PowerFlex 700S Adjustable Frequency Drive - Phase II Control Frames kw (1 200 Hp)

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1 Installation Instructions PowerFlex 00S Adjustable Frequency Drive - Phase II Control Frames 0. kw ( 00 Hp) Introduction This document explains the primary steps for mechanical installation and for connecting incoming power, the motor, and basic I/O to the PowerFlex 00S adjustable frequency AC drive with Phase II control. The information provided is intended for qualified installers only. The Additional Resources section on page is a directory of Rockwell Automation publications that provide detailed drive information from wiring and grounding recommendations to troubleshooting and repair. ATTENTION: This product contains a V Lithium battery if the DriveLogix Controller option board is installed. Perchlorate Material - special handling may apply. See Publication 0D-IN0C-EN-P - July 0

2 Rockwell Automation Publication 0D-IN0C-EN-P - July 0

3 Table of Contents Additional Resources Step : Read the General Precautions Qualified Personnel Personal Safety Product Safety Class LED Product Step : Prepare for Installation Catalog Number Explanation Drive Rating to Frame Size Cross References CE Conformity Common Bus and Precharge Considerations Operating Conditions and Temperatures Minimum Mounting Clearances Approximate Dimensions Step : Lift and Mount the Drive Drive Weights Attaching the Lifting Hardware Step : Power Wiring Grounding Requirements Shield Termination - SHLD Unbalanced, Ungrounded or Resistive Grounded Distribution Systems RFI Filter Ground Power Jumpers AC Input Phase Selection (Frames and Only) Selecting/Verifying Fan Voltage (Frames and Only) Important Common Bus (DC Input) Application Notes Auxiliary Control Power Supply Accessing the Terminals Power Wire Recommendations Power Terminal Block Specifications Dynamic Brake Resistor Considerations Using Input/Output Contactors Using PowerFlex 00S Drives with Regenerative Power Units Regenerative Unit to Drive Connections Fusing and Circuit Breakers Rockwell Automation Publication 0D-IN0C-EN-P - July 0

4 Step : Control and I/O Wiring Control and I/O Wiring Recommendations Main Control Board DIP Switch Settings Hardware Enable Circuitry I/O Terminals I/O Wiring Examples DriveLogix 0 Controller Option DriveGuard Safe Torque Off with Second Encoder Option Second Encoder Feedback Option Stegmann Hi-Resolution Encoder Feedback Option Resolver Feedback Option Multi-Device Interface (MDI) Feedback Option Rockwell Automation Publication 0D-IN0C-EN-P - July 0

5 Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource PowerFlex 00S Drives with Phase II Control Programming Manual, publication 0D-PM00 PowerFlex -Class HIM (DPI) Quick Reference, publication 0HIM-QR00 PowerFlex 00S Drives with Phase II Control Reference Manual, publication PFLEX-RM00 DriveLogix0 Controller for PowerFlex 00S Drives with Phase II Control User Manual, publication 0D-UM00 DriveGuard Safe-Off Option for PowerFlex 00S Drives with Phase II Control, publication 0D-UM00 Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN00 PowerFlex AC Drives in Common Bus Configurations, publication DRIVES-AT00 Safety Guidelines for the Application, Installation and Maintenance of Solid State Control, publication SGI-. A Global Reference Guide for Reading Schematic Diagrams, publication Guarding Against Electrostatic Damage, publication Product Certifications website, Description Provides the following detailed information: Drive start-up instructions Parameters and programming Faults, alarms, and troubleshooting Human Interface Module (HIM) Operation Instructions Provides a quick reference guide for using the PowerFlex - Class HIM. Provides detailed control functions and application programming examples. Provides instructions for developing DriveLogix controller projects. Provides information and instructions for properly planning for and installing the DriveGuard Safe Torque Off option board. Provides basic information needed to properly wire and ground PWM AC drives. Provides basic information needed to properly wire and ground PWM AC drives using a common DC bus. Provides general guidelines for the application, installation, and maintenance of solid-state control. Provides a simple cross-reference of common schematic/ wiring diagram symbols used throughout various parts of the world. Provides practices for guarding against Electrostatic damage (ESD) Provides declarations of conformity, certificates, and other certification details. You can view or download publications at To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

6 Step : Read the General Precautions Qualified Personnel ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, startup and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. Personal Safety 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 and DC terminals of the Power Terminal Block (refer to page 0 for location). The voltage must be zero. 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. ATTENTION: Risk of injury or equipment damage exists. DPI or SCANport host products must not be directly connected together via 0 cables. Unpredictable behavior can result if two or more devices are connected in this manner. 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 exists, an additional hardwired stop circuit may be required to remove the AC line to the drive. An auxiliary braking method may be required. ATTENTION: Hazard of personal injury or equipment damage due to unexpected machine operation exists if the drive is configured to automatically issue a Start or Run command. Do not use these functions without considering applicable local, national and international codes, standards, regulations or industry guidelines. ATTENTION: Parameters [Encdr0 Loss Cnfg] - [VoltFdbkLossCnfg] let you determine the action of the drive in response to operating anomalies. Precautions should be taken to be sure that the settings of these parameters do not create hazards of personal injury or equipment damage. ATTENTION: Parameters [SL CommLoss Data] - [NetLoss DPI Cnfg] let you determine the action of the drive if communications are disrupted. You can set these parameters so the drive continues to run. Precautions should be taken to ensure the settings of these parameters do not create hazards of personal injury or equipment damage. ATTENTION: This product contains a V Lithium battery if the DriveLogix Controller option board is installed. Perchlorate Material - special handling may apply. See Rockwell Automation Publication 0D-IN0C-EN-P - July 0

