Rockwell Automation Allen-Bradley 35E User manual

User Manual Original Instructions
Armor PowerFlex AC Drives
Bulletins 35E, 35S
This manual links to Armor PowerFlex AC Drive Fault Codes Reference Data,
publication 35-RD002 and to Armor PowerFlex AC Drive CIP Objects and Attributes
Reference Data, publication 35-RD001; download the spreadsheet now for offline
access.

2Rockwell Automation Publication 35-UM001A-EN-P - May 2022
Armor PowerFlex AC Drives User Manual
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.
These labels may also be on or inside the equipment to provide specific precautions.
The following icon may appear in the text of this document.
Rockwell Automation recognizes that some of the terms that are currently used in our industry and in this publication are not in alignment with the
movement toward inclusive language in technology. We are proactively collaborating with industry peers to find alternatives to such terms and making
changes to our products and content. Please excuse the use of such terms in our content while we implement these changes.
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 consequence.
IMPORTANT Identifies information that 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 or motor, 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).
Identifies information that is useful and can help to make a process easier to do or easier to understand.

Rockwell Automation Publication 35-UM001A-EN-P - May 2022 3
Table of Contents
Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Access Fault Code and CIP Object and Attribute Data. . . . . . . . . . . . . . . 11
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . 11
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Machinery Directive (2006/42/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
EMC Directive (2014/30/EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LVD Directive (2014/35/EU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
RoHS Directive (2011/65/EU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Ecodesign Directive (2019/1781) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chapter 1
Armor PowerFlex Variable
Frequency Drives Overview
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Input and Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Frame Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Location of Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Required Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Volts/Hertz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Sensorless Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Velocity Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Velocity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Flying Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Load Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Motor Thermal Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Velocity Skip Band. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fault Auto Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Safe Torque Off and Safe Monitor Functions . . . . . . . . . . . . . . . . . . . . . . 23
Hardwired Safe Torque Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Integrated Safety Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Standard Encoder Operation and Diagnostics . . . . . . . . . . . . . . . . . . . . . 24
Group Motor Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Local Disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
EMI Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Dynamic Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Power Input Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Factory-installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Internal Power Supply (IPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electromechanical Brake (EM Brake or EMB) . . . . . . . . . . . . . . . . . . 27
Typical Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4Rockwell Automation Publication 35-UM001A-EN-P - May 2022
Table of Contents
Standard Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Safety Drives Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hardwired STO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Integrated STO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Integrated Safe Speed Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Chapter 2
Install the Armor PowerFlex
Drive
Unpack and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Personal and Electrical Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . 34
Precautions for Cold Temperature Conditions. . . . . . . . . . . . . . . . . . 35
Precautions for Motor Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Avoid Electrostatic Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Mounting Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Armor PowerFlex Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Wiring and Workmanship Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cabling and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Product Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Shielding and Grounding of Motors and Motor Cables . . . . . . . . . . 43
Motor Cable Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Unshielded Motor Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Branch Circuit Protection Requirements. . . . . . . . . . . . . . . . . . . . . . . 44
Group Motor Installations for USA and Canada Markets . . . . . . . . 45
Auxiliary Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Power Supply Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Internal Power Supply Wiring and Local Disconnect Behavior . . . 47
Single External Power Supply Wiring and Local Disconnect
Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Multiple External Power Supply Wiring and Local Disconnect
Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Power Terminal Location and Internal Wiring . . . . . . . . . . . . . . . . . 49
Power and Motor Connector Pinouts and Cable Torques . . . . . . . . 51
Standard I/O Connections and Cable Torques . . . . . . . . . . . . . . . . . . 52
Safety I/O Connections and Cable Torques. . . . . . . . . . . . . . . . . . . . . 53
Ethernet Connections and Cable Torque . . . . . . . . . . . . . . . . . . . . . . . 53
Encoder Connections and Cable Torque . . . . . . . . . . . . . . . . . . . . . . . 54
Encoder Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ArmorConnect Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Local Disconnect Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Electronic Motor Disconnect (EMD). . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Control Block Explanations: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Chapter 3
EtherNet/IP Operation Set the IP Address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Set the IP Address using Rotary Switches . . . . . . . . . . . . . . . . . . . . . . 61

