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Rockwell Automation PowerFlex 40 Installation Instructions Manual

Configured ac drives
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PowerFlex 40 Configured AC Drives
INSTALLATION INSTRUCTIONS

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  • Page 1 PowerFlex 40 Configured AC Drives INSTALLATION INSTRUCTIONS...
  • Page 2 Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures. PowerFlex, DriveExplorer, DriveExecutive, DPI, and SCANport are either trademarks or registered trademarks of Rockwell Automation, Inc.

  • Page 3: Table Of Contents

    Chapter 1 PowerFlex 40 Standard Configured Drive Standard Features and Options Chapter Objectives ............1-1 Standard Features .
  • Page 4 Table of Contents Notes: Publication 23B-IN001G...

  • Page 5: Preface

    Installation Instructions is designed to provide only basic installation and operation information. For this reason, the following topics have not been included: • Troubleshooting • Start-Up • Programming and Parameters Please refer to the PowerFlex 40 User Manual for detailed drive information. Publication 23B-IN001G...

  • Page 6: Reference Materials

    Control A Global Reference Guide for Reading 0100-2.10 Schematic Diagrams Guarding Against Electrostatic Damage 8000-4.5.2 For detailed PowerFlex 40 information including drive parameters, programming, start-up, troubleshooting, specifications: Title Publication Available Online at … PowerFlex 40 User Manual 22B-UM001… www.rockwellautomation.com/literature PowerFlex Reference Manual PFLEX-RM001…...

  • Page 7: General Precautions

    ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive. Measure the voltage at the drive (Refer to the PowerFlex 40 User Manual for test point locations). The voltage must be zero. Compliance Certification Certifications are applicable to approved program defined options.

  • Page 8: Catalog Number Explanation

    Overview Catalog Number The PowerFlex 40 Adjustable Frequency AC Standard Configured Drives catalog numbering scheme is shown below. Explanation Position – – Drive Options Code Type Code Interface Module Code Description PowerFlex 40 Fixed Keypad on Drive DeviceNet Quick Disconnect...

  • Page 9: Chapter Objectives

    Chapter PowerFlex 40 Standard Configured Drive Standard Features and Options Chapter Objectives This chapter describes the standard features and operation for PowerFlex 40 Standard Configured Drives and associated options. For information on … See page … Standard Features Enclosure Options...

  • Page 10: Enclosure Options

    PowerFlex 40 Standard Configured Drive Standard Features and Options Enclosure Options NEMA/UL Type 4 (Position 9, Code D) The enclosure provided is a NEMA/UL Type 4, painted mild steel, which supports both NEMA/UL Type 4 and NEMA/UL Type 12 applications.

  • Page 11: Communication Options

    PowerFlex 40 Standard Configured Drive Standard Features and Options Communication Options DeviceNet (Position 12, Code D) The DeviceNet option is drive mounted and consists of the DeviceNet communication adaptor (22-COMM-D) and adaptor cover (22B-CCB for frame B drives or 22B-CCC for frame C drives). When DeviceNet is present, no other communication option is available other than the HIM.

  • Page 12: Power Disconnect Options

    PowerFlex 40 Standard Configured Drive Standard Features and Options Power Disconnect Options Drive Motor Circuit Protector (Position 16+, Code -P3) The Drive Motor Circuit Protector option is factory installed and provides a manual means of disconnecting input power to the drive. The Allen-Bradley Bulletin 140M switch is designed to meet short circuit requirements for branch circuit protection.
  • Page 13 PowerFlex 40 Standard Configured Drive Standard Features and Options Drive Input Fused Disconnect Switch (Position 16+, Code -P6) The Drive Input Fused Disconnect Switch option is factory installed and provides a manual means of disconnecting input power to the drive. The Allen-Bradley Bulletin 194R switch is designed to meet disconnect switch requirements for branch circuit protection.
  • Page 14 Table are applicable for one drive per branch circuit. No other load may be applied to that fused circuit. The recommended fuse type for all PowerFlex 40 Standard Configured Drives is UL Class J. Table 1.A Branch Fusing Voltage Rating...
  • Page 15 PowerFlex 40 Standard Configured Drive Standard Features and Options Input Power Wiring Refer to the PowerFlex 40 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 16 PowerFlex 40 Standard Configured Drive Standard Features and Options Output Power Wiring Refer to the PowerFlex 40 User Manual for additional detailed information about output power wiring recommendations and selection. ATTENTION: Unused wires in conduit must be grounded at both ends to avoid a possible shock hazard caused by induced voltages.

