Allen-Bradley PowerFlex 400 Installation Instructions Manual
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Allen-Bradley PowerFlex 400 Installation Instructions Manual

Ac drive packages for fan & pump applications
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PowerFlex 400 AC Drive Packages for
Fan & Pump Applications

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Summary of Contents for Allen-Bradley PowerFlex 400

  • Page 1 Installation Instructions PowerFlex 400 AC Drive Packages for Fan & Pump Applications...
  • Page 2 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.

  • Page 3: Table Of Contents

    Summary of Changes Manual Updates The information below summarizes the changes to the PowerFlex 400 Installation Instructions since the August 2008 release. Drawing/Schematic Updates Drawing Page 98D01537 1-15 95D01575 1-36 95D01576 1-37 95D01579 1-40 95D02442 1-41 95D01563 1-42 95D01565 1-44...
  • Page 4 Summary of Changes Notes: Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 5 Table of Contents Preface Overview Who Should Use this Manual? ......... . P-1 What Is Not in this Manual.
  • Page 6 Table of Contents Chapter 4 Mechanical Installation Chapter Objectives ........... . . 4-1 Mounting Considerations.

  • Page 7: Preface

    400 Adjustable Frequency AC Drive Packages for Fan & Pump Applications. User documentation for the PowerFlex 400 Drive Packages for Fan & Pump Applications includes these Installation Instructions and the PowerFlex 400 User Manual, Publication 22C-UM001…. Both manuals are required to properly install and operate the PowerFlex 400 Adjustable Frequency AC Drive Packages for Fan &...

  • Page 8: Reference Materials

    /literature Control A Global Reference Guide for Reading 0100-2.10 Schematic Diagrams Guarding Against Electrostatic Damage 8000-4.5.2 For detailed PowerFlex 400 information including drive parameters, programming, start-up, troubleshooting, specifications: Title Publication Available Online at … PowerFlex 400 User Manual 22C-UM001… www.rockwellautomation.com/literature PowerFlex Reference Manual PFLEX-RM001…...

  • Page 9: General Precautions

    Measure the voltage at the drive (Refer to the PowerFlex 400 User Manual for test point locations). The voltage must be zero. Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 10: Catalog Number Explanation

    Overview Catalog Number The PowerFlex 400 Adjustable Frequency AC Drive Packages for Fan & Pump Applications catalog numbering scheme is shown below. Explanation Position 23C – Drive Enclosure Package Code Type Code Enclosure Code Description PowerFlex 400 NEMA/UL Type 1...

  • Page 11: Main Input Disconnect Package (Style A/M)

    Main Disconnect Switch (DS1) An Allen-Bradley Bulletin 194R Fused Disconnect Switch with lockable rotary mounted operator handle is provided. The disconnect switch is designed to meet disconnect switch requirements for branch circuit protection.
  • Page 12 No other load may be applied to that fused circuit. The recommended fuse type for all PowerFlex 400 Drive Packages for Fan & Pump Applications is UL Class J. Table 1.A Fuse Recommendations...

  • Page 13: Electrical Installation

    Input Power Wiring Use 75 °C rated copper conductors only for customer power wiring. Refer to the PowerFlex 400 User Manual for additional detailed information about input power wiring recommendations and selection. ATTENTION: Protect the contents of the options cabinet from metal chips and other debris while drilling the conduit openings.
  • Page 14 Main Input Disconnect Package (Style A/M) Output Power Wiring Refer to the PowerFlex 400 User Manual for additional detailed information about output power wiring recommendations and selection. ATTENTION: Unused wires in conduit must be grounded at both ends to avoid a possible shock hazard caused by induced voltages.
  • Page 15 Main Input Disconnect Package (Style A/M) Control and Signal Wiring Refer to the PowerFlex 400 User Manual for additional detailed information about control and signal wiring. The Control I/O Terminal Block (TB1) and Relay Terminal Block (TB2) located on the drive Main Control Board provide terminals for interfacing customer supplied control inputs and outputs.

  • Page 16: Parameter Defaults

    0.0% parameter settings to the defaults list in the Testpoint Sel A196 Analog Out2 Sel T085 1 “OutCurr 0-10” PowerFlex 400 User Manual. Fault Clear A197 0 “Ready/Idle” Analog Out2 High T086 100% ATTENTION: Parameter A165 [Start At PowerUp] ships from the factory enabled. This feature allows a Run command to automatically cause the drive to resume running at commanded speed after drive input power is restored.

  • Page 17: Drawing Index

    Main Input Disconnect Package (Style A/M) Drawing Index 208V AC – Main Input Disconnect Drive Packages (Style A/M) Drawing Input Input Line Voltage Type Reactor Schematic Page interconnect Page Layout Page Outline Page NEMA/UL Type 1 95D00758 1-22 95D00689 1-53 98D00697 1-10 97D00696...

  • Page 18: D01575

    Main Input Disconnect Package (Style A/M) 460V AC – Main Input Disconnect Drive Packages (Style A/M) Drawing Input Input Line Voltage Type Reactor Schematic Page interconnect Page Layout Page Outline Page 95D00758 1-22 95D00689 1-53 98D00697 1-10 97D00696 1-17 95D00759 1-23 95D00691 1-54...
  • Page 19 Main Input Disconnect Package (Style A/M) Drawing Input Input Line Voltage Type Reactor Schematic Page interconnect Page Layout Page Outline Page 95D02442 1-41 95D01563 1-42 98D01537 1-15 95D01564 1-43 NEMA/UL With or 97D01548 1-21 95D01551 1-68 Type 4 Without 95D01565 1-44 95D01566 1-45...

