from 0 to 100. 151

Parameter Parameter Parameter

170 [Encoder Config] 435 [Act Spd Reg BW] 1106 [Spd Band Intgrtr]

213 [SCR Diag Test En] 436 [Spd Reg Damping] 1107 [Brk Release Ti me]

214 [SCR Di ag Status] 448 [SpdR eg BW Bypa ss] 1108 [Brk Se t Time]

215 [OpenSCR WarnLvl] 470 [UnderVlt Flt Dly] 1109 [Brk Alarm Travel]

216 [OpenSCR Flt Cfg] 475 [FldLoss Flt Dly] 1110 [Brk Slip Count]

217 [OpenSCR Thre shld] 1034 [SpdReg Kp Pc t] 1111 [Float Tolerance]

218 [OpenSCR Trip Lvl] 1035 [SpdReg Ki Pc t] 1112 [MicroPsnScalePc t]

332 [Drive Checksum] 1100 [Torq Prove Cfg] 1113 [ZeroSpdFloatTime]

333 [MtrOvrld Fac tor] 1101 [Torq Prove Setup] 1114 [Brake Test Torq]

334 [MtrOvrld Speed] 1103 [Torq Prove Sts] 1329 [Speed Ref Source]

433 [Total Inertia] 1104 [Torq Limit Slew] 1330 [Spd Ref Sel Sts]

434 [Spd Reg BW] 1105 [Speed Dev Band] 1394 [Drive Alarm 2]

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4 Rockwell Automation Publication 20P-UM001J-EN-P - February 2014

Summary of Changes

Changes to this manual for previous revisions are included in Appendix I Historyof Changeson page 383.

Renamed parameter 249 [Save MOP Ref] to [MOP Ref Config] and changed the following bits: Bit 0 At Pwr Down renamed to Save PwrDown Bit 1 At Stop was renamed to Save At Stop Bit 2 Reset AtStop was added Bit 3 Reset At Flt was added

171

Changed option 9 Torque Ref to Sel Torq Ref for parameter 6669 [Anlg OutxSel]. 192

Added options 6572 to parameters 133144 [Digital InxSel]. 193

Added option 30 Brake Slip to parameters 145152 [Digital OutxSel]. 197

Added options 30 Brake Slip and 31 TP Brake Cmd to parameters 629 [Relay Out 2 Sel] and 1392[Relay Out 1 Sel].

199,200

Added the following new faults to Chapter 4 - Troubleshooting: Shorted SCR (F89) Open SCR (F90) TorqPrv Spd Band (F94) Fwd End Limit (F95) Rev End Limit (F96) Fwd Over Travel (F97) Rev Over Travel (F98) Travel Lim Cflct (F99)

216

Changed the fault type to 2 (Non-Configurable) for fault 4 AC Undervoltage. 216

Added the BrakeSlipped and TrqProvCflct, and TP Encls Config alarms to Chapter 4 -Troubleshooting.

222

Updated the total dynamic brake resistance column in theDynamic Brake Resistor Kits and DC OutputContactorstables.

259

Added the new Lifting/Torque Proving topic to Appendix C Application Notes. 291

Added the Manually Tuning the Speed Regulator for Firmware Version 6.xxx procedure to Appendix CApplication Notes.

303

Add the SCR Diagnostic Testssection to Appendix C Application Notes. 314

Updated theSpeed Feedbackblock diagram. 355

Updated theField Current Regulator block diagram 359

Topic Page

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Table of Contents

Preface Drive Storage Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Drive Nameplate Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Drive Series Letter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Drive Firmware Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Standard Drive Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . 15Standard Drive Catalog Number Explanation, Cont.. . . . . . . . . . . . . . . . 16Standalone Regulator Catalog Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Chapter 1

Installation and Wiring Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Operating Conditions and Temperatures. . . . . . . . . . . . . . . . . . . . . . . 18Minimum Mounting Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Approximate Drive Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . 19Lifting PowerFlex DC Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Mounting Frame C and D Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Removing the Drive Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Frame A Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Frame B and C Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Frame D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Isolation Transformers / Line Reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30AC Input Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31DC Output Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Dynamic Brake Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Safety Ground (PE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Power Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Encoder/Resolver Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . 33Tachometer Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Grounding for Installations in an Ungrounded or High-Impedance

Neutral Ground or System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39EMC Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Installation Requirements Related to the Low Voltage Directive. . 40Installation Requirements Related to EN 61800-3 and the EMCDirective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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Table of Contents

Pollution Degree Ratings According to EN 61800-5-1 . . . . . . . . . . 41Power Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Control Power Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Cable and Wiring Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

AC Input Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44DC Output Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Typical Power Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Armature Converter Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Armature Voltage Feedback Connections. . . . . . . . . . . . . . . . . . . . . . . 53Field Converter Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Field Current Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Set DIP Switch S14 to the Correct Value . . . . . . . . . . . . . . . . . . . . . . . 60Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Thermistors and Thermal Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Control Circuit Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Frame C Heatsink Cooling Fan Specifications . . . . . . . . . . . . . . . . . . 69Frame D, Series B Heatsink Cooling Fan Specifications . . . . . . . . . . 71Frame C and D Armature Fuse Signal Terminals . . . . . . . . . . . . . . . . 72

DIP Switch and Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

I/O Signal and Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80I/O Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Digital Encoder Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85DC Analog Tachometer Terminal Block . . . . . . . . . . . . . . . . . . . . . . . 87Resolver Feedback Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87I/O and Control Wire Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Chapter 2

Drive Start Up Drive Start Up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Before Applying Power to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Verify all Drive Configuration Settings . . . . . . . . . . . . . . . . . . . . . . . . . 90Verify the Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Verify the Control and I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Applying Power to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Apply Voltage to the Control Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . 91

Verify the Control Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Load the Default Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Configure the Most Commonly Used Parameters . . . . . . . . . . . . . . . 93Tune the Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Verify Motor Rotation and Run Feedback Polarity Checks. . . . . . 101Configure the Speed Feedback Parameters . . . . . . . . . . . . . . . . . . . . . 104Tune the Speed Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Verify Speed Reference Settings and Drive Operation. . . . . . . . . . . 108

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Chapter 3

Programming and Parameters About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Parameters Table Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

How Parameters are Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113FileGroupParameter Order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Numbered List View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Cross Reference Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Basic Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Advanced Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Monitor File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121Motor Control File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Speed Command File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143Dynamic Control File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149Applications File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155Utility File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Communications File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Input / Output File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189Parameter Cross Reference by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Parameter Cross Reference by Number. . . . . . . . . . . . . . . . . . . . . . . . . . 207

