USER MANUAL Series B, Vector Control Firmware & Up

Transcription

1 PowerFlex 7 AC Drives USER MANUAL Series B, Vector Control Firmware 4. & Up

2 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-. available from your local Rockwell Automation sales office or online at 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 a hazard, and 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, DriveExplorer, DriveExecutive, PLC, Force Technology, DPI, and SCANport are either trademarks or registered trademarks of Rockwell Automation, Inc. ControlNet is a trademark of ControlNet International, Ltd. DeviceNet is a trademark of the Open DeviceNet Vendor Association.

3 Summary of Changes The information below summarizes the changes to the PowerFlex 7 User Manual, publication 2B-UM2 since the last release. Manual Updates Change General Maintenance Updates Page(s) All

4 soc-ii Summary of Changes Notes:

5 Table of Contents Preface Overview Who Should Use this Manual? P- What Is Not in this Manual P- ATEX Approved Drives & Motors P- Reference Materials P-2 Manual Conventions P-2 Drive Frame Sizes P-3 General Precautions P-3 Catalog Number Explanation P-5 Chapter Installation/Wiring Opening the Cover Mounting Considerations AC Supply Source Considerations General Grounding Requirements Fuses and Circuit Breakers Power Wiring Using Input/Output Contactors Disconnecting MOVs and CM Capacitors -4 I/O Wiring Reference Control Auto/Manual Examples Lifting/Torque Proving Using PowerFlex Drives w/regen Units. -26 Common Bus/Precharge Notes EMC Instructions Chapter 2 Start Up Prepare For Drive Start-Up Status Indicators Start-Up Routines Running S.M.A.R.T. Start Running an Assisted Start Up Chapter 3 Programming and Parameters About Parameters How Parameters are Organized Monitor File Motor Control File Speed Command File Dynamic Control File Utility File Communication File Inputs & Outputs File Applications File Pos/Spd Profile File Parameter Cross Reference by Name Parameter Cross Reference by Number 3-75 Chapter 4 Troubleshooting Faults and Alarms Drive Status Manually Clearing Faults Fault Descriptions Clearing Alarms Alarm Descriptions Common Symptoms/Corrective Actions 4-3 Testpoint Codes and Functions

6 ii Table of Contents Appendix A Supplemental Drive Information Specifications A- Communication Configurations A-6 Output Devices A-9 Drive, Fuse & Circuit Breaker Ratings... A-9 Dimensions A-2 Frame Cross Reference A-34 Appendix B HIM Overview External & Internal Connections B- LCD Display Elements B-2 ALT Functions B-2 Menu Structure B-3 Viewing and Editing Parameters B-5 Linking Parameters B-6 Removing/Installing the HIM B-8 Appendix C Application Notes Adjustable Voltage Operation C- External Brake Resistor C-3 Lifting/Torque Proving C-4 Limit Switches for Digital Inputs C- Minimum Speed C-2 Motor Control Technology C-2 Motor Overload C-4 Motor Overload Memory Retention.... C-6 Overspeed C-6 Position Indexer/Speed Profiler C-7 Power Loss Ride Through C-27 Process PID C-28 Reverse Speed Limit C-3 Skip Frequency C-32 Sleep Wake Mode C-34 Start At PowerUp C-36 Stop Mode C-36 Voltage Tolerance C-4 Appendix D Index ATEX Approved Drives General D- Motor Requirements D-2 Drive Wiring D-3 Drive Configuration D-3 Start-Up/Periodic Testing Requirement... D-4

7 Preface Overview The purpose of this manual is to provide you with the basic information needed to install, start-up and troubleshoot the PowerFlex 7 Adjustable Frequency AC Drive with Vector Control. For information on... See page... Who Should Use this Manual? P- What Is Not in this Manual P- Reference Materials P-2 ATEX Approved Drives & Motors P- Manual Conventions P-2 Drive Frame Sizes P-3 General Precautions P-3 Catalog Number Explanation P-5 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 7 Series B User Manual is designed to provide only basic start-up information for the Vector Control drive, Frames -6. For Frame 7- information, refer to the Frame 7- Installation Instructions, publication 2B-IN4. For detailed drive information, refer to the PowerFlex Reference Manual, publication PFLEX-RM4. Refer to the PowerFlex 7 Series A User Manual (publication 2B-UM) for Standard Control information. Literature is available online at literature. Refer to Reference Materials on the next page. ATEX Approved Drives & Motors For detailed information on using ATEX approved drives and motors, refer to Appendix D.

8 P-2 Overview Reference Materials The following manuals are recommended for general drive information: Title Publication Available Online at Wiring and Grounding Guidelines for DRIVES-IN PWM AC Drives Preventive Maintenance of Industrial DRIVES-TD Control and Drive System Equipment Safety Guidelines for the Application, SGI-. Installation and Maintenance of Solid State Control /literature A Global Reference Guide for -2. Reading Schematic Diagrams Guarding Against Electrostatic Damage For detailed PowerFlex 7 information: Title Publication Available Online at PowerFlex Reference Manual PFLEX-RM4 Frame 7- Installation Instructions 2B-IN4 literature Series A User Manual 2B-UM For Allen-Bradley Drives Technical Support: Title Allen-Bradley Drives Technical Support Online at Manual Conventions In this manual we refer to the PowerFlex 7 Adjustable Frequency AC Drive as; drive, PowerFlex 7 or PowerFlex 7 Drive. 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 Can Cannot May Must Shall Should Should Not Meaning Possible, able to do something Not possible, not able to do something Permitted, allowed Unavoidable, you must do this Required and necessary Recommended Not recommended

9 Overview P-3 Drive Frame Sizes Similar PowerFlex 7 drive sizes are grouped into frame sizes to simplify spare parts ordering, dimensioning, etc. A cross reference of drive catalog numbers and their respective frame size is provided in Appendix A. General Precautions!!!!!! ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference A-B publication , 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 DC bus voltage at the +DC & DC terminals of the Power Terminal Block (refer to Chapter for location). The voltage must be zero. ATTENTION: Risk of injury or equipment damage exists. DPI or SCANport host products must not be directly connected together via 22 cables. Unpredictable behavior can result if two or more devices are connected in this manner. ATTENTION: An incorrectly applied or installed bypass system can result in component damage or reduction in product life. The most common causes are: Wiring AC line to drive output or control terminals. Improper bypass or output circuits not approved by Allen-Bradley. Output circuits which do not connect directly to the motor. Contact Allen-Bradley for assistance with application or wiring.

