Allen-Bradley PowerFlex 4M User manual

Adjustable
Frequency AC
Drive
FRN 1.xx - 2.xx
User Manual
www.abpowerflex.com

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
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.
Allen-Bradley, Rockwell Automation, and PowerFlex are registered trademarks 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.

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
Summary of Changes
The information below summarizes the changes to the PowerFlex 4M
User Manual since the July 2008 release.
Manual Updates
The information below summarizes the changes to the PowerFlex 4M
User Manual since the August 2007 release.
Manual Updates
Description of New or Updated Information Page(s)
Minimum Enclosure Volume column and new footnotes added. 1-8, A-2
Drive, Fuse & Circuit Breaker Ratings topic updated. A-1
Electronic Motor Overload Protection description updated. A-4
Description of New or Updated Information Page(s)
Footnote (2) deleted from “EN61800-3 Second Environment” in Table 1.I.1-22
Note to stop drive before changing parameter t211 [Anlg In 0-10V Lo]
removed.
3-14
New option 13, I/O Control, for parameter t221 [Relay Out Sel] added. 3-15
Fault description for F3 corrected. 4-3
Corrected Ta ble B.F by adding the 0.75 kW (1.0 HP) and 1.5 kW (2.0 HP)
ratings for the 22F-RF025-BL EMC line filter.
B-4
Description for bits 14, 13, and 12 of register address 8192 corrected. C-4
Information on reading register address 8192 clarified. C-4
Description for bits 6, 7, and 15 of register address 8192 updated. C-4
Information on reading register address 8193 clarified. C-5
Figure C.1, Network Wiring Diagram, updated. C-1
Guidelines on standard RS485 wiring practices added. C-1

soc-2
PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
The information below summarizes the changes to the PowerFlex 4M
User Manual since the February 2007 release.
Manual Updates
Description of New or Updated Information Page(s)
Input description and attention text for Multiple Digital Input Connection
example corrected.
1-18
Description for option 21 of parameter t221 [Relay Out Sel] corrected. 3-15
Invalid catalog number for L Type Filter deleted. B-4, B-10
Graphic for the “Connecting an RS-485 Network” section corrected D-3

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
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
AC Supply Source Considerations . . . . . . 1-3
General Grounding Requirements . . . . . . 1-5
Fuses and Circuit Breakers . . . . . . . . . . . . 1-7
Power Wiring . . . . . . . . . . . . . . . . . . . . . . 1-9
I/O Wiring Recommendations . . . . . . . . 1-13
Start and Speed Reference Control . . . . . 1-19
EMC Instructions . . . . . . . . . . . . . . . . . . 1-21
Chapter 2 Start Up
Prepare For Drive Start-Up . . . . . . . . . . . . 2-1
Integral Keypad. . . . . . . . . . . . . . . . . . . . . 2-3
Viewing and Editing Parameters. . . . . . . . 2-4
Chapter 3 Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . 3-1
Parameter Organization. . . . . . . . . . . . . . . 3-2
Display Group . . . . . . . . . . . . . . . . . . . . . . 3-3
Basic Program Group . . . . . . . . . . . . . . . . 3-8
Terminal Block Group. . . . . . . . . . . . . . . 3-13
Communications Group . . . . . . . . . . . . . 3-17
Advanced Program Group. . . . . . . . . . . . 3-19
Parameter Cross Reference – by Name. . 3-31
Chapter 4 Troubleshooting
Drive Status. . . . . . . . . . . . . . . . . . . . . . . . 4-1
Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fault Descriptions . . . . . . . . . . . . . . . . . . . 4-3
Common Symptoms and Corrective Actions . .
4-5
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-6

ii Table of Contents
PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
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-5
Reading (03) Feedback . . . . . . . . . . . . . . . C-6
Reading (03) Drive Error Codes . . . . . . . . C-6
Reading (03) and Writing (06) Drive
Parameters . . . . . . . . . . . . . . . . . . . . . . C-7
Additional Information . . . . . . . . . . . . . . . C-7
Appendix D RJ45 DSI Splitter Cable
Connectivity Guidelines . . . . . . . . . . . . . . D-1
DSI Cable Accessories . . . . . . . . . . . . . . . D-2
Connecting an RS-485 Network . . . . . . . . D-3
Index

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
Preface
Overview
The purpose of this manual is to provide you with the basic information
needed to install, start-up and troubleshoot the PowerFlex 4M
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-SB001…
Safety Guidelines for the
Application, Installation and
Maintenance of Solid State
Control
SGI-1.1
A Global Reference Guide for
Reading Schematic Diagrams
0100-2.10
Guarding Against Electrostatic
Damage
8000-4.5.2