Chapter 4

Troubleshooting Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

HIM Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Clearing Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222Alarm Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222Common Drive Symptoms and Corrective Actions . . . . . . . . . . . . . . . . 225

Drive will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225Drive starts but motor does not turn and no armature current . . 226The motor does not reach commanded speed . . . . . . . . . . . . . . . . . . 226The motor is turning in the wrong direction . . . . . . . . . . . . . . . . . . 226The motor reaches maximum speed immediately . . . . . . . . . . . . . . 227

Testpoint Codes and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Appendix A

Supplemental Drive Information Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230IP20 NEMA/UL Type Open Watts Loss . . . . . . . . . . . . . . . . . . . . . . . . . 233Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Typical Programmable Controller Configurations . . . . . . . . . . . . . 235Logic Command/Status Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Drive Power Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237Frame A and B Fuse Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237Frame C and D Fuse Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

Control Power Circuit Protection Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 250

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Switching Power Supply Circuit Board Fuses . . . . . . . . . . . . . . . . . . 250Frame B Pulse Transformer Circuit Board Fuses . . . . . . . . . . . . . . . 252Frame C Transient Noise Filter Circuit Board Fuses . . . . . . . . . . . . 253Frame D Overvoltage Clipping Circuit Board Fuses . . . . . . . . . . . . 254

AC Input Line Reactors and AC Input Contactors. . . . . . . . . . . . . . . . . 255

Isolation Transformers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257Dynamic Brake Resistor Kits and DC Output Contactors . . . . . . . . . . 259DC Contactor Crimp Lug Kit Specifications . . . . . . . . . . . . . . . . . . . . . . 260Alternate Dynamic Brake Resistor Kits and DC Output Contactors . 261Alternate EMC Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262Terminal Adapter Kits for Frame D Drives . . . . . . . . . . . . . . . . . . . . . . . . 265

Appendix B

HIM Overview External and Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267LCD Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268ALT Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Using the S.M.A.R.T. List Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272LCD HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Removing/Installing the HIM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Appendix C

Application Notes Alpha Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275Alpha Test Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Analog Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

Example 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278Example 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278Analog Input Signal Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

Current / Speed Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280Drive Reference and Feedback Scaling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Armature Voltage Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282DC Analog Tachometer Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282Encoder Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282Drive Reference and Feedback Scaling Examples . . . . . . . . . . . . . . . 282Speed Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Droop Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

Field Weakening Mode Configuration (v1.006) . . . . . . . . . . . . . . . . . . . 287Using a DC Contactor Only (Firmware v1.006 Only) . . . . . . . . . . 288Using a DC Contactor and a Dynamic Brake(Firmware v1.006 Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288Using an Inverting Fault Device Only (Firmware v1.006 Only). . 288Using a DC Contactor and an Inverting Fault Device(Firmware v1.006 Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289Using a DC Contactor, a Dynamic Brake and an Inverting FaultDevice (Firmware v1.006 Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

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Table of Contents

Lifting/Torque Proving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291Tuning The Motor For Torque Prove Applications . . . . . . . . . . . . 293Crane Setup with Encoder/Resolver Feedback . . . . . . . . . . . . . . . . . 293Crane Setup - Encoderless. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

Manually Tuning the Speed Regulator for Firmware Version 6.xxx . . 303

PID Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304Configure a Line Speed Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305Configure the Feedback Signal in the Follower Drive(s) . . . . . . . . 306Configure the Tension Set Point Signal in the Follower Drive(s) 308

Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309Auto Speed Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309Manual Speed Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309Changing Speed Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309Torque Reference Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309Auto/Manual Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Resolver Cable Balance Tuning Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Performing the Cable Balance Tuning Test . . . . . . . . . . . . . . . . . . . . 311Resolver Type Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312Scale Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

Linking Parameters Via the Scale Block Parameters. . . . . . . . . . . . . 314SCR Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

Open SCR Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315Shorted SCR Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

S-curve Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317S-curve Acceleration Ramp Example: . . . . . . . . . . . . . . . . . . . . . . . . . 318

Speed Regulation Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319Adaptive Speed Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

Speed Up Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322Speed Threshold Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323Speed Zero Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324Speed Draw Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

Speed / Torque Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Zero Torque Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Speed Regulation Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327Torque Regulation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327Speed Limited Adjustable Torque (SLAT) Min Mode and SLAT MaxMode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327Sum Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

Start At Powerup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332Fine Tuning the Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Manually Adjusting the Current Regulator Tune Settings . . . . . . 334Fine Tuning the Field Current Regulator. . . . . . . . . . . . . . . . . . . . . . 336Fine Tuning the Speed Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339Fine Tuning the Voltage Regulator in the Field Converter . . . . . . 341Tuning the Field Current Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

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Table of Contents

Appendix D

Control Block Diagrams Diagram Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

Appendix E

Installing a Communication Adapter Communication Adapter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369What The Communication Adapter Kit Includes . . . . . . . . . . . . . . . . . . 369Tools That You Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370Installing the Communication Adapter Module in the Drive. . . . . . . . 370

Frame A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371Frames B and C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372Frame D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

Appendix F

Optional Analog and Digital I/O

Expansion Circuit Board

What This Option Board Provides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

I/O Expansion Board Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

Appendix G

Optional 115V AC to 24V DC I/O

Converter Circuit Board

What This Option Board Provides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377I/O Converter Board Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378

Appendix H

PowerFlex DC Standalone Regulator

Installation

Installation and Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381

Appendix I

History of Changes 20P-UM001I-EN-P, February 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38320P-UM001H-EN-P, April 2011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38320P-UM001G-EN-P, October 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38420P-UM001F-EN-P, June 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386

Index

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Preface

The purpose of this manual is to provide you with the basic information neededto install, start-up and troubleshoot the PowerFlex DC drive. This manual isintended for qualified personnel. You must be able to program and operate DCdrives. In addition, you must have an understanding of the parameter settings andfunctions detailed in this manual.

Drive Storage Conditions If it is necessary to store the drive for any length of time before installation, followthese storage guidelines to provide satisfactory start up operation and retainwarranty coverage:

After receipt and inspection, repack the drive in its original shippingcontainer and store in a clean, dry place.

Place where the ambient temperatures do not exceed -25C (-13F) or+55C (131F)

Place where the relative air humidity range does not exceed 595%.

At an altitude of less than 3,000 meters (10,000 ft.) above sea level.

Topic Page

Drive Storage Conditions Below

Drive Nameplate Data 12

Drive Specifications 12

Additional Resources 13Technical Support 13

Conventions 13

General Precautions 14

Standard Drive Catalog Number Explanation 15

Standalone Regulator Catalog Numbers 16

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Preface

Drive Nameplate Data The PowerFlex DC drive contains a data nameplate label on the side of each drivethat identifies the specific model number design, applicable AC input power andDC output power data. Include this information when communicating withRockwell Automation personnel about this product.