7 Product Safety ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring or application errors such as under sizing the motor, incorrect or inadequate AC supply, or excessive surrounding air temperatures may result in malfunction of the system. 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 Guarding Against Electrostatic Damage, publication or any other applicable ESD protection handbook. ATTENTION: Configuring an analog input for 0-0 ma operation and driving it from a voltage source could cause component damage. Verify proper configuration prior to applying input signals. 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. Class LED Product ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into module ports or fiber optic cable connectors. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

8 Step : Prepare for Installation Catalog Number Explanation Position D D P A 0 E Y N A N A N E a b c d e f g h i j k l m Code 0D a Drive b Type PowerFlex 00S Voltage Rating Code Voltage Ph. Prechg. B 0V AC ( pulse) _ C D E F 00V AC 0V AC 00V AC 0V AC ( pulse) ( pulse) ( pulse) ( pulse) H 0V DC _ N J 0V DC _ N K 0V DC _ N M V DC _ N N V DC _ Y P 0V DC _ Y R 0V DC _ Y T 0V DC _ Y W V DC _ Y Note: CE Certification testing has not been performed on 00V class drives, Frames. Frames & only. Frames & only. For DC input on Frames, use the corresponding AC input code B, C, D, or E. Code P P P c ND Rating 0/0V, 0Hz Input 0V Amps V Amps Hp Frame c ND Rating 00V, 0 Hz Input Code Amps kw P P P0 P c ND Rating 0V, 0 Hz Input Code Amps Hp P P P0 P Frame Frame c ND Rating 00V, 0 Hz Input Code Amps Hp Frame P P P P P Note: CE Certification testing has not been performed on 00V class drives Frames. c ND Rating 0V, 0 Hz Input Code Amps kw d Frame Enclosure Code Description A IP0, NEMA Type with Conformal Coat e HIM Code Operator Interface 0 Blank Cover Full Numeric LCD Rockwell Automation Publication 0D-IN0C-EN-P - July 0

9 Code E N Documentation g Brake Documents English Manual No Documentation Code w/brake IGBT Y N Yes No Brake IGBT is standard on Frames and optional on Frames ONLY. Brake Resistor Code w/resistor Y Yes N No Not available for Frame drives or larger. h Emission Code CE Filter CM Choke A Yes Yes i du/dt Filter No Note: CE Certification testing has not been performed on 00V class drives Frames. Catalog Number Explanation, Continued Comm Slot Code Version N None C DPI ControlNet (Coax) D DPI DeviceNet E DPI EtherNet/IP DriveLogix ControlNet (Coax) DriveLogix ControlNet Redundant (Coax) DriveLogix ControlNet (Fiber) DriveLogix ControlNet Redundant (Fiber) DriveLogix DeviceNet (Open Conn.) DriveLogix EtherNet/IP Code A B C G D H Logix Expansion No No Yes Yes N/A N/A j k Control Options Synchlink No Yes No Yes No Yes Phase II Contol available only. Frames... only. Cassette Expanded Expanded Expanded Expanded Slim Slim Code N A B C E S T U Feedback Option Standard (Incremental Encoder) Resolver Stegmann Hi-Resolution Encoder Expanded cassette required. Multi-Device Interface nd Encoder Safe-Off (w/nd Encoder) One encoder interface included with base drive. m Code L E K Stegmann Hi-Res Enc. (w/nd Encoder) Stegmann Hi-Res Enc. (w/safe-off) Additional Config. Description Phase II Control Phase II DriveLogix0 Phase II DriveLogix0 w/ethernet/ip This is an embedded EtherNet/IP option that is only available with DriveLogix0. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

10 Drive Rating to Frame Size Cross References Table - 0/0 Volt AC Input, Six Pulse Drives 0V AC Input () 0V AC Input Frame Cat. No. Normal Duty Heavy Duty kw Cat. No. Normal Duty Heavy Duty Hp Size kw Rating Rating Hp Rating Rating 0DBP DBP 0. 0DBP.. 0DBP. 0DBP.. 0DBP 0DB DB0 0DB0..0 0DB0. 0DB0.. 0DB0 0. 0DB0. 0DB0 0 0DB0 0DB0 0 0DB00. 0DB00 0 0DB00. 0DB00 0 0DB0 0 0DB DB0 0 0DB DB 0DB 0 0 0DB 0DB 0 0DB0 0DB0 00 () The drive must be programmed to this voltage. Table - 00/0 Volt AC Input, Six Pulse Drives 00V AC Input 0V AC Input Frame Cat. No. Normal Duty kw Heavy Duty kw Cat. No. Normal Duty Heavy Duty Hp Size Rating Rating Hp Rating Rating 0DCP DDP DCP.. 0DDP.0. 0DCP0.. 0DDP DCP.0.0 0DDP DC0..0 0DD0..0 0DC0.. 0DD0 0. 0DC0. 0DD0 0 0DC00 0DD0 0 0DC0. 0DD0 0 0DC0. 0DD00 0 0DC0 0 0DD DC0 0 0DD DC0 0DD DC0 0DD0 0 0DC 0DD 00 0DC0 0DC0 0 0DD 00 0DC DD0 0 0DC0 0 0DD 00 0 Table - 00/0 Volt AC Input, Six Pulse Drives 00V AC Input 0V AC Input Frame Cat. No. Normal Duty Hp Rating Heavy Duty Hp Rating Cat. No. Normal Duty kw Rating Heavy duty kw Rating Size 0DEP DEP.0. 0DEP.0.0 0DEP.0.0 0DEP Rockwell Automation Publication 0D-IN0C-EN-P - July 0