  • Page 20: Schematic Drawings

    1-10 Main Input Disconnect Package (Style A/M) Schematic Drawings Figure 1.1 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives - NEMA/UL Type 1 98D00697 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 21 Main Input Disconnect Package (Style A/M) 1-11 Figure 1.2 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 98D00756 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 22 1-12 Main Input Disconnect Package (Style A/M) Figure 1.3 200 Hp, 460V AC Drives - NEMA/UL Type 1 98D01888 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 23 Main Input Disconnect Package (Style A/M) 1-13 Figure 1.4 250…350 Hp, 460V AC Drives - NEMA/UL Type 1 98D01887 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 24 1-14 Main Input Disconnect Package (Style A/M) Figure 1.5 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives - NEMA/UL Type 12 & 3R 98D01535 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 25 Main Input Disconnect Package (Style A/M) 1-15 Figure 1.6 3.0…50 Hp, 208V AC & 3.0…100 Hp, 460V AC Drives - NEMA/UL Type 4 98D01537 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 26 1-16 Main Input Disconnect Package (Style A/M) Figure 1.7 125…150 Hp, 460V AC Drives - NEMA/UL Type 4 98D01538 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 27: Interconnect Drawings

    Main Input Disconnect Package (Style A/M) 1-17 interconnect Drawings Figure 1.8 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives - NEMA/UL Type 1 97D00696 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 28 1-18 Main Input Disconnect Package (Style A/M) Figure 1.9 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 97D00754 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 29 Main Input Disconnect Package (Style A/M) 1-19 Figure 1.10 200 Hp, 460V AC Drives - NEMA/UL Type 1 97D01890 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 30 1-20 Main Input Disconnect Package (Style A/M) Figure 1.11 250…350 Hp, 460V AC Drives - NEMA/UL Type 1 97D01889 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 31 Main Input Disconnect Package (Style A/M) 1-21 Figure 1.12 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives - NEMA/UL Type 12, 4, & 3R 97D01548 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 32: Layout Drawings

    1-22 Main Input Disconnect Package (Style A/M) Layout Drawings Figure 1.13 3.0…10 Hp, 208V AC & 3.0…20 Hp, 460V AC Drives - NEMA/UL Type 1 95D00758 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 33 Main Input Disconnect Package (Style A/M) 1-23 Figure 1.14 15…20 Hp, 208V AC & 25…40 Hp, 460V AC Drives - NEMA/UL Type 1 95D00759 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 34 1-24 Main Input Disconnect Package (Style A/M) Figure 1.15 25…30 Hp, 208V AC Drives - NEMA/UL Type 1 95D00775 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 35 Main Input Disconnect Package (Style A/M) 1-25 Figure 1.16 40 Hp, 208V AC & 50…100 Hp, 460V AC Drives - NEMA/UL Type 1 95D00760 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 36 1-26 Main Input Disconnect Package (Style A/M) Figure 1.17 50 Hp, 208V AC Drives - NEMA/UL Type 1 95D00776 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 37 Main Input Disconnect Package (Style A/M) 1-27 Figure 1.18 125…150 Hp, 460V AC Drives - NEMA/UL Type 1 95D01262 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 38 1-28 Main Input Disconnect Package (Style A/M) Figure 1.19 200…250 Hp, 460V AC Drives - NEMA/UL Type 1 95D01862 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 39 Main Input Disconnect Package (Style A/M) 1-29 Figure 1.20 300…350 Hp, 460V AC Drives - NEMA/UL Type 1 95D01864 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 40 1-30 Main Input Disconnect Package (Style A/M) Figure 1.21 3.0…5.0 Hp, 208V AC & 3.0…10 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D00791 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 41 Main Input Disconnect Package (Style A/M) 1-31 Figure 1.22 7.5…10 Hp, 208V AC & 15…20 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D00792 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 42 1-32 Main Input Disconnect Package (Style A/M) Figure 1.23 15…20 Hp, 208V AC & 25…40 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D01367 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 43 Main Input Disconnect Package (Style A/M) 1-33 Figure 1.24 25…30 Hp, 208V AC Drives with Line Reactor - NEMA/UL Type 1 95D01368 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 44 1-34 Main Input Disconnect Package (Style A/M) Figure 1.25 40…50 Hp, 208V AC & 50…100 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D01369 LABEL Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 45 Main Input Disconnect Package (Style A/M) 1-35 Figure 1.26 125…150 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D01370 LABEL Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 46: D01576

    1-36 Main Input Disconnect Package (Style A/M) Figure 1.27 3.0…10 Hp, 208V & 3.0…20 Hp, 460V AC Drives - NEMA/UL Type 12 95D01575 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 47: D01579

    Main Input Disconnect Package (Style A/M) 1-37 Figure 1.28 15…20 Hp, 208V AC & 25…40 Hp 460V AC Drives - NEMA/UL Type 12 95D01576 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 48 1-38 Main Input Disconnect Package (Style A/M) Figure 1.29 50…60 Hp, 460V AC Drives - NEMA/UL Type 12 95D01577 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 49 Main Input Disconnect Package (Style A/M) 1-39 Figure 1.30 40…50 Hp, 208V AC & 75…100 Hp, 460V AC Drives - NEMA/UL Type 12 95D01578 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 50 1-40 Main Input Disconnect Package (Style A/M) Figure 1.31 125…150 Hp, 460V AC Drives - NEMA/UL Type 12 95D01579 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 51: D02442

    Main Input Disconnect Package (Style A/M) 1-41 Figure 1.32 3.0…5.0 Hp, 460V AC Drives - NEMA/UL Type 4 95D02442 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 52: D01563

    1-42 Main Input Disconnect Package (Style A/M) Figure 1.33 5.0…10 Hp, 208V AC & 7.5…20 Hp, 460V AC Drives - NEMA/UL Type 4 95D01563 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 53: D01565

    Main Input Disconnect Package (Style A/M) 1-43 Figure 1.34 15 Hp, 208V AC & 25 Hp, 460V AC Drives - NEMA/UL Type 4 95D01564 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 54: D01568