Drive Series Letter

Series B drives are identified as such on the data nameplate label. The drive seriesletter is on the top, right side of the label.

Drive Frame Sizes

Similar PowerFlex DC drive sizes are grouped into frame sizes to simplify spareparts ordering, dimensioning, etc. The drive frame size is listed just above theserial number on the data nameplate label. See the Standard Drive CatalogNumber Explanationon page 15for a list of drive catalog numbers and theirrespective frame sizes.

Drive Firmware Version

The original firmware version of the drive as shipped from the factory appears onthe data nameplate label just above the certifications. If the firmware version has

been upgraded since the drive was shipped, you can view the current version onthe HIM (if installed). See Diagnostics Menuon page 271for details.

Drive Specifications For drive specification information, see the PowerFlex Digital DC Drive,Technical Data, 20P-TD001.

EXAMPLEO

NLY

20P41AD4P1RA0NNN

Made in Italy

Output: 500VDC 4.1A REGEN 2.0HP

1 Min Overload Amps3 Sec Overload Amps

MFD. in 2XXX on MMM DD

Cat No.

Input: 460VAC 50/60 Hz 3.3A 3 Phase

UL Type OPEN/IP20

Original Firmware V. 1.001

Serial Number: A23E0042

Series: A

Frame: A

6.28.2

I/O: 24VDC (Standard)

Ind.Cont.Listed

C R US

DC Field:Input: 460VAC 50/60 Hz 10A max. 1 PhaseOutput: 360VDC 10A max.

Regulator Power: 115/230VAC 50/ 60 Hz 1.0/0.5A 1 Phase

Eq. 31KF

N223Note: CertificationMarks Location.

See the datanameplate label onyour drive for actualagency certifications.

Drive frame sizeDrive serial number

Drive series letter
http://literature.rockwellautomation.com/idc/groups/literature/documents/td/20p-td001_-en-p.pdfhttp://literature.rockwellautomation.com/idc/groups/literature/documents/td/20p-td001_-en-p.pdf

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Preface

Additional Resources These documents contain additional information concerning related productsfrom Rockwell Automation.

You can view or download publications at: http://literature.rockwellautomation.com . To order paper copies of technical

documentation, contact your local Allen-Bradley distributor or RockwellAutomation sales representative.

Technical Support For Allen-Bradley Drives Technical Support:

Conventions To help differentiate parameter names and LCD display text from othertext, the following conventions are used:

Parameter names appear in [brackets].For example: [Armature Voltage].

Display text appears in quotes. For example: Enabled.

The following words are used throughout the manual to describe anaction:

Resource Description

Preventive Maintenance of Industrial Control and DriveSystem Equipment, DRIVES-TD001

Provides a checklist for performing preventivemaintenance.

Safety Guidelines for the Application, Installation and

Maintenance of Solid State Control, SGI-1.1

Provides general guidelines for the application,

installation, and maintenance of solid-state control in theform of individual devices or packaged assembliesincorporating solid-state components.

A Global Reference Guide for Reading Schematic Diagrams,100-2.10

Provides a simple cross-reference of common schematic/wiring diagram symbols used throughout various parts ofthe world.

Guarding Against Electrostatic Damage, 8000-4.5.2 Provides common practices to help guard against ESD.

Industrial Automation Wiring and Grounding Guidelines,publication 1770-4.1

Provides general guidelines for installing a RockwellAutomation industrial system.

Product Certifications website, http://ab.com Provides declarations of conformity, certificates, and othercertification details.

Title Online at . . .

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

Word Meaning

Can Possible, able to do something

Cannot No t p ossible, not abl e to d o something

May Permitted, allowed

Must Unavoidable, you must do this

Shall Required and necessary

Should Recommended

Sho uld Not Not r eco mmended
http://literature.rockwellautomation.com/http://literature.rockwellautomation.com/http://ab.com/http://literature.rockwellautomation.com/http://literature.rockwellautomation.com/http://ab.com/

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Preface

General PrecautionsATTENTION: 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 AgainstElectrostatic 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

surrounding air temperatures may result in malfunction of the system.

ATTENTION: Allow only qualified personnel, familiar with DC drives and

associated machinery, to plan or implement the installation, start-up and

subsequent maintenance of the system. Failure to comply may result in personal

injury and/or equipment damage.

ATTENTION: An incorrectly applied or installed bypass system can result incomponent damage or reduction in product life. The most common causes are:

Wiring AC line to drive output or control terminals.

Improper bypass or output circuits not approved by Allen-Bradley.

Output circuits which do not connect directly to the motor.

Contact Allen-Bradley for assistance with application or wiring.

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Preface

Standard Drive CatalogNumber Explanation

Position

1-3 4 5 6 7 8-10 11 12 13 14 15 16

20P 4 1 A D 4P1 R A 0 N N N

a b c d e f g h i j k l

aDrive

Code Type

20P PowerFlex DC

bMotor Operation

Code Type

2 Two Quadrant Operation

4 Four Quadrant Operation

cInput Type

Code Type

1 6 Pulse

dEnclosure

Code Enclosure RatingConform.

Coat

A IP20, NEMA/UL Type Open

e

Input VoltageCode Voltage

B 230V AC

D 460V AC

E 600V AC

F 690V AC

f1

f2Yes

Not available for 230V AC input drives.

Use this code for 400V AC input applications.

