Rockwell Automation Allen-Bradley PowerFlex 400 User manual

PowerFlex 400 AC Drive Packages for Fan and Pump
Catalog Number 23C
Installation Instructions
Original Instructions

Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are
required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may
be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
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).

Rockwell Automation Publication 23C-IN001D-EN-P - November 2019 3
Table of Contents
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 1
MainInput Disconnect Package (Style
A/M)
Style Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hardware Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Main Disconnect Switch (DS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Main Circuit Breakers (CB1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Main Fuses (FU1-FU3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Input Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Output Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Control and Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parameter Defaults (Style A/M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Drawing Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
208V AC Input – Main Input Disconnect
Drive Packages (Style A/M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
460V AC – Main Input Disconnect
Drive Packages (Style A/M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Schematic Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Interconnect Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Layout Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Chapter 2
3 Contactor Full Feature Bypass with
Disconnect Package (Style B/N)
Style Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Hardware Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Main Disconnect Switch (DS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Main Circuit Breakers (CB1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Main Fuses (FU1-FU3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Contactors (DIC, DOC, BC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Motor Overload Relay (OL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Control Transformer (T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Bypass Control Interface (CP1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Input Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Output Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Control and Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4Rockwell Automation Publication 23C-IN001D-EN-P - November 2019
Table of Contents
Customer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Freeze/Fire Stat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Autostart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Bypass Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Parameter Defaults (Style B/N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Drawing Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
208V AC – 3 Contactor Full Feature Bypass with
Disconnect Package (Style B/N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
460V AC – 3 Contactor Full Feature Bypass with
Disconnect Package (Style B/N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Schematic Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Interconnect Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Layout Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Chapter 3
Mechanical Installation
Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Maximum Surrounding Air Temperature. . . . . . . . . . . . . . . . . . . . . . 177
Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Lifting and Mounting the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Watts Loss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Chapter 4
Electrical Installation
Power Wire Size Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Power Terminal Block Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Control and Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Installing Input Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Installing Output Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Installing an Optional Transformer or Reactor. . . . . . . . . . . . . . . . . . . . . 187
Installing Fuses for Branch Circuit Protection. . . . . . . . . . . . . . . . . . 188
Installing the Required External/Separate Input Disconnect . . . . 189
Installing Input/Output Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . 189

Rockwell Automation Publication 23C-IN001D-EN-P - November 2019 5
Table of Contents
Appendix A
Supplemental Information
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Appendix B
Replacement Parts
Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Disconnect Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Bypass Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Enclosure Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Appendix C
History of Changes
23C-IN001B-EN-P, June 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
23C-IN001C-EN-P, November 2015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

6Rockwell Automation Publication 23C-IN001D-EN-P - November 2019
Table of Contents
Notes:

Rockwell Automation Publication 23C-IN001D-EN-P - November 2019 7
Summary of Changes
This manual contains new and updated information.
New and Updated
Information
This table contains the changes made to this revision.
Topic Page
Added ATTENTION statement clarifying branch circuit protection. 10
Updated Catalog Number Explanation to comply to current standards. 11
Added statement clarifying branch circuit protection. 13
Replaced Figure 4 with updated branch circuit protection drawing. 25
Replaced Figure 72 with updated branch circuit protection drawing. 105
Update part numbers for the Style A/B Fused Disconnect Packages, Operator Handle for NEMA/UL Type 1,
12, 3R, 4.
194
Added part numbers for Style M/N Circuit Breaker Packages Operator Handle (NEMA/UL Type 1/12) for
Enclosure Options A and H and Operator Handle (NEMA/UL Type 3R/4) for Enclosure Options X and E.
196

8Rockwell Automation Publication 23C-IN001D-EN-P - November 2019
Summary of Changes
Notes:

Rockwell Automation Publication 23C-IN001D-EN-P - November 2019 9
Preface
The purpose of this manual is to provide basic information that is needed to
install, start-up, and troubleshoot PowerFlex® 400 Adjustable Frequency AC
Drive Packages for Fan and Pump Applications.
User documentation for the PowerFlex 400 Drive Packages for Fan and Pump
Applications includes these Installation Instructions and the PowerFlex 400 User
Manual, publication 22C-UM001. Both manuals are required to properly install
and operate the PowerFlex 400 Adjustable Frequency AC Drive Packages for Fan
and Pump Applications.
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 PowerFlex 400 Adjustable Frequency AC Drive Packages for Fan and Pump
Applications Installation Instructions is designed to provide only basic
installation and operation information. For this reason, the following topics have
not been included:
•Specifications
•Troubleshooting
•Startup
•Programming and Parameters
Refer to the PowerFlex 400 User Manual, publication 22C-UM001 for detailed
drive information.
Topic Page
Manual Conventions 10
General Precautions 10
Catalog Number Explanation 11
Additional Resources 12

10 Rockwell Automation Publication 23C-IN001D-EN-P - November 2019
Preface
Manual Conventions •To help differentiate parameter names and LCD display text from other
text, the following conventions will be used:
•Parameter Names appear in [brackets].
For example: [DC Bus Voltage].
•Display Text appear in “quotes.” For example: “Enabled.”
•The following words are used throughout the manual to describe an
action:
General Precautions
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
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 Allen-Bradley® 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 400 User Manual, publication
22C-UM001for test point locations). The voltage must be zero.
ATTENTION: When provided with a circuit breaker, the circuit breaker serves as a
disconnect only. Suitable branch circuit protection, such as fuses, need to be
provided upstream of the circuit breaker.