Rockwell Automation PowerFlex 40 User manual

INSTALLATION INSTRUCTIONS
PowerFlex 40 Configured AC Drives

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, DriveExplorer, DriveExecutive, DPI, and SCANport are either trademarks or registered trademarks 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 a hazard, and 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.

Publication 23B-IN001G
Table of Contents
Preface Overview
Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1
What Is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-3
Compliance Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-3
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-4
Chapter 1 PowerFlex 40 Standard Configured Drive Standard Features and Options
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Enclosure Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Power Disconnect Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Operator Device Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Quick Disconnects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
I/O Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Chapter 2 Control Wiring Overview
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Wiring Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Schematic Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Chapter 3 Mechanical Installation
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Layout Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Appendix A Specifications
Appendix B Replacement Parts

Publication 23B-IN001G
2Table of Contents
Notes:

Publication 23B-IN001G
Preface
Overview
The purpose of this manual is to provide basic information needed to install
PowerFlex®40 Adjustable Frequency AC Standard Configured Drives.
User documentation for the PowerFlex 40 Standard Configured Drives
includes these Installation Instructions and the PowerFlex 40 User Manual,
Publication 22B-UM001…. Both manuals are required to properly install
and operate PowerFlex 40 Adjustable Frequency AC Standard Configured
Drives.
Who Should Use this
Manual?
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.
What Is Not in this Manual The PowerFlex 40 Adjustable Frequency AC Standard Configured Drives
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.
For information on … See page …
Who Should Use this Manual? P-1
What Is Not in this Manual P-1
Reference Materials P-2
Manual Conventions P-2
General Precautions P-3
Compliance Certification P-3
Catalog Number Explanation P-4

Publication 23B-IN001G
P-2 Overview
Reference Materials The following manuals are recommended for general drive information:
For detailed PowerFlex 40 information including drive parameters,
programming, start-up, troubleshooting, specifications:
The latest version of this Installation Instructions can be obtained online at …
www.rockwellautomation.com/literature
For Allen-Bradley Drives Technical Support:
Manual Conventions •To help differentiate parameter names and LCD display text from other
text, the following conventions will be used:
–Parameter Names will appear in [brackets].
For example: [DC Bus Voltage].
–Display Text will appear in “quotes.” For example: “Enabled.”
•The following words are used throughout the manual to describe an
action:
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
0100-2.10
Guarding Against Electrostatic Damage 8000-4.5.2
Title Publication Available Online at …
PowerFlex 40 User Manual 22B-UM001… www.rockwellautomation.com/literature
PowerFlex Reference Manual PFLEX-RM001…
Title Online at …
Allen-Bradley Drives Technical Support www.ab.com/support/abdrives
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

Publication 23B-IN001G
Overview P-3
General Precautions
Compliance Certification Certifications are applicable to approved program defined options.
U.S./Canada UL: UL508C
CUL: CAN/CSA-C22.2 No. 14
Please refer to the PowerFlex 40 User Manual, publication 22B-UM001,
for additional information.
!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: 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: 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.