10 P-4 Overview!! ATTENTION: The adjust freq portion of the bus regulator function is extremely useful for preventing nuisance overvoltage faults resulting from aggressive decelerations, overhauling loads, and eccentric loads. It forces the output frequency to be greater than commanded frequency while the drive's bus voltage is increasing towards levels that would otherwise cause a fault. However, it can also cause either of the following two conditions to occur.. Fast positive changes in input voltage (more than a % increase within 6 minutes) can cause uncommanded positive speed changes. However an OverSpeed Limit fault will occur if the speed reaches [Max Speed] + [Overspeed Limit]. If this condition is unacceptable, action should be taken to ) limit supply voltages within the specification of the drive and, 2) limit fast positive input voltage changes to less than %. Without taking such actions, if this operation is unacceptable, the adjust freq portion of the bus regulator function must be disabled (see parameters 6 and 62). 2. Actual deceleration times can be longer than commanded deceleration times. However, a Decel Inhibit fault is generated if the drive stops decelerating altogether. If this condition is unacceptable, the adjust freq portion of the bus regulator must be disabled (see parameters 6 and 62). In addition, installing a properly sized dynamic brake resistor will provide equal or better performance in most cases. Important: These faults are not instantaneous. Test results have shown that they can take between 2-2 seconds to occur. ATTENTION: Loss of control in suspended load applications can cause personal injury and/or equipment damage. Loads must always be controlled by the drive or a mechanical brake. Parameters 6-6 are designed for lifting/torque proving applications. It is the responsibility of the engineer and/or end user to configure drive parameters, test any lifting functionality and meet safety requirements in accordance with all applicable codes and standards.

11 Overview P-5 Catalog Number Explanation Position B D 2P A 3 A Y N A R C NN AD a b c d e f g h i j k l m n a Drive Code Type 2B PowerFlex 7 b Voltage Rating Code Voltage Ph. Prechg. B 24V ac 3 - C 4V ac 3 - D 48V ac 3 - E 6V ac 3 - F 69V ac 3 - H 54V dc - N J 65V dc - N N 325V dc - Y P 54V dc - Y R 65V dc - Y T 8V dc - Y W 932V dc - Y Only available for Frame 5 & Frame 6 drives. Code c ND Rating 28/24V, 6 Hz Input 28V Amps 24V Amps Hp 2P P P P c2 ND Rating 4V, 5 Hz Input Code Amps kw P P P P P c3 ND Rating 48V, 6 Hz Input Code Amps Hp P..5 2P 2.. 3P P P c4 ND Rating 6V, 6 Hz Input Code Amps Hp P7.7. 2P P P P c5 ND Rating 69V, 5 Hz Input Code Amps kw

12 P-6 Overview Position B D 2P A 3 A Y N A R C NN AD a b c d e f g h i j k l m n d Enclosure Code Enclosure A IP2, NEMA/UL Type Flange Mount F Front: IP2, NEMA/UL Type Open Back/Heatsink: IP54, NEMA/UL Type 2 Stand-Alone/Wall Mount G IP54, NEMA/UL Type 2 Only available for Frame 5 & Frame 6 drives, 4 69V. e HIM Code Operator Interface Blank Cover 3 Full Numeric LCD 5 Prog. Only LCD Remote (Panel Mount), IP66, NEMA/UL J Type 2 Full Numeric LCD HIM Remote (Panel Mount), IP66, NEMA/UL K Type 2 Prog. Only LCD HIM Only available with Stand-Alone IP54 drives. f Documentation Code Type A Manual N No Manual Chinese C Documentation Brake Resistor Code w/resistor Y Yes N No Not available for Frame 3 drives or larger. h Emission Code CE Filter CM Choke A Yes Yes B Yes No Note: 6V class drives below 77 Amps (Frames -4) are declared to meet the Low Voltage Directive. It is the responsibility of the user to determine compliance to the EMC directive. Code B C D E R S N i j Comm Slot Version BACnet ControlNet (Coax) DeviceNet EtherNet/IP Remote I/O RS485 DF None k I/O Code Control I/O Volts A Std. 24V dc/ac B Std. 5V ac C Vector 24V dc D Vector 5V ac N Std. None Vector Control Option utilizes DPI Only. l Feedback Code Type None Encoder, 2V/5V m Future Use n Special Firmware Code Type AD 6 Hz Maximum AE Cascading Fan/Pump Control Must be used with Vector Control option C or D (Position k). Positions m-n are only required when custom firmware is supplied. Code Y g Brake w/brake IGBT Yes N No Brake IGBT is standard on Frames -3 and optional on Frames 4-6.