    1-44 Main Input Disconnect Package (Style A/M) Figure 1.35 15…20 Hp, 208V AC & 25…40 Hp, 460V AC Drives - NEMA/UL Type 4 95D01565 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 55 Main Input Disconnect Package (Style A/M) 1-45 Figure 1.36 25…30 Hp, 208V AC & 50…60 Hp, 460V AC Drives - NEMA/UL Type 4 95D01566 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 56 1-46 Main Input Disconnect Package (Style A/M) Figure 1.37 40…50 Hp, 208V AC & 75…100 Hp, 460V AC Drives - NEMA/UL Type 4 95D01567 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 57 Main Input Disconnect Package (Style A/M) 1-47 Figure 1.38 125…150 Hp, 460V AC Drives - NEMA/UL Type 4 95D01568 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 58: D01553

    1-48 Main Input Disconnect Package (Style A/M) Figure 1.39 3.0…10 Hp, 208V AC & 3.0…20 Hp, 460V AC Drives - NEMA/UL Type 3R 95D01553 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 59: D01554

    Main Input Disconnect Package (Style A/M) 1-49 Figure 1.40 15…30 Hp, 208V AC & 25…40 Hp, 460V AC Drives - NEMA/UL Type 3R 95D01554 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 60: D01557

    1-50 Main Input Disconnect Package (Style A/M) Figure 1.41 50…60 Hp, 460V AC Drives - NEMA/UL Type 3R 95D01555 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 61: D01552

    Main Input Disconnect Package (Style A/M) 1-51 Figure 1.42 40…50 Hp, 208V AC & 75…100 Hp, 460V AC Drives - NEMA/UL Type 3R 95D01556 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 62: D01551

    1-52 Main Input Disconnect Package (Style A/M) Figure 1.43 125…150 Hp, 460V AC Drives - NEMA/UL Type 3R 95D01557 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 63: Outline Drawings

    Main Input Disconnect Package (Style A/M) 1-53 Outline Drawings Figure 1.44 3.0…10 Hp, 208V AC & 3.0…20 Hp, 460V AC Drives - NEMA/UL Type 1 95D00689 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 64 1-54 Main Input Disconnect Package (Style A/M) Figure 1.45 15…20 Hp, 208V AC & 25…40 Hp, 460V AC Drives - NEMA/UL Type 1 95D00691 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 65 Main Input Disconnect Package (Style A/M) 1-55 Figure 1.46 25…30 Hp, 208V AC Drives - NEMA/UL Type 1 95D00692 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 66 1-56 Main Input Disconnect Package (Style A/M) Figure 1.47 40 Hp, 208V AC & 50…100 Hp, 460V AC Drives - NEMA/UL Type 1 95D00693 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 67 Main Input Disconnect Package (Style A/M) 1-57 Figure 1.48 50 Hp, 208V AC Drives - NEMA/UL Type 1 95D00694 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 68 1-58 Main Input Disconnect Package (Style A/M) Figure 1.49 125…150 Hp, 460V AC Drives - NEMA/UL Type 1 95D01264 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 69 Main Input Disconnect Package (Style A/M) 1-59 Figure 1.50 200…250 Hp, 460V AC Drives - NEMA/UL Type 1 95D01866 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 70 1-60 Main Input Disconnect Package (Style A/M) Figure 1.51 300…350 Hp, 460V AC Drives - NEMA/UL Type 1 95D01868 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 71 Main Input Disconnect Package (Style A/M) 1-61 Figure 1.52 3.0…5.0 Hp, 208V AC & 3.0…10 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D00690 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 72 1-62 Main Input Disconnect Package (Style A/M) Figure 1.53 7.5…10 Hp, 208V AC & 15…20 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D00753 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 73 Main Input Disconnect Package (Style A/M) 1-63 Figure 1.54 15…20 Hp, 208V AC & 25…40 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D01359 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 74 1-64 Main Input Disconnect Package (Style A/M) Figure 1.55 25…30 Hp, 208V AC Drives with Line Reactor - NEMA/UL Type 1 95D01360 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 75 Main Input Disconnect Package (Style A/M) 1-65 Figure 1.56 40…50 Hp, 208V AC & 50…100 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D01361 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 76 1-66 Main Input Disconnect Package (Style A/M) Figure 1.57 125…150 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D01362 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 77: D01550

    Main Input Disconnect Package (Style A/M) 1-67 Figure 1.58 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives - NEMA/UL Type 12 95D01552 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 78 1-68 Main Input Disconnect Package (Style A/M) Figure 1.59 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives - NEMA/UL Type 4 95D01551 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 79 Main Input Disconnect Package (Style A/M) 1-69 Figure 1.60 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives - NEMA/UL Type 3R 95D01550 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 80 1-70 Main Input Disconnect Package (Style A/M) Notes: Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 81: Contactor Full Feature Bypass With Disconnect Package (Style B/N)

    Main Disconnect Switch (DS1) An Allen-Bradley Bulletin 194R fused disconnect switch with lockable rotary mounted operator handle is provided. The disconnect switch is designed to meet disconnect switch requirements for branch circuit protection.
  • Page 82 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Main Fuses (FU1-FU3) ATTENTION: Most codes require that upstream branch circuit protection be provided to protect input power wiring. Install the fuses recommended in Table 2.A. Do not exceed the fuse ratings. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
  • Page 83 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Contactors (DIC, DOC, BC) Allen-Bradley Bulletin 100 Contactors are provided for all ratings. The contactors function as follows: 1. Drive-input contactor (DIC) opens and closes input to the drive. 2. Drive-output contactor (DOC) opens and closes the connection between the drive and the motor.
  • Page 84 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Table 2.B Overload Ratings Drive Rating Overload Rating Adjustment Rating Input Voltage Trip Class (Amps) 208V AC – 3-Phase 3.2 - 16 5.4 - 27 9 - 45 9 - 45 18 - 90 18 - 90 18.5...
  • Page 85 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Control Transformer (T1) 115V AC control power is obtained via a supplied control power transformer. The control transformer is fused on the primary. Bypass Control Interface (CP1) The operator interface on the bypass option box shows the following LEDs: •...