Rockwell Automation Publication 35-UM001A-EN-P - May 2022 5
Table of Contents
Remove Front Logic Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Replace Front Logic Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Example of How to Set the IP Address Switches . . . . . . . . . . . . . . . . 63
Set the IP Address using the BOOTP/DHCP Server Utility . . . . . . . 64
Set the IP Address using the FactoryTalk Linx Application . . . . . . . 66
Device Level Ring (DLR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Protected Operations Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Ethernet Communication Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 71
Chapter 4
Keypad Operation Keypad Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Hand/Auto (Local Motor Control) Modes Operation . . . . . . . . . . . . 74
Function Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Fault Clear Button Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Temporarily Disable Keypad Motor Control via Message Instruction. 75
Keypad Actions in Hand and Function Modes . . . . . . . . . . . . . . . . . . . . . 76
Chapter 5
Standard and Configurable I/O
Operation
Standard I/O Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Standard Input Internal Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . 78
Standard Input Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Configurable I/O Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Configured Fault Actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Configurable I/O Internal Wiring Diagram (Output). . . . . . . . . . . . 79
Standard Output Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Standard I/O Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Chapter 6
Safety Functions Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Stop Category Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Performance Level (PL) and Safety Integrity Level (SIL). . . . . . . . . . . . . 83
Proof Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
PFD and PFH Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Safety Data for Armor PowerFlex Drives . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Safety Data for Integrated STO and Integrated Safety Functions . 84
Safety Data for Safety Functions with Safety Feedback . . . . . . . . . . 85
Safety Reaction Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Spurious Trip Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Contact Information If Safety Failure Occurs . . . . . . . . . . . . . . . . . . . . . . 87
Safe Torque Off (STO) Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Stop Category Definition for STO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Reset Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Out-of-Box State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Reset to Out-of-Box State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
STO Bypass Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Hardwired Safe Torque Off (STO) Function . . . . . . . . . . . . . . . . . . . . . . . 91
Hardwired STO Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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Table of Contents
Hardwired STO Fault Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Integrated Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Integrated Safety Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Integrated Safety System Application Requirements . . . . . . . . . . . . 94
Drive-based Integrated Safe Stop Functions . . . . . . . . . . . . . . . . . . . 95
Safety Output Assembly Safe Stop Function Tags . . . . . . . . . . . . . . . 95
Safety Input Assembly Safe Stop Function Tags . . . . . . . . . . . . . . . . 95
Safety Function in Response to Connection Event . . . . . . . . . . . . . . 96
Integrated Safe Torque Off Function . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Safe Torque Off Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Safe Torque Off Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Safe Torque Off Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Safe Torque Off Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Safe Torque Off With Delay Operation . . . . . . . . . . . . . . . . . . . . . . . . 99
Safe Torque Off Safety Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Safe Stop 1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Safe Stop 1 Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Safe Stop 1 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
SS1 Safety Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Timed Safe Stop 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Timed Safe Stop 1 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Monitored Safe Stop 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Monitored Safe Stop 1 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Safe Brake Control Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Safe Brake Control Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Safe Brake Control Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Safe Brake Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Not Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Used, No Test Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Used, Test Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
STO Activates SBC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
SBC Safety Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Connecting a Safety Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Safety Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Safety Encoder Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Encoder Voltage Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Maximum Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Maximum Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Maximum Encoder Input Frequency . . . . . . . . . . . . . . . . . . . . . . . . . 112
Digital AqB Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Inverse Signal Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Quadrature Error Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Sine/Cosine and Hiperface Diagnostics. . . . . . . . . . . . . . . . . . . . . . . 113
Sin2 + Cos2Vector Length Monitoring . . . . . . . . . . . . . . . . . . . . . . . . 113
Zero-crossing Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Signal Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Controller-based Safe Monitor Functions . . . . . . . . . . . . . . . . . . . . . . . . 114
Before Adding the Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 115
Drive Safety Instruction Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Safety Feedback Interface (SFX) Instruction Operation . . . . . . . . 115

Rockwell Automation Publication 35-UM001A-EN-P - May 2022 7
Table of Contents
Monitor Safety Status and Faults via a Message Instruction . . . . . . . . 116
Safety Supervisor State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Safety Core Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Safe Torque Off Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Safe Stop 1 Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Safe Brake Control Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
SLS, SLP, and SDI Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Safety Feedback Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Safety Fault Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Safety I/O Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Safe State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Safety Input Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Safety Input Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Single-channel Mode (Safety Inputs) . . . . . . . . . . . . . . . . . . . . . . . . . .121
Dual-channel Mode and Discrepancy Time (Safety Inputs) . . . . . 122
Dual-channel, Equivalent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Dual Channels, Complementary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Input Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Off to On Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
On to Off Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Using a Test Output with a Safety Input . . . . . . . . . . . . . . . . . . . . . . 125
Safety Input Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Safety Input Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Safety Input Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Safety Input Valid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Safety Input Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Configuration Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Discrepancy and Dual Channel Errors . . . . . . . . . . . . . . . . . . . . . . . . 129
Determining Safety Input Alarm Type . . . . . . . . . . . . . . . . . . . . . . . . 130
Safety Input Alarm Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Safety Output Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Safety Output Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Dual-channel Mode (Safety Outputs) . . . . . . . . . . . . . . . . . . . . . . . . . 131
Safety Output with Test Pulse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Safety Output Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Safety Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Safety Output Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Safety Output Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Test Output Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Test Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Safety Input or Output Fault Recovery . . . . . . . . . . . . . . . . . . . . . . . . 136
Safety I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Safety Input Internal Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . 136
Safety Output Internal Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . 137
Status and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Safety Input Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Safety Output Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Replacing an Armor PowerFlex Drive on a Safety Network . . . . . . . . . 139
Replace an Armor PowerFlex drive in a GuardLogix System. . . . . 139

