Allen-Bradley PowerFlex 20-750-S1 User manual

PowerFlex 750-Series AC Drives
Catalog Numbers 20F, 20G, 21G
Installation Instructions

Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize 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 required
to 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 be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
Allen-Bradley, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
WARNING: Identifies information aboutpractices 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 ahazard, avoida hazard, and recognize the consequence.
IMPORTANT
Identifies informationthat 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 ormotor, 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).

Rockwell Automation Publication 750-IN001O-EN-P - October 2014 3
Preface
Introduction
Instructions in Other Languages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Commonly Used Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
Read the General Precautions
Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Product Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Class 1 LED Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2
Prepare for Installation
Wall Mount Frames 1…7 Drive Rating Cross-References . . . . . . . . . . . . 15
Floor Mount Frames 8…10 Drive Rating Cross-References . . . . . . . . . . 17
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Access Panels, Covers, and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Minimum Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chapter 3
Lift and Mount the Drive
Drive Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Recommended Mounting Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Attach Lifting Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Release Floor Mount Drive Cabinet From Shipping Skid . . . . . . . . . . . . 41
Remove Drive Cabinet Lifting Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Install IP20, NEMA/UL Type 1 Debris Screen or
Optional Exhaust Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Install IP54, NEMA 12 Cabinet Blower Assembly and Exhaust Hood 43
Install Floor Mount Drive with Cabinet Options Bay and Wiring Bay 44
Approximate Dimensions - Wall Mount Frames 1…7 and
Floor Mount Frames 8…10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Approximate Dimensions - Floor Mount Drives
with Cabinet Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Release Drive Assembly From Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Fiber-Optic Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Disconnect Drive Control Pod Wiring Connections . . . . . . . . . . . . . . . 121
Disconnect Wire Connections - No Drive Control Pod . . . . . . . . . . . . 123
Disconnect Control and Power Wire Harnesses . . . . . . . . . . . . . . . . . . . 125
Disconnect DC Bus Fuse Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Release Cabinet Options Assembly From Cabinet . . . . . . . . . . . . . . . . . 127
Prepare the Roll-Out Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Remove Drive Assembly or Cabinet Options Assembly. . . . . . . . . . . . . 138
Remove DC Back Bus Guard - Common DC Input Drives . . . . . . . . . 143
Reinstall Drive Assembly or Cabinet Options Assembly . . . . . . . . . . . . 144

4Rockwell Automation Publication 750-IN001O-EN-P - October 2014
Chapter 4
Power Wiring
Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Power Cable Types Acceptable for 200…600 Volt Installations. . . . . . 147
Motor Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Terminal Block Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Three-Phase Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Wall Mount Frames 1…7 AC Input Power Terminals . . . . . . . . . . . . . . 151
Wall Mount Frames 5…7 Common DC Input Terminal Locations. . 153
Wall Mount Frames 5…7 Common DC Input Power Terminals . . . . 155
Floor Mount Frames 8…10 Bus Bar Locations . . . . . . . . . . . . . . . . . . . . . 156
Floor Mount Cabinet Options Bay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Floor Mount Frames 8…10 Power Wiring Options . . . . . . . . . . . . . . . . 161
Floor Mount Frames 8…10 Power Terminal L-Brackets . . . . . . . . . . . . 162
Recommended Motor Cable Spacing -
Floor Mount Frames 8 and Larger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Fuse and Circuit Breaker Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Short Circuit Current Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Short Circuit Current Ratings -
Floor Mount Drives with Cabinet Options. . . . . . . . . . . . . . . . . . . . . . . . 185
Input Contactor Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Output Contactor Precaution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Bypass Contactor Precaution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Applying and Removing Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Drives with Cabinet Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Input Power Circuit Breakers and Disconnect Switches . . . . . . . . . . . . 194
Cabinet Options Bay Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Drive Power Jumper Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Chapter 5
I/O Wiring
I/O Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Access Drive Control Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
PowerFlex 753 Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
PowerFlex 755 Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Hardware Enable Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Safety Enable Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
PowerFlex 755 Fiber Optic Interface Board . . . . . . . . . . . . . . . . . . . . . . . 233
AC Input Drive Control and Power Terminal Block . . . . . . . . . . . . . . . 234
Common DC Input Drive Control and Power Terminal Blocks . . . . 235
Control Transformer Connections - Common DC Input Drives. . . . 238
Uninterruptible Power Supply Connections -
Common DC Input Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
120/240V AC Power Supply Connections -
Common DC Input Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
753 Main Control Board I/O Wiring Examples . . . . . . . . . . . . . . . . . . . 241