  • Page 86: Electrical Installation

    Input Power Wiring Use 75 °C rated copper conductors only for customer power wiring. Refer to the PowerFlex 400 User Manual for additional detailed information about input power wiring recommendations and selection. ATTENTION: Protect the contents of the options cabinet from metal chips and other debris while drilling the conduit openings.
  • Page 87 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Output Power Wiring Refer to the PowerFlex 400 User Manual for additional detailed information about output power wiring recommendations and selection. ATTENTION: Unused wires in conduit must be grounded at both ends to avoid a possible shock hazard caused by induced voltages.
  • Page 88 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Control and Signal Wiring Refer to the PowerFlex 400 User Manual for additional detailed information about control and signal wiring. The Signal Terminal Block (TB1 Terminals 1…20 and R1…R6) located on the drive Main Control Board and Control Terminal Block (TB1 Terminals 31…40) located inside the Option Cabinet provide terminals for interfacing...

  • Page 89: Customer Connections

    3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Customer Connections The 3 Contactor Full Feature Bypass with Disconnect Package is set up to accommodate the following customer supplied contacts. Contacts should be rated for 120V AC. Interlock The “Interlock” input functions as an Enable input when operating in either Drive or Bypass mode.

  • Page 90: Operating Modes

    When “Auto” is selected, the Start Command is defined by P036 [Start Source]. Factory default is configured for terminal block control. Refer to the PowerFlex 400 User Manual for other control schemes. When “Auto” is selected, the Speed Reference is defined by P038 [Speed Reference]. Analog In1 has control by factory default.

  • Page 91: Parameter Defaults

    Testpoint Sel A196 PowerFlex 400 User Manual. ATTENTION: Parameter A165 [Start At PowerUp] ships from the factory enabled. This feature allows a Run command to automatically cause the drive to resume running at commanded speed after drive input power is restored. Equipment damage and/or personal injury may result if this parameter is used in an inappropriate application.

  • Page 92: Drawing Index

    2-12 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Drawing Index 208V AC – 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Drawing Input Input Line Voltage Type Reactor Schematic Page Interconnect Page Layout Page Outline Page 95D00761 2-37...

  • Page 93: D01581

    3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-13 460V AC – 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Drawing Input Input Line Voltage Type Reactor Schematic Page Interconnect Page Layout Page Outline Page 95D00761 2-37 95D00719 2-71...
  • Page 94 2-14 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Drawing Input Input Line Voltage Type Reactor Schematic Page Interconnect Page Layout Page Outline Page 95D02443 2-59 95D01569 2-60 98D01539 2-25 95D01570 2-61 NEMA/UL With or 460V AC 97D01549 2-35 95D01551 2-87...

  • Page 95: Schematic Drawings

    3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-15 Schematic Drawings Figure 2.3 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives (Sheet 1 of 2) - NEMA/UL Type 1 98D00705 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 96 2-16 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.4 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives (Sheet 2 of 2) - NEMA/UL Type 1 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 97 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-17 Figure 2.5 200 Hp, 460V AC Drives (Sheet 1 of 2) - NEMA/UL Type 1 98D01861 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 98 2-18 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.6 200 Hp, 460V AC Drives (Sheet 2 of 2) - NEMA/UL Type 1 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 99 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-19 Figure 2.7 250…350 Hp, 460V AC Drives (Sheet 1 of 2) - NEMA/UL Type 1 98D01860 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 100 2-20 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.8 250…350 Hp, 460V AC Drives (Sheet 2 of 2) - NEMA/UL Type 1 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 101 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-21 Figure 2.9 3.0…50 Hp, 208V AC & 3.0…100 Hp, 460V AC Drives with Line Reactor (Sheet 1 of 2) - NEMA/UL Type 1 98D00757 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 102 2-22 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.10 3.0…50 Hp, 208V AC & 3.0…100 Hp, 460V AC Drives with Line Reactor (Sheet 2 of 2) - NEMA/UL Type 1 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 103 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-23 Figure 2.11 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives (Sheet 1 of 2) - NEMA/UL Type 12 98D01541 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 104 2-24 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.12 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives (Sheet 2 of 2) - NEMA/UL Type 12 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 105 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-25 Figure 2.13 3.0…30 Hp, 208V AC & 3.0…40 Hp, 460V AC Drives (Sheet 1 of 2) - NEMA/UL Type 4 98D01539 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 106 2-26 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.14 3.0…30 Hp, 208V AC & 3.0…40 Hp, 460V AC Drives (Sheet 2 of 2) - NEMA/UL Type 4 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 107 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-27 Figure 2.15 125…150 Hp, 460V AC Drives (Sheet 1 of 2) - NEMA/UL Type 4 98D01540 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 108 2-28 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.16 125…150 Hp, 460V AC Drives (Sheet 2 of 2) - NEMA/UL Type 4 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 109 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-29 Figure 2.17 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives (Sheet 1 of 2) - NEMA/UL Type 3R 98D01536 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 110 2-30 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.18 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives (Sheet 2 of 2) - NEMA/UL Type 3R Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 111: Interconnect Drawings

    3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-31 Interconnect Drawings Figure 2.19 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives - NEMA/UL Type 1 97D00704 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 112 2-32 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.20 200 Hp, 460V AC Drives - NEMA/UL Type 1 97D01892 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 113 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-33 Figure 2.21 250…350 Hp, 460V AC Drives - NEMA/UL Type 1 97D01891 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 114 2-34 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.22 3.0…50 Hp, 208V AC & 3.0…100 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 97D00755 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 115 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-35 Figure 2.23 3.0…50 Hp, 208V & 3.0…150 Hp, 460V AC Drives - NEMA/UL Type 12, 4, 3R 97D01549 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 116 2-36 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.24 250…350 Hp, 460V AC Drives - NEMA/UL Type 1 97D01891 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 117: Layout Drawings

