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Installation Instructions Adjustable Frequency AC Standard Packaged Drives

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Page 1: Adjustable Frequency AC Standard Packaged Drives

Installation Instructions

Adjustable Frequency AC Standard Packaged Drives

Page 2: 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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Page 3: Adjustable Frequency AC Standard Packaged Drives

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

Page 4: Adjustable Frequency AC Standard Packaged Drives

2 Table of Contents

Page 5: Adjustable Frequency AC Standard Packaged Drives

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.

Page 6: Adjustable Frequency AC Standard Packaged Drives

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

Page 7: Adjustable Frequency AC Standard Packaged Drives

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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Page 8: Adjustable Frequency AC Standard Packaged Drives

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.

Page 9: Adjustable Frequency AC Standard Packaged Drives

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.

Page 10: Adjustable Frequency AC Standard Packaged Drives

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.

Page 11: Adjustable Frequency AC Standard Packaged Drives

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.

Page 12: Adjustable Frequency AC Standard Packaged Drives

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)

Page 13: Adjustable Frequency AC Standard Packaged Drives

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)

Page 14: Adjustable Frequency AC Standard Packaged Drives

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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Page 15: Adjustable Frequency AC Standard Packaged Drives

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

Page 16: Adjustable Frequency AC Standard Packaged Drives

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

Page 17: Adjustable Frequency AC Standard Packaged Drives

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

Page 18: Adjustable Frequency AC Standard Packaged Drives

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

Page 19: Adjustable Frequency AC Standard Packaged Drives

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

Page 20: Adjustable Frequency AC Standard Packaged Drives

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

Page 21: Adjustable Frequency AC Standard Packaged Drives

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

Page 22: Adjustable Frequency AC Standard Packaged Drives

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

Page 23: Adjustable Frequency AC Standard Packaged Drives

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

Page 24: Adjustable Frequency AC Standard Packaged Drives

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

Page 25: Adjustable Frequency AC Standard Packaged Drives

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

Page 26: Adjustable Frequency AC Standard Packaged Drives

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

Page 27: Adjustable Frequency AC Standard Packaged Drives

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

Page 28: Adjustable Frequency AC Standard Packaged Drives

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

Page 29: Adjustable Frequency AC Standard Packaged Drives

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

Page 30: Adjustable Frequency AC Standard Packaged Drives

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

Page 31: Adjustable Frequency AC Standard Packaged Drives

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

Page 32: Adjustable Frequency AC Standard Packaged Drives

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

Page 33: Adjustable Frequency AC Standard Packaged Drives

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

Page 34: Adjustable Frequency AC Standard Packaged Drives

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

Page 35: Adjustable Frequency AC Standard Packaged Drives

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"

Page 36: Adjustable Frequency AC Standard Packaged Drives

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"

Page 37: Adjustable Frequency AC Standard Packaged Drives

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"

Page 38: Adjustable Frequency AC Standard Packaged Drives

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"

Page 39: Adjustable Frequency AC Standard Packaged Drives

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"

Page 40: Adjustable Frequency AC Standard Packaged Drives

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

Page 41: Adjustable Frequency AC Standard Packaged Drives

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

Page 42: Adjustable Frequency AC Standard Packaged Drives

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

Page 43: Adjustable Frequency AC Standard Packaged Drives

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

Page 44: Adjustable Frequency AC Standard Packaged Drives

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

Page 45: Adjustable Frequency AC Standard Packaged Drives

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.

Page 46: Adjustable Frequency AC Standard Packaged Drives

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)

Page 47: Adjustable Frequency AC Standard Packaged Drives

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

Page 48: Adjustable Frequency AC Standard Packaged Drives

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

Page 49: Adjustable Frequency AC Standard Packaged Drives

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

Page 50: Adjustable Frequency AC Standard Packaged Drives

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

Page 51: Adjustable Frequency AC Standard Packaged Drives

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.

!

Page 52: Adjustable Frequency AC Standard Packaged Drives

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)

Page 53: Adjustable Frequency AC Standard Packaged Drives

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)

Page 54: Adjustable Frequency AC Standard Packaged Drives

3-4 Mechanical Installation

Layout Drawings Figure 3.4 PowerFlex 40 Frame B Layout Drawing

Page 55: Adjustable Frequency AC Standard Packaged Drives

Mechanical Installation 3-5

Figure 3.5 PowerFlex 40 Frame C Layout Drawing

Page 56: Adjustable Frequency AC Standard Packaged Drives

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

Page 57: Adjustable Frequency AC Standard Packaged Drives

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.

Page 58: Adjustable Frequency AC Standard Packaged Drives

A-2 Specifications

Notes:

Page 59: Adjustable Frequency AC Standard Packaged Drives

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

Page 60: Adjustable Frequency AC Standard Packaged Drives

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

Page 61: Adjustable Frequency AC Standard Packaged Drives

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.

Page 62: Adjustable Frequency AC Standard Packaged Drives

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

Page 63: Adjustable Frequency AC Standard Packaged Drives
Page 64: Adjustable Frequency AC Standard Packaged Drives

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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.