8Rockwell Automation Publication 35-UM001A-EN-P - May 2022
Table of Contents
Configure Only When No Safety Signature Exists . . . . . . . . . . . . . 140
Configure Always. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Chapter 7
Configure the Armor PowerFlex
Drive
Install Armor PowerFlex Add-on Profile . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Create a Logix Designer Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Add an Armor PowerFlex Drive to the Project . . . . . . . . . . . . . . . . . . . . . 143
Configure the Device Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
View or Generate a Safety Network Number . . . . . . . . . . . . . . . . . . 145
QuickStart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Configure Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Configure Motor Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Volts/Hertz Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Sensorless Vector Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Velocity Vector Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Configure Advanced Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Configure Motor Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Configure Motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Motor Overload Trip Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Derating for High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Configure Advanced Motor Protection. . . . . . . . . . . . . . . . . . . . . . . . 155
Configure Autotune. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Configure Flying Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Configure Auto Restart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Configure Encoder Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Configure Velocity Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Velocity Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Dynamic Acceleration Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Preset Velocity, Acceleration Time, Deceleration Time, S-Curve . 163
Output Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Configure Stop Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Configure DC Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Configure Dynamic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Light Duty Dynamic Brake Resistor Operation . . . . . . . . . . . . . . . . .167
Standard Duty Dynamic Brake Resistor Operation. . . . . . . . . . . . . 167
Configure Electromechanical (EM) Brake . . . . . . . . . . . . . . . . . . . . . 167
Configure Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Standard Connection Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Configure Standard I/O Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Configure Safety Functions (safety variants). . . . . . . . . . . . . . . . . . . . . . 171
Configure Safety Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Configure Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Configure Safe Torque Off (STO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Configure Safe Brake Control (SBC) . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Configure Safe Stop 1 (SS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Configure Safety Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Configure Test Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Configure Safety Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Configure Safety Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Rockwell Automation Publication 35-UM001A-EN-P - May 2022 9
Table of Contents
View or Edit Additional Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Using Automatic Device Configuration (ADC) . . . . . . . . . . . . . . . . . . . . 182
Auto-generated Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Chapter 8
Develop Secure Applications CIP Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Automatic Device Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Reset to Out-of-Box for Secure Erase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Disable Ethernet Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Disable the Ethernet Port on the FactoryTalk Linx Port
Configuration Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Disable the Ethernet Port with a MSG Instruction . . . . . . . . . . . . . 195
Chapter 9
Diagnostics, Status, and
Troubleshooting
View Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
System Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
I/O Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
EtherNet/IP Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Power Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Keypad Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Safety Function Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Monitor Faults, Alarms, and Events. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Access Fault, Alarm, and Event Codes. . . . . . . . . . . . . . . . . . . . . . . . . 203
Condition Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Chapter 10
Maintenance and Repair Remove Power Before Servicing the Armor PowerFlex Drive . . . . . . . 205
Test for Hazardous Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Fuse Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3-phase AC Power and EM Brake Fuse Replacement. . . . . . . . . . . . 208
Switched and Unswitched +24V DC Power Fuse Replacement . . 210
Appendix A
Integrated Safety Instruction
Validation Checklist
Safe Stop 1 (SS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Safely-limited Speed (SLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Safely-limited Position (SLP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Safe Direction (SDI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Safe Feedback Interface (SFX). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Safe Brake Control (SBC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Appendix B
Configure a Message Instruction Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Message Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Example: Read SS1 Fault Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

10 Rockwell Automation Publication 35-UM001A-EN-P - May 2022
Table of Contents
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223

