Rockwell Automation Allen Bradley PowerFlex40 User manual

Adjustable
Frequency AC
Drive
FRN 1.xx - 7.xx
User Manual
www.abpowerflex.com
22B-UM001.book Page 1 Tuesday, May 30, 2017 5:22 PM

PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application, Installation
and Maintenance of Solid State Controls (Publication SGI-1.1 available from your
local Rockwell Automation sales office or online at http://
www.rockwellautomation.com/literature) describes some important differences
between solid state equipment and hard-wired electromechanical devices. Because
of this difference, and also because of the wide variety of uses for solid state
equipment, all persons responsible for applying this equipment must satisfy
themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of
information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety
considerations.
Important: Identifies information that is critical for successful application and
understanding of the product.
Allen-Bradley, Rockwell Automation, and PowerFlex are registered trademarks of Rockwell Automation, Inc.
DriveExplorer and DriveExecutive are 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 the hazard
•recognize the consequences
Shock Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that surfaces may be at dangerous
temperatures.
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PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Summary of Changes
Manual Updates
The information below summarizes the changes to the PowerFlex 40
User Manual since the June 2013 release.
The information below summarizes the changes to the PowerFlex 40
User Manual since the August 2008 release.
The information below summarizes the changes to the PowerFlex 40
User Manual since the April 2008 release.
The information below summarizes the changes to the PowerFlex 40
User Manual since the January 2007 release.
Description of New or Updated Information Page(s)
Certifications for Australian RCM and CE Directives updated. 1-25,
A-3
Certifications for EAC, KCC, and NSF/ANSI added. A-3
Description of New or Updated Information Page(s)
Minimum Enclosure Volume column and new footnotes added. 1-9, A-2
Drive, Fuse & Circuit Breaker Ratings topic updated. A-1
Electronic Motor Overload Protection description updated. A-4
Description of New or Updated Information Page(s)
Description of A056 revised. 3-17
Description of A059/A062 revised. 3-19
Fault description for F3 revised. 4-3
A table row for electrical specifications added. A-4
Graphic for the “Network Wiring” section revised. C-1
Second last paragraph in the “Network Wiring” section revised. C-2
Text in the “Writing (06) Logic Command Data” section revised. C-4
Frequency source for logic command 001 of bits 14, 13, and 12 corrected. C-4
Text in the “Writing (06) Reference” section revised. C-5
Description of New or Updated Information Page(s)
Input description and attention text for Multiple Digital Input Connection
example corrected.
1-22
New method of changing speed reference for IP66, NEMA/UL Type 4X rated
drives described.
2-2
Description for Up Arrow and Down Arrow keys revised. 2-4
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soc-2
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Parameter Updates
The following parameters have been updated with firmware version 6.xx.
The following parameters have been updated with firmware version 5.xx.
New Parameter
The following parameter has been added with firmware version 5.xx.
Fault description for F3 revised. 4-3
Graphic for the “Network Wiring” section revised. C-1
Descriptions for bits 6, 7, and 15 of register address 8192 (Logic Command)
updated.
C-4
New information on reading register address 8192 added. C-4
New information on reading register address 8193 added. C-5
Graphic for the “Connecting an RS-485 Network” section corrected. D-4
New method for inverting sign of PID error added. F-6
Parameter Number Description Page
[Relay Out Sel] A055 Function of option 20, ParamControl,
changed.
Option 24, MsgControl, added.
3-16
[Relay Out Sel] A058, A061 Function of option 20, ParamControl,
changed.
Option 24, MsgControl, added.
3-18
Parameter Number Description Page
[Control Source] d012 Options 7 and 8 added. 3-5
[Start Source] P036 Description revised for option 6. 3-10
[Relay Out Sel] A055 Description revised for option 20. 3-16
[Relay Out Level] A056 Description revised. 3-17
[Opto Outx Sel] A058, A061 Description revised for option 20. 3-18
[Opto Outx Level] A059, A062 Description revised. 3-19
[Internal Freq] A069 Default value for IP66, NEMA/
UL Type 4X drives is 0.0 Hz.