11 00V AC Input 0V AC Input Frame Cat. No. Normal Duty Hp Heavy Duty Hp Cat. No. Normal Duty Heavy duty Size Rating Rating kw Rating kw Rating 0DE0 0. 0DE0 0 0DE0 0 0DE0 0 0DE0 0 0DE DE DE DF0. 0DF00 0DE0 0 0DF0 0DE0 00 0DF0 0 0DE 00 0DF 0 0 0DE 0 0DF 0 Table - Volt DC Input, Six Pulse Drives V DC input Frame Cat. No. Normal Duty Heavy Duty Hp Size Hp Rating Rating 0DB DB0..0 0DB0 0. 0DB0 0 0DB0 0 0DB00 0 0DB00 0 0DN DN DN 0 0 0DN 0 0DN0 00 Table - 0/0 Volt DC Input Drives 0V DC Input 0V DC Input Frame Cat. No. Normal Duty kw Heavy Duty kw Cat. No. Normal Duty Heavy Duty Size Rating Rating HP Rating HP Rating 0DCP.. 0DDP DCP0.. 0DDP.0. 0DCP.0.0 0DDP DC0..0 0DDP DC0.. 0DD0..0 0DC0. 0DD0 0. 0DD0 0 0DC00 0DD0 0 0DC0. 0DD0 0 0DC0. 0DD00 0 0DC0 0 0DD DC0 0 0DD DC0 0DD DH0 0DJ0 0 0DH 0DJ 00 0DH0 Rockwell Automation Publication 0D-IN0C-EN-P - July 0

12 0V DC Input 0V DC Input Frame Cat. No. Normal Duty kw Heavy Duty kw Cat. No. Normal Duty Heavy Duty Size Rating Rating HP Rating HP Rating 0DH0 0 0DJ 00 0DH DJ0 0 0DH0 0 0DJ 00 0 Table - 0/ Volt DC Input Drives 0V DC Input V DC Input Frame Cat. No. Normal Duty Hp Heavy Duty Hp Cat. No. Normal Duty Heavy Duty Size Rating Rating kw Rating kw Rating 0DEP DEP.0. 0DEP.0.0 0DEP.0.0 0DEP0..0 0DE0 0. 0DE0 0 0DE0 0 0DE0 0 0DE0 0 0DE DE DE DT0 00 0DW0 0 0DT 0 0DW 0 CE Conformity Compliance with the Low Voltage (LV) Directive and Electromagnetic Compatibility (EMC) Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. PowerFlex drives comply with the EN standards listed below when installed according to the PowerFlex 00S AC Drives Phase II Control User and Reference Manuals. CE Declarations of Conformity are available online at: Low Voltage Directive (00//EC) EN 00-- Adjustable speed electrical power drive systems Part -: Safety requirements Electrical, thermal and energy. EMC Directive (00/0/EC) EN 00- Adjustable Speed Electrical Power Drive Systems - Part : EMC Product Standard Including Specific Test Methods. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

13 General Considerations If the adhesive label is removed from the top of the drive, the drive must be installed in an enclosure with side openings less than. mm (0. in.) and top openings less than.0 mm (0.0 in.) to maintain compliance with the LV Directive. The motor cable should be kept as short as possible to avoid electromagnetic emission as well as capacitive currents. Use of line filters in ungrounded systems is not recommended. PowerFlex drives may cause radio frequency interference if used in a residential or domestic environment. The installer is required to take measures to prevent interference, in addition to the essential requirements for CE compliance provided in this section, if necessary. Conformity of the drive with CE EMC requirements does not guarantee an entire machine or installation complies with CE EMC requirements. Many factors can influence total machine/installation compliance. PowerFlex drives can generate conducted low frequency disturbances (harmonic emissions) on the AC supply system. More information regarding harmonic emissions can be found in the PowerFlex 00S AC Drives Phase II Control, Reference Manual, publication PFLEX-RM00. When operated on a public supply system, it is the responsibility of the installer or user to be sure, by consultation with the distribution network operator and Rockwell Automation, if necessary, that applicable requirements have been met. Essential Requirements for CE Compliance Conditions listed below must be satisfied for PowerFlex 00S Phase II drives to meet the requirements of EN00-.. Standard PowerFlex 00S CE compatible drive.. Review important precautions/attentions statements throughout this document before installing drive.. Grounding as described in Grounding Requirements on page.. Output power, control (I/O) and signal wiring must be braided, shield cable with a coverage of % or better, metal conduit or have shielding/ cover with equivalent attenuation.. All shielded cables should terminate with proper shielded connector.. Conditions in Table below. Table - PowerFlex 00S EN00- EMC Compatibility () Frames Second Environment First Environment Restricted Distribution Restrict Motor Cable to 0 m ( ft) Restrict Motor Cable to 0 m ( ft) Any Drive and Option Any Drive and Option External Filter Required () External filters for First Environment installations and increasing motor cable lengths in Second Environment installations are available. Roxburgh models KMFA (RF for UL installations) and MIF or Schaffner FN and FN models are recommended. Refer to and (USA) or respectively. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

