Allen-Bradley PowerFlex 40P User manual

Adjustable
Frequency AC
Drive
FRN 1.xx - 3.xx
User Manual
www.abpowerflex.com

Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application, Installation
and Maintenance of Solid State Controls (Publication SGI-1.1 available from your
local Rockwell Automation sales office or online at http://
www.rockwellautomation.com/literature) describes some important differences
between solid state equipment and hard-wired electromechanical devices. Because
of this difference, and also because of the wide variety of uses for solid state
equipment, all persons responsible for applying this equipment must satisfy
themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of
information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety
considerations.
Important: Identifies information that is critical for successful application and
understanding of the product.
PowerFlex is a registered trademark of Rockwell Automation, Inc.
DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.
PLC is a registered trademark of Rockwell Automation, Inc.
WARNING: Identifies information about practices or circumstances
that can cause an explosion in a hazardous environment, which may
lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances
that can lead to personal injury or death, property damage, or economic
loss. Attentions help you:
•identify a hazard
•avoid the hazard
•recognize the consequences
Shock Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that surfaces may be at dangerous
temperatures.

Summary of Changes
Manual Updates
The information below summarizes the changes to the PowerFlex 40P
User Manual since the June 2013 release.
The information below summarizes the changes to the PowerFlex 40P
User Manual since the May 2007 release.
Parameter Updates
The following parameters have been added or updated with Firmware
Revision Number (FRN) 3.xx.
Description of New or Updated Information See Page(s)
Replaced ISO 13849 with EN ISO 13849-1:2008+AC:2009 1-21, 3-11, and
A-3
Certification for Australian C-Tick, CE Directives, and TUV updated. 1-29, 1-30, and
A-3
Description of New or Updated Information See Page(s)
Link to Rockwell Automation Literature Library under Reference
Materials has been fixed
Preface-1
Minimum Enclosure Volume column and new footnotes added. 1-8, A-2
Information on swapping encoder channels updated 1-18 and F-2
Certification standard for DriveGuard Safe-Off Option updated to ISO
13849-1; Performance Level d (Safety Category 3)
1-21, 3-11 and
A-3
USB Converter Module added to Drive Programming Tools 2-3
Parameters A164 and d310–d316 added to Parameter Organzation 3-2
Max value for Parameter A069 [Internal Freq] updated to 500.0 Hz 3-24
Cross-reference to parameters d310–d316 added to description for
Parameter A100 [Fault Clear]
3-33
Attention added to Parameters A140–A147 [Stp Logic x] 3-45
Max vaule for A150–A157 [Stp Logic Time x] increased to 6553.5 sec 3-47
Parameters A164 and d310–d316 added to Parameter
Cross-Reference – by Name
3-66
Drive, Fuse & Circuit Breaker Ratings topic updated. A-1
Electronic Motor Overload Protection description updated. A-3, A-4
Description of Option 1 for Parameter E222 [Positioning Mode] updated F-5
Parameter Number Description Page
Stp Logic Time A150–A157 Max value increased to 6553.5 sec 3-47
PID Invert Error A164 New Parameter 3-48
Fault 4 Code d310 New Parameter 3-64

soc-2
Fault 5 Code d311 New Parameter 3-64
Fault 6 Code d312 New Parameter 3-64
Fault 7 Code d313 New Parameter 3-64
Fault 8 Code d314 New Parameter 3-65
Fault 9 Code d315 New Parameter 3-65
Fault 10 Code d316 New Parameter 3-65
Parameter Number Description Page