Default value for IP20 rated drives is
60.0 Hz.
3-22
[PID Trim Hi] A130 Description revised. 3-38
[PID Trim Lo] A131 Description revised. 3-38
Parameter Number Description Page
[PID Invert Error] A167 New 3-44
Description of New or Updated Information Page(s)
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PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Table of Contents
Preface Overview
Who Should Use this Manual? . . . . . . . . . P-1
Reference Materials . . . . . . . . . . . . . . . . . P-1
Manual Conventions . . . . . . . . . . . . . . . . . P-2
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . P-2
General Precautions . . . . . . . . . . . . . . . . . P-3
Catalog Number Explanation . . . . . . . . . . P-4
Chapter 1 Installation/Wiring
Opening the Cover . . . . . . . . . . . . . . . . . . 1-1
Mounting Considerations . . . . . . . . . . . . . 1-3
AC Supply Source Considerations . . . . . . 1-5
General Grounding Requirements . . . . . . 1-7
Fuses and Circuit Breakers . . . . . . . . . . . . 1-8
Power Wiring . . . . . . . . . . . . . . . . . . . . . 1-10
IP66, NEMA/UL Type 4X Installations . 1-14
I/O Wiring Recommendations . . . . . . . . 1-14
Start and Speed Reference Control . . . . . 1-23
EMC Instructions . . . . . . . . . . . . . . . . . . 1-25
Chapter 2 Start Up
Prepare For Drive Start-Up . . . . . . . . . . . . 2-1
Integral Keypad. . . . . . . . . . . . . . . . . . . . . 2-4
Viewing and Editing Parameters. . . . . . . . 2-5
Remote HIM Menu Structure . . . . . . . . . . 2-6
Chapter 3 Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . 3-1
Parameter Organization. . . . . . . . . . . . . . . 3-2
Display Group . . . . . . . . . . . . . . . . . . . . . . 3-3
Basic Program Group . . . . . . . . . . . . . . . . 3-9
Advanced Program Group. . . . . . . . . . . . 3-14
Parameter Cross Reference – by Name. . 3-45
Chapter 4 Troubleshooting
Drive Status. . . . . . . . . . . . . . . . . . . . . . . . 4-1
Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fault Descriptions . . . . . . . . . . . . . . . . . . . 4-3
Common Symptoms and Corrective Actions . .
4-5
Appendix A Supplemental Drive Information
Drive, Fuse & Circuit Breaker Ratings . . . A-1
Specifications . . . . . . . . . . . . . . . . . . . . . . A-2
Appendix B Accessories and Dimensions
Product Selection . . . . . . . . . . . . . . . . . . . B-1
Product Dimensions . . . . . . . . . . . . . . . . . B-7
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2Table of Contents
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Appendix C RS485 (DSI) Protocol
Network Wiring. . . . . . . . . . . . . . . . . . . . . C-1
Parameter Configuration . . . . . . . . . . . . . . C-3
Supported Modbus Function Codes . . . . . C-3
Writing (06) Logic Command Data. . . . . . C-4
Writing (06) Reference . . . . . . . . . . . . . . . C-5
Reading (03) Logic Status Data. . . . . . . . . C-5
Reading (03) Feedback . . . . . . . . . . . . . . . C-6
Reading (03) Drive Error Codes . . . . . . . . C-6
Reading (03) and Writing (06) Drive
Parameters . . . . . . . . . . . . . . . . . . . . . . . C-7
Additional Information . . . . . . . . . . . . . . . C-7
Appendix D RJ45 DSI Splitter Cable
Connectivity Guidelines . . . . . . . . . . . . . . D-1
DSI Cable Accessories . . . . . . . . . . . . . . . D-2
Connecting One Temporary Peripheral . . . D-3
Connecting One Temporary Peripheral and
One Permanent Peripheral . . . . . . . . . . . D-3
Connecting Two Permanent Peripherals . . D-4
Connecting an RS-485 Network . . . . . . . . D-4
Appendix E StepLogic, Basic Logic and
Timer/Counter Functions
StepLogic Using Timed Steps . . . . . . . . . . E-2
StepLogic Using Basic Logic Functions . . E-3
Timer Function . . . . . . . . . . . . . . . . . . . . . E-4
Counter Function. . . . . . . . . . . . . . . . . . . . E-6
Appendix F PID Set Up
PID Loop . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
PID Reference and Feedback . . . . . . . . . . F-4
Analog PID Reference Signals . . . . . . . . . F-5
Index
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PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Preface
Overview
The purpose of this manual is to provide you with the basic information
needed to install, start-up and troubleshoot the PowerFlex 40 Adjustable
Frequency AC Drive.