13 S.M.A.R.T. Exit Lang Auto / Man Remove Esc Alt Sel Exp Param # CAUTION Jog HOT surfaces can cause severe burns PORT MOD NET A NET B POWER STS Chapter Installation/Wiring This chapter provides information on mounting and wiring the PowerFlex 7 Drive, Frames -6. For information on.. See page For information on.. See page Opening the Cover - Disconnecting MOVs and -4 Mounting Considerations -2 Common Mode Capacitors AC Supply Source Considerations -2 I/O Wiring -7 General Grounding Requirements -4 Reference Control -24 Fuses and Circuit Breakers -5 Auto/Manual Examples -25 Power Wiring -5 Lifting/Torque Proving -26 EMC Instructions -27 Most start-up difficulties are the result of incorrect wiring. Every precaution must be taken to assure that the wiring is done as instructed. All items must be read and understood before the actual installation begins.! 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. Opening the Cover /- Frames -4 Locate the slot in the upper left corner. Slide the locking tab up and swing the cover open. Special hinges allow cover to move away from drive and lay on top of adjacent drive (if present). See page -7 for frame 4 access panel removal. Frame 5 Slide the locking tab up, loosen the right-hand cover screw and remove. See page -7 for access panel removal. Frame 6 Loosen 2 screws at bottom of drive cover. Carefully slide bottom cover down & out. Loosen the 2 screws at top of cover and remove.

14 PORT MOD NET A NET B PWR STS PORT MOD NET A NET B PWR STS PORT MOD NET A NET B PWR STS PORT MOD NET A NET B PWR STS -2 Installation/Wiring Mounting Considerations Operating Temperatures PowerFlex 7 drives are designed to operate at to 4 C ambient. To operate the drive in installations between 4 and 5 C, see the information below and refer to pages A- through A-9 for exceptions. Table.A Acceptable Surrounding Air Temperature & Required Actions Enclosure Rating Temperature Range Drive IP2, NEMA/UL Type (with Top Label) () -4 C Frames -4, All Ratings -5 C Frames 5-6, Most Ratings (2) IP2, NEMA/UL Type Open (Top Label -5 C Most Ratings (2) Removed) () -45 C 2BC72 Only IP, NEMA/UL Type Open (Top Label & -5 C 2BC72 Only (3) Vent Plate Removed) Flange Mount Front - IP, NEMA/UL Type Open -4 C Back (External) Frames 5-6 Back/Heat Sink - IP54, NEMA/UL Type 2-55 C Front (Inside Encl.) Stand-alone/Wall Mount - IP54, NEMA/UL 2-4 C Frames 5-6 () Removing the adhesive top label from the drive changes the NEMA/UL enclosure rating from Type to Open. Frames 5 and 6 do not have a top label. (2) Refer to pages A- through A-9 for exceptions. (3) To remove vent plate (see page A-25 for location), lift top edge of plate from the chassis. Rotate the plate out from the back plate..6 mm (4. in.).6 mm (4. in.) No Adhesive Label (see Table.A).6 mm (4. in.).6 mm (4. in.) With Adhesive Label (see Table.A) 5.8 mm (2. in.).6 mm (4. in.).6 mm (4. in.) Refer to Appendix A for detailed dimension information..6 mm (4. in.).6 mm (4. in.) Minimum Mounting Clearances Specified vertical clearance requirements are intended to be from drive to drive. Other objects can occupy this space; however, reduced airflow may cause protection circuits to fault the drive. In addition, inlet air temperature must not exceed the product specification. AC Supply Source Considerations PowerFlex 7 drives are suitable for use on a circuit capable of delivering up to a maximum of 2, rms symmetrical amperes, and a maximum of 69 volts.

15 Installation/Wiring -3! ATTENTION: To guard against personal injury and/or equipment damage caused by improper fusing or circuit breaker selection, use only the recommended line fuses/circuit breakers specified in Appendix A. If a system ground fault monitor (RCD) is to be used, only Type B (adjustable) devices should be used to avoid nuisance tripping. Unbalanced, Ungrounded, Resistive or B Phase Grounded Distribution Systems If phase to ground voltage will exceed 25% of normal line to line voltage or the supply system is ungrounded, refer to the Wiring and Grounding Guidelines for PWM AC Drives (pub. DRIVES-IN).! ATTENTION: PowerFlex 7 drives contain protective MOVs and common mode capacitors that are referenced to ground. These devices must be disconnected if the drive is installed on an ungrounded, resistive or B phase grounded distribution system. See page -4 for jumper locations. Input Power Conditioning Certain events on the power system supplying a drive can cause component damage or shortened product life. These conditions are divided into 2 basic categories:. All drives The power system has power factor correction capacitors switched in and out of the system, either by the user or by the power company. The power source has intermittent voltage spikes in excess of 6 volts. These spikes could be caused by other equipment on the line or by events such as lightning strikes. The power source has frequent interruptions HP or Less Drives (in addition to above) The nearest supply transformer is larger than kva or the available short circuit (fault) current is greater than,a. The impedance in front of the drive is less than.5%. If any or all of these conditions exist, it is recommended that the user install a minimum amount of impedance between the drive and the source. This impedance could come from the supply transformer itself, the cable between the transformer and drive or an additional transformer or reactor. The impedance can be calculated using the information supplied in Wiring and Grounding Guidelines for PWM AC Drives, publication DRIVES-IN.