Table of Contents
Preface Overview
Who Should Use this Manual? . . . . . . . . . P-1
Reference Materials . . . . . . . . . . . . . . . . . P-1
Manual Conventions . . . . . . . . . . . . . . . . . P-2
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . P-2
General Precautions . . . . . . . . . . . . . . . . . P-3
Catalog Number Explanation . . . . . . . . . . P-4
Chapter 1 Installation/Wiring
Opening the Cover . . . . . . . . . . . . . . . . . . 1-1
Mounting Considerations . . . . . . . . . . . . . 1-2
Plate Drive Installation . . . . . . . . . . . . . . . 1-3
AC Supply Source Considerations . . . . . . 1-4
General Grounding Requirements . . . . . . 1-6
Fuses and Circuit Breakers . . . . . . . . . . . . 1-7
Power Wiring . . . . . . . . . . . . . . . . . . . . . . 1-9
Common Bus/Precharge Notes . . . . . . . . 1-13
I/O Wiring Recommendations . . . . . . . . 1-13
Start and Speed Reference Control . . . . . 1-27
EMC Instructions . . . . . . . . . . . . . . . . . . 1-29
Chapter 2 Start Up
Prepare For Drive Start-Up . . . . . . . . . . . . 2-1
Display/Fault Reset . . . . . . . . . . . . . . . . . . 2-3
Drive Programming Tools. . . . . . . . . . . . . 2-3
Chapter 3 Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . 3-1
Parameter Organization. . . . . . . . . . . . . . . 3-2
Basic Display Group . . . . . . . . . . . . . . . . . 3-3
Basic Program Group . . . . . . . . . . . . . . . . 3-9
Advanced Program Group. . . . . . . . . . . . 3-15
Enhanced Program Group. . . . . . . . . . . . 3-49
Advanced Display Group . . . . . . . . . . . . 3-62
Parameter Cross Reference – by Name. . 3-66
Chapter 4 Troubleshooting
Drive Status. . . . . . . . . . . . . . . . . . . . . . . . 4-1
Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fault Descriptions . . . . . . . . . . . . . . . . . . . 4-3
Common Symptoms and Corrective Actions . .
4-6
Appendix A Supplemental Drive Information
Drive, Fuse & Circuit Breaker Ratings . . . A-1
Specifications . . . . . . . . . . . . . . . . . . . . . . A-2
Appendix B Accessories and Dimensions
Product Selection . . . . . . . . . . . . . . . . . . . B-1
Product Dimensions . . . . . . . . . . . . . . . . . B-7

2Table of Contents
Appendix C RS485 (DSI) Protocol
Network Wiring. . . . . . . . . . . . . . . . . . . . . C-1
Parameter Configuration . . . . . . . . . . . . . . C-3
Supported Modbus Function Codes . . . . . C-3
Writing (06) Logic Command Data. . . . . . C-4
Writing (06) Reference . . . . . . . . . . . . . . . C-5
Reading (03) Logic Status Data. . . . . . . . . C-6
Reading (03) Feedback . . . . . . . . . . . . . . . C-7
Reading (03) Drive Error Codes . . . . . . . . C-7
Reading (03) and Writing (06) Drive
Parameters . . . . . . . . . . . . . . . . . . . . . . . C-8
Additional Information . . . . . . . . . . . . . . . C-8
Appendix D RJ45 DSI Splitter Cable
Connectivity Guidelines . . . . . . . . . . . . . . D-1
DSI Cable Accessories . . . . . . . . . . . . . . . D-2
Connecting One Temporary Peripheral . . . D-3
Connecting One Temporary Peripheral and
One Permanent Peripheral . . . . . . . . . . . D-3
Connecting Two Permanent Peripherals . . D-4
Connecting an RS-485 Network . . . . . . . . D-4
Appendix E Velocity StepLogic™, Basic Logic and Timer/Counter Functions
Velocity StepLogic Using Timed Steps. . . E-2
Velocity StepLogic Using Basic Logic
Functions . . . . . . . . . . . . . . . . . . . . . . . . E-3
Timer Function . . . . . . . . . . . . . . . . . . . . . E-4
Counter Function. . . . . . . . . . . . . . . . . . . . E-6
Appendix F Encoder Usage and Position StepLogic Application
Encoder Usage. . . . . . . . . . . . . . . . . . . . . . F-1
Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . F-2
Positioning Overview . . . . . . . . . . . . . . . . F-2
Common Guidelines for All Applications. F-3
Positioning Operation . . . . . . . . . . . . . . . . F-5
Homing Routine . . . . . . . . . . . . . . . . . . . . F-8
Encoder and Position Feedback. . . . . . . . . F-9
Use Over Communications . . . . . . . . . . . F-10
Setup Notes . . . . . . . . . . . . . . . . . . . . . . . F-11
Appendix G PID Set Up
PID Loop . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
PID Reference and Feedback . . . . . . . . . . G-4
Analog PID Reference Signals . . . . . . . . . G-5
Appendix H Plate Drive Installation Instructions
Introduction . . . . . . . . . . . . . . . . . . . . . . . . H-1
General Requirements . . . . . . . . . . . . . . . . H-1
Heatsink Thermal Capacity . . . . . . . . . . . . H-2
Heatsink Surface and Flatness Requirements .
H-3
Mounting Dimensions and Requirements . H-4
Verification . . . . . . . . . . . . . . . . . . . . . . . . H-4
Index