14 Common Bus and Precharge Considerations The following notes must be read and understood. Also refer to Selecting/ Verifying Fan Voltage (Frames and Only) on page through Power Terminal Blocks on page for additional common bus information.. If drives without internal precharge are used (frames and only), then: a. precharge capability must be provided in the system to guard against possible damage, and b. disconnect switches Must Not be used between the input of the drive and a common DC bus without the use of an external precharge device.. If drives with internal precharge (frames ) are used with a disconnect switch to the common bus, then an auxiliary contact on the disconnect must be connected to a digital input of the drive. The corresponding input (parameter ) must be set to option 0, Precharge Enable. This provides the proper precharge interlock, guarding against possible damage to the drive when connected to a common DC bus. Refer to PowerFlex AC Drives in Common Bus Configurations, publication DRIVES-AT00, for more information. Operating Conditions and Temperatures PowerFlex 00S frame drives are designed to operate at 0 0 C ( 0 F) ambient. To operate most frame drives in installations between and 0 C (0. and F), you must remove the top adhesive label from the drive. Frames and do not have an adhesive label. See Table and Figure on page below for more information. IMPORTANT Removing the adhesive label from the top of frame drives changes the NEMA/UL enclosure rating from Type to Type Open. Table - Enclosure Types and Acceptable Surrounding Air Temperature Enclosure Type Temperature Rating Drive IP0, NEMA/UL Type 0 0 C ( 0 F) Frame, All Ratings (with Top Label) () 0 0 C ( F) Frames and, Most Ratings () IP0, NEMA/UL Type Open 0 0 C ( F) Most Ratings () (Top Label Removed) () 0 C ( F) 0DC0 and 0DE0 Only IP00, NEMA/UL Type Open 0 0 C ( F) 0DC0 Only (Top Label and Vent Plate Removed) () Flange Mount Frames and Front (Inside Encl.) - IP00, NEMA/UL Type Open 0 C ( F) Back/Heat Sink - IP, NEMA/UL 0 0 C ( 0 F) Type Stand-Alone/Wall Mount - IP, NEMA/UL Type 0 0 C ( 0 F) Frames and () Frames and do not have a label. () To remove the vent plate, lift the top edge of the plate away from the chassis and rotate the plate out from the back plate. Refer to Figure on page for location of vent plate. () Refer to the Fusing and Circuit Breakers tables on page, for exceptions. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

15 IMPORTANT PowerFlex 00S drives must be mounted in a clean, dry location. Contaminants such as oils, corrosive vapors and abrasive debris must be kept out of the enclosure. These enclosures are intended for indoor use primarily to provide a degree of protection against contact with enclosed equipment. These enclosures offer no protection against airborne contaminants. Minimum Mounting Clearances Specified vertical clearance requirements are intended to be from the drive to the closest object that can restrict airflow through the drive heat sink and chassis. The drive must be mounted in a vertical orientation as shown, and must make full contact with the mounting surface. Do not use standoffs or spacers. In addition, inlet air temperature must not exceed the product specification. See Table on page for ambient air temperature limits. Figure - Minimum Mounting Clearance Requirements With Adhesive Label Left in Place With Adhesive Label Removed Adhesive Label 0. mm (.0 in.) 0. mm (.0 in.) 0. mm (.0 in.) 0. mm (.0 in.) 0. mm (.0 in.) 0. mm (.0 in.) 0. mm (.0 in.) Air flow through the drive must not be impeded. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

16 Approximate Dimensions Figure - Frames. (0.) dia..0 (0.) AA A D. (0.) C Frame Shown B E (.).0 (0.) Dimensions are in millimeters and (inches) Frame () Slim Cassette A Expanded Cassette AA B C D E.0 (.). (.).0 (.) 00.0 (.) 0.0 (.) 0.0 (.0).0 (.). (.). (.) 00.0 (.).0 (.) 0.0 (.0).0 (.). (.). (0.) 00.0 (.).0 (.) 00.0 (.) () Refer to Drive Rating to Frame Size Cross References on page 0 for frame information. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