Publication 23B-IN001G
P-4 Overview
Catalog Number
Explanation
The PowerFlex 40 Adjustable Frequency AC Standard Configured Drives
catalog numbering scheme is shown below.
Position
1-3 4 56-89 10111213141516+
23B – D 4P0 D 1 0 4 N N – P6
abcdefghi j
a
Drive
Code Type
23B PowerFlex 40
b
Voltage Rating
Code Voltage Ph.
D 480V ac 3
c
Amp Rating
480V 60Hz 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)
d
Enclosure
Code Enclosure
C NEMA/UL Type 4X ‡
D NEMA/UL Type 4 ‡
‡ The design of the PowerFlex 40 Standard
Configured Drive supports indoor and outdoor
applications that are not in direct sunlight.
f
Emission Class
Code Rating
0 Not Filtered
g
Version
Code Version
4 RS485 (Standard)
C ControlNet
D DeviceNet
E EtherNet/IP
P PROFIBUS DP
h
Code Rating
N Reserved
i
Code Rating
N Reserved
e
HIM
Code Interface Module
1 Fixed Keypad on Drive
F 
Fixed Keypad on Drive and LCD
Display with Digital Speed Control
HIM on Enclosure Door
(22-HIM-C2S)
This option changes the enclosure rating to
indoor only.
j
Options
Code Description
-E22 DeviceNet Quick Disconnect
(Bottom)
-E23 DeviceNet Quick Disconnect (Left
Side)
-P3 Motor Circuit Protector
-P3T Motor Circuit Protector (Customer
wiring into top of device)
-P6 Disconnect Switch - Fused
-P6T Disconnect Switch - Fused
(Customer wiring into top of device)
-R3
DeviceNet I/O (4 In/2 Out) w/Spring
Return HOA and Power Disconnect
Aux. Contact
-R4 DeviceNet Point I/O w/IB4 (4 Inputs)
-R5 -R3 plus 4 I/O Quick Disconnects
and (1) 24V DC Receptacle
-S1 Hand/Off/Auto S.S.
(Start/Stop/Speed Ref.)
-S4 Auto/Manual S.S. (Speed Ref.)
-S7 Start and Stop P.B.
-S8 Forward/Reverse S.S.
-S18 Door Mounted Local Speed Pot (1-
Tur n)
-S20 Local/Remote and Local Control
Off/Run Forward Selector Switches
-S21 Local/Off/Remote with 1 N.O.
Interposing Relay
-S22 Spring Return Hand/Off Auto S.S.
(Start/Stop/Speed Ref.)
-S23 Clear Fault P.B.

Publication 23B-IN001G
Chapter 1
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.
Standard Features This package integrates the Standard PowerFlex 40 drive. The PowerFlex
40 drive can be used for Volts per hertz or Sensorless Vector applications
and offers an Autotune feature allowing the drive to adapt to individual
motor characteristics.
The PowerFlex 40 is assembled in an enclosure which includes the
following features…
•NEMA/UL Type 4/4X - indoor and outdoor applications other than
direct sunlight. (1)
•Flange mount drive/external heatsink reducing overall enclosure size.
•Mounting feet - orientation is adjustable per customer requirements.
If required, the drive can be removed from the front of the enclosure for
ease of assembly or repair.
Low cost, highly configurable I/O inputs and/or 0-10V/4-20 mA outputs
that are not used by program standard features and options are available for
customer use.
For information on … See page …
Standard Features 1-1
Enclosure Options 1-2
Communication Options 1-3
Power Disconnect Options 1-4
Operator Device Options 1-9
Quick Disconnects 1-15
I/O Options 1-16
(1) The enclosure does not normally protect electrical equipment from
condensation, corrosion or contamination, which may occur within the
enclosure or enter via the conduit or unsealed openings. Users must
make adequate provisions to safeguard against such conditions, and
satisfy themselves that the equipment is properly protected. For further
information on criteria associated with NEMA enclosure ratings, refer to
NEMA standards Publication No. 250-1991. When optional Door
Mounted HIM is supplied, enclosure is rated indoor only. See enclosure
options for specific enclosure style quoted.

1-2 PowerFlex 40 Standard Configured Drive Standard Features and Options
Publication 23B-IN001G
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.
Type 4 enclosures are intended for indoor or outdoor use primarily to
provide a degree of protection against windblown dust and rain, splashing
water, and hose directed water, and to be undamaged by the formation of ice
on the enclosure. They are designed to meet hose-down, dust, and external
icing and rust resistance design tests. Doors and openings will be gasket
sealed. There are no ventilation openings within the enclosure to allow for
free exchange of inside and outside air.
Note: If optional Door Mounted HIM is not supplied, the design of the
PowerFlex 40 Standard Configured Drive supports indoor and outdoor
applications that are not in direct sunlight.
NEMA/UL Type 4X (Position 9, Code C)
The enclosure provided is a NEMA/UL Type 4X. The material is type 304
stainless steel. Type 4X enclosures are intended for indoor or outdoor use
primarily to provide a degree of protection against corrosion, windblown
dust and rain, splashing water, and hose directed water, and to be
undamaged by the formation of ice on the enclosure. They are designed to
meet hose-down, dust, and external icing and rust resistance design tests.
Doors and openings will be gasket sealed. There are no ventilation openings
within the enclosure to allow for free exchange of inside and outside air.
Note: If optional Door Mounted HIM is not supplied, the design of the
PowerFlex 40 Standard Configured Drive supports indoor and outdoor
applications that are not in direct sunlight.