  • Page 17: Operator Device Options

    PowerFlex 40 Standard Configured Drive Standard Features and Options Operator Device Options Hand/Off/Auto Selector Switch (Position 16+, Code S1) This 800F door mounted operator device is factory installed and provides a Hand/Off/Auto selector switch. The Hand/Off/Auto selector switch will start the drive in Hand mode and stop the drive in Off mode.
  • Page 18 1-10 PowerFlex 40 Standard Configured Drive Standard Features and Options Auto/Manual Selector Switch (Position 16+, Code S4) This 800F door mounted operator device is factory installed and provides an Auto/Manual selector switch. The Auto/Manual selector switch determines the source of the actual drive speed reference.
  • Page 19 PowerFlex 40 Standard Configured Drive Standard Features and Options 1-11 Start and Stop Push Buttons (Position 16+, Code S7) This option provides factory installed 800F Start and Stop push buttons. In all cases, the Stop input to the drive must be present before the drive will start.
  • Page 20 1-12 PowerFlex 40 Standard Configured Drive Standard Features and Options Local Speed Potentiometer (Code S18) This option provides a factory installed 800F door mounted one turn potentiometer for speed control. The device provides the speed source when no digital inputs are active.
  • Page 21 PowerFlex 40 Standard Configured Drive Standard Features and Options 1-13 Local/Off/Remote Selector Switch With One Normally Open Interposing Relay (Code S21) This 800F door mounted operator device and interposing relay option is factory installed and provides a Local/Off/Remote selector switch.
  • Page 22 1-14 PowerFlex 40 Standard Configured Drive Standard Features and Options Spring Return Hand-Off-Auto Selector Switch (Code S22) This 800F door mounted operator device is factory installed and provides a Hand/Off/Auto selector switch. The Hand position is equipped with a spring return.

  • Page 23: Quick Disconnects

    PowerFlex 40 Standard Configured Drive Standard Features and Options 1-15 Clear Fault Push Button (Code S23) This option provides a factory installed 800F Clear Fault push button. Component Specifications Bulletin 800F IEC style, Internationally rated Devices Meet IP65/IP66 and NEMA/UL Type 4/4X/13...

  • Page 24: I/O Options

    1-16 PowerFlex 40 Standard Configured Drive Standard Features and Options I/O Options DeviceNet I/O (4 In/2 Out) w/Spring Return HOA and Power Disconnect Aux. Contact (Position 16+, Code R3) This option provides a factory installed 800F door mounted operator device, a 100-DNY42R and a power disconnect auxiliary contact mounted internal to the cabinet.
  • Page 25 PowerFlex 40 Standard Configured Drive Standard Features and Options 1-17 DeviceNet Point I/O w/IB4 (4 Inputs) (Position 16+, Code R4) This option provides a factory installed 1734-ADNX Point I/O Scanner in combination with a 1734-IB4 (4 input) four point, 24V DC sink input.
  • Page 26 1-18 PowerFlex 40 Standard Configured Drive Standard Features and Options DeviceNet I/O (4 In/ 2 Out) w/Spring Return HOA, Power Disconnect Aux. Contact, and 4 I/O Quick Disconnects (Position 16+, Code R5) This option provides a factory installed 800F door mounted operator device,...

  • Page 27: Chapter 2 Control Wiring Overview

    Control Wiring Overview Schematic Drawings Control Wiring Overview Refer to the PowerFlex 40 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 28: Schematic Drawings

    Control Wiring Overview Schematic Drawings Figure 2.1 Power Distribution Option Publication 23B-IN001G...
  • Page 29 Control Wiring Overview Figure 2.2 Drive Ratings Publication 23B-IN001G...
  • Page 30 Control Wiring Overview Figure 2.3 Control Logic Options 4, C, D, E & P Publication 23B-IN001G...
  • Page 31 Control Wiring Overview Figure 2.4 Control Logic Option S1 Publication 23B-IN001G...
  • Page 32 Control Wiring Overview Figure 2.5 Control Logic Option S1 & S8 Publication 23B-IN001G...
  • Page 33 Control Wiring Overview Figure 2.6 Control Logic Option S4 Publication 23B-IN001G...
  • Page 34 Control Wiring Overview Figure 2.7 Control Logic Option S4 & S7 Publication 23B-IN001G...
  • Page 35 Control Wiring Overview Figure 2.8 Control Logic Option S4 with S8 Publication 23B-IN001G...
  • Page 36 2-10 Control Wiring Overview Figure 2.9 Control Logic Option S7 Publication 23B-IN001G...
  • Page 37 Control Wiring Overview 2-11 Figure 2.10 Control Logic Option S7 and S8 Publication 23B-IN001G...
  • Page 38 2-12 Control Wiring Overview Figure 2.11 Control Logic Option S8 Publication 23B-IN001G...
  • Page 39 Control Wiring Overview 2-13 Figure 2.12 Control Logic Option S20 Publication 23B-IN001G...
  • Page 40 2-14 Control Wiring Overview Figure 2.13 Control Logic Option S18 Publication 23B-IN001G...
  • Page 41 Control Wiring Overview 2-15 Figure 2.14 Control Logic Option S21 Publication 23B-IN001G...
  • Page 42 2-16 Control Wiring Overview Figure 2.15 Control Logic Option S22 Publication 23B-IN001G...
  • Page 43 Control Wiring Overview 2-17 Figure 2.16 Control Logic Option S22 & S8 Publication 23B-IN001G...
  • Page 44 2-18 Control Wiring Overview Figure 2.17 Control Logic Option S23 Publication 23B-IN001G...
  • Page 45 Control Wiring Overview 2-19 Figure 2.18 Control Logic Option R3 with P3/P3T or P6/P6T Publication 23B-IN001G...
  • Page 46 2-20 Control Wiring Overview Figure 2.19 Control Logic Option R4 Publication 23B-IN001G...
  • Page 47 Control Wiring Overview 2-21 Figure 2.20 Control Logic Option R5 with P3/P3T or P6/P6T Publication 23B-IN001G...
  • Page 48 2-22 Control Wiring Overview Figure 2.21 Interconnect Wire & Parts List Publication 23B-IN001G...