Preface
Overview
The purpose of this manual is to provide you with the basic information
needed to install, start-up and troubleshoot the PowerFlex 40P
Adjustable Frequency AC Drive.
This manual is intended for qualified personnel. You must be able to
program and operate Adjustable Frequency AC Drive devices. In
addition, you must have an understanding of the parameter settings and
functions.
The following manuals are recommended for general drive information:
For information on… See page…
Who Should Use this Manual? P-1
Reference Materials P-1
Manual Conventions P-2
Drive Frame Sizes P-2
General Precautions P-3
Catalog Number Explanation P-4
Who Should Use this Manual?
Reference Materials
Title Publication Available Online at …
Wiring and Grounding
Guidelines for Pulse Width
Modulated (PWM) AC Drives
DRIVES-IN001…
www.rockwellautomation.com/
literature
Preventive Maintenance of
Industrial Control and Drive
System Equipment
DRIVES-TD001…
Safety Guidelines for the
Application, Installation and
Maintenance of Solid State
Control
SGI-1.1
A Global Reference Guide for
Reading Schematic Diagrams
100-2.10
Guarding Against Electrostatic
Damage
8000-4.5.2
DriveGuard® Safe-Off Option
(Series B) for PowerFlex AC
Drives
PFLEX-UM003…

P-2 Overview
•In this manual we refer to the PowerFlex 40P Adjustable Frequency
AC Drive as; drive, PowerFlex 40P or PowerFlex 40P Drive.
•Parameter numbers and names are shown in this format:
•The following words are used throughout the manual to describe an
action:
Similar PowerFlex 40P drive sizes are grouped into frame sizes to
simplify spare parts ordering, dimensioning, etc. A cross reference of
drive catalog numbers and their respective frame sizes is provided in
Appendix B.
Manual Conventions
P031 [Motor NP Volts]
Name
Number
Group
b = Basic Display Group
P = Basic Program Group
A = Advanced Program Group
E = Enhanced Program Group
d = Advanced Display Group
Word Meaning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Must Unavoidable, you must do this
Shall Required and necessary
Should Recommended
Should Not Not Recommended
Drive Frame Sizes

Overview P-3
General Precautions
!
ATTENTION: The drive contains high voltage capacitors which take
time to discharge after removal of mains supply. Before working on
drive, ensure isolation of mains supply from line inputs [R, S, T (L1,
L2, L3)]. Wait three minutes for capacitors to discharge to safe voltage
levels. Failure to do so may result in personal injury or death.
Darkened display LEDs is not an indication that capacitors have
discharged to safe voltage levels.
ATTENTION: Only qualified personnel familiar with adjustable
frequency AC drives and associated machinery should plan or
implement the installation, start-up and subsequent maintenance of the
system. Failure to comply may result in personal injury and/or
equipment damage.
ATTENTION: This drive contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Static control precautions are required
when installing, testing, servicing or repairing this assembly.
Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures,
reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic
Damage” or any other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in
component damage or a reduction in product life. Wiring or application
errors, such as, undersizing the motor, incorrect or inadequate AC
supply, or excessive ambient temperatures may result in malfunction of
the system.
ATTENTION: The bus regulator function is extremely useful for
preventing nuisance overvoltage faults resulting from aggressive
decelerations, overhauling loads, and eccentric loads. However, it can
also cause either of the following two conditions to occur.
1. Fast positive changes in input voltage or imbalanced input voltages
can cause uncommanded positive speed changes;
2. Actual deceleration times can be longer than commanded
deceleration times
However, a “Stall Fault” is generated if the drive remains in this state
for 1 minute. If this condition is unacceptable, the bus regulator must be
disabled (see parameter A117). In addition, installing a properly sized
dynamic brake resistor will provide equal or better performance in most
cases.
ATTENTION: Risk of injury or equipment damage exists. Drive does
not contain user-serviceable components. Do not disassemble drive
chassis.

