Rockwell Automation Allen-Bradley PowerFlex 400 Bedienungsanleitung

PowerFlex 400 AC Drive Packages for Fan and Pump

Catalog Number 23C

Installation Instructions

Original Instructions

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and

operation of this equipment before you install, configure, operate, or maintain this product. Users are required to

familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,

and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are

required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may

be impaired.

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.

Labels may also be on or inside the equipment to provide specific precautions.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous

environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous

voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may

reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to

potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 23C-IN001D-EN-P - November 2019 3

Table of Contents

Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Preface

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 1

MainInput Disconnect Package (Style

A/M)

Style Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Hardware Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Main Disconnect Switch (DS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Main Circuit Breakers (CB1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Main Fuses (FU1-FU3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Input Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Output Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Control and Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Parameter Defaults (Style A/M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Drawing Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

208V AC Input – Main Input Disconnect

Drive Packages (Style A/M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

460V AC – Main Input Disconnect

Drive Packages (Style A/M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Schematic Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Interconnect Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Layout Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Chapter 2

3 Contactor Full Feature Bypass with

Disconnect Package (Style B/N)

Style Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Hardware Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Main Disconnect Switch (DS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Main Circuit Breakers (CB1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Main Fuses (FU1-FU3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Contactors (DIC, DOC, BC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Motor Overload Relay (OL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Control Transformer (T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Bypass Control Interface (CP1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Input Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Output Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Control and Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4Rockwell Automation Publication 23C-IN001D-EN-P - November 2019

Table of Contents

Customer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Freeze/Fire Stat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Autostart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Bypass Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Parameter Defaults (Style B/N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Drawing Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

208V AC – 3 Contactor Full Feature Bypass with

Disconnect Package (Style B/N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

460V AC – 3 Contactor Full Feature Bypass with

Disconnect Package (Style B/N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Schematic Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Interconnect Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Layout Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Chapter 3

Mechanical Installation

Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Maximum Surrounding Air Temperature. . . . . . . . . . . . . . . . . . . . . . 177

Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Lifting and Mounting the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Watts Loss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Chapter 4

Electrical Installation

Power Wire Size Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Power Terminal Block Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Control and Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Installing Input Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Installing Output Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Installing an Optional Transformer or Reactor. . . . . . . . . . . . . . . . . . . . . 187

Installing Fuses for Branch Circuit Protection. . . . . . . . . . . . . . . . . . 188

Installing the Required External/Separate Input Disconnect . . . . 189

Installing Input/Output Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . 189

Rockwell Automation Publication 23C-IN001D-EN-P - November 2019 5

Table of Contents

Appendix A

Supplemental Information

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Appendix B

Replacement Parts

Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Disconnect Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Bypass Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Enclosure Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Appendix C

History of Changes

23C-IN001B-EN-P, June 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

23C-IN001C-EN-P, November 2015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

6Rockwell Automation Publication 23C-IN001D-EN-P - November 2019

Table of Contents

Notes:

Rockwell Automation Publication 23C-IN001D-EN-P - November 2019 7

Summary of Changes

This manual contains new and updated information.

New and Updated

Information

This table contains the changes made to this revision.

Topic Page

Added ATTENTION statement clarifying branch circuit protection. 10

Updated Catalog Number Explanation to comply to current standards. 11

Added statement clarifying branch circuit protection. 13

Replaced Figure 4 with updated branch circuit protection drawing. 25

Replaced Figure 72 with updated branch circuit protection drawing. 105

Update part numbers for the Style A/B Fused Disconnect Packages, Operator Handle for NEMA/UL Type 1,

12, 3R, 4.

194

Added part numbers for Style M/N Circuit Breaker Packages Operator Handle (NEMA/UL Type 1/12) for

Enclosure Options A and H and Operator Handle (NEMA/UL Type 3R/4) for Enclosure Options X and E.

196

8Rockwell Automation Publication 23C-IN001D-EN-P - November 2019

Summary of Changes

Notes:

Rockwell Automation Publication 23C-IN001D-EN-P - November 2019 9

Preface

The purpose of this manual is to provide basic information that is needed to

install, start-up, and troubleshoot PowerFlex® 400 Adjustable Frequency AC

Drive Packages for Fan and Pump Applications.

User documentation for the PowerFlex 400 Drive Packages for Fan and Pump

Applications includes these Installation Instructions and the PowerFlex 400 User

Manual, publication 22C-UM001. Both manuals are required to properly install

and operate the PowerFlex 400 Adjustable Frequency AC Drive Packages for Fan

and Pump Applications.

This manual is intended for qualified personnel. You must be able to program

and operate Adjustable Frequency AC Drive devices. In addition, you must have

an understanding of the parameter settings and functions.

The PowerFlex 400 Adjustable Frequency AC Drive Packages for Fan and Pump

Applications Installation Instructions is designed to provide only basic

installation and operation information. For this reason, the following topics have

not been included:

•Specifications

•Troubleshooting

•Startup

•Programming and Parameters

Refer to the PowerFlex 400 User Manual, publication 22C-UM001 for detailed

drive information.

Topic Page

Manual Conventions 10

General Precautions 10

Catalog Number Explanation 11

Additional Resources 12

10 Rockwell Automation Publication 23C-IN001D-EN-P - November 2019

Preface

Manual Conventions •To help differentiate parameter names and LCD display text from other

text, the following conventions will be used:

•Parameter Names appear in [brackets].

For example: [DC Bus Voltage].

•Display Text appear in “quotes.” For example: “Enabled.”

•The following words are used throughout the manual to describe an

action:

General Precautions

Word Meaning

Can Possible, able to do something

Cannot Not possible, not able to do something

May Permitted, allowed

Must Unavoidable, you must do this

Shall Required and necessary

Should Recommended

Should Not Not recommended

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 Allen-Bradley® 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 400 User Manual, publication

22C-UM001for test point locations). The voltage must be zero.

ATTENTION: When provided with a circuit breaker, the circuit breaker serves as a

disconnect only. Suitable branch circuit protection, such as fuses, need to be

provided upstream of the circuit breaker.

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