  • Page 49: Chapter 3 Mechanical Installation

    Maximum Surrounding Air Temperature PowerFlex 40 Standard Configured Drives are designed to operate at -10° to 40°C (14° to 104°F) surrounding air temperature. The design of the PowerFlex Standard Configured Drive supports indoor and outdoor applications that are not in direct sunlight.

  • Page 50: Dimensions

    Mechanical Installation Figure 3.1 Minimum Mounting Clearances Dimensions are in millimeters and (inches). 152.4 (6.00) Drive or other device 152.4 152.4 (6.00) (6.00) 152.4 (6.00) Dimensions Figure 3.2 Frame B Dimensions Dimensions are in millimeters and (inches). 405.9 (15.98) 393.2 (15.48) 355.6 287.5...
  • Page 51 Mechanical Installation Figure 3.3 Frame C Dimensions Dimensions are in millimeters and (inches). Frame C P3 Option 383.3 (15.09) P6 Option 364.2 16.0 457.2 (14.34) (0.63) (18.00) 425.2 177.8 146.1 (16.74) (7.00) (5.75) 460.8 (18.14) 427.2 (16.82) 406.4 (16.00) Detail 19.1 (0.38) (0.75)

  • Page 52: Layout Drawings

    Mechanical Installation Layout Drawings Figure 3.4 PowerFlex 40 Frame B Layout Drawing Publication 23B-IN001G...
  • Page 53 Mechanical Installation Figure 3.5 PowerFlex 40 Frame C Layout Drawing Publication 23B-IN001G...
  • Page 54 Mechanical Installation Figure 3.6 PowerFlex 40 General Option Layout Drawing Publication 23B-IN001G...

  • Page 55: Appendix A Specifications

    Carrier Frequency: 2-4 kHz. Drive rating and heat calculations are based on 4 kHz. (1) The design of the PowerFlex 40 Standard Configured Drive NEMA 4/12 and 4X packages support indoor and outdoor applications that are not in direct sunlight.
  • Page 56 Specifications Notes: Publication 23B-IN001G...
  • Page 57 Appendix Replacement Parts Table B.A Components Description Designation Voltage Part Number Manufacturer Motor Circuit MCP1 480V AC 140M-C2E-B40 Allen-Bradley Protector 140M-C2E-B63 Allen-Bradley Option P3 or P3T 140M-D8E-C10 Allen-Bradley 140M-D8E-C16 Allen-Bradley 140M-D8E-C25 Allen-Bradley 140M-F8E-C25 Allen-Bradley 140M-F8E-C32 Allen-Bradley 140M-F8E-C45 Allen-Bradley Replacement Kit MCP1 480V AC 363326...
  • Page 58 Replacement Parts Table B.A Components (Continued) Description Designation Voltage Part Number Manufacturer Drive Module 480V AC 22B-D1P4F104 Allen-Bradley (with Heatsink) 22B-D2P3F104 Allen-Bradley 22B-D4P0F104 Allen-Bradley 22B-D6P0F104 Allen-Bradley 22B-D010F104 Allen-Bradley 22B-D012F104 Allen-Bradley 22B-D017F104 Allen-Bradley 22B-D024F104 Allen-Bradley Drive Module 480V AC 22B-D1P4H204 Allen-Bradley (Plate Drive) 22B-D2P3H204 Allen-Bradley...
  • Page 59 Replacement Parts Table B.E Operator Devices/Control Options Option Description Designation Voltage Part Number Manufacturer Option S1 Selector Switch 800FP-SM32 Allen-Bradley Mounting Latch 800F-ALP Allen-Bradley Contact Block - 4 N.O. 800F-X10 Allen-Bradley Legend Plate 354614 Allen-Bradley Option S4 Selector Switch 800FP-SM22 Allen-Bradley Mounting Latch 800F-ALP...
  • Page 60 Replacement Parts Table B.F Miscellaneous Description Designation Voltage Part Number Manufacturer 0.5-5.0 2410ML-05W-B30-B00 NMB Tech Publication 23B-IN001G...
  • Page 62 Europe/Middle East/Africa: Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640 Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846 Publication 23B-IN001G-EN-P –...

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