P-4 Overview
Catalog Number Explanation
Code Voltage Ph.
B 240V AC 3
D 480V AC 3
E 600V AC 3
Code Version
4 Standard
Code HIM Version
1 Display/Fault Reset Only
2 Display/Fault Reset Only (Plate Drive)
Code Enclosure
N Panel Mount - IP 20 (NEMA Type Open)
F Flange Mount - IP 20 (NEMA Type Open)
H Plate Drive - IP 20 (NEMA Type Open)
1-3 4 5 6-8 9 10 11 12 13-14
22D - B 2P3 N 1 0 4 AA
Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Version Optional
Code EMC Filter
0 Not Filter
Output Current @ 380-480V Input
Code Amps kW (HP)
1P4 1.4 0.4 (0.5)
2P3 2.3 0.75 (1.0)
4P0 4.0 1.5 (2.0)
6P0 6.0 2.2 (3.0)
010 10.5 4.0 (5.0)
012 12 5.5 (7.5)
017 17 7.5 (10)
024 24 11 (15)
Code
22D PowerFlex 40P
Additional accessories, options and adapters are available. See Appendix B for details.
Output Current @ 460-600V Input
Code Amps kW (HP)
1P7 1.7 0.75 (1.0)
3P0 3.0 1.5 (2.0)
4P2 4.2 2.2 (3.0)
6P6 6.6 4.0 (5.0)
9P9 9.9 5.5 (7.5)
012 12 7.5 (10)
019 19 11 (15)
Code Purpose
AA Reserved for
thru custom firmware
ZZ
Output Current @ 200-240V Input
Code Amps kW (HP)
2P3 2.3 0.4 (0.5)
5P0 5.0 0.75 (1.0)
8P0 8.0 1.5 (2.0)
012 12 2.2 (3.0)
017 17.5 3.7 (5.0)
024 24 5.5 (7.5)
033 33 7.5 (10)

Chapter 1
Installation/Wiring
This chapter provides information on mounting and wiring the
PowerFlex 40P Drive.
Most start-up difficulties are the result of incorrect wiring. Every
precaution must be taken to assure that the wiring is done as instructed.
All items must be read and understood before the actual installation
begins.
1. Press and hold in the tabs on each side of the cover.
2. Pull the cover out and up to release.
For information on… See page For information on… See page
Opening the Cover 1-1 Fuses and Circuit Breakers 1-7
Mounting Considerations 1-2 Power Wiring 1-9
AC Supply Source Considerations 1-4 I/O Wiring
Recommendations
1-13
General Grounding Requirements 1-6 EMC Instructions 1-29
!
ATTENTION: The following information is merely a guide for proper
installation. Rockwell Automation, Inc. 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.
Opening the Cover

1-2 Installation/Wiring
•Mount the drive upright on a flat, vertical and level surface.
•Protect the cooling fan by avoiding dust or metallic particles.
•Do not expose to a corrosive atmosphere.
•Protect from moisture and direct sunlight.
Minimum Mounting Clearances
Refer to Appendix B for mounting dimensions.
Ambient Operating Temperatures
Table 1.A Enclosure and Clearance Requirements
Mounting Considerations
Frame Screw Size Screw Torque DIN Rail
B M4 (#8-32) 1.56-1.96 N-m (14-17 lb.-in.) 35 mm
C M5 (#10-24) 2.45-2.94 N-m (22-26 lb.-in.) –
Ambient Temperature Enclosure Rating Minimum Mounting
Clearances
Minimum Maximum
-10°C (14°F) 40°C (104°F) IP 20/Open Type Use Mounting Option A
IP 30/NEMA 1/UL Type 1(1)
(1) Rating requires installation of the PowerFlex 40P IP 30/NEMA 1/UL Type 1 option kit.
Use Mounting Option B
50°C (122°F) IP 20/Open Type Use Mounting Option B
25 mm
(1.0 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
RUN
REV
FAULT
RUN
REV
FAULT
RUN
REV
FAULT
RUN
REV
FAULT
Mounting Option A
No clearance required
between drives.
Mounting Option B
Closest object that
may restrict air flow
through the drive heat
sink and chassis