P-2 Overview
PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
•In this manual we refer to the PowerFlex 4M Adjustable Frequency
AC Drive as: drive, PowerFlex 4M or PowerFlex 4M Drive.
•Parameter numbers and names are shown in this format:
•The following words are used throughout the manual to describe an
action:
Similar PowerFlex 4M 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
P101 [Motor NP Volts]
Name
Number
Group
d = Display Group
P = Basic Program Group
t = Terminal Block Group
C = Communications Group
A = Advanced Program 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
PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
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 DC bus voltage at the –DC and +DC
terminals on the Power Terminal Block (refer to Chapter 1 Power
Terminal descriptions). The voltage must be zero.
Darkened LEDs or a darkened LCD display 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 A441). In addition, installing a properly sized
dynamic brake resistor will provide equal or better performance in most
cases.

P-4 Overview
PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
Catalog Number Explanation
Code Voltage Ph.
V 120V AC 1
A 240V AC 1
B 240V AC 3
D 480V AC 3
Code Version
3 No Brake IGBT
4 Standard
Code Interface Module
1 Fixed Keypad
Code Enclosure
N Panel Mount - IP 20 (NEMA Type Open)
1-3 4 5 6-8 9 10 11 12 13-14
22F - D 8P7 N 1 1 3 AA
Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Type Optional
Code
22F PowerFlex 4M
Code Purpose
AA Reserved for
thru custom firmware
ZZ
Output Current @ 380-480V Input
Code Amps kW (HP)
1P5 1.5 0.4 (0.5)
2P5 2.5 0.75 (1.0)
4P2 4.2 1.5 (2.0)
6P0 6.0 2.2 (3.0)
8P7 8.7 3.7 (5.0)
013 13.0 5.5 (7.5)
018 18.0 7.5 (10.0)
024 24.0 10.0 (15.0)
Output Current @ 100-120V Input
Code Amps kW (HP)
1P6 1.6 0.2 (0.25)
2P5 2.5 0.4 (0.5)
4P5 4.5 0.75 (1.0)
6P0 6.0 1.1 (1.5)
Output Current @ 200-240V Input
Code Amps kW (HP)
1P6 1.6 0.2 (0.25)
2P5 2.5 0.4 (0.5)
4P2 4.2 0.75 (1.0)
8P0 8.0 1.5 (2.0)
011 11.0 2.2 (3.0)
012 12.0 2.2 (3.0)
017 17.5 3.7 (5.0)
025 25.0 5.5 (7.5)
033 33.0 7.5 (10.0)
Code Rating
0 Not Filtered
1Filtered
Additional accessories, options and adapters are available. See Appendix B for details.

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
Chapter 1
Installation/Wiring
This chapter provides information on mounting and wiring the
PowerFlex 4M 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 1-3 I/O Wiring
Recommendations
1-13
General Grounding Requirements 1-5 EMC Instructions 1-21
!
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
PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
•Mount the drive upright on a flat, vertical and level surface.
–Install on 35 mm DIN Rail (for frames A and B).
or
–Install with screws.
Table 1.A Screw Mounting Recommendations
•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
Drive enclosure is rated IP20, NEMA/UL Type Open.
Mounting Considerations
Minimum Panel Thickness Screw Size Mounting Torque
1.9 mm (0.0747 in.) M4 (#8-32) 1.56-1.96 N-m (14-17 lb.-in.)
Table 1.B Enclosure and Clearance Requirements
Horizontal Clearance between drives Ambient Temperature
Minimum Maximum
0 mm and greater -10°C (14°F) 40°C (104°F)
25 mm and greater -10°C (14°F) 50°C (122°F)
76.2 mm (3.0 in.)
76.2 mm (3.0 in.)
Closest object that
may obstruct air flow
through the drive
heat sink and chassis
76.2 mm (3.0 in.)
76.2 mm (3.0 in.)
Airflow
See Table 1.B

Installation/Wiring 1-3
PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
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.
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 (Frame A shown)
AC Supply Source Considerations
!
ATTENTION: PowerFlex 4M 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.

1-4 Installation/Wiring
PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
Figure 1.2 Phase to Ground MOV Removal
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.C 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.C, 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.C Input Power Conditions
Input Power Condition Corrective Action
Low Line Impedance (less than 1% line reactance) •Install Line Reactor(1)
•or Isolation Transformer
(1) Refer to Appendix B for accessory ordering information.
Greater than 120 kVA supply transformer
Line has power factor correction capacitors
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
R/L1
S/L2
T/L3
1234
Three-Phase
AC Input
Jumper

Installation/Wiring 1-5
PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
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.
General Grounding Requirements
R/L1
S/L2
T/L3
U/T1
V/T2
W/T3
SHLD

1-6 Installation/Wiring
PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
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.
RFI Filter Grounding
Using single phase drives with integral filter, or 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.