f3

f4

2

3

5

7.5

10

15

20

25

30

40

50

60

75

100

125150

200

250

300

400

500

600

700

800

900

1.5

2.2

3.7

5.5

7.5

11

15

18.5

22

30

37

45

56

75

93112

149

187

224

298

373

447

552

597

671

4.1

6

10

14

19

27

35

45

52

73

86

100

129

167

207

250

330

412

495

667

830

996

1162

1238

1494

A

A

A

A

A

A

A

A

A

A

A

A

A

B

B

B

B

B

C

C

D

D

D

D

D

10

10

10

10

10

10

10

10

10

14

14

14

14

20

20

20

20

20

20

20

40

40

70

70

70

HpArmature

Amps

FrameField

Amps

Code kW

460V, 60 Hz Input

4P1

6P0

010

014

019

027

035

045

052

073

086

100

129

167

207250

330

412

495

667

830

996

1K1

1K3

1K4

1.5

2

3

5

7.5

10

15

20

2530

40

50

60

75

100

125

150

200

250

300

1.2

1.5

2.2

3.7

5.5

7.5

11

15

18.522

30

37

45

56

75

93

112

149

186

224

7

9

12

20

29

38

55

73

93110

146

180

218

265

360

434

521

700

875

1050

A

A

A

A

A

A

A

A

AA

B

B

B

B

B

B

C

C

D

D

10

10

10

10

10

10

10

14

1414

20

20

20

20

20

20

20

20

40

40

HpArmature

AmpsFrame

FieldAmps

Code kW

230V, 60 Hz Input

7P0

9P0

012

020

029

038

055

073

093110

146

180

218

265

360

434

521

700

875

1K0

50

75

100

200

300

400

500

600

800900

1000

1250

37

56

75

149

224

298

373

447

597671

746

932

67.5

101.3

135

270

405

540

675

810

10801215

1350

1668

B

B

B

B

B

C

C

D

DD

D

D

20

20

20

20

20

20

20

40

4040

40

40

HpArmature

AmpsFrame

FieldAmps

Code kW

575V, 60 Hz Input

067

101

135

270

405

540

675

810

1K01K2

1K3

1K6

298

373

447

552

597

671

746

820

932

1044

HpArmature

AmpsFrame

FieldAmps

Code kW

690V, 60 Hz Input

452

565

678

791

904

1K0

1K1

1K2

1K4

1K5

400

500

600

700

800

900

1000

1100

1250

1400

452

565

678

791

904

1017

1130

1243

1413

1582

C

C

D

D

D

D

D

D

D

D

20

20

40

40

40

40

70

70

70

70

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Preface

Standard Drive CatalogNumber Explanation, Cont.

Standalone RegulatorCatalog Numbers

All catalog numbers below are provided with conformally coated circuit boards.

Position

1-3 4 5 6 7 8-10 11 12 13 14 15 16

20P 4 1 A D 4P1 R A 0 N N N

a b c d e f g h i j k l

gField Supply

Code Type

R Single-Phase Regulated

hPackaging/Documentation

Code Shipping Carton User Manual

A Yes Yes

iHIM

Code Operator Interface

0 Blank Cover

Standard - for user installed options, seeHuman Interface and Wireless InterfaceModules on page 9.

j

I/O OptionsCode Control

NNone (8 - 24V DC Digital Inputs,

4 Digital Outputs, 3 Analog Inputs,and 2 Analog Outputs are Standard)

kCommunication Options

Code Description

N None

lCabinet Options

Code Type

N None

Standard - for user installed options, seeCommunication Option Kits on page 10.

All I/O Options are purchased separately andare user installed. See I/O Options on page 9.

230V / 460V AC Input Regulators 575V / 690V AC Input Regulators Field Amps

Catalog Number Catalog Number

23PMD4 23PMF4 40

23PMD7 23PMF7 70

23PAMP (1)

(1) Gate Amplifier - used with all voltage classes of the Standalone Regulator. Note: The Standalone Regulator and Gate Amplifier are

currently sold through Rockwell Automation Drive Systems only. Consult the factory for availability.

23PAMP (1) (1)

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Chapter1

Installation and Wiring

This chapter provides information on mounting and wiring the PowerFlex DCdrive.

Most start-up difficulties are the result of incorrect wiring. Every precaution mustbe taken to assure that the wiring is done as instructed. All items must be read andunderstood before the actual installation begins.

For PowerFlex DC Standalone Regulator (SAR) installations, see Appendix H

for important installation and configuration information. The SAR is identifiedby a 23PMDxcatalog number contained on the data nameplate on the drive (seeDrive Nameplate Dataon page 12for location).

Topic Page Topic Page

Mounting Considerations 18 CE Conformity 39

Approximate Drive Dimens ions andWeights

19 Power Circuit Protection 42

Lifting PowerFlex DC Drives 25 Control Power Circuit Protection 42

Removing the Drive Covers 27 Cable and Wiring Recommendations 43

Isolation Transformers / Line Reactors 29 Power Wiring 44

Contactors 30 DIP Switch and Jumper Settings 74

General Grounding Requirements 32 I/O Wiring 79

IMPORTANT The PowerFlex DC drive is not designed for use with multiple motor

applications or resistive loads. Please contact your Local Solution Center for

multiple motor applications. See Local Solution Centers, publication

DSDC-BR001, for more information.

IMPORTANT The recommended drive to motor horsepower ratio is 2:1.

ATTENTION: The following information is merely a guide for proper installation.

Rockwell Automation cannot assume responsibility for the compliance or the

noncompliance to any code, national, local or otherwise for the proper

installation of this drive or associated equipment. A hazard of personal injury

and/or equipment damage exists if codes are ignored during installation.
http://literature.rockwellautomation.com/idc/groups/literature/documents/br/dsdc-br001_-en-p.pdfhttp://literature.rockwellautomation.com/idc/groups/literature/documents/br/dsdc-br001_-en-p.pdf

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Chapter 1 Installation and Wiring

Mounting Considerations Operating Conditions and Temperatures

PowerFlex DC drives are designed to operate at 050 C (32122 F)surrounding air temperature without derating. The drive must be mounted in aclean, dry location. Contaminants such as oils, corrosive vapors and abrasivedebris must be kept out of the enclosure. NEMA/UL Type Open, IP20enclosures are intended for indoor use primarily to provide a degree of protectionagainst contact with enclosed equipment. These enclosures offer no protectionagainst airborne contaminants.

Minimum Mounting Clearances

Minimum clearance requirements (indicated in Figure 1) are intended to be fromdrive to drive. Other objects can occupy this space; however, reduced airflow maycause protection circuits to fault the drive. The drive must be mounted in avertical orientation as shown below and must not be mounted at an angle greater

than 30 degrees from vertical. Intake air temperature must not exceed theproduct specification. See Maximum Surrounding Air Temperature on page 230.

Figure 1 - Drive Enclosure Minimum Mounting Clearances

10 mm10 mm 50 mm(0.4 in.) (0.4 in.) (2.0 in.)

10 mm(0.4 in.)

150 mm (6.0 in.)

150 mm (6.0 in.)

150 mm (6.0 in.)

STS

PORT

MOD

NETA

NETB

STS

PORT

MOD

NETA

NETB

Airflow through the drivemust not be impeded.

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Installation and Wiring Chapter 1

Approximate DriveDimensions and Weights

The PowerFlex DC drive is available in a NEMA/UL Type Open, IP20 enclosureonly. Follow all mounting clearances to provide proper drive operation.

Figure 2 - Frame A Drive Dimensions

Table 1 - Frame A Weights

ATTENTION: Remove all loose packing materials, including the container(s) of

desiccants (if any), from the drive enclosure before mounting and energizing the

drive.