This manual is intended for qualified personnel. You must be able to
program and operate Adjustable Frequency AC Drive devices. In
addition, you must have an understanding of the parameter settings and
functions.
The following manuals are recommended for general drive information:
For information on… See page…
Who Should Use this Manual? P-1
Reference Materials P-1
Manual Conventions P-2
Drive Frame Sizes P-2
General Precautions P-3
Catalog Number Explanation P-4
Who Should Use this Manual?
Reference Materials
Title Publication Available Online at …
Wiring and Grounding
Guidelines for Pulse Width
Modulated (PWM) AC Drives
DRIVES-IN001…
www.rockwellautomation.com/
literature
Preventive Maintenance of
Industrial Control and Drive
System Equipment
DRIVES-TD001…
Safety Guidelines for the
Application, Installation and
Maintenance of Solid State
Control
SGI-1.1
A Global Reference Guide for
Reading Schematic Diagrams
100-2.10
Guarding Against Electrostatic
Damage
8000-4.5.2
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P-2 Overview
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
•In this manual we refer to the PowerFlex 40 Adjustable Frequency
AC Drive as; drive, PowerFlex 40 or PowerFlex 40 Drive.
•Parameter numbers and names are shown in this format:
•The following words are used throughout the manual to describe an
action:
Similar PowerFlex 40 drive sizes are grouped into frame sizes to
simplify spare parts ordering, dimensioning, etc. A cross reference of
drive catalog numbers and their respective frame sizes is provided in
Appendix B.
Manual Conventions
P031 [Motor NP Volts]
Name
Number
Group
d = Display Group
P = Basic Program Group
A = Advanced Program Group
Word Meaning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Must Unavoidable, you must do this
Shall Required and necessary
Should Recommended
Should Not Not Recommended
Drive Frame Sizes
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Overview P-3
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
General Precautions
!
ATTENTION: The drive contains high voltage capacitors which take
time to discharge after removal of mains supply. Before working on
drive, ensure isolation of mains supply from line inputs [R, S, T (L1,
L2, L3)]. Wait three minutes for capacitors to discharge to safe voltage
levels. Failure to do so may result in personal injury or death.
Darkened display LEDs is not an indication that capacitors have
discharged to safe voltage levels.
!
ATTENTION: Only qualified personnel familiar with adjustable
frequency AC drives and associated machinery should plan or
implement the installation, start-up and subsequent maintenance of the
system. Failure to comply may result in personal injury and/or
equipment damage.
!
ATTENTION: This drive contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Static control precautions are required
when installing, testing, servicing or repairing this assembly.
Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures,
reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic
Damage” or any other applicable ESD protection handbook.
!
ATTENTION: An incorrectly applied or installed drive can result in
component damage or a reduction in product life. Wiring or application
errors, such as, undersizing the motor, incorrect or inadequate AC
supply, or excessive ambient temperatures may result in malfunction of
the system.
!
ATTENTION: The bus regulator function is extremely useful for
preventing nuisance overvoltage faults resulting from aggressive
decelerations, overhauling loads, and eccentric loads. However, it can
also cause either of the following two conditions to occur.
1. Fast positive changes in input voltage or imbalanced input voltages
can cause uncommanded positive speed changes;
2. Actual deceleration times can be longer than commanded
deceleration times
However, a “Stall Fault” is generated if the drive remains in this state
for 1 minute. If this condition is unacceptable, the bus regulator must be
disabled (see parameter A117). In addition, installing a properly sized
dynamic brake resistor will provide equal or better performance in most
cases.
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P-4 Overview
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Catalog Number Explanation
Code Voltage Ph.
V 120V AC 1
A 240V AC 1
B 240V AC 3
D 480V AC 3
E 600V AC 3
Code Version
3 No Brake IGBT
4 Standard
Code Interface Module
1 Fixed Keypad
Code Enclosure
N Panel Mount - IP20, NEMA/UL Type Open
C Panel Mount - IP66, NEMA/UL Type 4X
F Flange Mount - IP20, NEMA/UL Type Open
H Replacement Plate Drive - IP20, NEMA/UL Type Open
- Contact factory for ordering information.