16 -4 Installation/Wiring General Grounding Requirements The drive Safety Ground - PE must be connected to system ground. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked. For installations within a cabinet, a single safety ground point or ground bus bar connected directly to building steel should be used. All circuits including the AC input ground conductor should be grounded independently and directly to this point/bar. Figure. Typical Grounding R (L) S (L2) T (L3) U (T) V (T2) W (T3) PE SHLD Safety Ground - PE This is the safety ground for the drive that is required by code. This point must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar (see above). Grounding points must comply with national and local industrial safety regulations and/or electrical codes. Shield Termination - SHLD The Shield terminal (see Figure.3 on page -) provides a grounding point for the motor cable shield. The motor cable shield should be connected to this terminal on the drive (drive end) and the motor frame (motor end). A shield terminating cable gland may also be used. When shielded cable is used for control and signal wiring, the shield should be grounded at the source end only, not at the drive end. RFI Filter Grounding Using an optional RFI filter may result in relatively high ground leakage currents. Therefore, the filter must only be used in installations with grounded AC supply systems and be permanently installed and solidly grounded (bonded) to the building power distribution ground. Ensure that the incoming supply neutral is solidly connected (bonded) to the same building power distribution ground. Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection. Some local codes may require redundant ground connections. The integrity of all connections should be periodically checked. Refer to the instructions supplied with the filter.

17 Installation/Wiring -5 Fuses and Circuit Breakers The PowerFlex 7 can be installed with input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations. Refer to Appendix A for recommended fuses/circuit breakers.! ATTENTION: The PowerFlex 7 does not provide branch short circuit protection. Specifications for the recommended fuse or circuit breaker to provide protection against short circuits are provided in Appendix A. Power Wiring! ATTENTION: National Codes and standards (NEC, VDE, BSI etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices. Failure to do so may result in personal injury and/or equipment damage. Cable Types Acceptable for 2-6 Volt Installations A variety of cable types are acceptable for drive installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, allow a spacing of.3 meters ( foot) for every meters (32.8 feet) of length. In all cases, long parallel runs must be avoided. Do not use cable with an insulation thickness less than or equal to 5 mils (.4mm/.5 in.). Use Copper wire only. Wire gauge requirements and recommendations are based on 75 C. Do not reduce wire gauge when using higher temperature wire. Unshielded THHN, THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space and/or conduit fill rates limits are provided. Do not use THHN or similarly coated wire in wet areas. Any wire chosen must have a minimum insulation thickness of 5 Mils and should not have large variations in insulation concentricity. Shielded/Armored Cable Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC Drive. Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other

18 -6 Installation/Wiring devices that may be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations or a high degree of communications/ networking are also good candidates for shielded cable. Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks. Refer to Reflected Wave in Wiring and Grounding Guidelines for PWM AC Drives, pub. DRIVES-IN. Consideration should be given to all of the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics and chemical resistance. In addition, a braided shield should be included and be specified by the cable manufacturer as having coverage of at least 75%. An additional foil shield can greatly improve noise containment. A good example of recommended cable is Belden 295xx (xx determines gauge). This cable has four (4) XLPE insulated conductors with a % coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a PVC jacket. Other types of shielded cable are available, but the selection of these types may limit the allowable cable length. Particularly, some of the newer cables bundle 4 conductors of THHN wire and wrap them tightly with a foil shield. This construction can greatly increase the cable charging current required and reduce the overall drive performance. Unless specified in the individual distance tables as tested with the drive, these cables are not recommended and their performance against the lead length limits supplied is not known. See Table.B. Table.B Recommended Shielded Wire Location Rating/Type Description Standard (Option ) Standard (Option 2) 6V, 9 C (94 F) Four tinned copper conductors with XLPE insulation. XHHW2/RHW-2 Copper braid/aluminum foil combination shield and Anixter B295-B2957, tinned copper drain wire. Belden , or PVC jacket. equivalent Tray rated 6V, 9 C (94 F) RHH/RHW-2 Anixter OLF-7xxxxx or equivalent Class I & II; Tray rated 6V, 9 C Division I & II (94 F) RHH/RHW-2 Anixter 7V-7xxxx-3G or equivalent Three tinned copper conductors with XLPE insulation. 5 mil single helical copper tape (25% overlap min.) with three bare copper grounds in contact with shield. PVC jacket. Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor. Black sunlight resistant PVC jacket overall. Three copper grounds on # AWG and smaller.

19 Installation/Wiring -7 EMC Compliance Refer to EMC Instructions on page -27 for details. CabIe Trays and Conduit If cable trays or large conduits are to be used, refer to the guidelines presented in the Wiring and Grounding Guidelines for PWM AC Drives, publication DRIVES-IN.! ATTENTION: To avoid a possible shock hazard caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled. This will help minimize the possible shock hazard from cross coupled motor leads. Motor Cable Lengths Typically, motor lead lengths less than 3 meters ( feet) are acceptable. However, if your application dictates longer lengths, refer to the Wiring and Grounding Guidelines for PWM AC Drives, publication DRIVES-IN or the PowerFlex 7 Technical Data, publication 2B-TD. Cable Entry Plate Removal If additional wiring access is needed, the Cable Entry Plate on -3 Frame drives can be removed. Simply loosen the screws securing the plate to the chassis. The slotted mounting holes assure easy removal. Important: Removing the Cable Entry Plate limits the maximum ambient temperature to 4 degrees C (4 degrees F). Power Wiring Access Panel Removal Frame Removal Procedure (Replace when wiring is complete),, 2 & 6 Part of front cover, see page -. 3 Open front cover and gently tap/slide cover down and out. 4 Loosen the 4 screws and remove. 5 Remove front cover (see page -), gently tap/slide panel up and out. Single-Phase Input Power The PowerFlex 7 drive is typically used with a three-phase input supply. Single-phase operation of the drive is not currently rated under the UL58C listing. Rockwell Automation has verified that single-phase operation with output current derated by 5% of the three-phase ratings identified on pages A- through A-5 will meet all safety requirements.