    3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-37 Layout Drawings Figure 2.25 3.0…5.0 Hp, 208V AC & 3.0…10 Hp, 460V AC Drives - NEMA/UL Type 1 95D00761 -1 -1 -1 -1 -1 -1 -1 -1 L2 5 L2 5 -3 -3 -3 -3...
  • Page 118 2-38 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.26 7.5…10 Hp, 208V AC & 15…20 Hp, 460V AC Drives - NEMA/UL Type 1 95D00762 13 NO 14 NO Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 119 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-39 Figure 2.27 15…20 Hp, 208V AC & 25…40 Hp, 460V AC Drives - NEMA/UL Type 1 95D00763 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 120 2-40 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.28 25…30 Hp, 208V AC Drives - NEMA/UL Type 1 95D00777 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 121 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-41 Figure 2.29 50…75 Hp, 460V AC Drives - NEMA/UL Type 1 95D00764 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 122 2-42 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.30 40 Hp, 208V AC & 100 Hp, 460V AC Drives - NEMA/UL Type 1 95D00765 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 123 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-43 Figure 2.31 50 Hp, 208V AC Drives - NEMA/UL Type 1 95D00778 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 124 2-44 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.32 125…150 Hp, 460V AC Drives - NEMA/UL Type 1 95D01263 AC_VND_LABEL AC_PART_NO AC_DESCRIPTION DEVICE_ID AC_CPART_NO AC_NOTE FASTENER AC_SCALE_UNIT AC_VIEW_CODE Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 125 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-45 Figure 2.33 200…250 Hp, 460V AC Drives - NEMA/UL Type 1 95D01863 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 126 2-46 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.34 300…350 Hp, 460V AC Drives - NEMA/UL Type 1 95D01865 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 127 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-47 Figure 2.35 3.0…5.0 Hp, 208V AC & 3.0…10 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D00793 L2 5 L3 13 L1 3 13 NO T2 6 T3 14 T1 4 T2 6...
  • Page 128 Figure 2.36 7.5…10 Hp, 208V AC & 15…20 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D00794 L1 3 L1 3 13 NO L1 3 T3 14 NO T1 4 T2 6 ALLEN-BRADLEY 193-EA2HC IEC OVERLOAD T1 4 T2 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 129 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-49 Figure 2.37 15…20 Hp, 208V AC & 25…40 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D01371 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 130 2-50 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.38 25 Hp, 208V AC Drives with Line Reactor - NEMA/UL Type 1 95D01372 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 131 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-51 Figure 2.39 50…60 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D01373 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 132 2-52 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.40 30 Hp, 208V AC Drives with Line Reactor - NEMA/UL Type 1 95D01377 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 133 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-53 Figure 2.41 40…50 Hp, 208V AC & 75…100 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D01374 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 134: D01584

    2-54 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.42 3.0…10 Hp, 208V AC & 3.0…20 Hp, 460V AC Drives - NEMA/UL Type 12 95D01580 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 135 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-55 Figure 2.43 15…20 Hp, 208V AC & 25…40 Hp, 460V AC Drives - NEMA/UL Type 12 95D01581 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 136 2-56 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.44 25…30 Hp, 208V AC & 50…60 Hp, 460V AC Drives - NEMA/UL Type 12 95D01582 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 137 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-57 Figure 2.45 40…50 Hp, 208V AC & 75…100 Hp, 460V AC Drives - NEMA/UL Type 12 95D01583 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 138 2-58 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.46 125…150 Hp, 460V AC Drives - NEMA/UL Type 12 95D01584 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 139: D02443

    3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-59 Figure 2.47 3.0…5.0 Hp, 460V AC Drives - NEMA/UL Type 4 95D02443 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 140: D01569

    2-60 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.48 5.0…10 Hp, 208V AC & 7.5…20 Hp, 460V AC Drives - NEMA/UL Type 4 95D01569 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 141: D01571

    3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-61 Figure 2.49 15 Hp, 208V AC & 25 Hp, 460V AC Drives - NEMA/UL Type 4 95D01570 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 142: D01574

    2-62 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.50 15…20 Hp, 208V AC & 25…40 Hp, 460V AC Drives - NEMA/UL Type 4 95D01571 45.30 [1 25/32] 45.30 [1 25/32] 45.30 [1 25/32] 45.30 [1 25/32] 45.30 [1 25/32] 45.30 [1 25/32] 45.30 [1 25/32]...
  • Page 143 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-63 Figure 2.51 25…30 Hp, 208V AC & 50…60 Hp, 460V AC Drives - NEMA/UL Type 4 95D01572 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 144 2-64 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.52 40…50 Hp, 208V AC & 75…100 Hp, 460V AC Drives - NEMA/UL Type 4 95D01573 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 145 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-65 Figure 2.53 125…150 Hp, 460V AC Drives - NEMA/UL Type 4 95D01574 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 146: D01559

    2-66 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.54 3.0…10 Hp, 208V AC & 3.0…20 Hp, 460V AC Drives - NEMA/UL Type 3R 95D01558 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 147 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-67 Figure 2.55 15…30 Hp, 208V AC & 25…40 Hp, 460V AC Drives - NEMA/UL Type 3R 95D01559 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 148: D01562

    2-68 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.56 50…60 Hp, 460V AC Drives - NEMA/UL Type 3R 95D01560 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 149 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-69 Figure 2.57 40…50 Hp, 208V AC & 75…100 Hp, 460V AC Drives - NEMA/UL Type 3R 95D01561 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 150 2-70 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.58 125…150 Hp, 460V AC Drives - NEMA/UL Type 3R 95D01562 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 151: Outline Drawings