1-3 4 5 6-8 9 10 11 12 (1) 13-14
22B - A 1P5 N 1 1 4 AA
Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Type Optional
Output Current
@ 100-120V 50/60 Hz Input
Code Amps kW (HP)
2P3 2.3 0.4 (0.5)
5P0 5.0 0.75 (1.0)
6P0 6.0 1.1 (1.5)
Code Rating
0 Not Filtered
1Filtered
Output Current
@ 380-480V 50/60 Hz Input
Code Amps kW (HP)
1P4 1.4 0.4 (0.5)
2P3 2.3 0.75 (1.0)
4P0 4.0 1.5 (2.0)
6P0 6.0 2.2 (3.0)
010 10.5 4.0 (5.0)
012 12 5.5 (7.5)
017 17 7.5 (10)
024 24 11 (15)
Code
22B PowerFlex 40
Additional accessories, options and adapters are available. See Appendix B for details.
Output Current
@ 500-600V 50/60 Hz Input
Code Amps kW (HP)
1P7 1.7 0.75 (1.0)
3P0 3.0 1.5 (2.0)
4P2 4.2 2.2 (3.0)
6P6 6.6 4.0 (5.0)
9P9 9.9 5.5 (7.5)
012 12.2 7.5 (10)
019 19 11 (15)
Code Purpose
AA Reserved for
thru custom firmware
ZZ
Output Current
@ 200-240V 50/60 Hz Input
Code Amps kW (HP)
2P3 2.3 0.4 (0.5)
5P0 5.0 0.75 (1.0)
8P0 8.0 1.5 (2.0)
012 12 2.2 (3.0)
017 17.5 3.7 (5.0)
024 24 5.5 (7.5)
033 33 7.5 (10)
(1) Position 12 of the Catalog Number now indicates drive type. All PowerFlex 40
drives are equipped with RS485 communication.
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PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Chapter 1
Installation/Wiring
This chapter provides information on mounting and wiring the
PowerFlex 40 Drive.
Most start-up difficulties are the result of incorrect wiring. Every
precaution must be taken to assure that the wiring is done as instructed.
All items must be read and understood before the actual installation
begins.
IP20, NEMA/UL Type Open
1. Press and hold in the tabs on each side of the cover.
2. Pull the cover out and up to release.
For information on… See page For information on… See page
Opening the Cover 1-1 Fuses and Circuit Breakers 1-8
Mounting Considerations 1-3 Power Wiring 1-10
AC Supply Source Considerations 1-5 I/O Wiring
Recommendations
1-14
General Grounding Requirements 1-7 EMC Instructions 1-25
!
ATTENTION: The following information is merely a guide for proper
installation. Rockwell Automation, Inc. cannot assume responsibility
for the compliance or the noncompliance to any code, national, local or
otherwise for the proper installation of this drive or associated
equipment. A hazard of personal injury and/or equipment damage
exists if codes are ignored during installation.
Opening the Cover
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1-2 Installation/Wiring
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
IP66, NEMA/UL Type 4X
1. Loosen the four captive cover screws.
2. Pull cover straight off chassis.
IP66, NEMA/UL Type 4X Cover Installation
1. Squarely align the cover on the chassis.
2. Lightly tighten the four captive cover screws.
3. Torque the cover screws using an alternating pattern.
!
ATTENTION: To avoid an electric shock hazard, ensure isolation of
mains supply from line inputs [R, S, T (L1, L2, L3)] and wait three
minutes for capacitors to discharge before removing the external cover.
Once the cover is removed, verify that the voltage on the bus capacitors
has discharged before performing any work on the drive. Measure the
DC bus voltage at the DC– and DC+ terminals on the Power Terminal
Block (refer to page 1-13 for Power Terminal descriptions). The voltage
must be zero.
1
3
4
2
0.8±0.2 N-m
(7.0 ±2.0 lb.-in.)
2
1
3
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Installation/Wiring 1-3
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
•Mount the drive upright on a flat, vertical and level surface.
•Protect the cooling fan by avoiding dust or metallic particles.
•Do not expose to a corrosive atmosphere.
•Protect from moisture and direct sunlight.
Minimum Mounting Clearances
Refer to Appendix B for mounting dimensions.