20 POWER TERMINAL RATINGS WIRE RANGE: 4-/ AWG ( MM 2 ) TORQUE: 32 IN-LB (3.6 N-M) STRIP LENGTH:.67 IN (7 MM) USE 75 C CU WIRE ONLY 7 GROUND TERMINAL RATINGS (PE) WIRE RANGE: 6-/ AWG (6-35 MM 2 ) TORQUE: 44 IN-LB (5 N-M) STRIP LENGTH:.83 IN (2 MM) 2 3 VDC EXT PWR SPLY TERM (PS+, PS-) WIRE RANGE: 22- AWG (.5-4 MM 2 ) TORQUE: 5.3 IN-LB (.6 N-M) STRIP LENGTH:.35 IN (9 MM) 9-8 Installation/Wiring AC Input Phase Selection (Frames 5 & 6 Only)! ATTENTION: To avoid a shock hazard, ensure that all power to the drive has been removed before performing the following. Moving the Line Type jumper shown in Figure.2 will allow single or three-phase operation. Important: When selecting single-phase operation, input power must be applied to the R (L) and S (L2) terminals only to assure power to the fan. Selecting/Verifying Fan Voltage (Frames 5 & 6 Only) Important: Read Attention statement above! Frames 5 & 6 utilize a transformer to match the input line voltage to the internal fan voltage. If your line voltage is different than the voltage class specified on the drive nameplate, it may be necessary to change transformer taps as shown below. Common Bus (DC input) drives require user supplied 2 or 24V AC to power the cooling fans. The power source is connected between VAC and the terminal corresponding to your source voltage (see Figure.4). Table.C Fan VA ratings (DC Input Only) Frame Rating (2V or 24V) 5 VA 6 38 VA Figure.2 Typical Locations - Phase Select Jumper & Transformer (Frame 5 shown) Optional Communications Module 3-PH -PH LINE TYPE SPARE SPARE 2 Phase Selection Jumper Fan Voltage OUTPUT INPUT AC 69 Volt Tap 6 Volt Tap 48 Volt Tap 4 Volt Tap

21 Installation/Wiring -9 Frame 6 Transformer Tap Access The transformer is located behind the Power Terminal Block in the area shown in Figure.2. Access is gained by releasing the terminal block from the rail. To release terminal block and change tap:. Locate the small metal tab at the bottom of the end block. 2. Press the tab in and pull the top of the block out. Repeat for next block if desired. 3. Select appropriate transformer tap. 4. Replace block(s) in reverse order. Auxiliary Control Power Supply An Auxiliary Control Power Supply such as the 2-24V-AUX can provide control power for certain PowerFlex 7 drives. See details below.! ATTENTION: The Auxiliary Control Power Supply Must Not be used with any PowerFlex 7 Standard Control drive or 2/24 Volt Vector Control drive. Using the power supply with these drives will cause equipment/component damage. The Auxiliary Control Power Supply Must Not be used with Any Standard Control drive (5 th position of the catalog number string equals A, B, or N ). Any 2/24V PowerFlex 7 drive, Standard or Vector Control (4 th position of the catalog number string equals B ). The Auxiliary Control Power Supply Can be used with 4/48 and 6/69 Volt drives with Vector Control (5 th position of the catalog number string equals C, or D ). Consult the factory when using an auxiliary power supply in these instances. Use of an auxiliary power supply to keep the drive control logic up when the main AC power is removed requires the use of some type of AC line monitoring as well as control of the Precharge Enable signal. Consult the factory for additional guidance.

22 - Installation/Wiring Power Terminal Block Refer to Figure.3 for typical locations. Table.D Power Terminal Block Specifications Wire Size Range () Torque No. Name Frame Description Maximum Minimum Maximum Recommended ➊ Power Terminal & Input power and 4. mm 2.5 mm 2.7 N-m.8 N-m Block motor connections ( AWG) (22 AWG) (5 lb.-in.) (7 lb.-in.) 2 Input power and. mm 2.8 mm 2.7 N-m.4 N-m motor connections (6 AWG) (8 AWG) (5 lb.-in.) (2 lb.-in.) 3 Input power and 25. mm mm N-m.8 N-m motor connections (3 AWG) (4 AWG) (32 lb.-in.) (6 lb.-in.) BR, 2 terminals. mm 2.8 mm 2.7 N-m.4 N-m (6 AWG) (8 AWG) (5 lb.-in.) (2 lb.-in.) 4 Input power and 35. mm 2. mm 2 4. N-m 4. N-m motor connections (/ AWG) (8 AWG) (35 lb.-in.) (35 lb.-in.) 5 Input power, BR, 5. mm 2 4. mm 2 75 HP, 48V/ 2, DC+, DC and motor connections (/ AWG) (2 AWG) HP, PE 5. mm 2 4. mm 2 6V (/ AWG) (2 AWG) 5 Input power, DC+, 7. mm 2. mm 2 See Note (2) HP DC and motor (2/ AWG) (8 AWG) BR, 2, terminals 5. mm 2 (/ AWG) 4. mm 2 (2 AWG) PE 5. mm 2 (/ AWG) 4. mm 2 (2 AWG) 6 Input power, DC+, 5. mm mm 2 6. N-m 6. N-m DC, BR, 2, PE, (3 MCM) (4 AWG) (52 lb.-in.) (52 lb.-in.) motor connections see note (3) ➋ SHLD Terminal -6 ➌ ➍ AUX Terminal Block Terminating point for wiring shields Auxiliary Control Voltage PS+, PS (4).5 mm 2 (6 AWG) 4. mm 2 (2 AWG) Fan Terminal 5-6 User Supplied Block (CB Only) Fan Voltage (page -8).6 N-m (4 lb.-in.) 4. mm 2 (2 AWG).2 mm 2 (24 AWG).5 mm 2 (22 AWG).6 N-m (4 lb.-in.).6 N-m (5.3 lb.-in.).5 mm 2.6 N-m (22 AWG) (5.3 lb.-in.).6 N-m (5.3 lb.-in.).6 N-m (5.3 lb.-in.) () Maximum/minimum wire sizes that the terminal block will accept - these are not recommendations. (2) Refer to the terminal block label inside the drive. (3) Two wires connected in parallel to any of these terminals using two lugs may be required. (4) External control power: UL Installation-3V DC, ±%, Non UL Installation-27-6V DC, ±% -3 Frame - 4 W, 65 ma, 5 Frame - 8 W, 9 ma. See Auxiliary Control Power Supply on page -9.