    3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-71 Outline Drawings Figure 2.59 3.0…5.0 Hp, 208V AC & 3.0…10 Hp, 460V AC Drives - NEMA/UL Type 1 95D00719 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 152 2-72 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.60 7.5…10 Hp, 208V AC & 15…20 Hp, 460V AC Drives - NEMA/UL Type 1 95D00698 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 153 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-73 Figure 2.61 15…20 Hp, 208V AC & 25…40 Hp, 460V AC Drives - NEMA/UL Type 1 95D00700 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 154 2-74 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.62 25…30 Hp, 208V AC Drives - NEMA/UL Type 1 95D00701 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 155 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-75 Figure 2.63 40 Hp, 208V AC & 50…100 Hp, 460V AC Drives - NEMA/UL Type 1 95D00702 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 156 2-76 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.64 50 Hp, 208V AC Drives - NEMA/UL Type 1 95D00703 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 157 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-77 Figure 2.65 125…150 Hp, 460V AC Drives - NEMA/UL Type 1 95D01265 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 158 2-78 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.66 200…250 Hp, 460V AC Drives - NEMA/UL Type 1 95D01867 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 159 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-79 Figure 2.67 300…350 Hp, 460V AC Drives - NEMA/UL Type 1 95D01869 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 160 2-80 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.68 3.0…5.0 Hp, 208V AC & 3.0…10 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D00720 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 161 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-81 Figure 2.69 7.5…10 Hp, 208V AC & 15…20 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D00699 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 162 2-82 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.70 15…20 Hp, 208V AC & 25…40 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D01363 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 163 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-83 Figure 2.71 25…30 Hp, 208V AC Drives with Line Reactor - NEMA/UL Type 1 95D01364 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 164 2-84 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.72 50…60 Hp, 460V AC Drives with Line Reactor - NEMAA/UL Type 1 95D01365 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 165 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-85 Figure 2.73 40…50 Hp, 208V AC & 75…100 Hp, 460V AC Drives with Line Reactor - NEMA/UL Type 1 95D01366 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 166 2-86 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.74 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drives - NEMA/UL Type 12 95D01552 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 167 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) 2-87 Figure 2.75 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drivess - NEMA/UL Type 4 95D01551 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 168 2-88 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Figure 2.76 3.0…50 Hp, 208V AC & 3.0…150 Hp, 460V AC Drivess - NEMA/UL Type 3R 95D01550 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 169: Chapter Objectives

    A lockable door-mounted operator handle is provided. The door- mounted handle accepts up to three (3) padlocks. For ratings 75 Hp and larger, an Allen-Bradley Bulletin 194R fused disconnect switch with lockable rotary-mounted operator handle is provided. The disconnect switch is designed to meet disconnect switch requirements for branch circuit protection.
  • Page 170 Amps 460V AC – 3-Phase Contactors (DIC, DOC, BC) Allen-Bradley Bulletin 100 Contactors are provided for all ratings. The contactors function as follows: • Drive Input Contactor (DIC) opens and closes input to the drive. • Drive Output Contactor (DOC) opens and closes the connection between the drive and the motor.
  • Page 171 3 Contactor Basic Bypass with Disconnect Package (Style C) Motor Overload Relay (OL) For units supplied with a fused disconnect switch, a motor overload relay is supplied. The motor overload relay is set at the factory to 100% of the drive output current.

  • Page 172: Electrical Installation

    Input Power Wiring Use 75 °C rated copper conductors only for customer power wiring. Refer to the PowerFlex 400 User Manual for additional detailed information about input power wiring recommendations and selection. ATTENTION: Protect the contents of the options cabinet from metal chips and other debris while drilling the conduit openings.
  • Page 173 3 Contactor Basic Bypass with Disconnect Package (Style C) Output Power Wiring Refer to the PowerFlex 400 User Manual for additional detailed information about output power wiring recommendations and selection. ATTENTION: Unused wires in conduit must be grounded at both ends to avoid a possible shock hazard caused by induced voltages.
  • Page 174 3 Contactor Basic Bypass with Disconnect Package (Style C) Control and Signal Wiring Refer to the PowerFlex 400 User Manual for additional detailed information about control and signal wiring. The Signal Terminal Block (TB1 Terminals 1…20 and R1…R6) located on the drive Main Control Board and Control Terminal Block (TB1 Terminals 19…24) located inside the Option Cabinet provide terminals for interfacing...

  • Page 175: Operating Modes

    The drive package ships with the speed reference configured for Analog In1 which would be wired to signal terminals 13-14 located on the drive. Refer to the PowerFlex 400 User manual for information on other control schemes.

  • Page 176: Parameter Defaults

    0.0% parameter settings to the defaults list in the Testpoint Sel A196 Analog Out2 Sel T085 1 “OutCurr 0-10” PowerFlex 400 User Manual. Fault Clear A197 0 “Ready/Idle” Analog Out2 High T086 100% ATTENTION: Parameter A165 [Start At PowerUp] ships from the factory enabled. This feature allows a Run command to automatically cause the drive to resume running at commanded speed after drive input power is restored.

  • Page 177: Drawing Index

    3 Contactor Basic Bypass with Disconnect Package (Style C) Drawing Index 460V AC – 3 Contactor Basic Bypass with Disconnect Package (Style C) Drawing Input Input Line Voltage Type Reactor Schematic Page Interconnect Page Layout Page Outline Page 98D00715 3-10 95D00766 3-16 95D00706...