Installation/Wiring 1-7
PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
The PowerFlex 4M 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 PowerFlex 4M has been UL tested and approved for use with input
fuses. The ratings in the table that follows are the maximum
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
!
ATTENTION: To guard against personal injury and/or equipment
damage caused by improper fusing or circuit breaker selection, use only
the recommended line fuses/circuit breakers specified in this section.

1-8 Installation/Wiring
PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
Table 1.D Minimum Recommended Branch Circuit Protective Devices
Voltage
Rating
Drive Rating
kW (HP)
Fuse Rating(1)
Amps
140M(2) (3)
Catalog No.
Recommended
MCS Contactors
Catalog No.
Min. Enclosure
Volume(4)
Inches3
120V AC –
1-Phase
0.2 (0.25)
0.4 (0.5)
0.75 (1.0)
1.1 (1.5)
10
15
30
40
140M-C2E-C10
140M-C2E-C16
140M-D8E-C20
140M-F8E-C32
100-C09
100-C12
100-C23
100-C30
1655
1655
1655
1655
240V AC –
1-Phase
0.2 (0.25)
0.4 (0.5)
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
10
10
15
35
40
140M-C2E-B63
140M-C2E-C10
140M-C2E-C16
140M-D8E-C25
140M-F8E-C32
100-C09
100-C09
100-C12
100-C23
100-C30
1655
1655
1655
1655
1655
240V AC –
3-Phase
0.2 (0.25)
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)
3
6
10
15
25
35
45
60
140M-C2E-B25
140M-C2E-B40
140M-C2E-B63
140M-C2E-C16
140M-D8E-C20
140M-F8E-C25
140M-F8E-C32
140M-F8E-C45
100-C09
100-C09
100-C09
100-C12
100-C23
100-C23
100-C37
100-C60
1655
1655
1655
1655
1655
1655
3441
3441
480V 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)
11.0 (15.0)
3
6
10
10
15
25
30
50
140M-C2E-B25
140M-C2E-B40
140M-C2E-C10
140M-C2E-C10
140M-C2E-C16
140M-D8E-C20
140M-F8E-C25
140M-F8E-C32
100-C09
100-C09
100-C09
100-C09
100-C12
100-C23
100-C23
100-C30
1655
1655
1655
1655
1655
3441
3441
3441
(1) Recommended Fuse Type: UL Class J, RK1, 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
PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
Motor Cable Types Acceptable for 200-600 Volt Installations
General
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.
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
PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual
Publication 22F-UM001D-EN-E
Shielded
Reflected Wave Protection
The drive should be installed as close to the motor as possible.
Installations with long motor cables may require the addition of external
devices to limit voltage reflections at the motor (reflected wave
phenomena). See Table 1.E for recommendations.
The reflected wave data applies to all frequencies 2 to 10 kHz.
For 240V ratings, reflected wave effects do not need to be considered.
Table 1.E Maximum Cable Length Recommendations
Output Disconnect
The drive is intended to be commanded by control input signals that will
start and stop the motor. A device that routinely disconnects then
reapplies output power to the motor for the purpose of starting and
stopping the motor should not be used. If it is necessary to disconnect
power to the motor with the drive outputting power, an auxiliary contact
should be used to simultaneously disable drive control run commands.
Location Rating/Type Description
Standard
(Option 1)
600V, 75°C or 90°C (167°F
or 194°F) RHH/RHW-2
Belden 29501-29507 or
equivalent
•Four tinned copper conductors with XLPE insulation
•Foil shield and tinned copper drain wire with 85% braid
coverage
•PVC jacket
Standard
(Option 2)
Tray rated 600V, 75°C or
90°C (167°F or 194°F)
RHH/RHW-2
Shawflex 2ACD/3ACD 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, 75°C or
90°C (167°F or 194°F)
RHH/RHW-2
•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 copper grounds on #10 AWG and smaller
Reflected Wave
380-480V Ratings Motor Insulation Rating Motor Cable Only(1)
(1) Longer cable lengths can be achieved by installing devices on the output of the drive.
Consult factory for recommendations.
1000 Vp-p 15 meters (49 feet)
1200 Vp-p 40 meters (131 feet)
1600 Vp-p 170 meters (558 feet)