Rockwell Automation Publication 750-IN001O-EN-P - October 2014 5
Drive Device Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Option Module Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
11-Series I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
11-Series I/O Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
22-Series I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
22-Series I/O Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Safe Torque Off Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Safe Speed Monitor Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Auxiliary Power Supply Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . 266
DeviceNet Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
ControlNet Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Dual-Port EtherNet/IP Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Profibus Option Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
BACnet/IP Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
20-COMM Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Single Incremental Encoder Option Module. . . . . . . . . . . . . . . . . . . . . . . 273
Dual Incremental Encoder Option Module. . . . . . . . . . . . . . . . . . . . . . . . 275
Universal Feedback Option Module - 755 Drives Only . . . . . . . . . . . . . 279
Motor Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Feedback Device Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Motor Feedback Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Control Pod Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Control Wiring - Early Frame 8 Drives with Cabinet Options . . . . . . 293
Control Wiring - Current Frame 8 Drives with Cabinet Options . . . 295
Control Wiring - Frame 9 and 10 Drives with Cabinet Options. . . . . 296
Enclosure Options - Floor Mount Frames 8…10 . . . . . . . . . . . . . . . . . . . 298
Integrated Motion Drives
Configuring Option Modules for Integrated Motion . . . . . . . . . . . . . . . 299

6Rockwell Automation Publication 750-IN001O-EN-P - October 2014
Notes:

Rockwell Automation Publication 750-IN001O-EN-P - October 2014 7
Preface
Introduction
This document explains the BASIC STEPS for mechanical installation and for
connecting incoming power, the motor, and basic I/O to the PowerFlex 750-
Series Adjustable Frequency AC drive.
The information that is provided is intended for qualified installers only.
The Additional Resources section is a directory of Rockwell Automation
publications that provide detailed drive information from wiring and grounding
recommendations to troubleshooting and repair.
Instructions in Other
Languages
English This instruction sheet is available in multiple languages at
http://rockwellautomation.com/literature. Select publication language and type “750-IN001“ in the
search field.
German Diese Anleitung steht in mehreren Sprachen unter
http://rockwellautomation.com/literature zurVerfügung.WählenSie IhreSprache aus,und gebenSie
„750-IN001“ in das Suchfeld ein.
French Ces instructions sont disponibles dans différentes langues à l’adresse suivante:
http://rockwellautomation.com/literature. Sélectionner la langue puis taper « 750-IN001» dans le
champ de recherche.
Italian La presente scheda d’istruzione è disponibile in varie lingue sul sito
http://rockwellautomation.com/literature. Selezionare la lingua desiderata e digitare “750-IN001“
nel campo di ricerca.
Spanish Puede encontrar esta hoja deinstrucciones en varios idiomas en
http://rockwellautomation.com/literature.Selecione el idioma de publicación y escriba “750-IN001“
en el campo de búsqueda.
Portuguese Esta folha de instruções está disponível em várias línguas em
http://rockwellautomation.com/literature.Seleccione a língua de publicação e entre com “750-
IN001“ no espaço de busca.
Chinese
(Simplified)
从以下网页可以获得本说明书的多种语言的版本 :
http://rockwellautomation.com/literature 。
请选择出版物的语言 , 并在搜索 输入 “750-IN001” 印。
Japanese 本説明書シートの多言語版は Web サイト
http://rockwellautomation.com/literature
にて入手できます。出版言語を 択し、検索フィールドに 「750-
IN001」とタイプしてください。
Korean
Russian Данное руководство на других языках можно найти по адресу
http://rockwellautomation.com/literature. Выберите язык и введите в окно поиска «750-IN001».
Chinese
(Complex)
以下網頁提供本說明書的多國語言版本：
http://rockwellautomation.com/literature. 請選擇出版語言，並於搜尋欄鍵入
“750-IN001” 即可。
Czech Tato stránka s pokyny je k dispozici ve více jazykových verzích na adrese
http://rockwellautomation.com/literature. Zvolte jazyk publikace a do vstupního pole pro
vyhledávání zadejte „750-IN001“.
Polish Niniejsza instrukcja dostępna jest w wielu językach na stronie
http://rockwellautomation.com/literature.Wybrać język publikacji, w polu wyszukiwania wpisać
“750-IN001”.
㢨⮹⥭ ⺴http://rockwellautomation.com/literature㜄㉐ 㜠⤠ 㛬㛨⦐ ㇠㟝䚔 ㍌㢼㏩⏼␘.
㻐䑄 㛬㛨㝴 㡔䝉㡸 ㉔䈑䚌㐡㐐㝘 "750 - IN001"ᶴㇽ 䙸☐㜄㢼␘.