17 Figure - Bottom Views, Frames Frame Frame. (.) Dia.. (.) 0. (.). (.). (.). (0.) Dia. Places. (0.) Dia. Places. (.). (.). (.) Dia. Places. (.). (.00). (.). (.). (.). (.0) 0. (.). (.). (.).0 (.) 0.0 (.). (.).0 (.). (.). (.). (.) 0.0 (.). (.). (.) Frame - All Drives, except 0 Hp, 0V ( kw, 00V) Frame - 0 Hp, 0V ( kw, 00V) Normal Duty. (0.) Dia.. (.) Dia. Places 0. (.). (.). (.) Dia. Places. (.) Dia. Places 0. (.). (.). (.) Dia. Places. (.) Dia. Places. (.0). (.). (.0) 0. (.0). (.). (.0). (.0) 0. (.0). (.) Vent Plate. (0.).0 (.).0 (.0).0 (.). (.0).0 (.). (0.).0 (.).0 (.0) 0.0 (.).0 (.) Dimensions are in millimeters and (inches) Rockwell Automation Publication 0D-IN0C-EN-P - July 0

18 Figure - Frame AA A D.0 (0.).0 (0.) Places. (0.) C (.) S B E Lifting Holes Places.0 (0.) Places.0 (0.) Bottom View. (0.) Dia..0 (.). (.). (.) Dia. Places.0 (.) Dia. Places. (.) Dia. Places. (.). (.00). (.). (.) 0. (.). (.0). (.) 0. (.00). (.).0 (.) 0.0 (.0) Dimensions are in millimeters and (inches) Frame () Slim Cassette Expanded Cassette B C (Max) D E A (Max) AA 0.0 (.). (.). (.) 0. (.).0 (.). (.0) () Refer to Drive Rating to Frame Size Cross References on page 0 for frame information. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

19 HOT surfaces can cause severe burns PowerFlex 00S Adjustable Frequency AC Drive - Phase II Control Figure - Frame, Hp, 0V (kw, 00V). (.) AA A. (0.0) D Detail. (0.).0 (0.) C B (.) E S CAUTION. (0.). (0.) Lifting Holes - Places. (0.0) Dia. Bottom View 0.0 (.0). (.). (.) Dia. Places. (0.) Dia. Places. (.) Dia. Places. (.). (.0) 0.0 (.).0 (.). (.).0 (.).0 (.0).0 (.).0 (.) 0.0 (.).0 (.).0 (0.0) Dimensions are in millimeters and (inches) Frame () Slim Cassette Expanded Cassette B C (Max) D E A (Max) AA 0.0 (.). (.). (.). (0.).0 (.).0 (.) () Refer to Drive Rating to Frame Size Cross References on page 0 for frame information. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

20 Figure - Frame, 00 Hp, 0V (kw, 00V) AA A. (0.) 0. (0.). (.). (0.0) D Detail.0 (0.) C x Ø. (0.) B E.0 (.).0 (.).0 (0.) Bottom View.0 (0.).0 (0.). (.). (.). (.). (.) Dia.. (0.) Dia. Places. (.) Dia. Places Removable Junction Box. (.). (.0). (.). (.). (.0).0 (.).0 (.0).0 (.). (.).0 (.0). (.) Dimensions are in millimeters and (inches) Frame () Slim Cassette Expanded Cassette B C (Max) D E A (Max) AA 0. (.) 0. (.). (.) 0. (0.).0 (.). (.) () Refer to Drive Rating to Frame Size Cross References on page 0 for frame information. 0 Rockwell Automation Publication 0D-IN0C-EN-P - July 0

21 Figure - Frame. (0.). (.) A 0. (.0) D Detail.0 (0.) C B E. (.). (0.) Old Style Junction Box New Style Junction Box Detail. (0.) Lifting Holes Places. (0.0) Dia.. (.). (.0). (.) Dia. Places. (.) Dia. Places. (0.) Dia. Places Removable Junction Box.0 (.). (.). (.). (.). (.0). (.).0 (.). (.). (.0). (.) 0. (.) 0. (.0) 0. (.0) 0. (.00) Dimensions are in millimeters and (inches) Frame () Slim Cassette Expanded Cassette B () C (Max) D E A (Max) AA 0. (.0). (.) 0.0 (.). (0.) 00.0 (.).0 (.) () Refer to Drive Rating to Frame Size Cross References on page 0 for frame information. () Junction Box can be removed if drive is mounted in a cabinet. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

22 Step : Lift and Mount the Drive Drive Weights Table - Approximate Drive Weights Frame Size Drive Rating Drive Weight () kw Hp kg (lb) (.).. 0. (.) 0. (0.) 0.. (.0) (.0) (.) () () Weights include HIM, DriveLogix controller with ControlNet daughtercard, Hi-Resolution Encoder Option, and 0-COMM-C ControlNet adapter. () Add an additional. kg (.0 lb) for 00 Hp drives. Attaching the Lifting Hardware All lifting equipment and lifting components (hooks, bolts, lifts, slings, chains, and so forth) must be properly sized and rated to safely lift and hold the weight of the drive while mounting. See Figure and Figure on page, and Figure 0 on page for lifting instructions. ATTENTION: To guard against possible personal injury and/or equipment damage Inspect all lifting hardware for proper attachment before lifting drive. Do not allow any part of the drive or lifting mechanism to make contact with electrically charged conductors or components. Do not subject the drive to high rates of acceleration or deceleration while transporting to the mounting location or when lifting. Do not allow personnel or their limbs directly underneath the drive when it is being lifted and mounted. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

23 Figure - Lifting Frame Drives < A >/ A S Figure - Lifting Frame Drives < >/ A A S Rockwell Automation Publication 0D-IN0C-EN-P - July 0