23 POWER TERMINAL RATINGS WIRE RANGE: 4-/ AWG ( MM 2 ) TORQUE: 32 IN-LB (3.6 N-M) STRIP LENGTH:.67 IN (7 MM) USE 75 C CU WIRE ONLY 7 GROUND TERMINAL RATINGS (PE) WIRE RANGE: 6-/ AWG (6-35 MM 2 ) TORQUE: 44 IN-LB (5 N-M) STRIP LENGTH:.83 IN (2 MM) 2 3 VDC EXT PWR SPLY TERM (PS+, PS-) WIRE RANGE: 22- AWG (.5-4 MM 2 ) TORQUE: 5.3 IN-LB (.6 N-M) STRIP LENGTH:.35 IN (9 MM) 9 AUX IN+ AUX OUT 75C Cu Wire 6 AWG [MM 2 ] Max. 2 IN. LBS..4 N-M } TORQUE WIRE STRIP ONLY (6 N-M) 22- AWG 5.3 IN-LB (.6 N-M) AUX IN + BR BR2 75C Cu Wire 6 AWG [MM 2 ] Max. 2 IN. LBS..4 N-M } TORQUE USE 75 C COPPER WIRE ONLY, TORQUE 52 IN-LB (6 N-M) OUTPUT INPUT WIRE STRIP 75C Cu Wire 3 AWG [25MM 2 ] Max. 6 IN. LBS..8 N-M } TORQUE Installation/Wiring - Figure.3 Typical Power Terminal Block Location ➌! DANGER ➊ BR BR2 DC+ DC PE U/T V/T2 W/T3 R/L S/L2 T/L3 Use 75C Wire Only #-#4 AWG Torque to 7 in-lbs BR B SHLD Optional Communications Module V/T2 W/T3 PE R/L S/L2 T/L3 ➋ ➊ ➋ Frames & ➌ Frame 2 SHLD CONTROL POWER / ➊ ➌ PE SHLD PE A Optional Communications Module PE B CONTROL POWER BR BR2 DC+ DC- U/T V/T2 W/T3 R/L S/L2 PE T/L3 SHLD ➋ Frames 3 & 4 ➋ Optional Communications Module ➋ Optional Communications Module ➌ OUTPUT INPUT AC ➌ WIRE STRIP PS+ PS BR2 BR DC+ DC ➊ Frame 5 ➊ ➍ Common Bus Drives Only USE 75 C COPPER WIRE TORQUE 52 IN-LB T T2 T3 L Frame 6 L2 L3

24 22- AWG 5.3 IN-LB (.6 N-M) 22- AWG 5.3 IN-LB (.6 N-M) 22- AWG 5.3 IN-LB (.6 N-M) -2 Installation/Wiring Figure.4 Power Terminal Block Frame Terminal Block + 2 BR BR2 DC+ DC PE U (T) V (T2) W (T3) R (L) S (L2) T (L3) * Note: Shaded BR & BR2 Terminals will only be present on drives ordered with the Brake Option BR BR2 DC+ DC U V W (T) (T2) (T3) PE R S T (L) (L2) (L3) BR BR2 DC+ DC U V W R S T (T) (T2) (T3) (L) (L2) (L3) AC Input (Ratings are Normal Duty) 5 24V, 4 HP 48V, 75 HP 69V, 45-9 kw 4V, 55 kw 6V, 75 HP DC Input (Ratings are Normal Duty) 24V, 4 HP 48V, 75 HP 69V, 45-9 kw 4V, 55 kw 6V, 75 HP PS BR2* BR*/ DC DC+ DC+ V/T2 U/T W/T3 PE PE R/L S/L2 T/L3 PS BR*/ BR2* DC+ DC+ DC U/T V/T2 W/T3 PE 24 VAC VAC PE PS+ PS+ Precharge Resistor Fuse DCT2-2 (Common Bus Drives w/precharge Only) 2 VAC 24V, 5 HP 48V, HP 4V, 75 kw 6V, HP 24V, 5 HP 48V, HP 4V, 75 kw 6V, HP BR*/ BR2* DC+ DC+ DC U/T V/T2 W/T3 PE PS PE R/L S/L2 T/L3 PS BR*/ BR2* DC+ DC+ DC 24 U/T V/T2 W/T3 VAC VAC PE PE PS HP 25-2 HP M8 Stud (All Terminals) Max. Lug Width = 3.8 mm (.25 in.) PS+ 2 VAC Precharge Resistor Fuse DCT2-2 (Common Bus Drives w/precharge Only) M8 Stud (All Terminals) Max. Lug Width = 25.4 mm ( in.) Common Mode Capacitor & MOV Jumpers WIRE STRIP PS+ PS BR2 BR DC+ DC USE 75 C COPPER WIRE ONLY, TORQUE 52 IN-LB (6 N-M) Common Mode Capacitor & MOV Jumpers Input Filter Capacitor WIRE STRIP PS+ PS BR2 BR DC+ DC USE 75 C COPPER WIRE ONLY, TORQUE 52 IN-LB (6 N-M) Input Filter Capacitor Precharge Resistor Fuse DCT2-2 (Common Bus Drives w/precharge Only) USE 75 C COPPER WIRE ONLY TORQUE 52 IN-LB (6 N-M) U T V T2 OUTPUT W T3 PE PE R L S L2 INPUT T L3 USE 75 C COPPER WIRE ONLY U V TORQUE T 52 IN-LB T2 (6 N-M) OUTPUT W T3 PE PE VAC 2 VAC 24 VAC FAN INPUT -PHASE