Rockwell Automation Publication 35-UM001A-EN-P - May 2022 11
Preface
About This Publication This manual describes Armor™ PowerFlex® AC drives with EtherNet/IP® and
Armor PowerFlex drives with Integrated Safety via EtherNet/IP. It includes
information on installation, configuration, programming, and use.
This manual is intended for engineers or technicians that are directly involved
in the installation, wiring, programming, operation, and maintenance of the
Armor PowerFlex drive.
Rockwell Automation recognizes that some of the terms that are currently
used in our industry and in this publication are not in alignment with the
movement toward inclusive language in technology. We are proactively
collaborating with industry peers to find alternatives to such terms and
making changes to our products and content. Please excuse the use of such
terms in our content while we implement these changes.
Conventions In this manual, we use the term GuardLogix® controller to collectively refer to
all of the following safety programmable controllers: GuardLogix, Compact
GuardLogix, Armor GuardLogix, and Armor Compact GuardLogix controllers.
We use the term Logix controller to collectively refer to all compatible
programmable controllers. See Integrated Safety Functions and Compatible
Controllers on page 81 for more information.
Access Fault Code and CIP
Object and Attribute Data
Download Firmware, AOP,
EDS, and Other Files
Download firmware, associated files (such as AOP, EDS, and DTM), and access
product release notes from the Product Compatibility and Download Center at
rok.auto/pcdc.
Terminology This table defines the abbreviations that are used in this manual.
This manual links to Armor PowerFlex AC Drive Fault Codes Reference
Data, publication 35-RD002 and to Armor PowerFlex AC Drive CIP
Objects and Attributes Reference Data, publication 35-RD001.
Download the spreadsheets from Literature Library.
Abbreviations and Definitions
Abbreviation Full Term Definition
1oo2 One out of Two Refers to the behavioral design of a dual-channel safety system.
CAT Category Classification of the safety-related parts of a control system in respect of their resistance to faults and their subsequent behavior in the fault condition, and which is achieved by the structural
arrangement of the parts, fault detection, and/or by their reliability (source ISO 13849).
CL Claim Limit The maximum SIL rating that can be claimed for a safety-related electrical control system subsystem
in relation to architectural constraints and systematic safety integrity (source IEC 62061).
DC Diagnostic Coverage The ratio of the detected failure rate to the total failure rate.
DeviceID Device ID A unique identifier, which is comprised of the module number and SNN, to make sure that duplicate
module numbers do not compromise communication between the correct safety devices.
EN European Norm The official European Standard.
ESD Emergency Shutdown Systems A system, usually independent of the main control system, which is designed to safely shut down an
operating system.

12 Rockwell Automation Publication 35-UM001A-EN-P - May 2022
ESPE Electro-sensitive Protective Equipment
An assembly of devices and/or components working together for protective tripping or presence-
sensing purposes and includes as a minimum:
•Asensingdevice.
• Controlling/monitoring devices.
• Output signal-switching devices (OSSD).
HFT Hardware Fault Tolerance The HFT equals n, where n+1 faults could cause the loss of the safety function. An HFT of one means
that two faults are required before safety is lost.
IEC International Electrotechnical Commission The International Electrotechnical Commission (IEC) is the organization that prepares and publishes
international standards for all electrical, electronic, and related technologies.
IGBT Insulated Gate Bipolar Transistors Typical power switch that is used to control main current.
ISO International Organization for Standardization The International Organization for Standardization is an international standard-setting body that is
composed of representatives from various national standards organizations.
MTTF Mean Time to Failure The length of time that a device or other product is expected to remain reliable in operation.
PELV Protective Extra Low Voltage An electrical system where the voltage cannot exceed ELV under normal conditions, and under single-
fault conditions, except earth faults in other circuits.
PFD Average Probability of a Dangerous Failure on
Demand The average probability of a system to fail to perform its design function on demand.
PFH Average Frequency of a Dangerous Failure per
hour The average frequency of a system to have a dangerous failure per hour.
PL Performance Level EN ISO 13849-1 safety rating
PM Permanent Magnet In permanent magnet (PM) motors, magnets mounted on or embedded in the rotor, couple with the
current-induced internal magnetic fields of the motor generated by electrical input to the stator.
SELV Safety Extra Low Voltage Circuit A secondary circuit that is designed and protected so that, under normal and single fault conditions,
its voltages do not exceed a safe value.
SIL Safety Integrity Level A measure of a products ability to lower the risk that a dangerous failure could occur.
SSN Safety Network Number A unique number that identifies a section of a safety network.
STR Spurious Trip Rate That part of the overall failure rate that does not lead to a dangerous undetected failure.
STO Safe Torque Off The Safe Torque Off (STO) function is used to help prevent unexpected motor rotation during an emergency while the drive remains connected to the power supply. When STO is activated, the torque
power cannot reach the drive, which stops and helps prevent any motor shaft rotation.
Abbreviations and Definitions (Continued)
Abbreviation Full Term Definition