  • Page 178: Schematic Drawings

    3-10 3 Contactor Basic Bypass with Disconnect Package (Style C) Schematic Drawings Figure 3.2 3.0…20 Hp, 460V AC Drives NEMA/UL Type 1 98D00715 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 179 3 Contactor Basic Bypass with Disconnect Package (Style C) 3-11 Figure 3.3 25…60 Hp, 460V AC Drives NEMA/UL Type 1 98D00717 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 180 3-12 3 Contactor Basic Bypass with Disconnect Package (Style C) Figure 3.4 75…100 Hp, 460V AC Drives NEMA/UL Type 1 98D00718 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 181: Interconnect Drawings

    3 Contactor Basic Bypass with Disconnect Package (Style C) 3-13 Interconnect Drawings Figure 3.5 3.0…40 Hp, 460V AC Drives NEMA/UL Type 1 97D00711 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 182 3-14 3 Contactor Basic Bypass with Disconnect Package (Style C) Figure 3.6 50…60 Hp, 460V AC Drives NEMA/UL Type 1 97D00713 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 183 3 Contactor Basic Bypass with Disconnect Package (Style C) 3-15 Figure 3.7 75…100 Hp, 460V AC Drives NEMA/UL Type 1 97D00714 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 184: Layout Drawings

    3-16 3 Contactor Basic Bypass with Disconnect Package (Style C) Layout Drawings Figure 3.8 3.0…20 Hp, 460V AC Drives NEMA/UL Type 1 95D00766 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 185 3 Contactor Basic Bypass with Disconnect Package (Style C) 3-17 Figure 3.9 25…40 Hp, 460V AC Drive NEMA/UL Type 1 95D00767 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 186 3-18 3 Contactor Basic Bypass with Disconnect Package (Style C) Figure 3.10 50…60 Hp, 460V AC Drives NEMA/UL Type 1 95D00768 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 187 3 Contactor Basic Bypass with Disconnect Package (Style C) 3-19 Figure 3.11 75…100 Hp, 460V AC Drives NEMA/UL Type 1 95D00769 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 188: Outline Drawings

    3-20 3 Contactor Basic Bypass with Disconnect Package (Style C) Outline Drawings Figure 3.12 3.0…20 Hp, 460V AC Drives NEMA/UL Type 1 95D00706 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 189 3 Contactor Basic Bypass with Disconnect Package (Style C) 3-21 Figure 3.13 25…40 Hp, 460V AC Drives NEMA/UL Type 1 95D00708 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 190 3-22 3 Contactor Basic Bypass with Disconnect Package (Style C) Figure 3.14 50…100 Hp, 460V AC Drives NEMA/UL Type 1 95D00710 Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 191: Chapter Objectives

    Lifting and Mounting the Drive Watts Loss ATTENTION: The following information is merely a guide for proper installation. The Allen-Bradley Company cannot assume responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this drive or associated equipment.
  • Page 192 Mechanical Installation Figure 4.1 NEMA/UL Type 1 Minimum Mounting Clearances 6.0" Drive or other device 2.0" 2.0" 6.0" Figure 4.2 NEMA/UL Type 12 Minimum Mounting Clearances 12.0" Drive or other device 12.0" 12.0" 12.0" Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 193 Mechanical Installation Figure 4.3 NEMA/UL Type 4 Minimum Mounting Clearances 6.0" 12.0" 12.0" Drive or other device 6.0" Figure 4.4 NEMA/UL Type 3R Minimum Mounting Clearances 2.0" 2.0" Drive or other device 2.0" 2.0" Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 194: Lifting And Mounting The Drive

    Mechanical Installation Lifting and Mounting the Care should be used to prevent damage due to dropping or jolting when moving the drive. A fork lift truck or similar means of lifting and Drive transporting may be used. Sling in a manner that will equalize the load at the pickup points.

  • Page 195: Watts Loss

    Mechanical Installation Watts Loss The following table lists watt loss data for PowerFlex Drive Packages for Fan and Pump Applications running at full load, full speed and a factory default PWM frequency of 4kHz. Table 4.A Watts Loss at Full Load/Speed, 4 kHz Voltage Total Watts 208V AC...

  • Page 196: Weights

    Mechanical Installation Weights The following tables list weights for PowerFlex 400 Drive Packages for Fan and Pump Applications. Weights are approximate. Table 4.B Main Input Disconnect Package (Style A/M) Weight Voltage Input Line Reactor kg (lbs) 208V AC 13.2 (29) 13.2 (29)
  • Page 197 Mechanical Installation Table 4.C 3 Contactor Full Feature Bypass with Disconnect Package (Style B/N) Weight Voltage Input Line Reactor kg (lbs) 208V AC 18.6 (41) 18.6 (41) Consult Factory Consult Factory 39.9 (88) 39.9 (88) 18.5 93.0 (205) 93.0 (205) Consult Factory Consult Factory Consult Factory...
  • Page 198 Mechanical Installation Table 4.D 3 Contactor Basic Bypass with Disconnect Package (Style C) Weight Voltage Input Line Reactor kg (lbs) 460V AC 14.1 (31) 14.1 (31) 14.1 (31) 14.1 (31) 14.1 (31) 14.1 (31) 18.5 28.1 (62) 28.1 (62) 28.1 (62) 101.6 (224) 101.6 (224) 101.6 (224)

  • Page 199: Chapter Objectives

    Chapter Electrical Installation Chapter Objectives This chapter provides information on electrical installation of a PowerFlex Drive Package for Fan and Pump Applications. For information on . . See page Power Wire Size Requirements Power Terminal Block Specification Control and Signal Wiring Installing Input Power Wiring Installing Output Power Wiring Installing an Optional Transformer or Reactor...

  • Page 200: Control And Signal Wiring

    Electrical Installation Wire Size Range Name Package 208V AC 480V AC Minimum Maximum Torque Output Power 3…10 3…20 16 AWG 8 AWG T1(U), T2(V), T3(W) 15…30 25…40 8 AWG 2 AWG – 50…60 12 AWG 2 AWG 49.5 40…50 75…150 1/0 AWG 4/0 AWG –...