A B C A1 A2 B1

mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)

267 (10.5) 359 (14.0) 287 (11.3) 7 (0.3) 250 (9.8) 275 (10.8)

Dr ive Cur rent Rating Code D rive Weight D rive & Pac kaging Weigh t

230V 460V kg (lb) kg (lb)

7P0 4P1

8.4 (18.5) 10.5 (23.2)

9P0 6P0

012 010

020 014

019

029 027

038 035

8.8 (19.4) 11 (24.3)055 045

052

073 073

10.8 (23.8) 13 (28.7)093 086

110 100

129

A

B

A2

B1

C

STS

PORT

MOD

NET A

NET B

A1

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Figure 3 - Frame B Drive Dimensions

Table 2 - Frame B Weights

A A1 A2 A3 B B1 C

mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)

311 (12.2) 275 (10.8) 16.5 (0.65) 7 (0.3) 388 (15.3) 375 (14.8) 350 (13.8)

Drive w/ND Rating Code Drive Weight Drive & Packaging Weight

230V 460V 575V kg (lb) kg (lb)

146 167 067

25.5 (56.2) 27.5 (60.6)180 207 101

218 135

265 250 270 29.5 (65.0) 31.5 (69.5)

360 330 40532 (70.5) 34 (75)

434 412

A

A1

B1

C

B

A2

STS

PORT

MOD

N E TA

N E TB

A3

45.2 (1.8)

98.5 (3.9)

53.1 (2.1)

48.5 (1.9)

14 7. 0 ( 5. 8) 53. 1 (2. 1)

48.5 (1.9)200.1 (7.9)

248.6 (9.8)

Terminal Details Dimensions in mm (in.)

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Figure 4 - Frame C Drive Dimensions

Table 3 - Frame C Weights

A A1 B B1 B2 B3 B4 B5 C

mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)

521 (20.5) 499 (19.7) 511 (20.1) 400 (15.7) 200 (7.9) 55 (2.2) 56 (2.2) 10.5 (0.4) 416 (16.4)

B1

B2

B3

A

A1 C

B

B4

STS

PORT

MOD

NET A

NET B

B5

310.0 (12.2)

155.0 (6.1)

113.0(4.5)

28.0(1.1)

28.0(1.1)

28.0(1.1)35.5 (1.4)

Terminal Details Dimensions in mm (in.)

Dr ive w/ND Rating Co de Weight - Regenerative Dr ives Weight - No n-regenerative Dr ives

Drive Drive & Packaging Drive Drive & Packaging

230V 460V 575V 690V kg (lb) kg (lb) kg (lb) kg (lb)

495 61 (134.5) 83 (183.0) 57 (125.7) 79 (174.2)

521 667 65 (143.3) 87 (191.8) 62 (136.7) 84 (185.2)

700

540 45272 (158.7) 94 (207.2) 68 (150.0) 90 (198.4)

675 565

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Figure 5 - Frame D Dimensions - Right Side and Front Views

1250(49.2)

436.5(17.2)

157.5(6.2)

144(5.7)

208(8.2)

792(31.2)

42(1.7)

32(1.3)

80.5(3.2)

10.5(0.4)

10(0.4)

252.5(10.0)

134(5.3)

437.5(17.2)

134(5.3)

22.6(0.9)

44.5(1.8)

44.5(1.8) 269.5

(10.6)100(4.0) 27.8

(1.1)

44.5(1.8)

704(27.7)

174(6.9)

359(14.1)

544(21.4)

60(2.4)

454.5(18.0)

100(4.0)

15

(0.6)

30(1.2)

25(1.0)

44.5(1.8)

146(5.7)

60(2.4)

25(1.0)

44.5(1.8) 15

(0.6)30

(1.2)

Dimensions of terminals U, V, and W are the same.

Dimensions are shown in mm and (in.)

Lifting flange

Note: 134 mm (5.3 in.) C and D terminals are installed on 460V AC input, 800 and 900 Hp, 575V AC input, 1000 Hp, and 690V AC input,1100, 1200, 1250, and 1400 Hp drives only. All other f rame D ratings have 100 mm (4.0 in.) C and D terminals.

PE C D PE C D

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Figure 6 - Frame D Dimensions - Left Side and Back Views

215.225(8.5)

103.25(4.1)

1435 MAX(56.5)

129(5.1)

129(5.1)

227.5(9.0)

157.5(6.2)

1230(48.4)

16(0.6)

10.5(0.4)

10(0.4)

10.5(0.4)

127(5.0)

531(21.0)

541(21.3)

94(3.7)

127(5.0)

127(5.0)

127(5.0)

23(0.9)

127(5.0)

127(5.0)

127(5.0)

127(5.0)

94(3.7)

94(3.7)

94(3.7)

Dimensions are shown in mm and (in.)

Mounting holes

Mounting holes

Lifting flange

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Table 4 - Frame D - 230V AC Input Drive Weights




Drive w/NDRating Code

Weight - Regenerative Drives Weight - Non-regenerative Drives


kg (lb) kg (lb) kg (lb) kg (lb)

875

203 (447.5) 281 (619.5) 152 (335.1) 230 (507.1)1K0


Weight - Regenerative Drives Weight - Non-regenerative Drives



830202 (445.3) 280 (617.3) 152 (335.1) 230 (507.1)

996

1K1

215 (474.0) 293 (646.0) 165 (363.8) 243 (535.7)1K3

1K4


Weight - Regenerati ve Drives Weight - Non-regenerative Drives



810198 (436.5) 276 (608.5) 148 (326.3) 226 (498.2)

1K0

1K2 215 (474.0) 293 (646.0) 165 (363.8) 243 (535.7)

1K3 222 (489.4) 300 (661.4) 172 (379.2) 250 (551.2)

1K6 241 (531.3) 319 (703.3) 191 (421.1) 269 (593.0)


Weight - R egenerative Drives Weight - Non-regenerative Drives



678198 (436.5) 276 (608.5) 148 (326.3) 226 (498.2)

791

904 200 (440.9) 278 (612.9) 150 (330.7) 228 (502.7)

1K0 202 (445.3) 280 (617.3)152 (335.1) 230 (507.1)

1K1215 (474.0) 293 (646.0)

1K2 165 (363.8) 243 (535.7)

1K4241 (531.3) 319 (703.3)

172 (379.2) 250 (551.2)

1K5 191 (421.1) 269 (593.0)

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Lifting PowerFlex DC Drives The dimensions and weights specified above must be taken into considerationwhen mounting the device. Use the proper equipment to safely lift and hold theweight of the drive while mounting.