24 Figure 0 - Lifting Frame Drives < >/ A A Rockwell Automation Publication 0D-IN0C-EN-P - July 0

25 Step : Power Wiring ATTENTION: National Codes and standards (NEC, VDE, BSI and so forth) 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. 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. Figure - Typical Grounding R (L) S (L) T (L) U (T) V (T) W (T) PE SHLD Shield Termination - SHLD The Shield terminal (see page ) provides a grounding point for the motor cable shield. It must be connected to an earth ground by a separate continuous lead. The motor cable shield should be connected to this terminal on the drive and the motor frame. Use a shield terminating or EMI clamp to connect shield to this terminal. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

26 Unbalanced, Ungrounded or Resistive Grounded Distribution Systems If phase to ground voltage will exceed % of normal or the supply system is ungrounded, refer to Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN00, for more information. ATTENTION: PowerFlex 00S drives contain protective MOVs and common mode capacitors that are referenced to ground. These devices must be configured according to the recommendations in Table 0 on page. RFI Filter Ground 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. Be sure 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. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

27 Power Jumpers PowerFlex 00S Phase II drives contain protective MOVs and Common Mode Capacitors that are referenced to ground (see below). To guard against unstable operation and/or damage, the drive must be properly configured as shown in Table 0 on page. MOV and AC EMI Capacitor Phase to Ground R/L S/L T/L Jumper Wire Common Mode Capacitor Phase to Ground DC+ DC Jumper Wire IMPORTANT All PowerFlex 00S Phase II drives are shipped with the DC bus common mode capacitors referenced to ground. The following installation instructions must be completed before applying power to the drive. Table 0 - Recommended Power Jumper Configurations Power Source Type () MOV /Input Filter DC Bus Common Benefits Of Correct Configuration on Caps () Mode Caps Power Source Type Solid Ground Connected Connected UL compliance, AC fed, solidly grounded Reduced electrical noise, DC fed from passive rectifier, which has Most stable operation, an AC source and solid ground EMC compliance, Reduced voltage stress on components and motor bearings Non-Solid Ground AC fed ungrounded Impedance grounded High resistive ground B phase ground Regenerative unit such as common DC bus supply & brake DC fed from an active converter Disconnected Disconnected Helps avoid severe equipment damage when ground fault occurs () It is highly recommended to accurately determine the power source type and then configure appropriately. () When MOVs are disconnected, the power system must have its own transient protection to verify known and controlled voltages. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

28 To connect or disconnect these devices, refer to pages through. IMPORTANT Common mode capacitors are required to conform with the EMC directive. Removing these devices will withdraw the associated directive. In addition, on an ungrounded distribution system where the line-to-ground voltages on any phase could exceed % of the nominal line-to-line voltage, an isolation transformer should be installed. See Wiring and Grounding Guidelines for PWM AC Drives, publication DRIVES-IN00 for more information on impedance grounded and ungrounded systems. Jumper Installation, Removal and Storage PowerFlex 00S drives utilize plug-in style jumpers and jumper wires. Most drives will have a jumper storage area inside the front cover. Extra jumpers or jumpers that have been removed should be stored in this location for use at a later time. Insulating Jumper Wires Some drives utilize nylon screws and spacers to insulate jumper wires from ground and secure them to the chassis. The components must be installed as shown. Drive Identification Refer to the drive nameplate and locate the Voltage Code, Current Rating, Frame, and Series. Use this information to locate the proper procedure in the following tables. Voltage Code Current Rating Series Cat No. 0D D xxx x x xxxxxxx UL TYPE /IP0 Normal Duty Power Heavy Duty Power Input: Phase, -Hz AC Voltage Range Amps 00V xxx kw xxx kw -0 xxx Output: Phase, 0-00 Hz AC Voltage Range 0-00 Base Hz (default) 0 Hz Continuous Amps xxx Min Overload Amps xxx Sec Overload Amps xxx 0V xxx kw xxx kw - xxx Hz xxx xxx xxx Series: B Original Firmware V. x.xxx c U L Listed Ind. Cont Eq. X Mfd. in 00 on Aug Frame: Serial Number: xxxxxxx US N Made in the USA (TAC J) Rockwell Automation, Mequon WI 0-00 Frame Rockwell Automation Publication 0D-IN0C-EN-P - July 0