Ambient Operating Temperatures
Table 1.A Enclosure and Clearance Requirements
Mounting Considerations
Frame Screw Size Screw Torque DIN Rail
B M4 (#8-32) 1.56-1.96 N-m (14-17 lb.-in.) 35 mm
C M5 (#10-24) 2.45-2.94 N-m (22-26 lb.-in.) –
B (IP66,
Type 4X) M6 (#12-24) 3.95-4.75 N-m (35-42 lb.-in.) –
Ambient Temperature Enclosure Rating Minimum Mounting
Clearances
Minimum Maximum
-10°C (14°F) 40°C (104°F)
IP20, NEMA/UL Type Open Use Mounting Option A
IP66, NEMA/UL Type 4X Use Mounting Option A
IP30, NEMA/UL Type 1(1)
(1) Rating requires installation of the PowerFlex 40 IP30, NEMA/UL Type 1 option kit.
Use Mounting Option B
50°C (122°F) IP20, NEMA/UL Type Open Use Mounting Option B
25 mm
(1.0 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
Mounting Option A
No clearance required
between drives.
Mounting Option B
Closest object that
may restrict air flow
through the drive heat
sink and chassis
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1-4 Installation/Wiring
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Debris Protection
A plastic top panel is included with the drive. Install the panel to prevent
debris from falling through the vents of the drive housing during
installation. Remove the panel for IP20, NEMA/UL Type Open
applications.
Storage
•Store within an ambient temperature range of -40° to +85°C.
•Store within a relative humidity range of 0% to 95%,
non-condensing.
•Do not expose to a corrosive atmosphere.
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Installation/Wiring 1-5
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Ungrounded Distribution Systems
Disconnecting MOVs
To prevent drive damage, the MOVs connected to ground shall be
disconnected if the drive is installed on an ungrounded distribution
system where the line-to-ground voltages on any phase could exceed
125% of the nominal line-to-line voltage. To disconnect these devices,
remove the jumper shown in the Figures 1.1 and 1.2.
1. Turn the screw counterclockwise to loosen.
2. Pull the jumper completely out of the drive chassis.
3. Tighten the screw to keep it in place.
Figure 1.1 Jumper Location (Typical)
Figure 1.2 Phase to Ground MOV Removal
AC Supply Source Considerations
!
ATTENTION: PowerFlex 40 drives contain protective MOVs that are
referenced to ground. These devices must be disconnected if the drive is
installed on an ungrounded or resistive grounded distribution system.
Important: Tighten screw after jumper removal.
IP66, NEMA/UL Type 4XIP20, NEMA/UL Type Open
R/L1
S/L2
T/L3
1234
Three-Phase
AC Input
Jumper
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1-6 Installation/Wiring
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Input Power Conditioning
The drive is suitable for direct connection to input power within the rated
voltage of the drive (see Appendix A). Listed in Table 1.B are certain
input power conditions which may cause component damage or
reduction in product life. If any of the conditions exist, as described in
Table 1.B, install one of the devices listed under the heading Corrective
Action on the line side of the drive.
Important: Only one device per branch circuit is required. It should be
mounted closest to the branch and sized to handle the total
current of the branch circuit.
Table 1.B Input Power Conditions
Input Power Condition Corrective Action
Low Line Impedance (less than 1% line reactance) •Install Line Reactor(2)
•or Isolation Transformer
•or Bus Inductor – 5.5 & 11 kW
(7.5 & 15 HP) drives only
(2) Refer to Appendix B for accessory ordering information.
Greater than 120 kVA supply transformer
Line has power factor correction capacitors •Install Line Reactor
•or Isolation Transformer
Line has frequent power interruptions
Line has intermittent noise spikes in excess of
6000V (lightning)
Phase to ground voltage exceeds 125% of normal
line to line voltage
•Remove MOV jumper to ground.
•or Install Isolation Transformer
with grounded secondary if
necessary.
Ungrounded distribution system
240V open delta configuration (stinger leg)(1)
(1) For drives applied on an open delta with a middle phase grounded neutral system, the
phase opposite the phase that is tapped in the middle to the neutral or earth is
referred to as the “stinger leg,” “high leg,” “red leg,” etc. This leg should be identified
throughout the system with red or orange tape on the wire at each connection point.
The stinger leg should be connected to the center Phase B on the reactor. Refer to
Table B.D for specific line reactor part numbers.
•Install Line Reactor
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Installation/Wiring 1-7
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
The drive Safety Ground - (PE) must be connected to system
ground. Ground impedance must conform to the requirements of
national and local industrial safety regulations and/or electrical codes.
The integrity of all ground connections should be periodically checked.
Figure 1.3 Typical Grounding
Ground Fault Monitoring
If a system ground fault monitor (RCD) is to be used, only Type B
(adjustable) devices should be used to avoid nuisance tripping.
Safety Ground - (PE)
This is the safety ground for the drive that is required by code. One of
these points must be connected to adjacent building steel (girder, joist), a
floor ground rod or bus bar. Grounding points must comply with national
and local industrial safety regulations and/or electrical codes.
Motor Ground
The motor ground must be connected to one of the ground terminals on
the drive.
Shield Termination - SHLD
Either of the safety ground terminals located on the power terminal
block provides a grounding point for the motor cable shield. The motor
cable shield connected to one of these terminals (drive end) should also
be connected to the motor frame (motor end). Use a shield terminating or
EMI clamp to connect the shield to the safety ground terminal. The
conduit box option may be used with a cable clamp for a grounding point
for the cable shield.
When shielded cable is used for control and signal wiring, the shield
should be grounded at the source end only, not at the drive end.
General Grounding Requirements
SHLD
U/T1
V/T2
W/T3
R/L1
S/L2
T/L3
22B-UM001.book Page 7 Tuesday, May 30, 2017 5:22 PM

1-8 Installation/Wiring
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
RFI Filter Grounding
Using single phase drives with integral filter, or an external filter with
any drive rating, may result in relatively high ground leakage currents.
Therefore, the filter must only be used in installations with grounded
AC supply systems and be permanently installed and solidly
grounded (bonded) to the building power distribution ground. Ensure
that the incoming supply neutral is solidly connected (bonded) to the
same building power distribution ground. Grounding must not rely on
flexible cables and should not include any form of plug or socket that
would permit inadvertent disconnection. Some local codes may require
redundant ground connections. The integrity of all connections should be
periodically checked.
The PowerFlex 40 does not provide branch short circuit protection. This
product should be installed with either input fuses or an input circuit
breaker. National and local industrial safety regulations and/or electrical
codes may determine additional requirements for these installations.
Fusing
The PowerFlex 40 has been UL tested and approved for use with input
fuses. The ratings in the table that follows are the minimum
recommended values for use with each drive rating. The devices listed in
this table are provided to serve as a guide.
Bulletin 140M (Self-Protected Combination Controller)/UL489
Circuit Breakers
When using Bulletin 140M or UL489 rated circuit breakers, the
guidelines listed below must be followed in order to meet the NEC
requirements for branch circuit protection.
•Bulletin 140M can be used in single and group motor applications.
•Bulletin 140M can be used up stream from the drive without the
need for fuses.
Fuses and Circuit Breakers
!
ATTENTION: To guard against personal injury and/or equipment
damage caused by improper fusing or circuit breaker selection, use only
the recommended line fuses/circuit breakers specified in this section.
22B-UM001.book Page 8 Tuesday, May 30, 2017 5:22 PM

Installation/Wiring 1-9
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Table 1.C Minimum Recommended Branch Circuit Protective Devices
Voltage
Rating
Drive Rating
kW (HP)
Fuse Rating(1)
Amps
140M Motor
Protectors(2) (3)
Catalog No.
Recommended
MCSContactors
Catalog No.
Min. Enclosure
Volume(4)
Inches3
120V AC –
1-Phase
0.4 (0.5)
0.75 (1.0)
1.1 (1.5)
15
35
40
140M-C2E-C16
140M-D8E-C20
140M-F8E-C32
100-C12
100-C23
100-C37
1655
1655
1655
240V AC –
1-Phase
0.4 (0.5)
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
10
20
30
40
140M-C2E-B63
140M-C2E-C16
140M-D8E-C20
140M-F8E-C32
100-C09
100-C12
100-C23
100-C37
1655
1655
1655
2069
240V AC –
3-Phase
0.4 (0.5)
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
3.7 (5.0)
5.5 (7.5)
7.5 (10.0)
6
10
15
25
30
40
60
140M-C2E-B40
140M-C2E-C10
140M-C2E-C16
140M-C2E-C16
140M-F8E-C25
140M-F8E-C32
140M-G8E-C45
100-C07
100-C09
100-C12
100-C23
100-C23
100-C37
100-C60
1655
1655
1655
1655
1655
2069
2069
480V AC –
3-Phase
0.4 (0.5)
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
4.0 (5.0)
5.5 (7.5)
7.5 (10.0)
11 (15)
3
6
10
15
20
25
30
50
140M-C2E-B25
140M-C2E-B40
140M-C2E-B63
140M-C2E-C10
140M-C2E-C16
140M-D8E-C20
140M-D8E-C20
140M-F8E-C32
100-C07
100-C07
100-C09
100-C09
100-C23
100-C23
100-C23
100-C43
1655
1655
1655
1655
1655
2069
2069
2069
600V AC –
3-Phase
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
4.0 (5.0)
5.5 (7.5)
7.5 (10.0)
11 (15)
6
6
10
15
20
25
40
140M-C2E-B25
140M-C2E-B40
140M-D8E-B63
140M-D8E-C10
140M-D8E-C16
140M-D8E-C16
140M-F8E-C25
100-C09
100-C09
100-C09
100-C09
100-C16
100-C23
100-C30
1655
1655
1655
1655
2069
2069
2069
(1) Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.
(2) The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See Bulletin 140M
Motor Protection Circuit Breakers Application Ratings.
(3) Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 208 Wye or Delta, 240
Wye or Delta, 480Y/277 or 600Y/347. Not UL listed for use on 480V or 600V Delta/Delta, corner
ground, or high-resistance ground systems.
(4) When using a Manual Self-Protected (Type E) Combination Motor Controller, the drive must be
installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this
column. Application specific thermal considerations may require a larger enclosure.
22B-UM001.book Page 9 Tuesday, May 30, 2017 5:22 PM

1-10 Installation/Wiring
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Motor Cable Types Acceptable for 200-600 Volt Installations
A variety of cable types are acceptable for drive installations. For many
installations, unshielded cable is adequate, provided it can be separated
from sensitive circuits. As an approximate guide, allow a spacing of 0.3
meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases,
long parallel runs must be avoided. Do not use cable with an insulation
thickness less than 15 mils (0.4 mm/0.015 in.). Do not route more than
three sets of motor leads in a single conduit to minimize “cross talk”. If
more than three drive/motor connections per conduit are required,
shielded cable must be used.
UL installations in 50°C ambient must use 600V, 75°C or 90°C wire.
UL installations in 40°C ambient should use 600V, 75°C or 90°C wire.
Use copper wire only. Wire gauge requirements and recommendations
are based on 75 degree C. Do not reduce wire gauge when using higher
temperature wire.
Unshielded
THHN, THWN or similar wire is acceptable for drive installation in dry
environments provided adequate free air space and/or conduit fill rates
limits are provided. Do not use THHN or similarly coated wire in wet
areas. Any wire chosen must have a minimum insulation thickness of 15
mils and should not have large variations in insulation concentricity.
Shielded/Armored Cable
Shielded cable contains all of the general benefits of multi-conductor
cable with the added benefit of a copper braided shield that can contain
much of the noise generated by a typical AC Drive. Strong consideration
for shielded cable should be given in installations with sensitive
equipment such as weigh scales, capacitive proximity switches and other
devices that may be affected by electrical noise in the distribution
system. Applications with large numbers of drives in a similar location,
imposed EMC regulations or a high degree of communications /
networking are also good candidates for shielded cable.
Power Wiring
!
ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.)
and local codes outline provisions for safely installing electrical
equipment. Installation must comply with specifications regarding wire
types, conductor sizes, branch circuit protection and disconnect
devices. Failure to do so may result in personal injury and/or equipment
damage.
!
ATTENTION: To avoid a possible shock hazard caused by induced
voltages, unused wires in the conduit must be grounded at both ends.
For the same reason, if a drive sharing a conduit is being serviced or
installed, all drives using this conduit should be disabled. This will help
minimize the possible shock hazard from “cross coupled” power leads.
22B-UM001.book Page 10 Tuesday, May 30, 2017 5:22 PM