Rockwell Automation Publication 35-UM001A-EN-P - May 2022 13
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
Armor PowerFlex AC Drives Fault Codes Reference Data,
publication 35-RD002 Provides a list of Armor PowerFlex drive fault codes.
Armor PowerFlex AC Drives CIP Objects and Attributes Reference Data,
publication 35-RD001 Provides a list of Armor PowerFlex drive CIP® objects and attributes.
Armor PowerFlex Drives Specifications Technical Data, publication 35-TD001 Provides information on product specifications, ratings, certifications, system interface,
and wiring diagrams to aid in product selection.
Armor PowerFlex Motor Controller Product Information, publication 35-PC001 Provides basic information on how to install, configure, and program the Armor PowerFlex
controllers.
On-Machine Media for Armor PowerFlex, ArmorStart, and ArmorConnect
Products Selection Guide, publication 280PWR-SG001 Provides information on product specifications, ratings, certifications, system interface,
wiring diagrams, and dimensions to aid in On-Machine™ media product selection.
EtherNet/IP Device Level Ring Application Technique, publication
ENET-AT007 Describes Device Level Ring (DLR) topologies, configuration considerations, and diagnostic methods.
EtherNet/IP Network Devices User Manual, publication ENET-UM006 Describes how to configure and use EtherNet/IP devices with a Logix 5000® controller and
communicate with various devices on the Ethernet network.
Group Installation Listing Requirements for Drives and Contactor-based
Motor Controllers White Paper, publication 280-WP001 Describes the importance of drives and motor controllers being Listed for group
installations and how to verify if they have been Listed for group installations.
Armor PowerFlex Fan Replacement Kit Installation Instructions, publication
35-IN008 Provides instructions on how to replace the Armor PowerFlex fan.
Logix5000 Controllers Common Procedures Programming Manual,
publication 1756-PM001
Provides access to the Logix 5000 Controllers set of programming manuals. The manuals
cover such topics as how to manage project files, organize tags, program logic, test
routines, handle faults, and more.
Logix5000 Controllers General Instructions Reference Manual, publication
1756-RM003 Provides information on the programming instructions available to use in Logix Designer
application projects.
GuardLogix Safety Application Instruction Set Reference Manual, publication
1756-RM095 Provides information on the GuardLogix Safety application instruction set.
GuardLogix 5570 and Compact GuardLogix 5370 Controller Systems Safety
Reference Manual, publication 1756-RM099 Provides information on safety application requirements for GuardLogix 5570 and Compact GuardLogix 5370 controllers in Studio 5000 Logix Designer® applications.
GuardLogix 5580 and Compact GuardLogix 5380 Controller Systems Safety
Reference, publication 1756-RM012 Provides information on safety application requirements for GuardLogix 5580 and Compact
GuardLogix 5380 controllers in Studio 5000 Logix Designer applications.
GuardLogix 5570 Controllers User Manual, publication 1756-UM022 Provides information on how to use standard Guard Logix 5570 controllers.
ControlLogix 5580 and GuardLogix 5580 Controllers User Manual, publication
1756-UM543 Provides information on how to use standard ControlLogix® 5580 controllers.
Compact GuardLogix 5370 Controllers User Manual, publication 1769-UM022 Provides information on how to use Compact GuardLogix 5370 controllers.
CompactLogix 5380 and Compact GuardLogix 5380 Controllers User Manual,
publication 5069-UM001 Provides information on how to use CompactLogix™ 5380 and Compact
GuardLogix 5380 controllers.
Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives,
publication DRIVES-IN001 Provides information to install, protect, wire, and ground pulse-width modulated (PWM) AC drives.
System Design for Control of Electrical Noise Reference Manual, publication
GMC-RM001 Information, examples, and techniques that are designed to minimize system failures
caused by electrical noise.
Safety Automation Builder and SISTEMA Library
Download Safety Automation Builder® software to help simplify machine safety design and
validation, and reduce time and costs.
The SISTEMA tool, also available for download from the Safety Automation Builder page,
automates calculation of the attained Performance Level from the safety-related parts of a
machine’s control system to (EN) ISO 13849-1.
Ethernet Reference Manual publication, ENET-RM002 Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
CIP Security with Rockwell Automation Products Application Technique,
publication SECURE-AT001 Provides information on CIP Security™, including which Rockwell Automation products
support CIP Security.
System Security Design Guidelines Reference Manual publication,
SECURE-RM001
Provides guidance on how to conduct security assessments, implement Rockwell
Automation® products in a secure system, harden the control system, manage user access,
and dispose of equipment.
American Standards, Configurations, and Ratings: Introduction to
Motor Circuit Design, publication IC-AT001 Provides an overview of American motor circuit design based on methods that are outlined in the NEC®.
Industrial Components Preventive Maintenance, Enclosures, and Contact
Ratings Specifications, publication IC-TD002 Provides a quick reference tool for Allen-Bradley® industrial automation controls and
assemblies.