Installation/Wiring 1-3
Debris Protection
A plastic top panel is included with the drive. Install the panel to prevent
debris from falling through the vents of the drive housing during
installation. Remove the panel for IP 20/Open Type applications.
Storage
•Store within an ambient temperature range of -40° to +85°C.
•Store within a relative humidity range of 0% to 95%,
non-condensing.
•Do not expose to a corrosive atmosphere.
For Plate drive installation instructions, refer to Appendix H.
Plate Drive Installation

1-4 Installation/Wiring
Ungrounded Distribution Systems
Disconnecting MOVs
To prevent drive damage, the MOVs connected to ground shall be
disconnected if the drive is installed on an ungrounded distribution
system where the line-to-ground voltages on any phase could exceed
125% of the nominal line-to-line voltage. To disconnect these devices,
remove the jumper shown in the Figures 1.1 and 1.2.
1. Turn the screw counterclockwise to loosen.
2. Pull the jumper completely out of the drive chassis.
3. Tighten the screw to keep it in place.
Figure 1.1 Jumper Location (Typical)
Figure 1.2 Phase to Ground MOV Removal
AC Supply Source Considerations
!
ATTENTION: PowerFlex 40P drives contain protective MOVs that
are referenced to ground. These devices must be disconnected if the
drive is installed on an ungrounded or resistive grounded distribution
system.
Important:
Tighten screw after
jumper removal.
R/L1
S/L2
T/L3
1234
Three-Phase
AC Input
Jumper

Installation/Wiring 1-5
Input Power Conditioning
The drive is suitable for direct connection to input power within the rated
voltage of the drive (see Appendix A). Listed in Table 1.B are certain
input power conditions which may cause component damage or
reduction in product life. If any of the conditions exist, as described in
Table 1.B, install one of the devices listed under the heading Corrective
Action on the line side of the drive.
Important: Only one device per branch circuit is required. It should be
mounted closest to the branch and sized to handle the total
current of the branch circuit.
Table 1.B Input Power Conditions
Input Power Condition Corrective Action
Low Line Impedance (less than 1% line reactance) •Install Line Reactor(2)
•or Isolation Transformer
•or Bus Inductor – 5.5 & 11 kW
(7.5 & 15 HP) drives only
(2) Refer to Appendix B for accessory ordering information.
Greater than 120 kVA supply transformer
Line has power factor correction capacitors •Install Line Reactor
•or Isolation Transformer
Line has frequent power interruptions
Line has intermittent noise spikes in excess of
6000V (lightning)
Phase to ground voltage exceeds 125% of normal
line to line voltage
•Remove MOV jumper to ground.
•or Install Isolation Transformer
with grounded secondary if
necessary.
Ungrounded distribution system
240V open delta configuration (stinger leg)(1)
(1) For drives applied on an open delta with a middle phase grounded neutral system, the
phase opposite the phase that is tapped in the middle to the neutral or earth is
referred to as the “stinger leg,” “high leg,” “red leg,” etc. This leg should be identified
throughout the system with red or orange tape on the wire at each connection point.
The stinger leg should be connected to the center Phase B on the reactor. Refer to
Table B.D for specific line reactor part numbers.
•Install Line Reactor

1-6 Installation/Wiring
The drive Safety Ground - (PE) must be connected to system
ground. Ground impedance must conform to the requirements of
national and local industrial safety regulations and/or electrical codes.
The integrity of all ground connections should be periodically checked.
Figure 1.3 Typical Grounding
Ground Fault Monitoring
If a system ground fault monitor (RCD) is to be used, only Type B
(adjustable) devices should be used to avoid nuisance tripping.
Safety Ground - (PE)
This is the safety ground for the drive that is required by code. One of
these points must be connected to adjacent building steel (girder, joist), a
floor ground rod or bus bar. Grounding points must comply with national
and local industrial safety regulations and/or electrical codes.
Motor Ground
The motor ground must be connected to one of the ground terminals on
the drive.
Shield Termination - SHLD
Either of the safety ground terminals located on the power terminal
block provides a grounding point for the motor cable shield. The motor
cable shield connected to one of these terminals (drive end) should also
be connected to the motor frame (motor end). Use a shield terminating or
EMI clamp to connect the shield to the safety ground terminal. The
conduit box option may be used with a cable clamp for a grounding point
for the cable shield.
When shielded cable is used for control and signal wiring, the shield
should be grounded at the source end only, not at the drive end.
General Grounding Requirements
SHLD
U/T1
V/T2
W/T3
R/L1
S/L2
T/L3
RUN
REV
FAULT