Mounting Frame C and D Drives

All lifting equipment and lifting components (hooks, bolts, lifts, slings, chains,etc.) must have a minimum lifting capacity of 453.6 kg (1,000 lb).

1. Verify the hole pattern on the panel on which the drive will be mounted.See Figure 4on page 21or 22on page 22.

2. Install the mounting hardware:

For frame C drives, insert, but do not tighten, a bolt in one of the topholes in the panel. The bolt must be fully threaded into the panelbefore hanging the drive.

For Frame D drives, insert, but do not tighten, the six bolts for the topmounting flange on the drive into the panel. The bolts must be fullythreaded into the panel before hanging the drive.

3. To limit the pull in forces on the drive, the lifting devices connected to thehooks must be long enough to make the angle between the chain or cableand a vertical line extending up from the flange center less than 45 angle asillustrated in Figure 7on page 26or Figure 8on page 26.

For frame C drives, insert the properly sized and rated lifting hooks

into the holes on the lifting flanges at the top of the drive. See Figure 7on page 26.

For frame D drives, insert the properly sized lifting rod into the holeson the lifting flanges at the top of the drive. See Figure 8on page 26.

ATTENTION: To guard against possible personal injury or equipment damage...

Inspect all lifting hardware for proper attachment before lifting the drive. Do Not let any part of the drive or lifting mechanism to make contact withelectrically charged conductors or components.

Do Not subject the drive to high rates of acceleration or deceleration whiletransporting to the mounting location or when lifting.

Do Not let personnel or their limbs be directly underneath the drive when it isbeing lifted and mounted.

IMPORTANT Verify that all mounting screws are properly tightened before and after drive

operation.

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Figure 7 - Lifting Frame C Drives

Figure 8 - Lifting Frame D Drives

4. Lift the drive into place onto the bolt(s) installed in the panel.

5. Install the remaining bolts into the panel. Tighten M8 bolts to a minimumtorque of 15 Nm (132.7 lbin) and M10 bolts to a minimum torque of 25Nm (221.2 lbin).

Lifting flanges

Must be lessthan 45 angle

Must be lessthan 45 angle

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Removing the Drive Covers Some protective cover(s) must be removed to provide access to the drives powerand I/O terminals. The upper cover only needs to be removed to install anoptional communication adapter and service the drive. (See Installing aCommunication Adapteron page 369for information.)

Frame A Drives

You must remove both the lower protective cover and the power terminal coveron frame A drives to access the power terminals.

Remove the Power Terminal Cover

Remove the two screws as shown below and slide the cover down and off thechassis.

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Remove the Lower Protective Cover

Remove the two screws as shown below and, while gently lifting along the topedge, slide the cover down and off the chassis.

Frame B and C Drives

Loosen, but do not remove, the two screws that secure the bottom cover. Then,slide the cover down until the screw heads line up with the key holes and lift thecover off the chassis.

STS

PORT

MOD

NET A

NET B

Frame B Shown

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Frame D

For any protective cover, loosen, but do not remove, the Hexalobular head screwsthat secure the cover to the drive frame. Then, slide the cover up until the screwheads line up with the key holes and lift the cover off the chassis. The top andbottom most covers are also secured by screws at the top and bottom of the drive,respectively.

Isolation Transformers / LineReactors

When connecting the drive directly to the main distribution system an isolationtransformer and/or 35% impedance AC line reactor must be used to guardagainst system disturbance. If the isolation transformer provides the required35% impedance, a line reactor is not required.

See Isolation Transformerson page 257for a list of recommended isolationtransformers.

See AC Input Line Reactors and AC Input Contactorson page 255for a list ofrecommended AC line reactors. The type of line reactor used depends upon thefollowing:

the current absorbed by the AC input

the AC input voltage

the relative short circuit voltage

the AC input frequency

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Contactors When an AC input contactor is used, the IEC AC1 rating of the contactor mustbe equal to the rated thermal (RMS) current value at the main input of the drive.

Drive configurations for AC or DC contactors, with or without a dynamic brake,are as follows (see Typical Power Wiring Diagramson page 45for wiringexamples):

When only an AC contactor is used:

Set parameter 1391[ContactorControl] to 1 AC Cntctr (defaultvalue) (1)

Set one [Relay Out x Sel] parameter and one [Digital Inx Sel]parameter to Contactor (default value for parameters 1392[RelayOut 1 Sel] and 140[Digital In8 Sel])

When only a DC contactor is used:

Set parameter 1391[ContactorControl] to 3 DC Cntctr (1)

Set one [Relay Out x Sel] parameter and one [Digital Inx Sel] toContactor (default value for parameters 1392[Relay Out 1 Sel] and140[Digital In8 Sel])

When an AC contactor and dynamic brake contactor are used:

Set parameter 1391[ContactorControl] to AC Cntctr+DB (1)

Set one [Relay Out x Sel] parameter (1392[Relay Out 1 Sel] or 629[Relay Out 2 Sel]) to Contactor and the other relay output toContactorDB

Set one [Digital Inx Sel] parameter to Contactor (default value for

parameter 140[Digital In8 Sel]) When a DC contactor and dynamic brake contactor are used:

Set parameter 1391[ContactorControl] to DC Cntctr+DB (1)

Set one [Relay Out x Sel] parameter (1392[Relay Out 1 Sel] or 629[Relay Out 2 Sel]) to Contactor and the other relay output toContactorDB

Set one [Digital Inx Sel] parameter to Contactor (default value forparameter 140[Digital In8 Sel])

When a contactor is NOT used:

Set parameter 1391[ContactorControl] to None (1)

Do NOT set either [Relay Out x Sel] parameter to Contactor orContactorDB

Do NOT set any [Digital Inx Sel] parameter to Contactor

(1) Par 1391 [ContactorControl] is contained in the Advanced parameter configuration group. See How Parameters are Organizedon

page 113for more information.

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When operating a drive with firmware version 1.006 in field weakening modewith a DC contactor and/or inverting fault device installed in the armaturecircuit, see Field Weakening Mode Configuration (v1.006)on page 287.

AC Input Contactors

See AC Input Line Reactors and AC Input Contactorson page 255for a list ofrecommended AC input contactors.

DC Output Contactors

A DC output contactor can be used to connect the output of the armature circuitto the DC motor. If a DC output contactor is used, an AC input contactor is notneeded.

See Dynamic Brake Resistor Kits and DC Output Contactorson page 259for alist of recommended DC output contactors.