14 Rockwell Automation Publication 35-UM001A-EN-P - May 2022
You can view or download publications at rok.auto/literature.
CE Conformity CE Declarations of Conformity are available online at: rok.auto/certifications.
The Armor PowerFlex drive when installed and maintained in accordance with
the instructions in this document, is in conformity with the essential
requirements of these directives:
• 2006/42/EC Machinery Directive
• 2014/30/EU EMC Directive
• 2014/35/EU Low Voltage Directive
• 2011/65/EU RoHS Directive
•2009/125/ECEcodesignDirective
The following standards have been applied to demonstrate conformity.
Machinery Directive (2006/42/EC)
• EN ISO 13849-1 Safety of machinery - Safety related parts of control
systems - Part 1: General principles for design
• EN 60204-1 Safety of machinery - Electrical equipment of machines -
Part 1: General requirements
• EN 62061 Safety of machinery - Functional safety of safety-related
electrical, electronic, and programmable electronic control systems
• EN 61800-5-2 Adjustable speed electrical power drive systems - Part 5- 2:
Safety requirement - Functional
• IEC 61508 Part 1…7 Functional safety of electrical/electronic/
programmable electronic safety-related systems
EMC Directive (2014/30/EU)
• EN 61800-3 Adjustable speed electric power drive systems - Part 3: EMC
requirements and specific test methods
LVD Directive (2014/35/EU)
• EN 61800-5 -1 Adjustable speed electrical power drive systems - Part 5-1:
Safety requirements – Electrical, thermal and energy (LVD)
RoHS Directive (2011/65/EU)
• EN 63000:2018 Technical documentation for the assessment of electrical
and electronic products with respect to the restriction of hazardous
substances
Ecodesign Directive (2019/1781)
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Safety Guidelines for the Application, Installation, and Maintenance of
Solid-state Control, publication SGI-1.1
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides
general guidelines for the application, installation, and maintenance of solid-state control in
the form of individual devices or packaged assemblies incorporating solid-state
components.
Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details.
Resource Description

Rockwell Automation Publication 35-UM001A-EN-P - May 2022 15
Chapter 1
Armor PowerFlex Variable Frequency Drives
Overview
Description The Armor™ PowerFlex® unit is a variable frequency drive (VFD) and is suited
for variable frequency applications where more precise motor control is
needed. The Armor PowerFlex drives are available in integrated safety
(Bulletin 35S) and standard (Bulletin 35E) versions.
All Armor PowerFlex drives feature an embedded dual-port EtherNet/IP™
switch, which supports star, linear, and DLR topologies.
The Armor PowerFlex drive provides an IP54/66, UL Type 4/12, and NEMA 4/12
enclosure design, which is suitable for water wash down environments, when
appropriate cables are attached or sealing caps are in place.
Fault diagnostic capabilities, including status indicators, are built in to the
Armor PowerFlex drive to help you pinpoint a problem for easy
troubleshooting and quick restarting.
Input and Outputs
All Armor PowerFlex drives include four standard inputs and two standard
configurable I/Os.
The Armor PowerFlex safety drive includes: two test outputs, four safety
inputs, and one bipolar safety output.
IMPORTANT The Armor PowerFlex drive ships with a rubber sealing boot
which is required to be installed when the power OUT connection
is not in use. (This scenario could apply when daisy chaining is
not in use or when the drive is the last unit in the daisy chain).
When installed, this rubber sealing boot provides an IP54 rating
to the power OUT connection. If a greater IP rating is required, for
example IP66, appropriately rated sealing caps are required to be
installed. For selection information, see Accessories in the
On-Machine Media for Armor PowerFlex, ArmorStart, and
ArmorConnect Products Selection Guide,
publication 280PWR-SG001.
Table 1 - Product Overview
Type Bulletin Inputs and Outputs On-board Safety Inputs
and Outputs
Armor PowerFlex with integrated safety on EtherNet/
IP network 35S 4 inputs
2 configurable I/Os
1 bipolar safety output
4 safety inputs
Armor PowerFlex on EtherNet/IP network 35E —

16 Rockwell Automation Publication 35-UM001A-EN-P - May 2022
Chapter 1 Armor PowerFlex Variable Frequency Drives Overview
Frame Size
The Armor PowerFlex drive is available in Frame size A.
For additional specifications see Armor PowerFlex AC Drives Specifications
Technical Data, publication 35-TD001.
Safety Functions
The Armor PowerFlex safety version (35S) is capable of hard-wired and
integrated safety. In hardwired mode, Safe Torque Off (STO) can be used.
Integrated safety supports Safe Torque Off (STO), integrated drive-based Safe
Stop functions and integrated controller-based Safe Monitor functions. See
Chapter 6, for details.
Table 2 - Frame Sizes
Frame Output
Current Input Voltage
Dimensions, approx.
Size Rating Diagram Width,
max. Depth, max. Height, max.
A
1 Hp
(0.75 kW) 2.3 A
380…480V AC 16.0 in.
(40.6 cm) 5.67 in. (14.4 cm) 8.0 in. (20.3 cm)
2 Hp
(1.5 kW) 4.0 A
3 Hp
(2.2 kW) 6.0 A
H
W
D