Installation/Wiring 1-7
RFI Filter Grounding
Using an external filter with any drive rating, may result in relatively
high ground leakage currents. Therefore, the filter must only be used in
installations with grounded AC supply systems and be permanently
installed and solidly grounded (bonded) to the building power
distribution ground. Ensure that the incoming supply neutral is solidly
connected (bonded) to the same building power distribution ground.
Grounding must not rely on flexible cables and should not include any
form of plug or socket that would permit inadvertent disconnection.
Some local codes may require redundant ground connections. The
integrity of all connections should be periodically checked.
The PowerFlex 40P does not provide branch short circuit protection.
This product should be installed with either input fuses or an input
circuit breaker. National and local industrial safety regulations and/or
electrical codes may determine additional requirements for these
installations.
Fusing
The ratings in the table that follows are the recommended values for use
with each drive rating. The devices listed in this table are provided to
serve as a guide.
Bulletin 140M (Self-Protected Combination Controller)/UL489
Circuit Breakers
When using Bulletin 140M or UL489 rated circuit breakers, the
guidelines listed below must be followed in order to meet the NEC
requirements for branch circuit protection.
•Bulletin 140M can be used in single and group motor applications.
•Bulletin 140M can be used up stream from the drive without the
need for fuses.
Fuses and Circuit Breakers

1-8 Installation/Wiring
Table 1.C Recommended Branch Circuit Protective Devices
Voltage
Rating
Drive Rating
kW (HP)
Fuse Rating(1)
Amps
140M Motor
Protectors(2) (3)
Catalog No.
Recommended
MCS Contactors
Catalog No.
Min. Enclosure
Volume(4)
Inches3
240V AC –
3-Phase
0.4 (0.5)
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
3.7 (5.0)
5.5 (7.5)
7.5 (10.0)
6
10
15
25
30
40
60
140M-C2E-B40
140M-C2E-C10
140M-C2E-C16
140M-C2E-C16
140M-F8E-C25
140M-F8E-C32
140M-G8E-C45
100-C07
100-C09
100-C12
100-C23
100-C23
100-C37
100-C60
1655
1655
1655
1655
1655
2069
2069
480V AC –
3-Phase
0.4 (0.5)
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
4.0 (5.0)
5.5 (7.5)
7.5 (10.0)
11 (15)
3
6
10
15
20
25
30
50
140M-C2E-B25
140M-C2E-B40
140M-C2E-B63
140M-C2E-C10
140M-C2E-C16
140M-D8E-C20
140M-D8E-C20
140M-F8E-C32
100-C07
100-C07
100-C09
100-C09
100-C23
100-C23
100-C23
100-C43
1655
1655
1655
1655
1655
2069
2069
2069
600V AC –
3-Phase
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
4.0 (5.0)
5.5 (7.5)
7.5 (10.0)
11 (15)
6
6
10
15
20
25
40
140M-C2E-B25
140M-C2E-B40
140M-D8E-B63
140M-D8E-C10
140M-D8E-C16
140M-D8E-C16
140M-F8E-C25
100-C09
100-C09
100-C09
100-C09
100-C16
100-C23
100-C30
1655
1655
1655
1655
2069
2069
2069
(1) Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.
(2) The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See Bulletin 140M
Motor Protection Circuit Breakers Application Ratings.
(3) Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 208 Wye or Delta, 240
Wye or Delta, 480Y/277 or 600Y/347. Not UL listed for use on 480V or 600V Delta/Delta, corner
ground, or high-resistance ground systems.
(4) When using a Manual Self-Protected (Type E) Combination Motor Controller, the drive must be
installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this
column. Application specific thermal considerations may require a larger enclosure.