Dynamic Brake Resistors

See Dynamic Brake Resistor Kits and DC Output Contactorson page 259for alist of recommended dynamic brake resistor kits.

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General GroundingRequirements

The drive Safety Ground (PE) must be connected to system ground.Groundimpedance must conform to the requirements of national and local industrialsafety regulations and/or electrical codes. Periodically check the integrity of allground connections.

For installations within a cabinet, use a single safety ground point or ground bus

bar connected directly to building steel. Ground all circuits, including the ACinput ground conductor, independently and directly to this point/bar.

For installations in distribution systems that have ungrounded or high impedanceneutral connections or systems, see Grounding for Installations in anUngrounded or High-Impedance Neutral Ground or System on page 34.

Figure 9 - Typical Grounding

ATTENTION: To comply with the essential requirements of the CE Low Voltage

Directive 2006/95/EC, PowerFlex DC drives may not be powered from a corner-

earthed (TN with one phase earthed) supply system. When operating PowerFlex

DC drives from an IT or impedance-earthed supply system, only temporary

operation is permitted after an earth fault is detected in the power system.

L1

L2

L3

U V WC D

PE1/

STS

PORT

MOD

NETA

NETB

Earth

All wires (including motor

ground) must be connectedinside the motor terminal box.

TransformerSafetyGround

ACMainsSupply

AC Line Reactor

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Safety Ground (PE)

This is the safety ground for the drive that is required by code. This point must beconnected to adjacent building steel (girder, joist), a floor ground rod or bus bar(see above). Grounding points must comply with national and local industrialsafety regulations and/or electrical codes.

Power Feeder

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

Encoder/Resolver Ground Connections

If used, the encoder or resolver ground connections must be routed in grounded

steel conduit. The conduit must be grounded at both ends. The encoder/resolvercable shield must be connected to the shield ground on the drive side. Do notconnect the encoder/resolver cable shield to ground on the motor side.

Tachometer Ground Connections

If used, ground connections must be routed in grounded steel conduit. Theconduit must be grounded at both ends. Ground the cable shield at the drive endby using only the shield clamps on the grounded metal plate supporting thecontrol board (see Figure 58on page 80for shield clamp location).

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Grounding for Installationsin an Ungrounded or High-Impedance Neutral Groundor System

The PowerFlex DC drive was designed to work in distribution systems where theisolation transformer Wye neutral is connected to earth ground. PowerFlex DCdrives are notdesigned to work in distribution systems that have ungrounded orhigh impedance neutral connections or systems that have a phase referenced toearth. Symmetrical incoming power is required for correct drive operation.

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

If the PowerFlex DC drive is installed in a system with an ungrounded Wyeneutral or with an impedance ground connection, see Table 8on page 35for thenecessary drive modifications that are required for proper installation.

Power Distribution

Figure 10 - Delta/Wye with Grounded Wye Neutral

Rockwell Automation strongly recommends the use of grounded neutral systems

for the following reasons: Controlled path for common mode noise current

Consistent line to ground voltage reference, which minimizes insulationstress

Accommodation for system surge protection schemes

Figure 11 - Ungrounded Secondary

Grounding the transformer secondary is essential to the safety of personnel andsafe operation of the drive. Leaving the secondary floating allows dangerouslyhigh voltages between the chassis of the drive and the internal power structurecomponents.

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Figure 12 - High Resistance Ground

Grounding the wye secondary neutral through a resistor is an acceptable methodof grounding. Under a short circuit secondary condition, any of the outputphases to ground will not exceed the normal line to line voltage. The resistor isoften used to detect ground current by monitoring the associated voltage drop.

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

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

Frame Circuit Board Jumper/Connection Figure to see for Details

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

B Pulse transformer (FIR2-xx-xx) Remove jumper S9 Figure 14on page 36

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

Transient noise filter (FIL-31),200V500V AC drives

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

Figure 16on page 37

Transient noise filter (FIL-57,FIL-69), 575V690V AC drives

Remove jumper S1 Figure 17on page 37

D Pulse transformer (FIR-D-xx-xx) Remove capacito rs C1 21 and C12 2 Figure 18on page 38

Overvoltage clipping (CFSF-xxx) Remove jumper S1 Figure 19on page 38

S9

T01 T04 T02 T05 T03 T06

T1 T4 T2 T5 T3 T6

78 79 35 36 75 76 U2 V2

S4

S3

XY

XR

TR2 TR1

XPXSWXSW1X3

X4

S9

Note: Remove the front covers from thedrive to access the pulse transformer circuitboard. See page 27for instructions.

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

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

S9

PE

XCD_IO

XTA

78 79 35 36 75 76 U2 V2

T01

T4

T1

T2 T02

T5

T3

T6

T03

T06

T04

T05

TR1 TR2

S9

PE

Note: Remove the front covers from thedrive to access the pulse transformer circuitboard. See page 28for instructions.

X3

XCD_IO

TO5 TO3 TO6TO2

4 KGO2 KGO5 KGO3 KGO6

T5 T3 T6T2

KG2 KG5KG3

KG6

XCT

PE

PE1

XCD

S3 S4

XUVW

1 1

XTA

TR3

XR

S9

XCD_IO

PE

PE1

XCD

S9

Note: The pulse transformer circuit board is behind the control EMI shield, near the top of the drive. See page 28forinstructions on removing the f ront covers from the drive and page68for instructions on moving the control EMI shield.

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Figure 16 - Frame C Transient Noise Filter Circuit Board (FIL-31), 200V500V AC Input Drives,Ground Wire Location

Figure 17 - Frame C Transient Noise Filter Circuit Board (FIL-57, FIL-69), 575V690V AC InputDrives, S1 Jumper Location

STS

PORT

MOD

NETA

NETB

U V

C

Yellow/Green (ground) wire

Transient noise filter board

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

S1

F1 F2 F3

P4 P3

S1

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

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

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

XUV

XSWXSW1

XCD_IO XUVW

XCD

XR

XSPF

S3

7 8 7 9 3 5 3 6 7 5 76 8 1 8 2 U 2 V 2

X4 X5 X6

XTA

TR2

TR1

T1

T4

T2

T5

T3

T6

PE

XP1

XP2

KG1

KG4

KG2

KG5

KG3

KG6

KG01

KG04

KG02

KG05

KG03

KG06

T01

T04

T02

T05

T03

T06

XCTS4

XY

X3

C122 C121

XCD_IO XUVW

C122 C121

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

XCD

X1UVW1

XUVW

F31 F21 F11

S1

XCD

S1

90

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

Overvoltage clipping boardlocation inside drive

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

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

3. Open the control panel to the left.

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

EU Declarations of Conformity are available online at:www.rockwellautomation.com/products/certification/ce/

Low Voltage Directive

EN 50178 Electronic equipment for use in power installations.