Rockwell Automation Publication 35-UM001A-EN-P - May 2022 17
Chapter 1 Armor PowerFlex Variable Frequency Drives Overview
Location of Features
Figure 1 - Bulletin 35E Armor PowerFlex Standard VFD
Figure 2 - Bulletin 35S Armor PowerFlex with Integrated Safety VFD
Standard I/Os
Gigabit Ethernet Port
Status Indicators
24V DC Auxiliary Power OUT
24V DC Auxiliary
Power IN
3-phase Power IN
3-phase Power OUT
Encoder
Local Disconnect
Configurable I/O
With internal power supply Without internal power supply
Jog and Direction
Dynamic Brake Connection
Motor and Electromechanical Brake Connection
Standard I/Os
Gigabit Ethernet Port
Status Indicators
3-phase Power IN
3-phase Power OUT
Encoder
Local Disconnect
Configurable I/O
Jog and Direction
Dynamic Brake Connection
Gigabit Ethernet Port
Motor and Electromechanical
Brake Connection
Safety I/Os
With internal power supply Without internal power supply
Standard I/Os
Status Indicators
24V DC Auxiliary Power OUT
24V DC Auxiliary
Power IN
3-phase Power IN
3-phase Power OUT
Encoder
Local Disconnect
Configurable I/O
Jog and Direction
Dynamic Brake Connection
Gigabit Ethernet Port
Safety I/Os
Standard I/Os
Gigabit Ethernet Port
Status Indicators
Encoder Local Disconnect
Configurable I/O
Jog and Direction
Motor and Electromechanical Brake Connection
3-phase Power IN 3-phase Power OUT
Dynamic Brake Connection
Motor and Electromechanical
Brake Connection

18 Rockwell Automation Publication 35-UM001A-EN-P - May 2022
Chapter 1 Armor PowerFlex Variable Frequency Drives Overview
Catalog Number Explanation
Examples that are given in this section are not intended to be used for product
selection. Not all combinations produce a valid catalog number. Use
ProposalWorks™ software to configure the Armor PowerFlex Drive.
ProposalWorks software is available from rok.auto/systemtools.
Catalog Number Explanation for Bulletin 35 Armor PowerFlex VFDs
Required Software Table 3 lists the software that is required to operate Armor PowerFlex drives.
Studio 5000 Logix Designer® application is the single software that is used for
setup and commissioning. It’s accomplished through the installation and use
of an Add-on Profile (AOP) downloaded from Product Compatibility and
Download Center (PCDC). See page 11 for more information.
35 S - 6 D 1 - L 2 1 1
abcdefghi
abcd
Bulletin Number Type Enclosure Type Line Voltage
Code Description Code Description Code Description Code Description
35 Armor PowerFlex Drive S Integrated Safety version 6 IP54/66, Type 1/4/12,
NEMA Type 1/4/12 D480Y/277VAC,50/60Hz
E EtherNet/IP
ef ghi
Motor Power Output Rating 24V DC Auxiliary Power Source Power-in Gland EM Brake EMI Filter
Code Description Code Description Code Description Code Description Code Description
1 1 Hp, 0.75 kW, 2.3 A L External 0Cord/conduit 0None 1Included
22Hp,1.5kW,4.0A P Internal 1 Round Quick Connect 1Included
3 3 Hp, 2.2 kW, 6.0 A 2 Square Quick Connect
Table 3 - Armor PowerFlex Drives Required Software
Network Software Version
EtherNet/IP
FactoryTalk® Linx 6.20 or later
Studio 5000® 31.0 or later
Add-on Profile Download the most current version from the Product Compatibility and
Download Center at rok.auto/pcdc
BOOTP/DHCP Utility Version 2.3 or later
(BOOTP is not supported.)
Programmable Controller Firmware Version
35S and 35E
Armor PowerFlex
versions
GuardLogix and Compact GuardLogix controllers (see
page 81 for the listing of compatible controllers) 31.0 or later
35E
Armor PowerFlex
version
ControlLogix and CompactLogix controllers (see
page 81 for the listing of compatible controllers) 31.0 or later