Installation/Wiring 1-9
Motor Cable Types Acceptable for 200-600 Volt Installations
A variety of cable types are acceptable for drive installations. For many
installations, unshielded cable is adequate, provided it can be separated
from sensitive circuits. As an approximate guide, allow a spacing of 0.3
meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases,
long parallel runs must be avoided. Do not use cable with an insulation
thickness less than 15 mils (0.4 mm/0.015 in.). Do not route more than
three sets of motor leads in a single conduit to minimize “cross talk”. If
more than three drive/motor connections per conduit are required,
shielded cable must be used.
UL installations in 50°C ambient must use 600V, 75°C or 90°C wire.
UL installations in 40°C ambient should use 600V, 75°C or 90°C wire.
Use copper wire only. Wire gauge requirements and recommendations
are based on 75 degree C. Do not reduce wire gauge when using higher
temperature wire.
Unshielded
THHN, THWN or similar wire is acceptable for drive installation in dry
environments provided adequate free air space and/or conduit fill rates
limits are provided. Do not use THHN or similarly coated wire in wet
areas. Any wire chosen must have a minimum insulation thickness of 15
mils and should not have large variations in insulation concentricity.
Shielded/Armored Cable
Shielded cable contains all of the general benefits of multi-conductor
cable with the added benefit of a copper braided shield that can contain
much of the noise generated by a typical AC Drive. Strong consideration
for shielded cable should be given in installations with sensitive
equipment such as weigh scales, capacitive proximity switches and other
devices that may be affected by electrical noise in the distribution
system. Applications with large numbers of drives in a similar location,
imposed EMC regulations or a high degree of communications /
networking are also good candidates for shielded cable.
Power Wiring
!
ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.)
and local codes outline provisions for safely installing electrical
equipment. Installation must comply with specifications regarding wire
types, conductor sizes, branch circuit protection and disconnect
devices. Failure to do so may result in personal injury and/or equipment
damage.
!
ATTENTION: To avoid a possible shock hazard caused by induced
voltages, unused wires in the conduit must be grounded at both ends.
For the same reason, if a drive sharing a conduit is being serviced or
installed, all drives using this conduit should be disabled. This will help
minimize the possible shock hazard from “cross coupled” power leads.

1-10 Installation/Wiring
Shielded cable may also help reduce shaft voltage and induced bearing
currents for some applications. In addition, the increased impedance of
shielded cable may help extend the distance that the motor can be
located from the drive without the addition of motor protective devices
such as terminator networks. Refer to Reflected Wave in “Wiring and
Grounding Guidelines for PWM AC Drives,” publication
DRIVES-IN001A-EN-P.
Consideration should be given to all of the general specifications
dictated by the environment of the installation, including temperature,
flexibility, moisture characteristics and chemical resistance. In addition,
a braided shield should be included and be specified by the cable
manufacturer as having coverage of at least 75%. An additional foil
shield can greatly improve noise containment.
A good example of recommended cable is Belden® 295xx (xx
determines gauge). This cable has four (4) XLPE insulated conductors
with a 100% coverage foil and an 85% coverage copper braided shield
(with drain wire) surrounded by a PVC jacket.
Other types of shielded cable are available, but the selection of these
types may limit the allowable cable length. Particularly, some of the
newer cables twist 4 conductors of THHN wire and wrap them tightly
with a foil shield. This construction can greatly increase the cable
charging current required and reduce the overall drive performance.
Unless specified in the individual distance tables as tested with the drive,
these cables are not recommended and their performance against the lead
length limits supplied is not known.
Recommended Shielded Wire
Location Rating/Type Description
Standard
(Option 1)
600V, 90°C (194°F)
XHHW2/RHW-2
Anixter
B209500-B209507,
Belden 29501-29507,
or equivalent
•Four tinned copper conductors with XLPE insulation.
•Copper braid/aluminum foil combination shield and tinned
copper drain wire.
•PVC jacket.
Standard
(Option 2)
Tray rated 600V, 90°C
(194°F) RHH/RHW-2
Anixter OLF-7xxxxx or
equivalent
•Three tinned copper conductors with XLPE insulation.
•5 mil single helical copper tape (25% overlap min.) with three
bare copper grounds in contact with shield.
•PVC jacket.
Class I & II;
Division I & II
Tray rated 600V, 90°C
(194°F) RHH/RHW-2
Anixter 7V-7xxxx-3G
or equivalent
•Three bare copper conductors with XLPE insulation and
impervious corrugated continuously welded aluminum armor.
•Black sunlight resistant PVC jacket overall.
•Three copper grounds on #10 AWG and smaller.