EMC Directive

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

General Considerations

For CE compliance, the drive installation must satisfy requirements related toboth EN 50178 and EN 61800-3 provided in this document.

PowerFlex DC drives comply with the EMC requirements of EN 61800-3when installed according to good EMC practices and the instructionsprovided in this document. However, many factors can influence the EMC

compliance of an entire machine or installation, and compliance of the driveitself does not ensure compliance of all applications.

PowerFlex DC drives are not intended to be used on public low-voltagenetworks that supply domestic premises. Without additional mitigation,radio frequency interference is expected if used on such a network. Theinstaller is responsible to take measures such as supplementary line filters andenclosures to prevent interference, in addition to the installation requirementsof this document.

PowerFlex DC drives generate notching and harmonic current emissions onthe AC supply system. When operated on a public low-voltage network it isthe responsibility of the installer or user to ensure that applicablerequirements of the distribution network operator have been met.

ATTENTION: PowerFlex DC drives may produce DC current in the protective

earthing conductor, which can reduce the ability of RCDs (residual current-

operated protective devices) or RCMs (residual current-operated monitoring

devices), of type A or AC, to provide protection for other equipment in the

installation.
http://www.rockwellautomation.com/products/certification/ce/http://www.rockwellautomation.com/products/certification/ce/

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Installation Requirements Related to the Low Voltage Directive

PowerFlex DC drives are designed to be CE compliant only if they are NOTconnected to corner-earthed supply systems where one of the three phases ofthe supply system has been earthed.

PowerFlex DC drives are compliant with the CE LV Directive when used at

altitudes no greater than 2000 m (6562 ft).

PowerFlex DC drives provided in enclosure type IP20 must be installed in apollution degree 1 or 2 environment to be compliant with the CE LVDirective. Characteristics of the different pollution degree ratings areprovided onpage 41.

PowerFlex DC drives may produce leakage current in the protective earthingconductor that exceeds 3.5 mA AC and/or 10 mA DC. The minimum size ofthe protective earthing (grounding) conductor used in the application mustcomply with local safety regulations for high protective earthing conductorcurrent equipment.

Frame D PowerFlex DC drives must be installed in a supplementary enclosurethat provides protection from electric shock to be compliant with the CE LVDirective.

Installation Requirements Related to EN 61800-3 and the EMC

Directive

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

PowerFlex DC drives require the use of an external EMC filter to comply withthe EMC directive and emission limits of EN 61800-3: 2004. PowerFlex DCdrives have been tested and verified for compliance to the emission limits of

EN 61800-3: 2004 by using only the specific input filters and motor cablelengths identified in Table 9. See Typical Power Wiring Diagramson page 45for additional installation information.

Table 9 - Standards and Limits for EMC Input Filters

Drive FrameCatalog Number

Standard / Limits (Compliance with any of the limits in the table below satisfies RF emission requirements for the EMC Directive)

EN61800-3 Category C1EN61000-6-3 CISPR 11 Group 1Class B

EN61800-3 Category C2EN61000-6-4 CISPR11 Group 1Class AP < 20kVA

CISPR11 Group 1Class AP > 20kVA

EN61800-3 CategoryC3I < 100A

EN61800-3 CategoryC3I > 100A

Frame A

20Px1Ax4P1

20Px1Ax129

Compliance may be possiblewith supplementary mitigation(Consult factory)

Compliance may be possiblewith supplementarymitigation (Consult factory)

RF line filter required(2)

50 m motor cable limit





Frame B

20Px1Ax167

20Px1Ax412










Frame C

20Px1Ax495

20Px1Ax667









Frame D

20Px1Ax

20Px1Ax








More Stringent Limits Less Stringent Limits

(1) RF 3xxx-MHU EMC filter from Rasmi Electronics Ltd.xxxdesignates filter current rating. Rasmi EMC filters are manufactured by Rasmi Electronics Ltd. Refer to the manufacturers literature for details.

(2) RF 3xxx-SIEI EMC filter from Rasmi Electronics Ltd.xxxdesignates filter c urrent rating. Rasmi EMC filters are manufactured by Rasmi Electronics Ltd. Refer to the manufacturers literature for details.

(3) EPCOS B84143B Type S081 EMC filter from EPCOS AG. EPCOS EMC filters are manufactured by EPCOS AG. Refer to the manufacturers literature for details.

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Output power wiring to the motor must employ cable with a braidedshield providing 75% or greater coverage, or the cables must be housed inmetal conduit, or equivalent shielding must be provided. Continuousshielding must be provided from the drive enclosure to the motorenclosure. Both ends of the motor cable shield (or conduit) must terminatewith a low-impedance connection to earth.

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

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

Motor cabling must be separated from control and signal wiring whereverpossible.

Maximum motor cable length must not exceed the maximum lengthindicated in the table onpage 40for compliance with radio frequencyemission limits for the specific standard and installation environment.

Pollution Degree Ratings According to EN 61800-5-1

IMPORTANT Use of EMC filters other than those listed in Table 9on page page 40must be

verified in the application. Additional filters are listed in Alternate EMC Filters

on page 262.

PollutionDegree

Description

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

2 Normally, only non-conductive pollution occurs. Occasionally, however, a temporary conductivity causedby condensation is to be expected, when the drive is out of operation.

3 Conductive pollution or dry non-conductive pollution occurs, which becomes conductive due tocondensation, which is to be expected.

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

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Power Circuit Protection It is recommended that you install frame A and B PowerFlex DC drives with fastacting fuses to protect the armature converter on the AC input and DC output(for four quadrant drives only) sides. Internally mounted fuses for armatureconverter protection are provided with frame C and D PowerFlex DC drives. SeeDrive Power Circuit Protectionon page 237for a list of replacement fuses andgeneral fuse locations.

Control Power CircuitProtection

The 115V / 230V AC control circuit power input terminals U2 and V2 arerequired to be short circuit protected. This protection can be provided by usingstandard time delay fuses or a circuit breaker. The time delay fuses or circuitbreaker must be selected to survive the short circuit available current of the feedersource for this circuit and the inrush current of the drives power supply.

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

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

Table 10 - Control Power Protection

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

Fr ame Co ntro l Power Supply

C ircuit Board ID / Revision Power Rated input current Inrush input current

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

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

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

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

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

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

SW3

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