25 Installation/Wiring -3 Terminal Description Notes BR BR2 DC Brake (+) DC Brake ( ) DB Resistor Connection - Important: Only one DB resistor can be used with Frames -3. Connecting an internal & external resistor could cause damage. DC+ DC Bus (+) DC Input/Brake Connections DC DC Bus ( ) PE PE Ground Refer to Figure.3 for location on 3 Frame drives PS+ AUX (+) Auxiliary Control Voltage (see Table.D) PS AUX ( ) Motor Ground Refer to Figure.3 for location on 3 Frame drives U V W R S T U (T) V (T2) W (T3) R (L) S (L2) T (L3) To Motor Input Contactor Precautions AC Line Input Power Three-Phase = R, S & T Single-Phase = R & S Only Using Input/Output Contactors!! ATTENTION: A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor. If an input device is used, operation must not exceed one cycle per minute or drive damage will occur. ATTENTION: The drive start/stop/enable control circuitry includes solid state components. If hazards due to accidental contact with moving machinery or unintentional flow of liquid, gas or solids exist, an additional hardwired stop circuit may be required to remove the AC line to the drive. An auxiliary braking method may be required. Output Contactor Precaution! ATTENTION: To guard against drive damage when using output contactors, the following information must be read and understood. One or more output contactors may be installed between the drive and motor(s) for the purpose of disconnecting or isolating certain motors/ loads. If a contactor is opened while the drive is operating, power will be removed from the respective motor, but the drive will continue to produce voltage at the output terminals. In addition, reconnecting a motor to an active drive (by closing the contactor) could produce excessive current that may cause the drive to fault. If any of these conditions are determined to be undesirable or unsafe, an auxiliary contact on the output contactor should be wired to a drive digital input that is programmed as Enable. This will cause the drive to execute a coast-to-stop (cease output) whenever an output contactor is opened.

26 -4 Installation/Wiring Bypass Contactor Precaution! ATTENTION: An incorrectly applied or installed bypass system can result in component damage or reduction in product life. The most common causes are: Wiring AC line to drive output or control terminals. Improper bypass or output circuits not approved by Allen-Bradley. Output circuits which do not connect directly to the motor. Contact Allen-Bradley for assistance with application or wiring. Disconnecting MOVs and Common Mode Capacitors PowerFlex 7 drives contain protective MOVs and common mode capacitors that are referenced to ground. To guard against drive damage, these devices must be disconnected if the drive is installed on a resistive grounded distribution system, an ungrounded distribution system, or B phase grounded distribution system. On ungrounded distribution systems where the line-to-ground voltages on any phase could exceed 25% of the nominal line-to-line voltage, an isolation transformer should be installed. To disconnect these devices, remove the jumper(s) listed in Table.E. Jumpers can be removed by carefully pulling the jumper straight out. See Wiring and Grounding Guidelines for PWM AC Drives, publication DRIVES-IN for more information on ungrounded systems.! ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before removing/installing jumpers. Measure the DC bus voltage at the +DC & DC terminals of the Power Terminal Block. The voltage must be zero.

27 Installation/Wiring -5 Table.E Jumper Removal Frame Jumper Component Jumper Location No., PEA Common Mode Cap. Remove the I/O Cassette (page -8). Jumpers located ➊ PEB MOV s on the Power Board (Figure.5). ➋ 2-4 PEA Common Mode Cap. Jumpers are located above the Power Terminal Block ➌ PEB MOV s (see Figure.5). ➍ 5 Wire Common Mode Cap. Remove the I/O Cassette as described on page -8. All The green/yellow jumper is located on the back of chassis ➎ except 4A, 4V & (see Figure.5 for location). Disconnect, insulate and secure the wire to guard against unintentional contact with chassis or components. 6/ MOV s Note location of the two green/yellow jumper wires next ➏ 69V Input Filter Cap. to the Power Terminal Block (Figure.5). Disconnect, ➏ insulate and secure the wires to guard against unintentional contact with chassis or components. 5 4A, 4V, 6/ 69V Wire Common Mode Cap. Note location of the green/yellow jumper wire shown in ➐ MOV s Figure.5. Disconnect, insulate and secure the wire to ➑ guard against unintentional contact with chassis or Input Filter Cap. components. ➑ 6 Wire Common Mode Cap. Remove the wire guard from the Power Terminal Block. MOV s Input Filter Cap. Disconnect the three green/yellow wires from the two PE terminals shown in Figure.4. Insulate/secure the wires to guard against unintentional contact with chassis or components.