  • Page 201: Installing Output Power Wiring

    Electrical Installation Installing Output Power ATTENTION: Unused wires in conduit must be grounded at Wiring both ends to avoid a possible shock hazard caused by induced voltages. Also, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled to eliminate the possible shock hazard from cross-coupled motor leads.
  • Page 202 Electrical Installation Observe these guidelines when installing an isolation transformer: • A power disconnecting device must be installed between the power line and the primary of the transformer. • If the user-installed power disconnecting device is a circuit breaker, the circuit breaker trip rating must be coordinated with the in-rush current (10 to 12 times full load current) of the transformer.
  • Page 203 Electrical Installation Installing the Required External/Separate Input Disconnect An input disconnect must be installed in the line before the drive input terminals in accordance with local, national, and international codes, such as NEC/CEC. If an input disconnect is not installed as a factory option, the disconnect should be sized according to the in-rush current as well as any additional loads the disconnect might supply.
  • Page 204 Electrical Installation Notes: Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 205: Specifications

    5 to 95% non-condensing Shock: 15 G peak for 11 ms duration (+/- 1.0 ms) Vibration: 0.152 mm (0.006 in.) displacement, 1 G peak, 5.5 Hz All Others Refer to the PowerFlex 400 User Manual. Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 206 Supplemental Information Notes: Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...

  • Page 207: Common Parts

    Appendix Replacement Parts Common Parts Components are manufactured by Allen-Bradley except as noted. Description Designation Voltage Part Number Drive Module 208V AC 22C-B012N103 22C-B017N103 22C-B024N103 22C-B033N103 22C-B049A103 22C-B065A103 22C-B075A103 22C-B090A103 22C-B120A103 22C-B145A103 460V AC 22C-D6P0N103 22C-D010N103 22C-D012N103 22C-D017N103 22C-D022N103 22C-D030N103...

  • Page 208: Disconnect Parts

    1321-3R25-B 20…25 1321-3R35-B 1321-3R45-B 1321-3R55-B 50…60 1321-3R80-B 1321-3R100-B 1321-3R130-B 1321-3R160-B 1321-3R200-B Disconnect Parts Components are manufactured by Allen-Bradley except as noted. Description Designation Voltage Part Number Style A/B Fused Disconnect Packages Disconnect Switch 208V AC 3.0…5.0 194R-NJ30P3 7.5…10 194R-NJ60P3 15…20 194R-NJ100P3 25…40...
  • Page 209 Replacement Parts Description Designation Voltage Part Number FU1…FU3 Main Fuses 460V AC AJT-10 (continued) AJT-15 7.5…10 AJT-20 15…20 AJT-35 AJT-60 AJT-70 AJT-80 AJT-100 AJT-150 AJT-175 AJT-200 AJT-250 AJT-350 AJT-400 Style M/N Circuit Breaker Packages Circuit Breakers 208V AC 140U-H3C3-C15 140U-H3C3-C30 140U-H3C3-C40 140U-H3C3-C50 140U-H3C3-C80...

  • Page 210: Bypass Parts

    194R-HM1 Operator Shaft 460V AC 3.0…60 140M-C-DN66 75…100 194R-R4 (1) Manufactured by Gould-Shawmut. Bypass Parts Components are manufactured by Allen-Bradley except as noted. Description Designation Voltage Part Number Style B/N Full Feature Bypass Packages Bypass Contactor 208V AC 100-C23D10 7.5…10...
  • Page 211 Replacement Parts Description Designation Voltage Part Number Input Contactor 208V AC 3.0…7.5 100-C16D10 10…15 100-C37D00 100-C43D00 25…30 100-C72D00 40…50 100-D110ED11 460V AC 3.0…20 100-C16D10 25…30 100-C37D00 100-C43D00 50…60 100-C72D00 100-C85D00 100…125 100-D110ED11 100-D140ED11 100-D210ED11 100-D300ED11 300…350 100-D420ED11 Output Contactor 208V AC 3.0…7.5 100-C16D10 100-C23D10...
  • Page 212 Replacement Parts Description Designation Voltage Part Number Power Terminal Blocks T1…T3 208V AC 3.0…7.5 1492-W10 10…20 1492-W16S 25…30 1492-W35 40…50 67013 460V AC 3.0…15 1492-W10 20…30 1492-W16S 40…75 1492-W35 67013 125…150 67003 200…300 69313 PDB-26-750-1 Control Terminal Blocks T31…T40 208V AC 3.0…50 1492-W4 460V AC...

  • Page 213: Enclosure Parts

    Replacement Parts Enclosure Parts Description Designation Voltage Part Number NEMA/UL Type 1 (Style B only) Control Transformer 208V AC 3.0…10 TB-69300 15…30 TB-69301 40…50 TB-69302 460V AC 3.0…20 TB-69300 25…60 TB-69301 75…300 TB-69302 TB-81215 Control Transformer Fuses FU4…FU5 208V AC 3.0…10 ATQR-1 15…30...
  • Page 214 Replacement Parts Description Designation Voltage Part Number NEMA/UL Type 3R Control Transformer 208V AC 3.0…10 TB-69302 15…30 TA-2-69302 45…50 TA-2-69303 460V AC 3.0…5.0 TA-2-69302 7.5…20 TB-69302 25…40 TA-2-69302 50…100 TA-2-69303 125…150 TB-69303 Control Transformer Fuse 208V AC 3.0…30 PL-112701 Holder 40…50 PL-112702 460V AC...
  • Page 215 Replacement Parts Description Designation Voltage Part Number Control Transformer Fuse 208V AC 3.0…30 PL-112706 Holder 40…50 PL-112707 460V AC 3.0…5.0 PL-112701 7.5…60 PL-112706 75…100 PL-112707 125…150 PL-112702 Air Conditioner 208V AC No Air Conditioner 5.0…10 IQ1800VS-126 15…20 IQ3000VS-126 25…30 IQ5000V16-126 40…50 IQ8000V16-126 460V AC...
  • Page 216 B-10 Replacement Parts Notes: Rockwell Automation Publication 22C-IN002E-EN-P - November 2010...
  • Page 218 U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives *PN-101913* PN-101913 www.rockwellautomation.com Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444...

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