Rockwell Automation Publication 35-UM001A-EN-P - May 2022 19
Chapter 1 Armor PowerFlex Variable Frequency Drives Overview
Motor Control Armor PowerFlex drives provide you with selectable choices for accurate motor
control.
For induction motors, the Control Axis leverages the IEEE recommended
phase-neutral equivalent circuit motor model based on "Wye" configuration.
Reactance values, X, are related to their corresponding Inductance values, L,
by X = wL, where wis the rated frequency of the motor. The prime notation, for
example, X2', R2', indicates that the actual rotor component values X2, and R2
are referenced to the stator side of the stator-to-rotor winding ratio.
Figure 3 - IEEE per Phase Motor Model
Table 4 - IEEE Phase Motor Model Diagram Designations
Control Modes
Velocity control is accomplished via three options for control mode:
• Volts/Hertz (V/Hz)
• Sensorless Vector
•VelocityVector
Volts/Hertz
Volts/Hz control is a simple, low-cost method for controlling variable
frequency drives (VFD), and is generally regarded as the most common VFD
control scheme. It’s suitable for both constant torque and variable torque
applications and can provide up to 150% of the rated torque at zero speed for
startup and peak loads. The magnetic field strength is proportional to the ratio
of voltage (V) to frequency (Hz), or V/Hz. The VFD controls the motor speed by
varying the frequency of the applied voltage, according to the synchronous
speed equation.
Operation in this mode, creates a fixed relationship between output voltage
and output frequency. Voltage is applied to the motor, which is based on the
operating frequency command at a fixed volts/Hertz ratio. The ratio is
calculated from the motor nameplate data.
I1Stator current [Amps]
I2Rotor current [Amps]
R1Stator circuit resistance [Ohms]
R2Stator circuit resistance [Ohms]
X1Stator leakage reactance [Ohms]
X2Rotor circuit reactance [Ohms]
IwMagnetizing current [Amps]
XwMagnetizing reactance [Ohms]
V1Applied stator voltage [Volts]

20 Rockwell Automation Publication 35-UM001A-EN-P - May 2022
Chapter 1 Armor PowerFlex Variable Frequency Drives Overview
Sensorless Vector
Sensorless vector control (SVC) provides better torque production and a wider
speed range than V/Hz. However, it may not be appropriate when more than
one motor is connected to the same drive.
SVC does not have an external sensor to obtain feedback from a motor. SVC
mode monitors the voltage and current of the motor via the already-connected
power leads, and then mathematically determines the motor speed with
optimum accuracy. This is a simpler and less costly solution than installing
and connecting an encoder. While not as good as a dedicated sensor, SVC
provides sufficient feedback in most applications to enable pseudo closed-loop
operation.
SVC uses a V/Hz core that is enhanced by current resolution, a slip estimator, a
high-performance current limiter, and the vector algorithms. The algorithms
operate on the knowledge that motor current is the vector sum of the torque
and flux producing components.
Values can be entered to identify the motor values or an autotune routine can
be run to identify the motor values (see Configure Autotune on page 156).
Velocity Vector
In Velocity Vector Control (VVC), a high bandwidth regulator that separates
and controls the components of stator current, replaces the volts/hertz core
used in V/Hz and SVC control modes. The high bandwidth characteristics of
this control help eliminate nuisance trips due to shock-loads and will
continuously adapt to changes in the motor and load characteristics.
A separate adaptive controller uses information gained during auto tuning;
actual reference information and motor feedback information, to give
independent torque and flux control. This allows continuous regulation of the
motor speed and improved overall control. For the Armor PowerFlex drive, this
mode should be operated with feedback to provide the fastest response to load
changes.
A rotate tune must be done in order to provide the optimal motor velocity
control using vector mode (see Configure Autotune on page 156).
Velocity Control
Velocity control refers to controlling the speed of a connected motor.
Acceleration and deceleration times can be specified, which indicate the time
it should take the velocity to go from zero to the rated speed of the motor (or
vice versa). From these times, actual acceleration/deceleration values (rates)
can be calculated and the motor output controlled to meet these desired values.
Velocity control also allows the rate of change of acceleration and deceleration
(also known as "jerk") to be adjusted. This control function is known as S-
Curve. By enabling/configuring the S-Curve function, the transition between
velocities can be made smoother by not immediately applying or removing the
desired acceleration/deceleration rate.
When S Curve is enabled, it adds time to the overall acceleration by a
percentage of the programmed acceleration time. This is shown in the curve in
Figure 4 which represents 0%, 25%, 50%, and 100% S Curve. Note that half of
the “S” is added to the beginning and half is added to the end of the ramp.