28 POWER TERMINAL RATINGS WIRE RANGE: 4-/ AWG ( MM 2 ) TORQUE: 32 IN-LB (3.6 N-M) STRIP LENGTH:.67 IN (7 MM) USE 75 C CU WIRE ONLY 7 GROUND TERMINAL RATINGS (PE) WIRE RANGE: 6-/ AWG (6-35 MM 2 ) TORQUE: 44 IN-LB (5 N-M) STRIP LENGTH:.83 IN (2 MM) 2 3 VDC EXT PWR SPLY TERM (PS+, PS-) WIRE RANGE: 22- AWG (.5-4 MM 2 ) TORQUE: 5.3 IN-LB (.6 N-M) STRIP LENGTH:.35 IN (9 MM) 9-6 Installation/Wiring Figure.5 Typical Jumper Locations (see Table.E for description) ➌ ➍ PE 2 PE MOV-PE JMPR PE 4 PE 3 DC FILTER CAP-PE JMPR! DANGER Use 75C Wire Only #-#4 AWG Torque to 7 in-lbs BR BR2 DC+ DC- U/T V/T2 W/T3 WIRE STRIP CONTROL 75C Cu Wire 6 AWG [MM 2 ] Max. 2 IN. LBS..4 N-M } TORQUE PE R/L S/L2 T/L3 POWER AUX IN+ AUX OUT ➋ ➊ BR BR2 DC+ DC PE U/T V/T2 W/T3 R/L S/L2 T/L3 Frames & (I/O Cassette Removed) SHLD Frame 2 SHLD ➌ ➍ ➎ PE B PE A AUX IN + WIRE STRIP BR BR2 75C Cu Wire 75C Cu Wire 6 AWG [MM 2 ] Max. 3 AWG [25MM 2 ] Max. 2 IN. LBS. 6 IN. LBS..4 N-M } TORQUE.8 N-M } TORQUE BR BR2 DC+ DC- U/T V/T2 W/T3 R/L S/L2 T/L3 CONTROL POWER ➐ Optional Communications Module PE OUTPUT INPUT AC SHLD SHLD Important: Do Not discard or replace grounding hardware. Frames 3 & 4 ➏ Frame 5 ➑

29 Installation/Wiring -7 I/O Wiring Important points to remember about I/O wiring: Use Copper wire only. Wire gauge requirements and recommendations are based on 75 degrees C. Do not reduce wire gauge when using higher temperature wire. Wire with an insulation rating of 6V or greater is recommended. Control and signal wires should be separated from power wires by at least.3 meters ( foot). Important: I/O terminals labeled ( ) or Common are not referenced to earth ground and are designed to greatly reduce common mode interference. Grounding these terminals can cause signal noise.!! ATTENTION: Configuring an analog input for -2mA operation and driving it from a voltage source could cause component damage. Verify proper configuration prior to applying input signals. ATTENTION: Hazard of personal injury or equipment damage exists when using bipolar input sources. Noise and drift in sensitive input circuits can cause unpredictable changes in motor speed and direction. Use speed command parameters to help reduce input source sensitivity. Signal and Control Wire Types Table.F Recommended Signal Wire Signal Type/ Where Used Belden Wire Type(s) (or equivalent) Description Min. Insulation Rating Analog I/O & PTC Remote Pot 876/ mm 2 (8AWG), twisted pair, % shield with drain (5).75 mm 2 (8AWG), 3 cond., shielded 3V, 75-9 C (67-94 F) Encoder/Pulse I/O <3 m ( ft.) Combined: 973 ().96 mm 2 (24AWG), individually shielded Encoder/Pulse I/O 3 to 52 m ( to 5 ft.) Encoder/Pulse I/O 52 to 259 m (5 to 85 ft.) Signal: 973/9728 ().96 mm 2 (24AWG), indiv. shielded Power: 879 (2).75 mm 2 (8AWG) Combined: 9892 (3).33 mm 2 or.5 mm 2 (3) Signal: 973/9728 ().96 mm 2 (24AWG), indiv. shielded Power: 879 (2).75 mm 2 (8AWG) Combined: 9773/9774 (4).75 mm 2 (8AWG), indiv. shielded pair () 973 is 3 individually shielded pairs (2 channel + power). If 3 channel is required, use (2) 879 is shielded pair. (3) 9892 is 3 individually shielded pairs (3 channel),.33 mm 2 (22 AWG) + shielded pair.5 mm 2 (2 AWG) for power. (4) 9773 is 3 individually shielded pairs (2 channel + power). If 3 channel is required, use (5) If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessary, but is always recommended.

30 L2 PE DC- -8 Installation/Wiring Table.G Recommended Control Wire for Digital I/O Type Wire Type(s) Description Minimum Insulation Rating Unshielded Per US NEC or applicable national or local code 3V, 6 degrees C Shielded Multi-conductor shielded cable such as Belden 877(or equiv.).75 mm 2 (8AWG), 3 conductor, shielded. (4 degrees F) The I/O Control Cassette Figure.6 shows the I/O Control Cassette and terminal block locations. The cassette provides a mounting point for the various PowerFlex 7 I/O options. To remove the cassette, follow the steps below. Cassette removal will be similar for all frames (Frame drive shown). Step A B C D Description Disconnect the two cable connectors shown in Figure.6. Loosen the two screw latches shown in Figure.6. Slide the cassette out. Remove screws securing cassette cover to gain access to the boards. B Figure.6 PowerFlex 7 Typical Cassette & I/O Terminal Blocks C ➌ ➋ B ➊ Pin D A Detail U/T V/T2 W/T3 R/L DC+ BR2 BR = No. Name ➊ I/O Cassette ➋ I/O Terminal Block ➌ Encoder Terminal Block I/O Terminal Blocks Table.H I/O Terminal Block Specifications Description Removable I/O Cassette Wire Size Range () Torque Maximum Minimum Maximum Recommended Signal & control connections 2. mm 2 (4 AWG).3 mm 2 (22 AWG).6 N-m (5.2 lb.-in.).6 N-m (5.2 lb.-in.) Encoder power & signal.75 mm 2.96 mm 2.6 N-m.6 N-m connections (8 AWG) (24 AWG) (5.2 lb.-in.) (5.2 lb.-in.) () Maximum/minimum that the terminal block will accept - these are not recommendations.