29 AUX IN+ AUX OUT PE PE BR BR C Cu Wire AWG [0MM ] Max. IN. LBS.. N-M } TORQUE C Cu Wire AWG [0MM ] Max. C Cu Wire AWG [MM ] Max. PE PE MOV-PE JMPR WIRE STRIP WIRE STRIP PowerFlex 00S Adjustable Frequency AC Drive - Phase II Control Table - Jumper Settings and Locations Frame B C D E Voltage Code Current Rating All Factory Default Jumper Settings MOV/Input Filter DC Bus Common Caps Mode Caps PE_B PE_A Installed Installed Power Source Type Solid Ground Remove the I/O Cassette (refer to the Installation Instructions for details). Verify that jumpers are installed at the PE_A and PE_B locations on the Power Board. Non-Solid Ground Remove the I/O Cassette (refer to the Installation Instructions for details). Remove jumpers at the PE_A and PE_B locations on the Power Board. PE A PE B CM Cap MOV BR BR DC+ DC PE! DANGER Use C Wire Only #0-# AWG Torque to in-lbs B C D E All PE_MOV Installed PE_CAP Installed Solid Ground Verify that jumpers are installed at the PE_CAP and PE_MOV locations. Non-Solid Ground Remove jumpers at the PE_CAP and PE_MOV locations. CM Cap PE_CAP U/T V/T W/T R/L S/L T/L MOV PE_MOV IN. LBS.. N-M } TORQUE CONTROL POWER BR BR DC+ DC- U/T V/T W/T PE R/L S/L T/L SHLD SHLD & B C D E All PE_MOV Installed PE-CAP Installed Solid Ground Verify that jumpers are installed at the PE_CAP and PE_MOV locations. Non-Solid Ground Remove jumpers at the PE_CAP and PE_MOV locations. CM Cap PE_CAP PE CAP MOV PE_MOV PE MOV IN. LBS.. N-M } TORQUE CONTROL POWER AUX IN + BR BR DC+ DC- U/T V/T W/T R/L S/L T/L PE SHLD SHLD Rockwell Automation Publication 0D-IN0C-EN-P - July 0

30 POWER TERMINAL RATINGS WIRE RANGE: -/0 AWG (.- MM ) TORQUE: IN-LB (. N-M) STRIP LENGTH: 0. IN ( MM) USE C CU WIRE ONLY GROUND TERMINAL RATINGS (PE) WIRE RANGE: -/0 AWG (- MM ) TORQUE: IN-LB ( N-M) STRIP LENGTH: 0. IN ( MM) POWER TERMINAL RATINGS WIRE RANGE: -/0 AWG (.- MM ) TORQUE: IN-LB (. N-M) STRIP LENGTH: 0. IN ( MM) USE C CU WIRE ONLY GROUND TERMINAL RATINGS (PE) WIRE RANGE: -/0 AWG (- MM ) TORQUE: IN-LB ( N-M) STRIP LENGTH: 0. IN ( MM) 00 VDC EXT PWR SPLY TERM (PS+, PS-) WIRE RANGE: -0 AWG (0.- MM ) TORQUE:. IN-LB (0. N-M) STRIP LENGTH: 0. IN ( MM) 00 VDC EXT PWR SPLY TERM (PS+, PS-) WIRE RANGE: -0 AWG (0.- MM ) TORQUE:. IN-LB (0. N-M) STRIP LENGTH: 0. IN ( MM) PowerFlex 00S Adjustable Frequency AC Drive - Phase II Control Frame Voltage Code Current Rating C F W Factory Default Jumper Settings Power Source Type MOV / Input Filter Caps () () DC Bus Common Mode Caps Two green/yellow Green/yellow wire to Solid Ground wires connected to CM Cap Board is. CM Cap jumper wire should be connected to ground the Power Terminal connected to ground with a metal screw. Verify. If necessary, remove the Block rail nylon screw/spacer and insert a metal M x screw. Torque to. N m ( lb in).. MOV/Input Filter Cap jumper wires should be connected to ground with a metal screw. Verify. If necessary, remove the nylon screw/spacer and insert a metal M x screw. Optional Communications Module Non-Solid Ground. CM Cap jumper wire should be insulated from ground with a nylon screw/spacer. Verify. If necessary, remove the metal screw and insert a M x nylon screw/spacer.. MOV/Input Filter Cap jumper wires should be insulated from ground with a nylon screw/spacer. Verify. If necessary, remove the metal screw and insert a M x 0 nylon screw/spacer. CM Cap OUTPUT INPUT AC MOV E F T W Two green/yellow wires connected to chassis ground Green/yellow wire to CM Cap Board is connected to ground Solid Ground. CM Cap jumper wire should be connected to ground with a metal screw. Verify. If necessary, remove the nylon screw/spacer and insert a metal M x screw. Torque to. N m ( lb in).. MOV jumper wire should be connected to ground with metal screws. Verify. If necessary, remove the nylon screw/spacers and insert metal M x screws.. Input Filter Cap jumper wire should be connected to ground with a metal screw. Verify. If necessary, remove the nylon screw/spacer and insert metal M x screw. Non-Solid Ground. CM Cap jumper wire should be insulated from ground with a nylon screw/spacer. Verify. If necessary, remove the metal screw and insert a M x nylon screw/spacer.. MOV jumper wire should be insulated from ground with a nylon screw/spacer. Verify. If necessary, remove the metal screws and insert a M x 0 nylon screw/spacer.. Input Filter Cap jumper wire should be insulated from ground with a nylon screw/spacer. Verify. If necessary, remove the metal screws and insert a M x nylon screw/spacer. CM Cap MOV / Input Filter Cap OUTPUT MOV Optional Communications Module PE INPUT AC MOV Input Filter Cap () AC input drives only. MOV s and input filter caps do not exist on DC input drives. () When removing MOV s, the input filter capacitor must also be removed. 0 Rockwell Automation Publication 0D-IN0C-EN-P - July 0