8Rockwell Automation Publication 750-IN001O-EN-P - October 2014
Preface
Additional Resources The following table lists publications that provide general drive-related
information.
Resource Description
PowerFlex 750-Series AC Drives Programming Manual,
publication 750-PM001 Provides detailed information on: •I/O, control, and feedback options
•Parameters and programming
•Faults, alarms, and troubleshooting
PowerFlex 750-Series AC Drives Technical Data,
publication 750-TD001 Provides detailed information on: •Drive specifications
•Option specifications
•Fuse and circuit breaker ratings
PowerFlex 20-HIM-A6 / -C6S HIM (Human Interface
Module) User Manual, publication 20HIM-UM001 Provides detailed information on HIM components,
operation, features.
PowerFlex 750-Series AC Drives Hardware Service Manual
- Frame8 and Larger, publication 750-TG001 Provides detailed information on: •Preventive maintenance
•Component testing
•Hardware replacement procedures
PowerFlex 755 Drive Embedded EtherNet/IP Adapter User
Manual, publication 750COM-UM001 These publications providedetailed information on to configure, use, and troubleshoot PowerFlex750-Series
communication option modules and adapters.
PowerFlex750-SeriesDriveDeviceNetOption ModuleUser
Manual, publication 750COM-UM002
PowerFlex 7-Class Network Communication Adapter User
Manuals, publications 750COM-UMxxx
PowerFlex 750-Series Safe Torque Off User Manual,
publication 750-UM002 These publications provide detailed information on to install, configure, and operate the 750-Series safety
option modules.
Safe Speed Monitor Option Module for PowerFlex
750-SeriesACDrivesSafetyReferenceManual,publication
750-RM001
Wiring and Grounding Guidelines for Pulse Width
Modulated (PWM) AC Drives, publication DRIVES-IN001 Provides basic information to properly wire and ground
PWM AC drives.
PowerFlex AC Drives in Common Bus Configurations,
publication DRIVES-AT002 Provides basic information to properly wire and ground PWM AC drives with a common bus.
Safety Guidelines for the Application, Installation, and
Maintenance of Solid-StateControl, publication SGI-1.1 Provides general guidelines for the application,
installation, and maintenance of solid-state control.
Guarding Against Electrostatic Damage, publication 8000-
4.5.2 Providespractices for guarding against Electrostatic damage (ESD)
Product Certifications website, http://ab.com Providesdeclarationsofconformity,certificates,and other
certification details.

Rockwell Automation Publication 750-IN001O-EN-P - October 2014 9
Preface
Commonly Used Tools Installation and Service Tools
This list covers the tools that are needed for drive installation.
IMPORTANT
Care must be taken to be sure that tools and/or hardware components do not
fall into open drive assemblies. Do not energize the drive unless all loose tools
and/or hardware components have been removed from the drive assemblies
and enclosure.
Tool Description Details
ESD-protected place of work Work surface, Floor cover, seat, and ground connections
ESD-protective clothing Wrist wrap, shoes, overall clothing (coat)
Multimeter Digital multimeter, capable of AC and DC voltage, continuity, resistance,
capacitancemeasurements,andforward diodebias tests.Flukemodel 87III or
equivalent.
Allen socket wrench 4 mm, 5 mm
Allen-socket wrenchextension 254 mm (10 in.)
Flat-nose screw driver 5 mm (0.19 in.), 6.4 mm (0.25 in.), 9.5 mm (0.375 in.), #1, #2
Hexalobular screw driver/bit #15, #20, #25, #40, #45
Hexagonal socket wrench 7 mm, 8 mm, 10 mm, 12 mm, 13 mm, 17 mm, 18 mm
Combination wrench 10 mm, 17 mm
Phillips® screw driver/bit (1)
(1) Phillips and Pozidriv are registered trademarks of the Phillips Screw Company.
#2, 492-C
Pozidriv® (1) #2, M3 x 7
Torque wrench 1...12 N•m (8.8…106 lb•in)
Torque wrench 6...50 N•m (53…443 lb•in)
Roll-out cart 20-750-CART1-F8
Note: The roll-out cart is required to remove the Frame 8 and larger drive
assembly from the enclosure.

10 Rockwell Automation Publication 750-IN001O-EN-P - October 2014
Preface
Notes: