Post on 17-Nov-2021
Installation Instructions
Adjustable Frequency AC Standard Packaged Drives
Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety considerations.
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.
Important: Identifies information that is critical for successful application and understanding of the product.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you:• identify a hazard• avoid the hazard• recognize the consequences
Shock Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures.
PowerFlex is a registered trademark of Rockwell Automation, Inc.
DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.
PLC is a registered trademark of Rockwell Automation, Inc.
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Table of Contents
Preface OverviewWho Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1What Is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3Compliance Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Chapter 1 PowerFlex 40 Standard Packaged Drive Standard Features and OptionsChapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Enclosure Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Power Disconnect Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Operator Device Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9Quick Disconnects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13I/O Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14Zone Controller Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Chapter 2 Control Wiring OverviewChapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Control Wiring Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Schematic Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Chapter 3 Mechanical InstallationChapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Layout Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Appendix A Specifications
Appendix B Replacement Parts
2 Table of Contents
Preface
Overview
The purpose of this manual is to provide basic information needed to install PowerFlex® 40 Adjustable Frequency AC Standard Packaged Drives.
User documentation for the PowerFlex 40 Standard Packaged Drives includes these Installation Instructions and the PowerFlex 40 User Manual, Publication 22B-UM001…. Both manuals are required to properly install and operate PowerFlex 40 Adjustable Frequency AC Standard Packaged Drives.
For information on … See page …Who Should Use this Manual? P-1What Is Not in this Manual P-1Reference Materials P-2Manual Conventions P-2General Precautions P-3Compliance Certification P-3Catalog Number Explanation P-4
Who Should Use this Manual?
This manual is intended for qualified personnel. You must be able to program and operate Adjustable Frequency AC Drive devices. In addition, you must have an understanding of the parameter settings and functions.
What Is Not in this Manual The PowerFlex 40 Adjustable Frequency AC Standard Packaged Drives Installation Instructions is designed to provide only basic installation and operation information. For this reason, the following topics have not been included:
• Troubleshooting• Start-Up• Programming and Parameters
Please refer to the PowerFlex 40 User Manual for detailed drive information.
P-2 Overview
Reference Materials The following manuals are recommended for general drive information:
Title Publication Available Online at …Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives
DRIVES-IN001…
www.rockwellautomation.com/literature
Preventive Maintenance of Industrial Control and Drive System Equipment
DRIVES-TD001…
Safety Guidelines for the Application, Installation and Maintenance of Solid State Control
SGI-1.1
A Global Reference Guide for Reading Schematic Diagrams
0100-2.10
Guarding Against Electrostatic Damage 8000-4.5.2
For detailed PowerFlex 40 information including drive parameters, programming, start-up, troubleshooting, specifications:
Title Publication Available Online at …PowerFlex 40 User Manual 22B-UM001…
www.rockwellautomation.com/literaturePowerFlex Reference Manual PFLEX-RM001…
The latest version of this Installation Instructions can be obtained online at … www.rockwellautomation.com/literature
For Allen-Bradley Drives Technical Support:
Title Online at …Allen-Bradley Drives Technical Support www.ab.com/support/abdrives
Manual Conventions • To help differentiate parameter names and LCD display text from other text, the following conventions will be used:
– Parameter Names will appear in [brackets]. For example: [DC Bus Voltage].
– Display Text will appear in “quotes.” For example: “Enabled.”
• The following words are used throughout the manual to describe an action:
Word MeaningCan Possible, able to do somethingCannot Not possible, not able to do somethingMay Permitted, allowedMust Unavoidable, you must do thisShall Required and necessaryShould RecommendedShould Not Not recommended
Overview P-3
General PrecautionsATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring or application errors, such as, undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system.
ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive. Measure the voltage at the drive (Refer to the PowerFlex 40 User Manual for test point locations). The voltage must be zero.
Compliance Certification Certifications are applicable to approved program defined options.
U.S./Canada UL: UL508C CUL: CAN/CSA-C22.2 No. 14
Please refer to the PowerFlex 40 User Manual, publication 22B-UM001, for additional information.
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P-4 Overview
Catalog Number Explanation
The PowerFlex 40 Adjustable Frequency AC Standard Packaged Drives catalog numbering scheme is shown below.
Position
1-3 4 5 6-8 9 10 11 12 13 14 15 16+
23B – D 4P0 D 1 0 4 N N – P6a b c d e f g h i j
aDrive
Code Type
23B PowerFlex 40
bVoltage Rating
Code Voltage Ph.
D 480V ac 3
cAmp Rating
480V 60Hz Input
Code Amps kW (Hp)
1P4 1.4 0.4 (0.5)
2P3 2.3 0.75 (1.0)
4P0 4.0 1.5 (2.0)
6P0 6.0 2.2 (3.0)
010 10.5 4.0 (5.0)
012 12 5.5 (7.5)
017 17 7.5 (10)
024 24 11 (15)
dEnclosure
Code Enclosure
C NEMA/UL Type 4X ‡
D NEMA/UL Type 4 ‡
‡ The design of the PowerFlex 40 StandardConfigured Drive supports indoor and outdoorapplications that are not in direct sunlight.
eHIM
Code Interface Module
1 Fixed Keypad on Drive
F
Fixed Keypad on Drive and LCDDisplay with Digital Speed Control
HIM on Enclosure Door(22-HIM-C2S)
This option changes the enclosure rating toNEMA/UL Type 12.
fEmission Class
Code Rating
0 Not Filtered
gVersion
Code Version
4 RS485 (Standard)
C ControlNet
D DeviceNet
E EtherNet/IP
P PROFIBUS DP
hCode Rating
N Reserved
iCode Rating
N Reserved
jOptions
Code Description
-E22DeviceNet Quick Disconnect
(Bottom)
-E23DeviceNet Quick Disconnect (Left
Side)
-J10 ZAC Master (Left Feed)
-J11 ZAC Master (Right Feed)
-J12 ZAC Infeed (Left Feed)
-J13 ZAC Infeed (Right Feed)
-J14 ZAC Intermediate (Left Feed)
-J15 ZAC Intermediate (Right Feed)
-P3 Motor Circuit Protector
-P3TMotor Circuit Protector (Customer
wiring into top of device)
-P6 Disconnect Switch - Fused
-P6TDisconnect Switch - Fused
(Customer wiring into top of device)
-R3DeviceNet I/O (4 In/2 Out) w/SpringReturn HOA and Power Disconnect
Aux. Contact
-R4 DeviceNet Point I/O w/IB4 (4 Inputs)
-R5-R3 plus 4 I/O Quick Disconnects
and (1) 24V dc Receptacle
-S1Hand/Off/Auto S.S.
(Start/Stop/Speed Ref.)
-S4 Auto/Manual S.S. (Speed Ref.)
-S7 Start and Stop P.B.
-S8 Forward/Reverse S.S.
-S18Door Mounted Local Speed Pot (1-
Turn)
-S20Local/Remote and Local Control
Off/Run Forward Selector Switches
-S21Local/Off/Remote with 1 N.O.
Interposing Relay
This option changes the enclosure rating toNEMA/UL Type 1.
Chapter 1
PowerFlex 40 Standard Packaged Drive Standard Features and Options
Chapter Objectives This chapter describes the standard features and operation for PowerFlex 40 Standard Packaged Drives and associated options.
For information on … See page …Standard Features 1-1Enclosure Options 1-2Communication Options 1-3Power Disconnect Options 1-4Operator Device Options 1-9Quick Disconnects 1-13I/O Options 1-14
Standard Features This package integrates the Standard PowerFlex 40 drive. The PowerFlex 40 drive can be used for Volts per hertz or Sensorless Vector applications and offers an Autotune feature allowing the drive to adapt to individual motor characteristics.
The PowerFlex 40 is assembled in an enclosure which includes the following features…
• NEMA/UL Type 4/4X/12 - indoor and outdoor applications other than direct sunlight. (1)
• Flange mount drive/external heatsink reducing overall enclosure size.
• Mounting feet - orientation is adjustable per customer requirements.
If required, the drive can be removed from the front of the enclosure for ease of assembly or repair.
Low cost, highly configurable I/O inputs and/or 0-10V/4-20 mA outputs that are not used by program standard features and options are available for customer use.
(1) The enclosure does not normally protect electrical equipment from condensation, corrosion or contamination, which may occur within the enclosure or enter via the conduit or unsealed openings. Users must make adequate provisions to safeguard against such conditions, and satisfy themselves that the equipment is properly protected. For further information on criteria associated with NEMA enclosure ratings, refer to NEMA standards Publication No. 250-1991. When optional Door Mounted HIM is supplied, enclosure is rated NEMA/UL Type 12. See enclosure options for specific enclosure style quoted.
1-2 PowerFlex 40 Standard Packaged Drive Standard Features and Options
Enclosure Options NEMA/UL Type 1
The enclosure provided is a NEMA/UL Type 1. Type 1 enclosures are intended for indoor use primarily to provide a degree of protection against limited amounts of falling dirt. Doors and openings will be gasket sealed. There are no ventilation openings within the enclosure to allow for free exchange of inside and outside air.
Note: Enclosures will be rated NEMA/UL Type 1 only if option -J10, -J11, -J12, -J13, -J14 or -J15 are selected.
NEMA/UL Type 12
The enclosure provided is a NEMA/UL Type 12. Type 12 enclosures are intended for indoor use primarily to provide a degree of protection against dust, falling dirt and dripping noncorrosive liquids. Doors and openings will be gasket sealed. There are no ventilation openings within the enclosure to allow for free exchange of inside and outside air.
Note: Enclosures will be rated NEMA/UL Type 12 only if optional door mounted HIM is supplied. NEMA/UL Type 4/4X enclosures can be used either indoor or outdoor. Door mounted HIM cannot be exposed to sunlight and thus when selected, enclosure rating is changed to NEMA/UL Type 12 which is indoor use only.
NEMA/UL Type 4 (Position 9, Code D)
The enclosure provided is a NEMA/UL Type 4, painted mild steel, which supports both NEMA/UL Type 4 and NEMA/UL Type 12 applications. Type 4 enclosures are intended for indoor or outdoor use primarily to provide a degree of protection against windblown dust and rain, splashing water, and hose directed water, and to be undamaged by the formation of ice on the enclosure. They are designed to meet hose-down, dust, and external icing and rust resistance design tests. Doors and openings will be gasket sealed. There are no ventilation openings within the enclosure to allow for free exchange of inside and outside air.
Note: If optional Door Mounted HIM or Zone Controller options are not supplied, the design of the PowerFlex 40 Standard Packaged Drive supports indoor and outdoor applications that are not in direct sunlight.
NEMA/UL Type 4X (Position 9, Code C)
The enclosure provided is a NEMA/UL Type 4X. The material is type 304 stainless steel. Type 4X enclosures are intended for indoor or outdoor use primarily to provide a degree of protection against corrosion, windblown dust and rain, splashing water, and hose directed water, and to be undamaged by the formation of ice on the enclosure. They are designed to meet hose-down, dust, and external icing and rust resistance design tests. Doors and openings will be gasket sealed. There are no ventilation openings within the enclosure to allow for free exchange of inside and outside air.
Note: If optional Door Mounted HIM or Zone Controller options are not supplied, the design of the PowerFlex 40 Standard Packaged Drive supports indoor and outdoor applications that are not in direct sunlight.
PowerFlex 40 Standard Packaged Drive Standard Features and Options 1-3
Communication Options DeviceNet (Position 12, Code D)
The DeviceNet option is drive mounted and consists of the DeviceNet communication adaptor (22-COMM-D) and adaptor cover (22B-CCB for frame B drives or 22B-CCC for frame C drives). When DeviceNet is present, no other communication option is available other than the HIM. When used as a slave, the HIM will have limited functionality. For details related to the DeviceNet option, refer to the PowerFlex DeviceNet Adapter User Manual, publication 22COMM-UM003….
To review this schematic see Figure 2.1 on page 2-2 and Figure 2.3 on page 2-4.
EtherNet/IP (Position 12, Code E)
The EtherNet/IP option is drive mounted and consists of the EtherNet/IP communication adaptor (22-COMM-E) and adaptor cover (22B-CCB for frame B drives or 22B-CCC for frame C drives). When EtherNet/IP is present, no other communications option is available other than the HIM. When used as a slave, the HIM will have limited functionality. For details related to the EtherNet/IP option, refer to the PowerFlex EtherNet/IP Adapter User Manual, publication 22COMM-UM004….
To review this schematic see Figure 2.1 on page 2-2 and Figure 2.3 on page 2-4.
PROFIBUS (Position 12, Code P)
The PROFIBUS option is drive mounted and consists of the PROFIBUS communication adaptor (22-COMM-P) and adaptor cover (22B-CCB for frame B drives or 22B-CCC for frame C drives). When PROFIBUS is present, no other communication option is available other than the HIM. When used as a slave, the HIM will have limited functionality. For details related to PROFIBUS option, refer to the PowerFlex PROFIBUS Adapter User Manual, publication 22COMM-UM005….
To review this schematic see Figure 2.1 on page 2-2 and Figure 2.3 on page 2-4.
ControlNet (Position 12, Code C)
The ControlNet option is drive mounted and consists of the ControlNet communication adaptor (22-COMM-C) and adaptor cover (22B-CCB for frame B drives or 22B-CCC for frame C drives). When ControlNet is present, no other communication option is available other than the HIM. When used as a slave, the HIM will have limited functionality. For details related to ControlNet option, refer to the PowerFlex ControlNet Adapter User Manual, publication 22COMM-UM006….
To review this schematic see Figure 2.1 on page 2-2 and Figure 2.3 on page 2-4.
1-4 PowerFlex 40 Standard Packaged Drive Standard Features and Options
Power Disconnect Options Drive Motor Circuit Protector (Position 16+, Code -P3)
The Drive Motor Circuit Protector option is factory installed and provides a manual means of disconnecting input power to the drive. The Allen-Bradley Bulletin 140M switch is designed to meet short circuit requirements for branch circuit protection. The rotary style handle is padlockable in On or Off position. This option has a 65 kA short circuit withstand rating. Over load protection is supplied by the drive not the motor circuit protector. Incoming customer supplied power cables terminate at terminals R, S, T (L1, L2, L3) located on the bottom of the device.
Component Specifications
Drive Motor Circuit Protector (Position 16+, Code -P3T)
The Drive Motor Circuit Protector option is factory installed and provides a manual means of disconnecting input power to the drive. The Allen-Bradley Bulletin 140M switch is designed to meet short circuit requirements for branch circuit protection. The rotary style handle is padlockable in On or Off position. This option has a 65 kA short circuit withstand rating. Over load protection is supplied by the drive not the motor circuit protector. Incoming customer supplied power cables terminate at terminals R, S, T (L1, L2, L3) located on the top of the device.
Component Specifications
Switch A-B Bulletin 140M, 480V, 65 kA short circuit withstand rating3-pole, Rod operatedUL listed, CE Approved, CSA Certified
Handle Rotary style handle through the door, Door interlockedPadlockable in On or Off position, Defeatable in the On positionIP66 (Type 3R, 3, 12, 4, 4X)
Switch A-B Bulletin 140M, 480V, 65 kA short circuit withstand rating3-pole, Rod operatedUL listed, CE Approved, CSA Certified
Handle Rotary style handle through the door, Door interlockedPadlockable in On or Off position, Defeatable in the On positionIP66 (Type 3R, 3, 12, 4, 4X)
PowerFlex 40 Standard Packaged Drive Standard Features and Options 1-5
Drive Input Fused Disconnect Switch (Position 16+, Code -P6)
The Drive Input Fused Disconnect Switch option is factory installed and provides a manual means of disconnecting input power to the drive. The Allen-Bradley Bulletin 194R switch is designed to meet disconnect switch requirements for branch circuit protection. The rotary style handle is padlockable in On or Off position. This option has a 100 kA short circuit withstand rating. Class J fuses are supplied with the disconnect switch. Incoming customer supplied power cables terminate at terminals R, S, T (L1, L2, L3) located on the bottom of the device.
Component Specifications
Drive Input Fused Disconnect Switch (Position 16+, Code -P6T)
The Drive Input Fused Disconnect Switch option is factory installed and provides a manual means of disconnecting input power to the drive. The Allen-Bradley Bulletin 194R switch is designed to meet disconnect switch requirements for branch circuit protection. The rotary style handle is padlockable in On or Off position. This option has a 100 kA short circuit withstand rating. Class J fuses are supplied with the disconnect switch. Incoming customer supplied power cables terminate at terminals R, S, T (L1, L2, L3) located on the top of the device.
Component Specifications
Switch A-B Bulletin 194R, 600V, 100 kA short circuit withstand ratingIntegral class J fuses, Captive terminal clamps3-pole, Rod operatedUL listed, CE Approved, CSA, ASTA, and LOVAG Certified
Handle Rotary style handle through the door, Door interlockedPadlockable in On or Off position, Defeatable in the On positionTrue switch status indicationIP66 (Type 3R, 3, 12, 4, 4X)
Switch A-B Bulletin 194R, 600V, 100 kA short circuit withstand ratingIntegral class J fuses, Captive terminal clamps3-pole, Rod operatedUL listed, CE Approved, CSA, ASTA, and LOVAG Certified
Handle Rotary style handle through the door, Door interlockedPadlockable in On or Off position, Defeatable in the On positionTrue switch status indicationIP66 (Type 3R, 3, 12, 4, 4X)
1-6 PowerFlex 40 Standard Packaged Drive Standard Features and Options
Main Fuses (F1-F3)
ATTENTION: Most codes require that upstream branch circuit protection be provided to protect input power wiring. Install the fuses recommended in Table 1.A. Do not exceed the fuse ratings. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
Input line branch circuit protection fuses must be used to protect the input power lines. If input fuses are not provided with your drive, recommended fuse values are shown in Table 1.A. The input fuse ratings listed in Table 1.A are applicable for one drive per branch circuit. No other load may be applied to that fused circuit.
The recommended fuse type for all PowerFlex 40 Standard Packaged Drives is UL Class J.
Table 1.A Branch Fusing
Voltage Rating Drive Rating HP Fuse Rating Amps
480V AC 0.5 3
1.0 6
2.0 10
3.0 15
5.0 20
7.5 25
10 30
15 50
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PowerFlex 40 Standard Packaged Drive Standard Features and Options 1-7
Input Power Wiring
Refer to the PowerFlex 40 User Manual for additional detailed information about input power wiring recommendations and selection.
ATTENTION: Protect the contents of the options cabinet from metal chips and other debris while drilling the conduit openings. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
ATTENTION: Do not route signal and control wiring with power wiring in the same conduit. This can cause interference with drive operation. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
To connect AC input power to the drive package:
❏ 1. Select the proper wire size according to NEC and all applicable local codes and standards. Note that you must punch openings in the Option Cabinet of the desired conduit size, following NEC and all applicable local codes and standards. Power terminal block specifications are listed in Table 1.B.
❏ 2. Connect the three-phase AC input power leads (three-wire VAC) to the appropriate terminals. Connect the AC input power leads to terminals L1, L2, L3 on the fused disconnect switch or motor circuit protector.
Note: Drive Input Fused Disconnect Switch (-P6) and Drive Motor Circuit Protector (-P3) options are bottom fed. Drive Input Fused Disconnect Switch (-P6T) and Drive Motor Circuit Protector (-P3T) options are top fed.
❏ 3. Tighten the AC input terminal power terminals to the proper torque according to drive type as shown in Table 1.B.
Table 1.B Component Current Ratings and Wire Sizing
PowerFlex 40 SPD Drive Rating - 480V
HP Continuous Current Rating Amps
Factory Power Wire Size(1)(2)
(1) Wire is Black Hypalon.
0.5-3 30 2.5 mm2
(14 AWG)2.5-8.4 mm2
(14-8 AWG)4.0 N-m (35 lb.-in.)
5-7.5 30 3.5 mm2
(12 AWG)2.5-8.4 mm2
(14-8 AWG)4.0 N-m (35 lb.-in.)
10-15 60 4.0 mm2
(10 AWG)2.5-16.0 mm2
(14-4 AWG)4.0 N-m (35 lb.-in.)
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(2) Maximum/minimum sizes that the terminal block will accept - these are not recommendations.
Customer Terminal Wire Size
Operating Torque
1-8 PowerFlex 40 Standard Packaged Drive Standard Features and Options
Output Power Wiring
Refer to the PowerFlex 40 User Manual for additional detailed information about output power wiring recommendations and selection.
ATTENTION: Unused wires in conduit must be grounded at both ends to avoid a possible shock hazard caused by induced voltages. Also, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled to eliminate the possible shock hazard from cross-coupled motor leads. Failure to observe these precautions could result in bodily injury.
ATTENTION: Do not route signal and control wiring with power wiring in the same conduit. This can cause interference with drive operation. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
To connect AC output power wiring from the drive to the motor:
❏ 1. Wire the three-phase AC output power motor leads by routing them according to the drive option type. Note that you must punch openings in the option cabinet of the desired conduit size, following NEC and all applicable local codes and standards. Power terminal block specifications are listed in Table 1.C.
Do not route more than three sets of motor leads through a single conduit. This will minimize cross-talk that could reduce the effectiveness of noise reduction methods. If more than three drive/motor connections per conduit are required, shielded cable must be used. If possible, each conduit should contain only one set of motor leads.
❏ 2. Connect the three-phase AC output power motor leads to terminals U, V, W (T1, T2, T3) on the power terminal block located on the drive.
❏ 3. Tighten the three-phase AC output power terminals to the proper torque according to drive type as shown in Table 1.C.
Table 1.C AC Output Power Terminal Block Specifications
Frame Maximum Wire Size
(1) Maximum/minimum sizes that the terminal block will accept - these are not recommendations.
(1)
B 5.3 mm2 (10 AWG) 1.3 mm2 (16 AWG) 1.7-2.2 N-m (16-19 lb.-in.)
C 8.4 mm2 (8 AWG) 1.3 mm2 (16 AWG) 2.9-3.7 N-m (26-33 lb.-in.)
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Minimum Wire Size Recommended Torque
PowerFlex 40 Standard Packaged Drive Standard Features and Options 1-9
Operator Device Options Hand/Off/Auto Selector Switch (Position 16+, Code S1)
This 800F door mounted operator device is factory installed and provides a Hand/Off/Auto selector switch.
The Hand/Off/Auto selector switch will start the drive in Hand mode and stop the drive in Off mode. In Auto mode the drive will be stopped and started from remote contact closures. In all cases, the Stop input to the drive must be present before the drive will start.
The Hand/Off/Auto selector switch also determines the source of the actual drive speed reference. In Hand mode, speed source is parameter A072 [Preset Freq 2]. In Auto mode, speed source is parameter A071 [Preset Freq 1].
If the door mounted speed potentiometer (Option S18) is supplied and it is intended to be the speed reference in Hand mode, set parameter A052 [Digital In2 Sel] to option 13 “10V In Ctrl”. Refer to the table below and the PowerFlex 40 User Manual, publication 22B-UM001, for other options.
Auto/Manual Selector Switch (Code S4)
Component Specifications
This option is not compatible with Codes J10-J15, R3, R5, S4, S7, S20 or S21.
Speed Reference Parameter Settings
Hand Mode Auto Mode P038 [Speed Reference] A051 [Digital In1 Sel] A052 [Digital In2 Sel]
Preset Speed Preset Speed 4 “Preset Freq” 4 “Preset Freq” 4 “Preset Freq”
Analog Input (0-10V) 4 “Preset Freq” 13 “10V In Ctrl” 4 “Preset Freq”
Analog Input (4-20mA) 4 “Preset Freq” 14 “20mA In Ctrl” 4 “Preset Freq”
Communication Port(1) 4 “Preset Freq” 6 “Comm Port” 4 “Preset Freq”
Speed Pot (Door) Preset Speed 4 “Preset Freq” 4 “Preset Freq” 13 “10V In Ctrl”
Analog Input (4-20mA) 4 “Preset Freq” 14 “20mA In Ctrl” 13 “10V In Ctrl”
Communication Port(1) 4 “Preset Freq” 6 “Comm Port” 13 “10V In Ctrl”
HIM (Door) Preset Speed 4 “Preset Freq” 4 “Preset Freq” 6 “Comm Port”
Analog Input (0-10V) 4 “Preset Freq” 13 “10V In Ctrl” 6 “Comm Port”
Analog Input (4-20mA) 4 “Preset Freq” 14 “20mA In Ctrl” 6 “Comm Port”(1) Communication port will have both logic and reference control.
Bulletin 800F Devices
IEC style, Internationally ratedMeet IP65/IP66 and NEMA/UL Type 4/4X/13UL Listed, CSA Certified10 amp contactsScrew terminals, 0.3–3.5 mm2 (22–12 AWG) maximum
Hand/Off/AutoSelector Switch
3 position, Maintained3 N.O. contacts
Legend Plate 30 x 50 mm, Black with white letteringWiring 0.8 mm2 (18 AWG), BlueSchematics Figure 2.4 on page 2-5
Figure 2.5 on page 2-6
1-10 PowerFlex 40 Standard Packaged Drive Standard Features and Options
Auto/Manual Selector Switch (Position 16+, Code S4)
This 800F door mounted operator device is factory installed and provides an Auto/Manual selector switch.
The Auto/Manual selector switch determines the source of the actual drive speed reference. Using 2-wire control in Auto mode, speed source is parameter A071 [Preset Freq 1]. In Manual mode, the speed source is parameter A072 [Preset Freq 2].
If the door mounted speed potentiometer (Option S18) is supplied and it is intended to be the speed reference in Manual mode, set parameter P052 [Digital In2 Sel] to option 13 “10V In Ctrl”. Refer to the table below and the PowerFlex 40 User Manual, publication 22B-UM001, for other options.
Auto/Manual Selector Switch (Code S4)
Component Specifications
This option is not compatible with Codes J10-J15, R3, R5, S1, S20 or S21.
Speed Reference Parameter Settings
Manual Mode Auto Mode P038 [Speed Reference] A051 [Digital In1 Sel] A052 [Digital In2 Sel]
Preset Speed Preset Speed 4 “Preset Freq” 4 “Preset Freq” 4 “Preset Freq”
Analog Input (0-10V) 4 “Preset Freq” 13 “10V In Ctrl” 4 “Preset Freq”
Analog Input (4-20mA) 4 “Preset Freq” 14 “20mA In Ctrl” 4 “Preset Freq”
Communication Port(1) 4 “Preset Freq” 6 “Comm Port” 4 “Preset Freq”
Speed Pot (Door) Preset Speed 4 “Preset Freq” 4 “Preset Freq” 13 “10V In Ctrl”
Analog Input (4-20mA) 4 “Preset Freq” 14 “20mA In Ctrl” 13 “10V In Ctrl”
Communication Port(1) 4 “Preset Freq” 6 “Comm Port” 13 “10V In Ctrl”
HIM (Door) Preset Speed 4 “Preset Freq” 4 “Preset Freq” 6 “Comm Port”
Analog Input (0-10V) 4 “Preset Freq” 13 “10V In Ctrl” 6 “Comm Port”
Analog Input (4-20mA) 4 “Preset Freq” 14 “20mA In Ctrl” 6 “Comm Port”(1) Communication port will have both logic and reference control.
Bulletin 800F Devices
IEC style, Internationally ratedMeet IP65/IP66 and NEMA/UL Type 4/4X/13UL Listed, CSA Certified10 amp contactsScrew terminals, 0.3–3.5 mm2 (22–12 AWG) maximum
Auto/Manual Selector Switch
2 position, Maintained1 N.C. contact
Legend Plate 30 x 50 mm, Black with white letteringWiring 0.8 mm2 (18 AWG), BlueSchematics Figure 2.6 on page 2-7
Figure 2.7 on page 2-8Figure 2.8 on page 2-9
PowerFlex 40 Standard Packaged Drive Standard Features and Options 1-11
Start and Stop Push Buttons (Position 16+, Code S7)
This option provides factory installed 800F Start and Stop push buttons.
In all cases, the Stop input to the drive must be present before the drive will start. Using 3-wire control, speed source is parameter A070 [Preset Freq 0]. The Stop push button may also be used as a fault reset.
Component Specifications
This option is not compatible with Codes J10-J15, R3, R5, S1, S20 or S21.
Forward/Reverse Selector Switch (Position 16+, Code S8)
This 800F door mounted operator device is factory installed and provides a Forward/Reverse selector switch.
When configured for 2-wire control, the drive will start when the selector switch is set to Forward. When the selector switch is set to Reverse, the drive will run in reverse. If the selector switch is operated while the drive is running, a change of direction command will occur. If the drive is stopped and the selector switch is operated, a change of direction command will occur. The speed source is parameter P070 [Preset Freq 0].
When configured for 3-wire control (Code S7 with S8), the selector switch only changes direction. The drive is started and stopped via the Start and Stop push buttons (Code S7).
Component Specifications
This option is not compatible with Codes J10-J15, R3, R5, S20 or S21.
Bulletin 800F Devices
IEC style, Internationally ratedMeet IP65/IP66 and NEMA/UL Type 4/4X/13UL Listed, CSA Certified10 amp contactsScrew terminals, 0.3–3.5 mm2 (22–12 AWG) maximum
Start Push Button Flush head, Green, 1 N.O. contactStop Push Button Extended head, Red, 1 N.C. contactLegend Plate 30 x 50 mm, Black with white letteringWiring 0.8 mm2 (18 AWG), BlueSchematics Figure 2.7 on page 2-8
Figure 2.9 on page 2-10Figure 2.10 on page 2-11
Bulletin 800F Devices
IEC style, Internationally ratedMeet IP65/IP66 and NEMA/UL Type 4/4X/13UL Listed, CSA Certified10 amp contactsScrew terminals, 0.3–3.5 mm2 (22–12 AWG) maximum
Forward/Reverse Selector Switch
2-Wire: 2 position, Maintained, 1 N.O. & 1 N.C. contacts3-Wire: 2 position, Maintained, 1 N.C. contact
Legend Plate 30 x 50 mm, Black with white letteringWiring 0.8 mm2 (18 AWG), BlueSchematics 2-Wire Control: Figure 2.5 on page 2-6, Figure 2.8 on page 2-9,
Figure 2.11 on page 2-123-Wire Control: Figure 2.10 on page 2-11
1-12 PowerFlex 40 Standard Packaged Drive Standard Features and Options
Local Speed Potentiometer (Code S18)
This option provides a factory installed 800F door mounted one turn potentiometer for speed control. The device provides the speed source when no digital inputs are active.
When this option is provided, it becomes the speed source for the Hand mode of the Hand/Off/Auto selector switch (Option S1) and the Manual mode of the Auto/Manual selector switch (Option S4).
Component Specifications
This option is not compatible with Codes J10-J15, R3-R5.
Local Control Off/Run Forward and Local/Remote Selector Switches (Code S20)
This option provides two factory installed 800F door mounted selector switches. The Local/Remote selector switch determines the source of the start, stop, speed and direction commands. In Local mode, the factory default setting for parameter P038 [Speed Reference] = 4 “Preset Freq.”
In Remote mode, the factory default setting for parameter A051 [Digital In1 Sel] = 6 “Comm Port.” The Off/Run Forward selector switch allows the drive to be started and stopped when in Local Control.
Component Specifications
This option is not compatible with Codes J10-J15, R3, R5, S1, S4, S7, S8 or S21.
Bulletin 800F Devices
IEC style, Internationally ratedMeet IP65/IP66 and NEMA/UL Type 4/4X/13UL Listed, CSA CertifiedScrew terminals, 0.3–3.5 mm2 (22–12 AWG) maximum
Speed Potentiometer 1-turn, 10k, 2.25W, 500VLegend Plate 30 x 50 mm, Black with white letteringWiring 0.8 mm2 (18 AWG), BlueSchematic Figure 2.13 on page 2-14
Bulletin 800F Devices IEC style, Internationally ratedMeet IP65/IP66 and NEMA/UL Type 4/4X/13UL Listed, CSA Certified10 amp contactsScrew terminals, 0.3–3.5 mm2 (22–12 AWG) maximum
Local Control Off/Run Forward Selector Switch
2 position, Maintained, 1 N.O. contact
Local/Remote Selector Switch
2 position, Maintained, 1 N.O. contact
Legend Plate 30 x 50 mm, Black with white letteringWiring 0.8 mm2 (18 AWG), BlueSchematic Figure 2.12 on page 2-13
PowerFlex 40 Standard Packaged Drive Standard Features and Options 1-13
Local/Off/Remote Selector Switch With One Normally Open Interposing Relay (Code S21)
This 800F door mounted operator device and interposing relay option is factory installed and provides a Local/Off/Remote selector switch.
The Local/Off/Remote selector switch will start the drive in Local mode and stop it in Off mode. In Remote mode, the drive will be stopped and started from the factory installed CR1 contact which is energized by a customer supplied and protected 120V AC source. In all cases, the Stop input to the drive must be present before the drive will start.
In both Local and Remote modes, the speed source is parameter A070 [Preset Freq 0].
Component Specifications
This option is not compatible with Codes J10-J15, R3, R5, S1, S4, S7, S8 or S20.
Quick Disconnects DeviceNet Quick Disconnect - Bottom (Code E22)
A Brad Harrison, 5 pin, bulkhead, male receptacle is provided and wired to the drive mounted DeviceNet module. The connector is located through the bottom of the enclosure providing a quick disconnect. This option is designed to enhance the DeviceNet offering (Position 12, Code D) and is not compatible with options 4, C, E, P (Position 12), E23 or J10-J15.
To review schematic refer to Figure 2.4 on page 2-5.
To review layout refer to Figure 3.4 on page 3-4.
For NEMA/UL Type 4 or less stringent environments, the outer connector construction is made of plastic designed to withstand washdown conditions.
DeviceNet Quick Disconnect - Left Side (Code E23)
A Brad Harrison, 5 pin, bulkhead, male receptacle is provided and wired to the drive mounted DeviceNet module. The connector is located through the left side of the enclosure providing a quick disconnect. This option is designed to enhance the DeviceNet offering (Position 12, Code D) and is not compatible with options 4, C, E, P (Position 12), E22 or J10-J15.
To review schematic refer to Figure 2.4 on page 2-5.
To review layout refer to Figure 3.4 on page 3-4.
For NEMA/UL Type 4 or less stringent environments the outer connector construction is made of plastic designed to withstand washdown conditions.
Bulletin 800F Devices
IEC style, Internationally ratedMeet IP65/IP66 and NEMA/UL Type 4/4X/13UL Listed, CSA Certified10 amp contactsScrew terminals, 0.3–3.5 mm2 (22–12 AWG) maximum
Local/Off/Remote Selector Switch
3 position, Maintained, 2 N.O. contacts
Interposing Control Relay
1 relay, 10 amp, 120V AC coil, Octal base
Legend Plate 30 x 50 mm, Black with white letteringWiring 0.8 mm2 (18 AWG), BlueSchematic Figure 2.14 on page 2-15
1-14 PowerFlex 40 Standard Packaged Drive Standard Features and Options
I/O Options DeviceNet I/O (4 In/2 Out) w/Spring Return HOA and Power Disconnect Aux. Contact (Position 16+, Code R3)
This option provides a factory installed 800F door mounted operator device, a 100-DNY42R and a power disconnect auxiliary contact mounted internal to the cabinet.
The Hand/Off/Auto selector switch will start the drive while held in the Hand mode and stop it in the Off mode. The default speed reference comes from parameter P038, option 4 (Preset Freq). The selector switch has a spring return disallowing the operator to remain in Hand. When in Auto the default speed reference is derived parameter A051, option 4 (Preset Freq).
The 100-DNY42R is powered by DeviceNet and provides control based on customer control parameters.
This option is prewired with an auto contact from the Hand/Off/Auto selector switch between the I/O V+ and IN0 terminals. The main power disconnect auxiliary contact is wired between the I/O V+ and IN1 terminals indicating if the disconnect is on or off. Two inputs and two outputs are available for customer use.
This option must be used with the drive mounted DeviceNet option D (Position 12) and is not compatible with options J10-J15, R4, R5, S1, S4, S7, S8, S20, or S21. The drive mounted DeviceNet and the 100-DNY42R will appear as separate nodes on the communication system.
Component Specifications
Bulletin 800F Devices
IEC style, Internationally ratedMeet IP65/IP66 and NEMA/UL Type 4/4X/13UL Listed, CSA Certified10 amp contactsScrew terminals, 0.3–3.5 mm2 (22–12 AWG) maximum
Hand/Off/Auto Selector Switch
3 position, Hand (spring return), Off, Auto (maintained)3 N.O. & 3 N.C. contacts
Legend Plate 30 x 50 mm, Black with white letteringWiring 0.8 mm2 (18 AWG), Blue100-DNY42R cULus Listed, CSA, CE
DeviceLogix™, Rotary address switches24V DC or 120V AC inputsHigh-Capacity transistor or Relay outputsODVA Compliance v2.0 TestedPower Disconnect Auxiliary Contact1 N.O. & 1 N.C. Side mounted contacts
Schematic Figure 2.15 on page 2-16
PowerFlex 40 Standard Packaged Drive Standard Features and Options 1-15
DeviceNet Point I/O w/IB4 (4 Inputs) (Position 16+, Code R4)
This option provides a factory installed 1734-ADNX Point I/O Scanner in combination with a 1734-IB4 (4 input) four point, 24V DC sink input.
The drive DeviceNet is prewired to the subnet connector of the 1734-ADNX. The customer is required to make the DeviceNet connection directly to the 1734-ADNX network connector. The 1734-IB4 is connected via a backplane offering four available inputs for customer use.
The Point I/O Scanner allows data to be gathered from the drive mounted DeviceNet and the 1734-IB4 (4 input) appear as one node on the communication system.
This option must be used with the drive mounted DeviceNet option D (Position 12) and is not compatible with options 4, C, E, P (Position 12), J10-J15, R3, or R5.
Refer to publication 1734-IN051 for more detail on the 1734-IB4.
Note: Customer is required to supply external 24V DC/AC to power 1734-ADNX scanner.
Component Specifications
1734-ADNX Devices IEC style, Internationally ratedMeet IP65/IP66 and NEMA/UL Type 4/4X/13UL Listed, CSA Certified10 amp contactsScrew terminals, 0.3–3.5 mm2 (22–12 AWG) maximum
1734-IB4 Devices Refer to publication 1734-IN051Schematic Figure 2.16 on page 2-17
1-16 PowerFlex 40 Standard Packaged Drive Standard Features and Options
DeviceNet I/O (4 In/ 2 Out) w/Spring Return HOA, Power Disconnect Aux. Contact, and 4 I/O Quick Disconnects (Position 16+, Code R5)
This option provides a factory installed 800F door mounted operator device, a 100-DNY42R mounted internal to the cabinet, a power disconnect auxiliary contact, four I/O quick disconnects, and a 24V DC male receptacle.
The Hand/Off/Auto selector switch will start the drive while held in the Hand mode and stop it in the Off mode. The default speed reference comes from parameter P038, option 4 (Preset Freq). The selector switch has a spring return disallowing the operator to remain in Hand. When in Auto the default speed reference is derived parameter A051, option 4 (Preset Freq).
The 100-DNY42R is powered by DeviceNet and provides control based on customer control parameters. The inputs and outputs are powered by customer supplied 24V DC.
This options is prewired with an auto contact from the Hand/Off/Auto selector switch between the I/O V+ and IN0 terminals. The main power disconnect auxiliary contact is wired between the I/O V+ and IN1 terminals indicating if the disconnect is on or off. The four I/O quick disconnects allow the customer to quickly connect to the remaining two inputs and outputs that are available for customer use.
This option must be used with the drive mounted DeviceNet option D (Position 12) and is not compatible with options J10-J15, R3, R4, S1, S4, S7, S8, S20, or S21. The drive mounted DeviceNet and the 100-DNYR42 will appear as separate nodes on the communication system.
Component Specifications
Bulletin 800F Devices
IEC style, Internationally ratedMeet IP65/IP66 and NEMA/UL Type 4/4X/13UL Listed, CSA Certified10 amp contactsScrew terminals, 0.3–3.5 mm2 (22–12 AWG) maximum
Hand/Off/Auto Selector Switch
3 position, Hand (spring return), Off, Auto (maintained)3 N.O. & 3 N.C. contacts
Legend Plate 30 x 50 mm, Black with white letteringWiring 0.8 mm2 (18 AWG), Blue100-DNY42R cULus Listed, CSA, CE
DeviceLogix™, Rotary address switches24V DC or 120V AC inputsHigh-Capacity transistor or Relay outputsODVA Compliance v2.0 TestedPower Disconnect Auxiliary Contact1 N.O. & 1 N.C. Side mounted contacts
Receptacle Shell Black anodized machined aluminumConnector Insert NylonContacts Machined brass with gold over nickel platingSchematic Figure 2.17 on page 2-18
PowerFlex 40 Standard Packaged Drive Standard Features and Options 1-17
Zone Controller Options Master Zone Accumulation Controller-Left to Right (Position 16+, Code J10)
This option provides a factory installed 22ZC-413 master Zone Accumulation Controller wired to the drive and a power feed connector.
This option is designed to support product flowing from left to right. The enclosure is typically mounted on the conveyor in the most right position. The power feed connector is on the left side of the enclosure. The actuator terminals are prewired to the start circuitry of the drive.
The power feed connector is a quick connect that supports a four conductor flat cable. This flat cable is the main trunk line between zone controllers providing 24V DC power for each zone controller, connected photoelectric sensors and internally powered actuators. It also provides for a means of communication between zone controllers. This cable is not supplied with this option.
For more details specific to the Zone Accumulation Conveyor products, refer the Photoelectric Sensor catalog.
Selecting this option will change the environmental rating to NEMA/UL Type 1.
This option is not compatible with options J11-J15, R3, R4, R5, S1, S7, S8, S20, or S21.
Component Specifications
22ZC Devices cULus Listed, CEInput: 24V DC, two or three wire, sinking (NPN)Output: 24V DC, two wire, sinking (NPN), 100mA @ 24V DCResponse Time: 1ms maximum
Schematic Figure 2.18 on page 2-19
1-18 PowerFlex 40 Standard Packaged Drive Standard Features and Options
Master Zone Accumulation Controller-Right to Left (Position 16+, Code J11)
This option provides a factory installed 22ZC-413 master Zone Accumulation Controller wired to the drive and a power feed connector.
This option is designed to support product flowing from right to left. The enclosure is typically mounted on the conveyor in the most left position. The power feed connector is on the right side of the enclosure. The actuator terminals are prewired to the start circuitry of the drive.
The power feed connector is quick connect that supports a four conductor flat cable. This flat cable is the main truck line between zone controllers providing 24V DC power for each zone controller, connected photoelectric sensors and internally powered actuators. It also provides for a means of communication between zone controllers. This cable is not supplied with this option.
For more details specific to the Zone Accumulation Conveyor products, refer the Photoelectric Sensor catalog.
Selecting this option will change the environmental rating to NEMA/UL Type 1.
This option is not compatible with options J10, J12-J15, R3, R4, R5, S1, S7, S8, S20, or S21.
Component Specifications
22ZC Devices cULus Listed, CEInput: 24V DC, two or three wire, sinking (NPN)Output: 24V DC, two wire, sinking (NPN), 100mA @ 24V DCResponse Time: 1ms maximum
Schematic Figure 2.18 on page 2-19
PowerFlex 40 Standard Packaged Drive Standard Features and Options 1-19
Infeed Zone Accumulation Controller-Left to Right (Position 16+, Code J12)
This option provides a factory installed 22ZC-343 infeed Zone Accumulation Controller wired to the drive and a power feed connector.
This option is designed to support product flowing from left to right. The enclosure is typically mounted on the conveyor in the most left position. The power feed connector is on the right side of the enclosure. The actuator terminals are prewired to the start circuitry of the drive.
The power feed connector is quick connect that supports a four conductor flat cable. This flat cable is the main truck line between zone controllers providing 24V DC power for each zone controller, connected photoelectric sensors and internally powered actuators. It also provides for a means of communication between zone controllers. This cable is not supplied with this option.
For more details specific to the Zone Accumulation Conveyor products, refer the Photoelectric Sensor catalog.
Selecting this option will change the environmental rating to NEMA/UL Type 1.
This option is not compatible with options J10, J11, J13-J15, R3, R4, R5, S1, S7, S8, S20, or S21.
Component Specifications
22ZC Devices cULus Listed, CEInput: 24V DC, two or three wire, sinking (NPN)Output: 24V DC, two wire, sinking (NPN), 100mA @ 24V DCResponse Time: 1ms maximum
Schematic Figure 2.18 on page 2-19
1-20 PowerFlex 40 Standard Packaged Drive Standard Features and Options
Infeed Zone Accumulation Controller-Right to Left (Position 16+, Code J13)
This option provides a factory installed 22ZC-343 infeed Zone Accumulation Controller wired to the drive and a power feed connector.
This option is designed to support product flowing from right to left. The enclosure is typically mounted on the conveyor in the most right position. The power feed connector is on the left side of the enclosure. The actuator terminals are prewired to the start circuitry of the drive.
The power feed connector is quick connect that supports a four conductor flat cable. This flat cable is the main truck line between zone controllers providing 24V DC power for each zone controller, connected photoelectric sensors and internally powered actuators. It also provides for a means of communication between zone controllers. This cable is not supplied with this option.
For more details specific to the Zone Accumulation Conveyor products, refer the Photoelectric Sensor catalog.
Selecting this option will change the environmental rating to NEMA/UL Type 1.
This option is not compatible with options J10-J12, J14, J15, R3, R4, R5, S1, S7, S8, S20, or S21.
Component Specifications
22ZC Devices cULus Listed, CEInput: 24V DC, two or three wire, sinking (NPN)Output: 24V DC, two wire, sinking (NPN), 100mA @ 24V DCResponse Time: 1ms maximum
Schematic Figure 2.18 on page 2-19
PowerFlex 40 Standard Packaged Drive Standard Features and Options 1-21
Intermediate Zone Accumulation Controller-Left to Right (Position 16+, Code J14)
This option provides a factory installed 22ZC-223 intermediate Zone Accumulation Controller wired to the drive and two powers feed connectors.
This option is designed to support product flowing from left to right. The enclosure is typically mounted in the middle of the conveyor. The power feed connectors are on both sides of the enclosure. The actuator terminals are prewired to the start circuitry of the drive.
The power feed connectors are quick connects that supports a four conductor flat cable. This flat cable is the main truck line between zone controllers providing 24V DC power for each zone controller, connected photoelectric sensors and internally powered actuators. It also provides for a means of communication between zone controllers. This cable is not supplied with this option.
For more details specific to the Zone Accumulation Conveyor products, refer the Photoelectric Sensor catalog.
Selecting this option will change the environmental rating to NEMA/UL Type 1.
This option is not compatible with options J11-J13, J15, R3, R4, R5, S1, S7, S8, S20, or S21.
Component Specifications
22ZC Devices cULus Listed, CEInput: 24V DC, two or three wire, sinking (NPN)Output: 24V DC, two wire, sinking (NPN), 100mA @ 24V DCResponse Time: 1ms maximum
Schematic Figure 2.18 on page 2-19
1-22 PowerFlex 40 Standard Packaged Drive Standard Features and Options
Intermediate Zone Accumulation Controller-Right to Left (Position 16+, Code J15)
This option provides a factory installed 22ZC-223 intermediate Zone Accumulation Controller wired to the drive and two power feed connectors.
This option is designed to support product flowing from right to left. The enclosure is typically mounted in the middle of the conveyor. The power feed connectors are on both sides of the enclosure. The actuator terminals are prewired to the start circuitry of the drive.
The power feed connectors are quick connects that supports a four conductor flat cable. This flat cable is the main truck line between zone controllers providing 24V DC power for each zone controller, connected photoelectric sensors and internally powered actuators. It also provides for a means of communication between zone controllers. This cable is not supplied with this option.
For more details specific to the Zone Accumulation Conveyor products, refer the Photoelectric Sensor catalog.
Selecting this option will change the environmental rating to NEMA/UL Type 1.
This option is not compatible with options J11-J14, R3, R4, R5, S1, S7, S8, S20, or S21.
Component Specifications
22ZC Devices cULus Listed, CEInput: 24V DC, two or three wire, sinking (NPN)Output: 24V DC, two wire, sinking (NPN), 100mA @ 24V DCResponse Time: 1ms maximum
Schematic Figure 2.18 on page 2-19
Chapter 2
Control Wiring Overview
Chapter Objectives This chapter describes the control and signal wiring connection options.
For information on … See page …Control Wiring Overview 2-1Schematic Drawings 2-2
Control Wiring Overview Refer to the PowerFlex 40 User Manual for additional detailed information about control and signal wiring.
The Control I/O Terminal Block (TB1) and Relay Terminal Block (TB2) located on the drive Main Control Board provide terminals for interfacing customer supplied control inputs and outputs. All analog and discrete control wiring will be made at these terminals.
To connect control and signal wiring to the drive package:
❏ 1. Wire the control and signal leads by routing them according to the drive option type. Note that you must punch openings in the option cabinet of the desired conduit size, following NEC and all applicable local codes and standards. I/O terminal block specifications are listed in Table 2.A.
Control and signal wires should be separated from power wires by at least 0.3 meters (1 foot).
❏ 2. Connect the control and signal wiring to the I/O terminals located on the drive.
❏ 3. Tighten the I/O terminals to the proper torque according to drive type as shown in Table 2.A.
Table 2.A I/O Terminal Block Specifications
Voltage Rating Maximum Wire Size
(1) Maximum/minimum sizes that the terminal block will accept - these are not recommendations.
(1)
208-460V AC 1.3 mm2 (16 AWG) 0.13 mm2 (26 AWG) 0.5-0.8 N-m (4.4-7 lb.-in.)
Minimum Wire Size Torque
2-2 Control Wiring Overview
Schematic Drawings Figure 2.1 Power Distribution Option
T2
T1
T3
L1
L2
L3
HIM
ESC SEL
REMOTE
KEYPADINTERGAL
MOTOR *
(T2)(T1)(G)
(T3)AC
3PH, 50/60HZAC LINES
LINE-PE
HP
REFER TO MOTOR NAMEPLATE FOR DATA.
FLAVOLTS
RPM (BASE)
MOTOR DATA
I/O TERMINAL BOCK TB1
REFER TO PAGE 2 FOR DETAILED INFORMATION
CATALOG NUMBER:
FRAME C ONLY
PowerFlex 40 DIGITAL AC DRIVE
USER MANUAL PUBLICATION 22B-UM001C-EN-EFOR FURTHER DRIVE INFORMATION, REFER TO
DSI PORTP2 P1
POWER TERMINAL BLOCKDC- DC+ BR+ BR- U V W
POWER TERMINAL BLOCKPOWER TERMINAL BLOCKRR SS TT
05
(#)
# ## #
132 04
3 041
4 07075
6 067 05
10 069
805
05120511
081401
13
EA1
33 34 41 42
TABLE 2
15 06
EA1
33 34 41 42
16 0417 05
18 020919
EA2
15-13
15-13
1061
1071
1051
T3
T1
T2
CHASSIS
4. COIL AND CONTACT CROSS REFERENCING - NUMBERS ADJACENT TOCOIL AND UNDER CONTACT INDICATE SHEET AND LINE NUMBERS.
OFF-PAGE CROSS REFERENCING - NUMBERS ADJACENT TO SOURCEAND DESTINATION SYMBOLS INDICATE SHEET AND LINE NUMBERS.-INDICATES TB4 TERMINAL BLOCK.3.
-INDICATES TERMINAL ON INDIVIDUAL COMPONENTS.
TO 1-24
FROM 1-24 1-24
- BUILDING GROUND TO BE GROUNDED
- POWER EQUIPMENT GROUND
-INDICATES WIRE SUPPLIED BY OTHERS.2. * -INDICATES COMPONENTS SUPPLIED BY OTHERS.
- SIGNAL COMMON
GENERAL NOTES:
- CHASSIS CONNECTION.
TE
PE
1. BY CUSTOMER.
SURGE SUPPRESSOR
1-31-3
2-18
L2
L3
L1
-INDICATES SHEET NO. 1.
-INDICATES LINE NO. 24.
-INDICATES LINE NO. 3.
-INDICATES SHEET NO. 1.
-UNDERSCORED TEXT LINE INDICATESA NORMALLY CLOSED CONTACT.
C-349932-2WS\STD\349932\02-01
12
SCHEMATIC, POWERFLEX 40 AC DRIVE
POWER DISTRIBUTION OPTION
PROJECT: DRIVE
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG10
09-15-05ARS
1016845
1023319ARS
07-30-0611 12
09-29-06ARS
1023319
ARS12-15-06
131026258
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
REV. STATUS OF SHEETS
SHT.REV.
480 VOLTS
CUSTOMER DEVICENET/
CONTROLNET CONNECTIONETHERNET/PROFIBUS/
CONNECTOROPTIONS
E23E22
OPTIONAL
ETHERNET MODULEDEVICENET MODULE
PROFIBUS MODULE
COMM. OPTION KITS
TABLE 2 PAGE 2-3
DISCONNECTING
PROTECTION
OTHERS WHEN P3,PROVIDED BY
SHORT CIRCUIT
P3T, P6 OR P6TOPTIONS
MEANS AND
AUX CONTACTS FOR
DS1
P6 OR P6T OPTIONS
POWER DISCONNECTING OPTION
L3
L2
L1
600V
F3
F1
F2
TO15-13
(DEVICENET ONLY)
TABLE 2
AUX CONTACTS FOR
MCP1TABLE 2
POWER DISCONNECTING OPTION
P3 OR P3T OPTIONS16-10
17-13
17-13
(R3 OR R5) WITH P6 OR P6T OPTION
(R3 OR R5) WITH P6 OR P6T OPTION
17-13
CONTROLNET MODULE
DEVICENET
ARE NOT ORDERED
Control Wiring Overview 2-3
Figure 2.2 Drive Ratings
0108-31-04
ARS1009799
02 01-28-05
ARS 1012358
03 09-15-05
ARS 1016845
0407-31-06
ARS1023319
C-349932-2WS\STD\349932\02-02
23
SCHEMATIC, BULLETIN PF40 AC DRIVEDRIVE RATINGSPROJECT: DRIVE
ACAD07-15-04ARS07-15-04BAH07-15-04
MASTER_PF40.DWG
TYPE AMP VOLT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
10 600V4.0 LPJ/AJT2 342-52822B-D4P0F104
22B-D010F104
22B-D012F104
22B-D024F10422B-D017F104
22B-D6P0F104342-528
342-528
342-528342-528
342-528
7.5
1510
53
LPJ/AJT
LPJ/AJTLPJ/AJT
LPJ/AJT
12.0
24.017.0
10.56.0
LPJ
25
5030
2015
600V
600V600V
600V600V
TABLE 2
CATALOG NO. FRAME HP VOLTAGE FLA
THREE PHASE
22B-D1P4F10422B-D2P3F104
DRIVE RATINGS
342-528342-528
1.5
FUSE RATINGS (P6 OPTION)
LPJ/AJTLPJ/AJT
1.42.3
36 600V
600V
P3/P3T OPTIONS
CATALOG NO.
140M-C2E-B40140M-C2E-B63140M-D8E-C10140M-D8E-C16140M-D8E-C25
140M-F8E-C32140M-F8E-C25
140M-F8E-C45
CATALOG NO.
194R-NJ030P3194R-NJ030P3194R-NJ030P3194R-NJ030P3194R-NJ030P3
194R-NJ030P3194R-NJ030P3
194R-NJ060P3
P6/P6T OPTIONS
B
BB
BB
C
CC
363357
363349363353
363345363341363337363333363326
KIT NO.
P3 OPTION
2-4 Control Wiring Overview
Figure 2.3 Control Logic Options 4, C, D, E & P
FANRED BLACK
11
12
13
14
15
16
17
18
19
I/O TERMINAL BLOCK
TERMINAL BLOCK TB2
RELAY - N.O.
PARAMETER A055=0RELAY COMMON
RELAY - N.C.
R1
R3
R2
8
9
7
2
6
5
4
3
1
TERMINAL BLOCK TB1
OPTO OUTPUT 2
RS485 (DSI) SHIELD
ANALOG OUTPUT
OPTO OUTPUT 1
ANALOG COMMON
4-20mA IN
0-10V IN
+10V DC
+24V DC
DIGITAL IN3
DIGITAL IN4
OPTO COMMON
I/O TERMINAL BLOCK
2021
2021
C-349932-2WS\STD\349932\02-03
34
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTIONS 4, D, E, PPROJECT: DRIVE
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG08-31-04
10-22-04
10-28-04
01-28-050402 0301
1011137
1009799
1012358
1011326
ARS
ARS
ARS
ARS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
START/RUN FWD
DIGITAL IN1
DIGITAL IN2
P036 = 5 COMM PORTP038 = 5 COMM PORT
DIGITAL COMMON
DIR/RUN REV
STOP SNK
SRCX
Control Wiring Overview 2-5
Figure 2.4 Control Logic Option S1
FANRED BLACK
*
12
13
14
15
16
17
18
19
I/O TERMINAL BLOCK
RELAY - N.O.
TERMINAL BLOCK TB2
RELAY COMMONPARAMETER A055=0
RELAY - N.C.
R1
R3
R2
11
8
9
7
2
6
5
4
3
1
TERMINAL BLOCK TB1
OPTO OUTPUT 2
RS485 (DSI) SHIELD
ANALOG OUTPUT
OPTO OUTPUT 1
ANALOG COMMON
4-20mA IN
0-10V IN
+10V DC
+24V DC
DIGITAL IN3
DIGITAL IN4
OPTO COMMON
I/O TERMINAL BLOCK
3OOX
4
AUTO RUN
3
SS2XOO
4
3
HANDOFF
XOO
AUTO
4
3OOX
4
2021
2021
2101
2022
2081
C-349932-2WS\STD\349932\02-04
45
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION S1PROJECT: DRIVE
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG
0609-29-06
1023635ARS
ARS1012358
01-28-0505
ARS1011629
11-12-0404
102625807
12-15-06ARS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
START/RUN FWD
P038 = 4 PRESET FREQ.
DIGITAL IN1
DIGITAL IN2
P036 = 2-WIRE
DIGITAL COMMON
DIR/RUN REV
STOPSRC
SNK
X
A051 = 4 "PRESET FREQ"
A052 = 4 "PRESET FREQ"
2-6 Control Wiring Overview
Figure 2.5 Control Logic Option S1 & S8
FANRED BLACK
*
11
12
13
14
15
16
17
18
19
I/O TERMINAL BLOCK
RELAY - N.O.
TERMINAL BLOCK TB2
PARAMETER A055=0RELAY COMMON
RELAY - N.C.
R1
R3
R2
8
9
7
2
6
5
4
3
1
TERMINAL BLOCK TB1
OPTO OUTPUT 2
RS485 (DSI) SHIELD
ANALOG OUTPUT
OPTO OUTPUT 1
ANALOG COMMON
4-20mA IN
0-10V IN
+10V DC
+24V DC
DIGITAL IN3
DIGITAL IN4
OPTO COMMON
I/O TERMINAL BLOCK
2
REVERSE
XO
FORWARD
1
4
SS3OX
3
3OOX
4
3
HANDOFF
XOO
AUTO
4
3
SS2XOO
4
3OOX
4
AUTO RUN
2021
2042
2052
2081
2022
2101
C-349932-2WS\STD\349932\02-05
56
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION S1 + S8PROJECT: DRIVE
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG04
11-12-041011629
ARS
0501-28-05
1012358ARS
ARS1023635
09-29-0606
ARS12-15-06
071026258
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
START/RUN FWD
DIGITAL IN1
P038 = 4 PRESET FREQ.
DIGITAL IN2
P036 = 2-WIRE
DIGITAL COMMON
DIR/RUN REV
STOP SNK
SRCX
A052 = 4 "PRESET FREQ"
A051 = 4 "PRESET FREQ"
Control Wiring Overview 2-7
Figure 2.6 Control Logic Option S4
FANRED BLACK
*
*
11
12
13
14
15
16
17
18
19
I/O TERMINAL BLOCK
RELAY - N.O.
TERMINAL BLOCK TB2
RELAY COMMONPARAMETER A055=0
RELAY - N.C.
R1
R3
R2
8
9
7
2
6
5
4
3
1
TERMINAL BLOCK TB1
OPTO OUTPUT 2
RS485 (DSI) SHIELD
ANALOG OUTPUT
OPTO OUTPUT 1
ANALOG COMMON
4-20mA IN
0-10V IN
+10V DC
+24V DC
DIGITAL IN3
OPTO COMMON
DIGITAL IN4
I/O TERMINAL BLOCK
DEVICE2-WIRE
2
MANUAL
XO
AUTO
1
3
SS1OX
4
2021
2021
2082
2101
C-349932-2WS\STD\349932\02-06
67
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION S4PROJECT: DRIVE
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG
0509-29-06
1023635ARS
ARS1012358
01-28-0504
ARS1011326
10-28-0403
ARS12-15-06
061026258
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
START/RUN FWD
P038 = 4 PRESET FREQ.
DIGITAL IN1
DIGITAL IN2
P036 = 2-WIRE
DIGITAL COMMON
DIR/RUN REV
STOPSRC
SNK
X
A051 = 4 "PRESET FREQ"
A052 = 4 "PRESET FREQ"
2-8 Control Wiring Overview
Figure 2.7 Control Logic Option S4 & S7
FANRED BLACK
12
13
14
15
16
17
18
19
I/O TERMINAL BLOCK
TERMINAL BLOCK TB2
RELAY - N.O.
RELAY - N.C.
PARAMETER A055=0RELAY COMMON
R1
R3
R2
11
8
9
7
2
6
5
4
3
1
TERMINAL BLOCK TB1
OPTO OUTPUT 2
RS485 (DSI) SHIELD
ANALOG OUTPUT
OPTO OUTPUT 1
ANALOG COMMON
4-20mA IN
0-10V IN
+10V DC
+24V DC
DIGITAL IN3
DIGITAL IN4
OPTO COMMON
I/O TERMINAL BLOCK
PB24
START
3
1 2
PB3
STOP
3
SS1OX
4
2
MANUAL
XO
AUTO
1
2021
2021
2041
2022
2101
2082
C-349932-2WS\STD\349932\02-07
78
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION S4 AND S7PROJECT: DRIVE
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG
1023635
0210-22-04
1011137ARS
0310-28-04
1011326ARS
0401-28-05
1012358ARS
ARS09-29-06
05
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
START/RUN FWD
P038 = 4 PRESET FREQ.
DIGITAL IN1
DIGITAL IN2
P036 = 3-WIRE
DIGITAL COMMON
DIR/RUN REV
STOP
SRC
SNK
X
A051 = 4 "PRESET FREQ"
A052 = 4 "PRESET FREQ"
Control Wiring Overview 2-9
Figure 2.8 Control Logic Option S4 with S8
FANRED BLACK
11
12
13
14
15
16
17
18
19
I/O TERMINAL BLOCK
RELAY - N.O.
TERMINAL BLOCK TB2
RELAY COMMONPARAMETER A055=0
RELAY - N.C.
R1
R3
R2
8
9
7
2
6
5
4
3
1
TERMINAL BLOCK TB1
OPTO OUTPUT 2
RS485 (DSI) SHIELD
OPTO OUTPUT 1
ANALOG OUTPUT
ANALOG COMMON
4-20mA IN
0-10V IN
+10V DC
+24V DC
OPTO COMMON
DIGITAL IN4
DIGITAL IN3
I/O TERMINAL BLOCK
2
REVERSE
XO
FORWARD
1
3
SS3OX
4
2
MANUAL
XO
AUTO
1
3
SS1OX
4
2021
2021
2042
2052
2082
2101
C-349932-2WS\STD\349932\02-08
89
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION S4 WITH S8
PROJECT: DRIVE
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG
0509-29-06
ARS
ARS1012358
01-28-0504
ARS1011326
10-28-0403
ARS1011137
10-22-0402
1023635
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
START/RUN FWD
P038 = 4 PRESET FREQ.
DIGITAL IN1
DIGITAL IN2
DIR/RUN REV
DIGITAL COMMON
P036 = 2-WIRE
STOP SNK
SRCX
A052 = 4 "PRESET FREQ"
A051 = 4 "PRESET FREQ"
2-10 Control Wiring Overview
Figure 2.9 Control Logic Option S7
FANRED BLACK
11
12
13
14
15
16
17
18
19
I/O TERMINAL BLOCK
TERMINAL BLOCK TB2
PARAMETER A055=0
RELAY - N.C.
RELAY - N.O.
RELAY COMMON
R1
R3
R2
8
9
7
2
6
5
4
3
1
TERMINAL BLOCK TB1
OPTO OUTPUT 2
RS485 (DSI) SHIELD
ANALOG OUTPUT
OPTO OUTPUT 1
ANALOG COMMON
4-20mA IN
0-10V IN
+10V DC
+24V DC
DIGITAL IN3
DIGITAL IN4
OPTO COMMON
I/O TERMINAL BLOCK
PB24
START
3
1 2
PB3
STOP2021
2041
2022
C-349932-2WS\STD\349932\02-09
910
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION S7 PROJECT: DRIVE
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG02
10-22-04ARS
1011137
0310-28-04
ARS1011326
0411-05-04
ARS1011477
051012358
01-28-05ARS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
START/RUN FWD
DIGITAL IN1
DIGITAL IN2
P036 = 3-WIRE
DIR/RUN REV
DIGITAL COMMON
STOP
SRC
SNK
X
P038 = 4 PRESET FREQ.
DIGITAL IN1
Control Wiring Overview 2-11
Figure 2.10 Control Logic Option S7 and S8
BLACKFAN
RED
11
12
13
14
15
16
17
18
19
I/O TERMINAL BLOCK
TERMINAL BLOCK TB2
RELAY - N.O.
PARAMETER A055=0RELAY COMMON
RELAY - N.C.
R1
R3
R2
8
9
7
2
6
5
4
3
1
TERMINAL BLOCK TB1
OPTO OUTPUT 2
RS485 (DSI) SHIELD
ANALOG OUTPUT
OPTO OUTPUT 1
ANALOG COMMON
4-20mA IN
0-10V IN
+10V DC
+24V DC
DIGITAL IN3
DIGITAL IN4
OPTO COMMON
I/O TERMINAL BLOCK
PB24
START
3
1 2
PB3
STOP
4
REVERSE
SS3OX
FORWARD
3
2021
2021
2041
2022
2052
C-349932-2WS\STD\349932\02-10
1011
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION S7 AND S8PROJECT: DRIVE
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG
0607-30-06
ARS1023319
0501-28-05
ARS1012358
0411-05-04
ARS1011477
0310-28-04
ARS1011137
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
START/RUN FWD
DIGITAL IN1
DIGITAL IN2
DIR/RUN REV
P036 = 3-WIRE
DIGITAL COMMON
STOP
SRC
SNK
X
P038 = 4 PRESET FREQ.
DIGITAL IN1
2-12 Control Wiring Overview
Figure 2.11 Control Logic Option S8
FANRED BLACK
11
12
13
14
15
16
17
18
19
I/O TERMINAL BLOCK
RELAY - N.O.
TERMINAL BLOCK TB2
RELAY COMMONPARAMETER A055=0
RELAY - N.C.
R1
R3
R2
8
9
7
2
6
5
4
3
1
TERMINAL BLOCK TB1
OPTO OUTPUT 2
RS485 (DSI) SHIELD
ANALOG OUTPUT
OPTO OUTPUT 1
ANALOG COMMON
4-20mA IN
0-10V IN
+10V DC
+24V DC
DIGITAL IN3
OPTO COMMON
DIGITAL IN4
I/O TERMINAL BLOCK
2
REVERSE
XO
FORWARD
1
3
SS3OX
4
2021
2021
2042
2052
C-349932-2WS\STD\349932\02-11
1112
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION S8PROJECT: DRIVE
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG02
10-22-04ARS
1011137
0310-28-04
ARS1011326
0411-05-04
ARS1011477
0501-28-05
ARS1012358
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
START/RUN FWD
DIGITAL IN2
P036 = 2-WIRE
DIGITAL COMMON
DIR/RUN REV
STOPSRC
SNK
X
P038 = 4 PRESET FREQ.
DIGITAL IN1
Control Wiring Overview 2-13
Figure 2.12 Control Logic Option S20
FANRED BLACK
11
12
13
14
15
16
17
18
19
I/O TERMINAL BLOCK
RELAY - N.O.
RELAY COMMON
RELAY - N.C.
PARAMETER A055=0
TERMINAL BLOCK TB2
R1
R3
R2
8
9
7
2
6
5
4
3
1
TERMINAL BLOCK TB1
OPTO OUTPUT 2
RS485 (DSI) SHIELD
ANALOG OUTPUT
OPTO OUTPUT 1
ANALOG COMMON
4-20mA IN
0-10V IN
+10V DC
+24V DC
DIGITAL IN3
DIGITAL IN4
OPTO COMMON
I/O TERMINAL BLOCK
4
RUN FORWARD
SS2
LOCAL CONTROL
OX
OFF
3
4
REMOTE
SS1OX
LOCAL
3
2021
2021
2042
2082
C-349932-2WS\STD\349932\02-12
1213
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION S20PROJECT: DRIVE
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG02
10-22-04ARS
1011137
0310-28-04
ARS1011326
0411-05-04
ARS1011477
0501-28-05
ARS1012358
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
START/RUN FWD
P038 = 4 PRESET FREQ.
DIGITAL IN1 (COMM PORT)(PARAMETER A051 = 6)
DIGITAL IN2
P036 = 2-WIRE
DIGITAL COMMON
DIR/RUN REV
STOPSRC
SNK
X
2-14 Control Wiring Overview
Figure 2.13 Control Logic Option S18
FANRED BLACK
11
12
13
14
15
16
17
18
19
I/O TERMINAL BLOCK
RELAY - N.O.
TERMINAL BLOCK TB2
RELAY COMMONPARAMETER A055=0
RELAY - N.C.
R1
R3
R2
8
9
7
2
6
5
4
3
1
TERMINAL BLOCK TB1
OPTO OUTPUT 2
RS485 (DSI) SHIELD
ANALOG OUTPUT
OPTO OUTPUT 1
ANALOG COMMON
4-20mA IN
0-10V IN
+10V DC
+24V DC
DIGITAL IN3
OPTO COMMON
DIGITAL IN4
I/O TERMINAL BLOCK
RH1
SPEEDREFERENCE
10K
2021
2021
2201
2191
2181
C-349932-2WS\STD\349932\02-11
1314
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION S18PROJECT: DRIVE
ACAD08-30-05ARS08-30-05ARS08-30-05
MASTER_PF40.DWG01
09-15-05ARS
1016845
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
START/RUN FWD
DIGITAL IN2
P036 = 2-WIRE
DIGITAL COMMON
DIR/RUN REV
STOPSRC
SNK
X
DIGITAL IN1
SHLD
P038 = 2 0-10V INPUT
Control Wiring Overview 2-15
Figure 2.14 Control Logic Option S21
FANRED BLACK
4
RELAY - N.O.
TERMINAL BLOCK TB2
RELAY COMMONPARAMETER A055=0
RELAY - N.C.
I/O TERMINAL BLOCK
R3
R2
R1
TERMINAL BLOCK TB1
RS485 (DSI) SHIELD
OPTO OUTPUT 2
19
18
OPTO OUTPUT 1
ANALOG OUTPUT
ANALOG COMMON
16
17
4-20Ma IN15
0-10V IN13
14
+10V DC12
OPTO COMMON
DIGITAL IN4
DIGITAL IN3
+24V DC11
9
8
7
6
5
I/O TERMINAL BLOCK
1
3
2
PLC OUTPUTCUSTOMER
CR1
3
LOCALOFF
XOO
REMOTE
4
3
SS2OOX
4
CR1
*14-4
14-22
2021 2022
2041
C-349932-2WS\STD\349932\02-13
1415
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION S21PROJECT: DRIVE
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG
0709-15-05
ARS1016845
061012358
01-28-05ARS
051011629
11-12-04ARS
ARS12-15-06
081026258
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
CUSTOMER SUPPLIED ANDPROTECTED 120VAC
DIGITAL IN2
DIGITAL IN1
DIR/RUN REV
DIGITAL COMMON
START/RUN FWDP036 = 2-WIRE
STOPX SRC
SNK
P038 = 4 PRESET FREQ.
2-16 Control Wiring Overview
Figure 2.15 Control Logic Option R3 with P6 or P6T
CAN HV+
CAN LSHD
COM
OUT B
DEVICENET SYSTEM
3
4
TO
IN3
OUT A1
2
IN0
IN1
IN2
V +
BULLETIN 100
ACCESSORY
EA4
FAN
2131
RED BLACK
19
11
12
13
14
15
16
17
18
I/O TERMINAL BLOCK
RELAY - N.O.
TERMINAL BLOCK TB2
PARAMETER A055=0RELAY COMMON
RELAY - N.C.
R1
R3
R2
8
9
7
2
6
5
4
3
1
TERMINAL BLOCK TB1
RS485 (DSI) SHIELD
OPTO OUTPUT 2
ANALOG OUTPUT
OPTO OUTPUT 1
ANALOG COMMON
4-20mA IN
0-10V IN
+10V DC
+24V DC
DIGITAL IN3
OPTO COMMON
DIGITAL IN4
I/O TERMINAL BLOCK
DS1 OR MCP1
1XOO
2
3
SS2OOX
4
3OOX
4
3OOX
4
1
HAND OFF
XOO
AUTO
2
1-19 1-15 OR 1-27
2042
2101 2102
2082
2021 2022
C-349932-2WS\STD\349932\02-14
1516
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION R3 WITH P3/P3T OR
P6/P6TPROJECT: DRIVE
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG
1016845
03 04 05
1011326
1012358
ARS09-15-05
10-28-04
01-28-05
ARS
ARS
0607-30-06
ARS1023319
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
START/RUN FWD
DIGITAL IN2
P036 = 2-WIRE
DIGITAL COMMON
DIR/RUN REV
STOP SNK
SRCX
P038 = 4 PRESET FREQ.
DIGITAL IN1 (COMM PORT)(PARAMETER A051 = 6)
Control Wiring Overview 2-17
Figure 2.16 Control Logic Option R4
IB4
BLACK OUTPUT
LT. OUTPUT
BL. OUTPUT
LT. OUTPUT
CONNECTOR
FROM
4 5
V6
V7
SUBNET
C C
V+
CAN L
CAN HSHD
COM
COM
V+
COM
V+
EA4
POINT I/OSCANNER
1734-ADNX
CONNECTOR
V+
NETWORK
CAN H
CAN LSHD
COM
CUSTOMER SUPPLIED
0
2
1
3
1-19
12/24 VDC
C-349932-2WS\STD\349932\02-15
1617
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION R4PROJECT: DRIVE
ACAD12-15-04ARS12-15-04ARS12-15-04
MASTER_PF40.DWG01
01-28-05ARS
1012358
0209-15-05
ARS1016845
03 09-15-06
ARS 1026258
ARS12-15-06
041026258
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
IN 3
IN 2
IN 1
INPUT MODULE
IN 0
*
*
PHOTOELECTRIC
42EFP2MPBF4SENSOR
42EFP2MPBF4
PHOTOELECTRICSENSOR
* *
BROWN
BLACK
WHITE
BLUE
*
3
2
4
*
4-PIN RECEPTACLE
WHITE
BLACK
BROWN
BLUE2
3
4
1
*
5-PIN CONNECTOR
CUSTOMERDEVICE-NETCONNECTION
4-PIN RECEPTACLE
4-PIN RECEPTACLE
4-PIN RECEPTACLE
2-18 Control Wiring Overview
Figure 2.17 Control Logic Option R5 with P3, P3T, P6 or P6T
& DENOTES CONNECTION FROM 24V COM THAT CAN BE REMOVED.@ DENOTES JUMPER TO BE REMOVED FOR USE AS CONTACT OUTPUT
COM
COM
BL. OUTPUT
BLACK OUTPUT
LT. OUTPUT
&
&
V+
LT. OUTPUT
V+
RED BLACKFAN
PWR SUPPLYFROM 24VDC
EA4
DEVICENET SYSTEMACCESSORY
BULLETIN 100
IN3
3OUT B
4
NEG
OUT A2
1
IN2
IN1
IN0
V+
2121
@
@
TOCAN H
CAN LSHD
V+
V-
2141
I/O TERMINAL BLOCK
RELAY - N.O.
TERMINAL BLOCK TB2
PARAMETER A055=0RELAY COMMON
RELAY - N.C.
R1
R3
R2
TERMINAL BLOCK TB2
I/O TERMINAL BLOCK
R1RELAY - N.O.
RELAY - N.C.
RELAY COMMONPARAMETER A055=0
R3
R2
4-20mA IN
OPTO OUTPUT 1
ANALOG OUTPUT
OPTO OUTPUT 2
RS485 (DSI) SHIELD
TERMINAL BLOCK TB1
19
18
17
16
15
I/O TERMINAL BLOCK
DIGITAL IN4
DIGITAL IN3
OPTO COMMON
ANALOG COMMON
4
12 +10V DC
0-10V IN
14
13
+24V DC11
9
8
7
6
5
3
2
1
3
SS2OOX
4
3OOX
4
1
HAND OFF
XOO
AUTO
2
3OOX
4
1XOO
2
F6
3A250V
(5)
(6)
(7)
DS1 OR MCP1
(2)
(1)
(3)
(4)1-15 OR 1-27
1-19
2101 2102
2082
2021 2022
2042
C-349932-2WS\STD\349932\02-16
1718
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION R5 WITH P3/P3T OR
P6/P6TPROJECT: DRIVE
ACAD12-15-04ARS12-15-04ARS12-15-04
MASTER_PF40.DWG
0512-15-06
ARS1026258
0407-30-06
ARS1023319
0309-15-05
ARS1016845
0205-27-05
ARS1015554
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
BLUE
BLUE
BLUE
WHITE
BROWN
WHITE
BROWN
BLACK
BROWN
BROWN
BLACK
BLUE BLUE
BLUE
4-PIN RECEPTACLE 4
BLACK
BLUE
BROWN
WHITE
BLACK
4-PIN RECEPTACLE 3
4-PIN RECEPTACLE 2
3
BROWN
WHITE
BLACK 4
BROWN
WHITE
BLUE
BLACK
2
4
3
*
PHOTOELECTRIC
42EFP2MPBF4SENSOR
*
DIGITAL COMMON
DIR/RUN REV
P038 = 4 PRESET FREQ.P036 = 2-WIRE
DIGITAL IN2
DIGITAL IN1
START/RUN FWD
4-PIN RECEPTACLE 1
WHITE
BROWN
2
142EFP2MPBF4
PHOTOELECTRICSENSOR
STOPSRC
SNK
X
WHITE +24VDC
4-PIN RECEPTACLE
RED (V+)
BLACK (V-)
BROWN
BLACK
BLUE COM
RCPT 1
RCPT 2
RCPT 3
RCPT 4
RCPT 5
Control Wiring Overview 2-19
Figure 2.18 Control Logic Option J10–J15
FAN
BLACK
RED BLACK
BLUE
I/O TERMINAL BLOCK
DIGITAL IN3
DIGITAL IN4
+24V DC
OPTO COMMON
0-10V IN
4-20Ma IN
ANALOG COMMON
ANALOG OUTPUT
OPTO OUTPUT 1
OPTO OUTPUT 2
RS485 (DSI) SHIELD
TERMINAL BLOCK TB1
19
18
17
15
16
14
13
11
+10V DC12
7
9
8
6
5
4
3
2
1
I/O TERMINAL BLOCK
RELAY - N.O.
TERMINAL BLOCK TB2
RELAY COMMONPARAMETER A055=0
RELAY - N.C. R3
R2
R1
2021
C-349932-2WS\STD\349932\02-17
1819
SCHEMATIC, POWERFLEX 40 AC DRIVE
CONTROL LOGIC OPTION J10 THRU J15PROJECT: DRIVE
ACAD12-15-04ARS12-15-04ARS12-15-04
MASTER_PF40.DWG01
01-28-05ARS
1012358
0209-15-05
ARS1016845
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
P038 = 4 PRESET FREQ.
START/RUN FWDP036 = 2-WIRE
DIR/RUN REV
DIGITAL COMMON
DIGITAL IN2
DIGITAL IN1
STOP SNK
SRCX
SENSOR
ACTUATOR
J10,J11,J14,J15
OUT
(S)*
CABLEFLAT
(+)ZAC
IN
(-)*
(+)J12,J13
FLAT CABLE
(-)CONDUIT ADAPTORCONDUIT ADAPTOR
ZAC
PRODUCTFLOW
2-20 Control Wiring Overview
Figure 2.19 Interconnect Wire & Parts List
EXTERNAL INTERCONNECTWIRING REQUIREMENTS
EXPLANATION
INTERCONNECTION INFORMATION
SEE DRIVE USER MANUAL FOR CABLE RECOMMENDATIONS AND RESTRICTIONS.
REPLACEMENT COMPONENTS LIST
MANUFACTURER/PART NO.DESCRIPTIONSYM. PART NO.A-B
NO.WIRE DEVICE
TORQUE WIRE RANGE
POWER
TERMINAL TERMINAL
C-349932-2WS\STD\349932\02-18
19END
INTERCONNECTION, POWERFLEX 40 AC DRIVE
INTERCONNECT WIRE & PARTS LIST
PROJECT: DRIVE
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG09-15-05
061016845
ARS
0707-31-06
ARS1023319
1023635ARS
09-29-0608 09
12-15-06ARS
1026258
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
ABCDEFGH
40
41
39
38
37
36
35
28
33
34
32
31
30
29
27
26
25
24
23
22
14
20
19
18
17
16
15
13
12
11
9
10
8
7
6
5
4
2
3
1
212831 30 29 27 26 25 24 23 22 1420 19 18 17 16 15 13 12 11 910 8 7 6 5 4 23 132INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
SH:
SH:NEXT
BY
THIS DRAWING IS THE PROPERTY OF ROCKW
ELL AUTOMATION, INC. OR ITS SUBSIDIARIES AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT AS AUTHORIZED IN W
RITING BY ROCKW
ELL AUTOMATION, INC.
EA1 DRIVE UNIT N/A REFER TO C-349932-12 FOR CAT NO.F1-3 FUSES REFER TO TABLE 2 PAGE 2-3 FOR FUSE SIZE AND MANUFACTURERDS1 DISCONNECT A-B/(194R-NJ030P3 OR 194R-NJ060P3) REFER TO TABLE 2 PAGE 2-3 FOR SIZE
EA1 DEVICENET MOD A-B/22-COMM-DEA1 ETHERNET MOD A-B/22-COMM-EEA1 PROFIBUS MOD A-B/22-COMM-P
N/AN/A
N/AN/AN/A
N/AAUTO/MAN SSSS1SS2 H/O/A SEL SW A-B/800FP-SM32MX40N/A
PB2 START PB N/A A-B/800FP-F3PX10N/AFOR/REV SSSS3
STOP PBPB3 A-B/800EP-F4PX01N/ACR1
EA4
RELAY
DEVNET I/O REL
N/A
N/A
A-B/700-HA32A1
A-B/100-DNY42R
RH1 S18 OPTION ONLY
SS2 LCL-OFF-REM SS N/ARELAY N/A A-B/700-HA32A1CR1 S21 OPTION ONLY
16-19 LB-IN
16-19 LB-IN
35 LB-IN
35 Lb-IN
35 LB-IN
20 Lb-IN
--------------------------------------------------------
16-19 LB-IN
16-19 LB-IN--------------------------------------------------------
DS1-L2DS1-L3LINE-PE
DS1-L2DS1-L3LINE-PE
EA1-PEEA1-WEA1-VEA1-U
DS1-L1
DS1-L1
MTR-GROUND
INCOMINGPOWER LINES
LINE-GROUND
INCOMINGPOWER LINES
LINE-GROUND
DRIVE OUTPUT
LINE-PE
EA1-SEA1-T
EA1-R DRIVE INPUT
LINE-GROUND
16-10 GA
14-4 GA
8-2 GA
14-8 GA
14-6 GA
16-10 GA
16-10 GA
16-10 GAOPTIONNO INPUT
30A DS
T3PE
L2L3PE
L2L3PE
T2T1
L1
L1
L2L3PE
L1
A-B/800FP-SM22PX11
A-B/800FP-SM22PX11
SPEED POT/OPRATOR N/A A-B/800FP-POT6
A-B/800FP-SM32PX20
FAN FAN N/A NMB TECH/2410ML-05W-B30
SS2 H/O/A SEL SW N/A A-B/800FP-SL32CRPX50R3 OPTION
MCP1 MTR CIRCUIT PROT. N/A A-B (REFER TO TABLE 2 PAGE 2-3 FOR P3 KIT NUMBER OR P3T PART NUMBERS)
A-B/22ZC-413ZAC MASTER ZONE CONTROLLER N/AA-B/22ZC-343ZAC INFEED ZONE CONTROLLER N/AA-B/22ZC-223ZAC INTERMEDIATE ZONE CONT. N/A
EA4 DEVICENET ADAPTER N/A A-B/1734-ADNXA-B/1734-IB4
R4 OPTION ONLYN/APLC I/O MODIB4
B-FRAME
DRIVE INPUT
LINE-GROUNDL3PE
L1L2
EA1-R
LINE-PEEA1-TEA1-S
16-8 GA26-33 LB-IN
26-33 LB-IN 16-8 GAC-FRAME
NO INPUTOPTION
LINE-GROUND
POWER LINESMCP1
PE
L1
L3L2
LINE-PE
MCP1-L1
MCP1-L3MCP1-L2
INCOMING
8-2 GA
16-12 GA22 LB-IN
35 Lb-INB-FRAME DRIVE
POWER LINES
LINE-GROUND
L1L2L3PE
MCP1-L2MCP1-L3
MCP1-L1
LINE-PE
INCOMING 14-6 GA
8-2 GA35 Lb-IN
31 LB-IN
C-FRAME DRIVEMCP1
DRIVE OUTPUT
MTR-GROUND
--------------------------------------------------------T1
T3T2
PE
EA1-UEA1-VEA1-WEA1-PE
16-8 GA26-33 LB-IN
DRIVE OUTPUTB-FRAME
DRIVE OUTPUTC-FRAME
26-33 LB-IN 16-8 GA
P6/P6TOPTION
60A DSOPTIONP6/P6T
P3/P3T OPTION
P3/P3T OPTION
ZAC MASTER ZAC N/A A-B/22ZC-413 J10 & J11 OPTIONS ONLY
J10 & J11 OPTIONS ONLY
J10 & J11 OPTIONS ONLY
INFEED ZACZAC N/A A-B/22ZC-343
INTERMEDIATE ZACZAC N/A A-B/22ZC-223
A-B/800FP-SL32CRPX50A-B/100-DNY42R
R5 OPTION
N/AN/A
H/O/A SEL SWDEVNET I/O REL
SS2EA4
RECEPTACLE 24VDCRECEPTACLE,MICRO, FEMALERCPT1-4
RCPT5N/AN/A
A-B/888D-F4AC2-1A-B/888D-MA4AE1-A
F6 FUSE N/A BUSSMANN/MDA-3
A-B/800FP-SM22PX10A-B/800FP-SM22PX10OFF/RUN FWD SS
LOC/REM SSSS2SS1
N/AN/A
S20 OPTION ONLY
A-B/22-COMM-CN/ACONTORLNET MODEA1
EA1 HIM N/A A-B/22-HIM-C2S
Chapter 3
Mechanical Installation
Chapter Objectives This chapter provides information on mounting a PowerFlex 40 Standard Packaged Drive.
For information on … See page …Mounting Considerations 3-1Dimensions 3-2Layout Drawings 3-4
ATTENTION: The following information is merely a guide for proper installation. The Allen-Bradley Company 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.
Mounting Considerations Environment
Before deciding on an installation site, verify that the PowerFlex Drive Packages are not installed in an area where the ambient atmosphere contains volatile or corrosive gas, vapors or dust. The drives are to be installed per the environmental rating they have been designed for.
Maximum Surrounding Air Temperature
PowerFlex 40 Standard Packaged Drives are designed to operate at -10° to 40°C (14° to 104°F) surrounding air temperature. The design of the PowerFlex Standard Packaged Drive supports indoor and outdoor applications that are not in direct sunlight.
Minimum Mounting Clearances
Be sure there is adequate clearance for air circulation around the drive. For best air movement, do not mount drives directly above each other. Note that no devices are to be mounted behind the drive. This area must be kept clear of all control and power wiring.
!
3-2 Mechanical Installation
Figure 3.1 Minimum Mounting Clearances
ON
FF
O
152.4(6.00)
152.4(6.00)
152.4(6.00)
152.4(6.00)
Drive orother device
Dimensions are in millimeters and (inches).
Dimensions Figure 3.2 Frame B Dimensions Dimensions are in millimeters and (inches).
ON
FF
O
355.6(14.00)
9.4(0.37)
393.2(15.48)
405.9(15.98)
336.6(13.25)
287.5(11.32)
177.8(7.00)
69.3(2.73)
355.1(13.98)
342.4(13.48)
304.8(12.00)
285.8(11.25)
Optional mounting bracket orientation.
6.35(0.25)
Mechanical Installation 3-3
Figure 3.3 Frame C Dimensions Dimensions are in millimeters and (inches).
ON
FF
O
19.1 (0.75)
19.1(0.75)
12.7 (0.50)
177.8(7.00)
Detail
146.1(5.75)
460.8(18.14)
406.4(16.00)
427.2(16.82)
16.0(0.63)
425.2(16.74)
457.2(18.00)
Frame C
9.7(0.38)
P3 Option383.3
(15.09)P6 Option
364.2(14.34)
3-4 Mechanical Installation
Layout Drawings Figure 3.4 PowerFlex 40 Frame B Layout Drawing
Mechanical Installation 3-5
Figure 3.5 PowerFlex 40 Frame C Layout Drawing
3-6 Mechanical Installation
Figure 3.6 PowerFlex 40 General Option Layout Drawing
C-349932-3WS\STD\349932\03-02
34
LAYOUT DRAWING, PF40 AC DRIVE,
NEMA 4/4X/12-(0.5-15 HP) 3PH, 480V
ACAD07-15-04ARS07-15-04ARS07-15-04
MASTER_PF40.DWG08
09-15-05ARS
1016845
0907-31-06
ARS1023319
1023635ARS
09-29-0610 11
12-15-06ARS
1026258
12345678910111213141516171819202223242526272829303132333435363738394041
12345678910111213141516171819202223242526272829303132333435363738394041
PO
NM
LK
JI
HG
FE
DC
BA
SNK
SRC
BR+
BR-
R2
L2L3
T2T1
T3L1
TB2
L1L3
L2T1
T3T2
R1
SelEsc R
EV
RUN
FWD
PROGRAM
VOLTS
HERTZ
AMPS
FAULTPOWER TERMINAL BLOCK
BR-
BR+
TB1
14
42
13
0-20mA
R313
1112
0-10V
95
87
6
1716
1518
19RJ45
B FRAME WITH COVER REMOVEDBOTTOM W
IRE COVER CAN BE REMOVED AND DISCARDED IF PRESENT.
EA1
AUTOMANUAL(1)(2)(3)
REVERSEFORW
ARDDS1
L1/T1
CLEARANCE FOR LUG COVER
CLEARANCE FOR LUG COVER
F3
F2
F1
FROM ONE TERMINAL HOLE
DO NOT RUN 2 POWER W
IRES
PORT
DEVICENET
RS485/HIM
PORT
COMMUNICATION CARD
FAN
+RED
-BLACK
MODNETOUTPUTA 2
INPUT3
OUTPUT B 1 0
CLERANCE FOR AUX CONTACT
TYPICAL CONTROL RELAYMAC# 123775, CR1
6 8 5 43 1
42 41
34 33
AUX CONTACTSW
HEN ORDERED
S4 OPTION
12
S20 OPTION
REMOTELOCAL
OFFRUNLOCAL CONTROL
4(2)
(1)(3)
3
4(2)
(1)(3)
3
R3 & R5
12(1) 4(2)(3)
3
S8 OPTIONS8 W
HEN ORDERED
FORWARD
4(2)(3)
3
REVERSE
(1)
WITH S7 OPTION
S21 OPTION
(1) 4(2)(3)
REMOTE3 OFFLOCAL
S7 OPTION
(3)(1)(2)
START
12(3)
(1)(2)
STOP
12 3
45
678
+-
34
CR1
FWD
REMOTE HIM/ RS485
DEVICENET
POWER TERMINAL BLOCK PORTTB2
BOTTOM WIRE COVER CAN BE REMOVED AND DISCARDED IF PRESENT.
C FRAME WITH COVER REMOVED
BR+
BR-
L2L1
T2L3
T1P2
T3P1
TB1
SelEsc R
EV
RUN
FWD
PROGRAM
VOLTS
HERTZ
AMPS
FAULT
R3
L3L2
L1P1
P2T3
T1T2
R2R1
BR-
BR+ 13
0-10V
0-20mA
SNK
SRC
11 21
12 3
1615
76
54
14
91819
17 8
PORT
RJ45
EA1
(3)(2)
(1)
HAND
3&4=NO
33 44
AUTOOFF
34
PRODUCT FLOW
ZAC
J10, J11, J12, J13, J14, J15 OPTION
B-FRAME DRIVEC-FRAME DRIVE
P3/P3T OPTIONS
MCP1MCP1
EA4
1 5
NETWORK
SUBNET
IB4
Dig In
StatusModule
StatusNetwork
Sink24 VDC
Node
0
1
R4 OPTION
CLERANCE FOR AUX CONTACT
CLERANCE FOR AUX CONTACT
34 3342 41
WHEN ORDERED
AUX CONTACTS42 41
34 33
AUX CONTACTSW
HEN ORDERED
P6/P6T OPTIONSS1 OPTION
-BLUE
+BLACK
L1/T1L2/T2
L3/T3
T1/L1T2/L2
T3/L3
IT
O
4.0A
2.5
L1/T1L2/T2
L3/T3
T1/L1T2/L2
T3/L3
IT
O
32A
23
OPTIONS
1734IB4
1734-ADNX
33
12
12
66
45
45
99
78
78
1212
1011
1011
1515
1314
1314
JUMPER TERMINALS 1,2,3 AND 4 ON THE INPUT SIDE USING 18GA.
USE THE OUTPUT SIDE OF TERMINAL 3 TO CONNECT BROWN W
IRESOF RECPTACLE 1 AND RECEPTACLE 2 ONLY.
JUMPER TERMINALS 5,6 AND 7 ON THE INPUT SIDE USING 16 GA.
2 GOING TO EA4.CONNECT ONLY 1 W
IRE TO THE OUTPUT SIDE OF TERMINALS 1 AND
6 (BLUE WIRES FROM RECEPTACLES 3 AND 4 RESPECTIVELY).
CONNECT ONLY 1 WIRE TO THE OUTPUT SIDE OF TERMINALS 5 AND
R5 OPTION
INPUTSIDE
OUTPUTSIDE
BLUE WIRE 103819.
BLUE WITH W
HITE TRACER 16GA. 144183
K D TL E HB R WCW
SL CCW
RH1
S18 OPTION
L2/T2L3/T3
T1/L1T2/L2
T3/L3
43
3&4=NO
43
34
3 4
3&4=NO
3 4 OFFAUTO
4 43 3 HAND
(1)(2)(3)
3&4=NO
3
3&4=NO
4
INDEX NO.
REFERENCE DWG.
DATE
APP'D
DATE
DATE
DR.
TITLE:
DWG.
NO.REV.
DATEECN NUM
BER
LEAD ENG.
BE USED ONLY FOR REFERENCE IN DEALING WITH ROCKW
ELL
REPRESENTATIVE SO CERTIFIES ON ITS FACE.
THIS DOCUMENT IS PROPRIETARY TO ROCKWELL AUTOMATION AND
ITS CONTENTS ARE CONFIDENTIAL. THIS DOCUMENT SHALL
AUTOMATION AND SHALL NOT BE DISCLOSED TO ANY THIRD PARTIESW
ITHOUT OUR EXPRESS APPROVAL. IF YOU CAN NOT COMPLY
THE CONTENTS OF THIS DOCUMENT ONLY IF OUR AUTHORIZED
SH:
SH:NEXT
WITH THE ABOVE, YOU SHOULD IM
MEDIATELY RETURN THIS
DOCUMENT TO ROCKWELL AUTOMATION. W
E ARE RESPONSIBLE FOR
BY
Appendix A
SpecificationsTable A.A Standard Packaged Drive Products
Input/Output Ratings Output Frequency: 0-400 Hz (Programmable) Efficiency: 97.5% (Typical)
ApprovalsUL®
LISTED 966X
IN D C O NT EQ
UL508C UL®
LISTED 966X
IN D C O NT EQ
C CSA C 22.2 No. 14
Fuses and Power Disconnecting Means
140M Motor Circuit Protector: Provides branch circuit protection, 65 kA short circuit withstand194R Fused Disconnect: Provides branch circuit protection, 100 kA short circuit withstand, Class J fuses
Protective Features Over Voltage: 480V AC Input – Trip occurs at 810V DC bus voltage (equivalent to 575V AC incoming line)Under Voltage: 480V AC Input – Trip occurs at 390V DC bus voltage (equivalent to 275V AC incoming line)
Environment Ambient Operating Temperature, NEMA 4/12, 4X (IP66): –10 to 40 degrees C (14 to 104 degrees F)
(1) The design of the PowerFlex 40 Standard Packaged Drive NEMA 4/12 and 4X packages support indoor and outdoor applications that are not in direct sunlight. When optional Door Mounted HIM is supplied, enclosure is rated for indoor use only.
(1)
Cooling Method: Fan (All drive ratings)
Control Carrier Frequency: 2-4 kHz. Drive rating and heat calculations are based on 4 kHz.
Table A.B Standard PowerFlex 40 Drives
Digital Control Inputs(Input Current = 6 mA)
SRC (Source) Mode: 18 – 24 Volts = ON; 0 – 6 Volts = OFFSNK (Sink) Mode: 0 – 6 Volts = ON; 18 – 24 Volts = OFF
Analog Control Inputs 4-20mA Analog: 250 ohm input impedance0-10V DC Analog: 100k ohm input impedanceExternal Pot: 1-10k ohms, 2 Watt minimum
Control Output Programmable Output (form C relay) Resistive Rating: 3.0A at 30V DC, 3.0A at 125V AC, 3.0A at 240V AC Inductive Rating: 0.5A at 30V DC, 0.5A at 125V AC, 0.5A at 240V AC
Opto Outputs 30V DC, 50 mA Non-inductive
Analog Output (10-bit) 0-10V, 1k ohm Min.
Fuses and Circuit Breakers Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.Recommended Circuit Breakers: HMCP circuit breaker or equivalent.
Protective Features Motor Protection: I2t overload protection – 150% for 60 Secs, 200% for 3 Secs (Provides Class 10 protection)Overcurrent: 200% hardware limit, 300% instantaneous faultControl Ride Through: Minimum ride through is 0.5 Secs - typical value 2 SecsFaultless Power Ride Through: 100 milliseconds
Dynamic Braking Internal brake IGBT included with all ratings
Environment Altitude: 1000 m (3300 ft) max. without deratingStorage Temperature: –40 to 85 degrees C (–40 to 185 degrees F)Atmosphere: Important: Drive must not be installed in an area where the ambient atmosphere contains
volatile or corrosive gas, vapors or dust. If the drive is not going to be installed for a period of time, it must be stored in an area where it will not be exposed to a corrosive atmosphere.
Relative Humidity: 0 to 95% non-condensingShock (operating): 15G peak for 11ms duration (±1.0ms)Vibration (operating): 1G peak, 5 to 2000 Hz
Control Frequency AccuracyDigital Input: Within ±0.05% of set output frequency.Analog Input: Within 0.5% of maximum output frequency.Analog Output: ±2% of full scale, 10-bit resolution
Speed Regulation - Open Loop with Slip Compensation: ±2% of base speed across a 40:1 speed range. 1% of base speed across a 60:1 speed range.
Stop Modes: Multiple programmable stop modes including - Ramp, Coast, DC-Brake, Ramp-to-Hold and S Curve.Accel/Decel: Two independently programmable accel and decel times. Each time may be programmed from 0 -
600 seconds in 0.1 second increments.Intermittent Overload: 150% Overload capability for up to 1 minute; 200% Overload capability for up to 3 secondsElectronic Motor Overload Protection: Class 10 protection with speed sensitive response.
A-2 Specifications
Notes:
Appendix BReplacement PartsTable B.A ComponentsDescription Designation Voltage HP Part Number ManufacturerMotor Circuit ProtectorOption P3 or P3T
MCP1 480V AC 0.5 140M-C2E-B40
(2) Part of Motor Circuit Protector Replacement Kit.
(2) Allen-Bradley1.0 140M-C2E-B63(2) Allen-Bradley2.0 140M-D8E-C10(2) Allen-Bradley3.0 140M-D8E-C16(2) Allen-Bradley5.0 140M-D8E-C25(2) Allen-Bradley7.5 140M-F8E-C25(2) Allen-Bradley10 140M-F8E-C32(2) Allen-Bradley15 140M-F8E-C45(2) Allen-Bradley
Replacement Kit
(1) Replacement Kit includes Motor Circuit Protector and top and bottom terminal labels/instructions. Does not include handle, adaptor, or connection rod.
(1)
Option P3MCP1 480V AC 0.5 363326 Allen-Bradley
1.0 363333 Allen-Bradley2.0 363337 Allen-Bradley3.0 363341 Allen-Bradley5.0 363345 Allen-Bradley7.5 363349 Allen-Bradley10 363353 Allen-Bradley15 363357 Allen-Bradley
Operator Handle Option P3 or P3T
MCP1 480V AC 0.5-57.5-15
190-HS4140M-C-DN66
Allen-BradleyAllen-Bradley
Operator Handle Adaptor Option P3 or P3T
MCP1 480V AC 0.5-15 140M-D-HA Allen-Bradley
Operator Shaft Option P3 or P3T
MCP1 480V AC 0.5-57.5-15
194R-NX12140M-C-DS
Allen-BradleyAllen-Bradley
Operator Terminal Markings
MCP1 480V AC 0.5-5.0 A46006-086-01(2)
140M-C-TE(2)Allen-BradleyAllen-Bradley
7.5-15 A46006-091-01(2)
140M-F-TE(2)Allen-BradleyAllen-Bradley
Disconnect Switch Option P6 or P6T
DS1 480V AC 0.5-10 194R-NJ030P3 Allen-Bradley15 194R-NJ060P3 Allen-Bradley
Operator Handle Option P6 or P6T
DS1 480V AC 0.5-15 194R-HS4 Allen-Bradley
Operator Shaft Option P6 or P6T
DS1 480V AC 0.5-15 194R-R1 Allen-Bradley
Main Fuses Option P6 or P6T
F1, F2, F3 480V AC 0.5 LPJ-3SP BussmanAJT-3 Ferraz-Shawmut
1.0 LPJ-6SP Bussman2.0 LPJ-10 Bussman
LPJ-10SP BussmanAJT-10 Ferraz-Shawmut
3.0 LPJ-15 BussmanLPJ-15SP Bussman
5.0 LPJ-20 BussmanLPJ-20SP BussmanAJT-20 Ferraz-Shawmut
7.5 LPJ-25 BussmanLPJ-25SP BussmanAJT-25 Ferraz-Shawmut
10 LPJ-30 BussmanLPJ-30SP BussmanAJT-30 Ferraz-Shawmut
15 LPJ-50 BussmanLPJ-50SP Bussman
B-2 Replacement Parts
Table B.A Components (Continued)
Table B.B Communication OptionsDescription Designation Voltage HP Part Number ManufacturerControlNet EA1 All All 22-COMM-C Allen-BradleyDeviceNet EA1 All All 22-COMM-D Allen-BradleyEtherNet EA1 All All 22-COMM-E Allen-BradleyPROFIBUS EA1 All All 22-COMM-P Allen-BradleyAdaptor
Frame BFrame C
EA1EA1
AllAll
AllAll
22B-CCB22B-CCC
Allen-BradleyAllen-Bradley
Table B.C Quick Disconnect OptionsDescription Designation Voltage HP Part Number ManufacturerDeviceNet - Bottom E22 All All 41358N Brad HarrisonDeviceNet - L Side E23 All All 41358N Brad Harrison
Table B.D HIM OptionsDescription Designation Voltage HP Part Number ManufacturerDoor MountedIP 66 (NEMA/UL Type
All All 22-HIM-C2S Allen-Bradley
Description Designation Voltage HP Part Number ManufacturerDrive Module(with Heatsink)
EA1 480V AC 0.5 22B-D1P4F104 Allen-Bradley1.0 22B-D2P3F104 Allen-Bradley2.0 22B-D4P0F104 Allen-Bradley3.0 22B-D6P0F104 Allen-Bradley5.0 22B-D010F104 Allen-Bradley7.5 22B-D012F104 Allen-Bradley10 22B-D017F104 Allen-Bradley15 22B-D024F104 Allen-Bradley
Drive Module(Plate Drive)
EA1 480V AC 0.5 22B-D1P4H204 Allen-Bradley1.0 22B-D2P3H204 Allen-Bradley2.0 22B-D4P0H204 Allen-Bradley3.0 22B-D6P0H204 Allen-Bradley5.0 22B-D010H204 Allen-Bradley7.5 22B-D012H104 Allen-Bradley10 22B-D017H104 Allen-Bradley15 22B-D024H104 Allen-Bradley
Replacement Parts B-3
Table B.E Operator Devices/Control OptionsOption Description Designation Voltage HP Part Number ManufacturerOption S1 Selector Switch
Anti-Rotation SwitchMounting LatchContact Block - 3 N.O.Legend Plate
SS2SS2SS2SS2SS2
All All 800FP-SM32800F-ALC1800F-ALP800F-X10162084
Allen-BradleyAllen-BradleyAllen-BradleyAllen-BradleyAllen-Bradley(8)
Option S4 Selector SwitchAnti-Rotation SwitchMounting LatchContact Block - 1 N.C.Legend Plate
SS1SS1SS1SS1SS1
All All 800FP-SM22800F-ALC1800F-ALM800F-X01162200
Allen-BradleyAllen-BradleyAllen-BradleyAllen-BradleyAllen-Bradley(8)
Option S7 Push Button (Green)Push Button (Red)Mounting LatchContact Block - 1 N.O.Contact Block - 1 N.C.Legend PlateLegend Plate
PB2PB3PB2, PB3PB2PB3PB2PB3
All All 800FP-F3800FP-E4800F-ALP800F-X10800F-X01162800162799
Allen-BradleyAllen-BradleyAllen-BradleyAllen-BradleyAllen-BradleyAllen-Bradley(8)
Allen-Bradley(8)
Option S8 Selector SwitchAnti-Rotation SwitchMounting LatchContact Block - 1 N.O.Contact Block - 1 N.C.Legend Plate
SS3SS3SS3SS3SS3SS3
All All 800FP-SM22800F-ALC1800F-ALP800F-X10800F-X01(7)
162801
Allen-BradleyAllen-BradleyAllen-BradleyAllen-BradleyAllen-Bradley(8)
Allen-Bradley
Option S18 Potentiometer/Operator RH1 All All 800F-POT6 Allen-Bradley
Option S20 Selector SwitchAnti-Rotation SwitchMounting LatchContact Block - 1 N.O.Legend PlateLegend Plate
SS1, SS2SS1, SS2SS1, SS2SS1, SS2SS1SS2
All All 800FP-SM22800F-ALC1800F-ALP800F-X10186532345583
Allen-BradleyAllen-BradleyAllen-BradleyAllen-BradleyAllen-Bradley(8)
Allen-Bradley(8)
Option S21 Selector SwitchAnti-Rotation SwitchMounting LatchContact Block - 2 N.O.Legend PlateMOVRelayRelay Socket (Base)Relay Retainer Clip
SS2SS2SS2SS2SS2CR1CR1CR1CR1
All All 800FP-SM22800F-ALC1800F-ALP800F-X01330856V130LA10A700-HA 32A1700-HN125700HN159
Allen-BradleyAllen-BradleyAllen-BradleyAllen-BradleyAllen-Bradley(8)
HarrisAllen-BradleyAllen-BradleyAllen-Bradley
Option R3/R5 Selector SwitchAnti-Rotation SwitchAux Contact Adapter(1)
Aux Contact(1)
Aux Contact(2)
Contact Block - 1 N.O.Legend PlateI/O ModuleQuick Disconnect(3)
Quick Disconnect(3)
Terminal Block(3)
Fuse Block(3)
Fuse(3)
SS2SS2DS1DS1MCP1SS2SS2EA4RCPT1-RCPT4RCPT5TB4F6F6
All All 800FP-SL32CR800F-ALC1194R-AA195-GA11140M-C-ASA11800F-X10162084100-DNY42R888D-F4AMC2888D-M4AE1-11492-WTF31492-H6MDA-3
Allen-BradleyAllen-BradleyAllen-BradleyAllen-BradleyAllen-BradleyAllen-BradleyAllen-Bradley(8)
Allen-BradleyAllen-BradleyAllen-BradleyAllen-BradleyAllen-BradleyBussmann
Option R4 DeviceNet AdaptorPoint I/O Terminal BaseInput I/O Module
EA4EA4IB4
All All 1734-ADNX1734-TB3SQ101734-IB4
Allen-BradleyAllen-BradleyAllen-Bradley
Option J10-J15 Master ZAC(4)
Infeed ZAC(5)
Intermediate(6)
Output ActuatorCable GlandGasket
ZACZACZACZAC
All All 22ZC-41322ZC-34322ZC-22360-2743-21485A-CAD314259-7
Allen-BradleyAllen-BradleyAllen-BradleyAllen-BradleyAllen-BradleyCrouse-Hinds
(1) P6 and P6T option only. (2) P3 and P3T option only.(3) R5 option only. (4) J10 & J11 only.(5) J12 & J13 only. (6) J14 & J15 only(7) Option S8 when S7 is not ordered.(8) Legend plates are not stocked for general sale. A custom quote is required to purchase.
B-4 Replacement Parts
Table B.F MiscellaneousDescription Designation Voltage HP Part Number ManufacturerFan FAN All 0.5-5.0 2410ML-05W-B30-B00 NMB Tech
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Publication 23B-IN001F-EN-P – January 2007 350679-P06Supersedes August 2006 Copyright © 2007 Rockwell Automation, Inc. All rights reserved. Printed in USA.