31 POWER TERMINAL RATINGS WIRE RANGE: -/0 AWG (.- MM ) TORQUE: IN-LB (. N-M) STRIP LENGTH: 0. IN ( MM) USE C CU WIRE ONLY GROUND TERMINAL RATINGS (PE) WIRE RANGE: -/0 AWG (- MM ) TORQUE: IN-LB ( N-M) STRIP LENGTH: 0. IN ( MM) 00 VDC EXT PWR SPLY TERM (PS+, PS-) WIRE RANGE: -0 AWG (0.- MM ) TORQUE:. IN-LB (0. N-M) STRIP LENGTH: 0. IN ( MM) PowerFlex 00S Adjustable Frequency AC Drive - Phase II Control Frame B C D H J N P R Voltage Code Current Rating All, except C0 (see next page) Factory Default Jumper Settings MOV /Input Filter DC Bus Common Caps () () Mode Caps Two green/yellow Green/yellow wire is wires connected to connected to ground the Power Terminal Block rail Power Source Type Solid Ground. CM Cap jumper wire should be connected to ground with a metal screw. Verify. Newer Drives - If necessary, remove the nylon screw/spacer and insert a metal M x screw. Torque to. N m ( lb in). Older Drives - Remove the I/O Cassette (see Installation Instructions for details). The green/ yellow CM Cap jumper wire is located on the back of chassis and should be connected to ground with a metal screw. If necessary, remove the insulation from the wire terminal and connect to chassis with a metal M x screw. Torque screw to. N m ( lb in). CM Cap - Older Drives CM Cap - Newer Drives Optional Communications Module. MOV/Input Filter Cap jumper wires should be connected to ground with a metal screw. Verify. If necessary, remove the nylon screw/spacer and insert a metal M x screw. MOV OUTPUT INPUT AC Non-Solid Ground. CM Cap jumper wire should be insulated from ground. Verify. Newer Drives - If necessary, remove the metal screw and insert a M x nylon screw/spacer. Older Drives - Remove the I/O Cassette (see Installation Instructions for details). If necessary, insulate/secure jumper wire to guard against unintentional contact with chassis or components. MOV / Input Filter Cap () AC input drives only. MOV s and input filter caps do not exist on DC input drives. () When removing MOV s, the input filter capacitor must also be removed.. MOV/Input Filter Cap jumper wires should be insulated from ground with a nylon screw/spacer. Verify. If necessary, remove the metal screw and insert a M x 0 nylon screw/spacer. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

32 USE C COPPER WIRE ONLY TORQUE IN-LB ( N-M) USE C COPPER WIRE ONLY TORQUE IN-LB ( N-M) -0 AWG. IN-LB (0. N-M) USE C COPPER WIRE ONLY, TORQUE IN-LB ( N-M) -0 AWG. IN-LB (0. N-M) USE C COPPER WIRE ONLY, TORQUE IN-LB ( N-M) PowerFlex 00S Adjustable Frequency AC Drive - Phase II Control Frame B C D H J N P R Voltage Code Current Rating All Factory Default Jumper Settings MOV /Input Filter DC Bus Common Caps () () Mode Caps Two green/yellow Green/yellow wire to wires connected to CM Cap Board is Power Terminal connected to Power Block PE Terminal Block PE Power Source Type Solid Ground. The green/yellow CM Cap jumper wire should be connected to PE.. The MOV/Input Filter Cap jumper wires should be connected to PE. Non-Solid Ground. The green/yellow CM Cap jumper wire should be insulated from ground. If necessary, remove the jumper wire from PE and insulate/secure it to guard against unintentional contact with chassis or components. Important: Do Not Remove/Disconnect the larger green/ yellow wire.. MOV/Input Filter Cap jumper wires should be insulated from ground. If necessary, remove the jumper wires from PE and individually insulate/ secure each jumper wire to guard against unintentional contact with chassis or components. DO NOT REMOVE Optional Communications Module MOV WIRE STRIP PS+ PS BR BR DC+ DC Input Filter Cap CM Cap U T V T OUTPUT MOV W T PE PE R L S L INPUT T L PE PE E F T W All Two green/yellow wires connected to Power Terminal Block PE and chassis Green/yellow wire to CM Cap Board is connected to Power Terminal Block PE Solid Ground. The green/yellow CM Cap and MOV jumper wires should be connected to PE.. The Input Filter Cap jumper wire (top right) should be connected to chassis ground with a metal screw. Verify. If necessary, remove the nylon screw/spacer and insert a metal M x 0 screw. Torque to. N m ( lb in). Optional Communications Module Input Filter Cap Non-Solid Ground. The green/yellow CM Cap and MOV jumper wires should be insulated from ground. If necessary, remove them from PE and individually insulate/secure each jumper wire to guard against unintentional contact with chassis or components. Important: Do Not Remove/Disconnect the larger green/ yellow wire.. The Input Filter Cap jumper wire (top right) should be insulated from ground with a nylon screw/spacer. Verify. If necessary, remove the metal screw and insert a M x nylon screw/ spacer. DO NOT REMOVE WIRE STRIP PS+ PS BR BR DC+ DC MOV CM Cap U V W T T T OUTPUT MOV PE PE R L S L INPUT T L PE PE () AC input drives only. MOV s and input filter caps do not exist on DC input drives. () When removing MOV s, the input filter capacitor must also be removed. Rockwell Automation Publication 0D-IN0C-EN-P - July 0

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