20p td001 - en P
20p td001 - en P
20p td001 - en P
Topic Page
Additional Resources 3
The PowerFlex DC Drive 3
The PowerFlex DC Field Controller 5
The PowerFlex DC Standalone Regulator 6
Unsurpassed Capability in Network Communication 5
PowerFlex DC Drive Catalog Number Explanation 6
PowerFlex DC Field Controller Catalog Number Explanation 7
PowerFlex DC Field Controller Product Selection 7
Factory-installed Options 8
User-installed Options 8
Isolation Transformers 10
Installation Considerations 21
Typical Power Wiring Diagrams 24
PowerFlex DC Drives Terminal Block Locations 30
PowerFlex DC Drives and Field Controller Circuit Protection 48
Mounting 60
Approximate Dimensions – PowerFlex DC Drives 62
PowerFlex DC Drive and Field Controller
Topic Page
Approximate Dimensions and Weights – PowerFlex DC Field Controllers 68
PowerFlex DC Drive Specifications 70
PowerFlex DC Field Controller Specifications 73
IP20 NEMA/UL Type Open Watts Loss 74
Summary of Changes
This publication contains new and updated information as indicated in the following table.
Topic Page
Added 23PFC to catalog numbers on front cover. 1
Added ‘PowerFlex DC Drives’ to titles and subtitles to distinguish content-specific information. Throughout
Added ‘and field controllers’ to existing content where appropriate. Throughout
Added the top seven publications to the Additional Resources table. 3
Added ‘and/or field controller’ to the last bullet-point sentence in the Communication Tools section. 4
Added The PowerFlex DC Field Controller section. 5
Added The PowerFlex DC Standalone Regulator section. 5
Added the PowerFlex DC Field Controller Catalog Number Explanation section. 7
Added the PowerFlex DC Field Controller Product Selection section. 7
Added the PowerFlex DC Field Controller Isolation Transformers tables. 12
Added the PowerFlex DC Field Controller AC Input Line Reactors and AC Contactors section. 16
Added PowerFlex DC field controller information to Installation Considerations section. 22
Revised the introductory sentence to the DC Output Voltages section. 24
Added the PowerFlex Field Controller with AC Input Contactor section and artwork. 29
Added the PowerFlex Field Controller Power Wiring Diagram Notes section. 30
Added the field controller column to each of the four I/O Terminal Block Designation tables. 43
Added the PowerFlex DC Field Controller Input Fuses section. 58
Added Approximate Dimensions and Weights – PowerFlex DC Field Controllers section. 68
Added PowerFlex DC Field Controller Specifications section. 73
Changed title from ‘Watts Loss and Cooling Fan Attributes’ to ‘IP20 NEMA/UL Type Open Watts Loss.’ 74
Added PowerFlex DC field controller tables to IP20 NEMA/UL Type Open Watts Loss section. 76
Additional Resources
These documents contain more information on related products from Rockwell Automation.
Resource Description
PowerFlex Digital DC Drive User Manual, publication 20P-UM001 Provides basic information that is required to install, start up, and troubleshoot the
PowerFlex DC drive.
PowerFlex DC Field Controller Installation Instructions, publication 23PFC-IN001 Provides installation instructions for the PowerFlex DC field controller.
PowerFlex DC Fiber-optic Interface Option Module Installation Instructions, Provides installation instructions for the PowerFlex DC fiber-optic interface module.
publication 20P-IN078
PowerFlex DC Field Controller Programming Manual, publication 23PFC-PM001 Provides information on how to start up, program, and troubleshoot the PowerFlex DC
field controller.
PowerFlex Digital DC Drive - Frame A Hardware Service Manual, publication Provides hardware test procedures and spare parts replacement instructions for Frame A
20P-TG001 PowerFlex DC drives and field controllers.
PowerFlex Digital DC Drive - Frame B Hardware Service Manual, publication Provides hardware test procedures and spare parts replacement instructions for Frame B
20P-TG002 PowerFlex DC drives and field controllers.
A Global Reference Guide for Reading Schematic Diagrams, publication 100-2.10 Provides a simple cross-reference of common schematic/wiring diagram symbols that are
used throughout various parts of the world.
Guarding Against Electrostatic Damage, publication 8000-4.5.2 Explains the causes of electrostatic damage (ESD) and how to guard against its effects.
Preventive Maintenance of Industrial Control and Drive System Equipment, Provides a recommended preventative maintenance checklist.
publication DRIVES-TD001
Safety Guidelines for the Application, Installation, and Maintenance of Solid-state Provides general guidelines for the application, installation, and maintenance of solid-
Control, publication SGI-1.1 state control in the form of individual devices or packaged assemblies that incorporate
solid-state components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, Provides declarations of conformity, certificates, and other certification details.
https://www.rockwellautomation.com/global/certification/overview.page?
You can view or download publications at http://www.rockwellautomation.com/literature/. To order paper copies of technical documentation,
contact your local Allen-Bradley distributor or Rockwell Automation sales representative.
For other information, contact Allen-Bradley® Drives Technical Support at http://www.ab.com/support/abdrives.
Drive Features
• Fast-acting Current Limit and Voltage Regulation result in maximum accelerate/decel without tripping.
• High-speed analog inputs improve drive response to torque or speed commands.
• Programming flexibility allows parameters to be linked within the drive.
• Field-flashable firmware through DPI interface.
• Flying Start delivers smooth and instantaneous connection into a rotating load, regardless of commanded direction, without the need for
any speed feedback.
• Single Phase Regulated Field supply (10A, 14A, 20A, 40A, and 70A, depending on the drive size) standard on all frames.
• Integral Process PI Control replaces the need for a separate controller for a process loop.
• TorqProve™ helps assure control of the load when control is transferred between the drive and a mechanical brake.
• Speed Regulation - open-loop or closed-loop
– Armature Feedback provides a 2000:1 rpm speed range
– DC Tachometer Feedback provides up to 0.1% speed regulation
– Encoder Feedback provides up to 0.1% speed regulation for the tightest application requirements.
• Torque Regulation - open-loop or closed-loop
– Open-loop torque regulation provides ±5% regulation.
– Encoder Feedback provides ±1% regulation and the ability to hold full load at zero speed.
Communication Tools
The PowerFlex DC drive and field controller provides common communication tools that are familiar and easy to use, including the LCD Human
Interface Module (HIM) and PC-based configuration tools.
• The LCD HIM provides:
– Large and easy to read 7 line x 21 character, backlit display
– Alternate function keys for shortcuts to common tasks
– ‘Calculator-like’ number pad for fast and easy data entry (full numeric version only)
– Control keys for local start, stop, speed, and direction
– Remote versions for panel mount applications
• PC-based configuration tools include:
– Connected Components Workbench™ (CCW) software v2.0. This software leverages proven Rockwell Automation and Microsoft®
Visual Studio® technologies for drive configuration and programming. CCW software can be downloaded for free from
https://www.rockwellautomation.com/global/support/connected-components/workbench.page?.
– DriveTools™ SP (v4.01 or higher is required with a PowerFlex DC drive specific software patch. The patch can be downloaded from
https://compatibility.rockwellautomation.com/Pages/home.aspx. A suite of software tools that provide an intuitive way to program,
troubleshoot, and maintain Allen-Bradley drives, including the PowerFlex DC Drive Start-Up Wizard.
• Internal communications allow you to integrate the drive and/or field controller into the manufacturing process. Status indicators for all
internal communication options are visible on the cover for easy setup and monitoring of drive communications. You can easily manage
information from ‘shop floor to top floor’ and seamlessly integrate a complete system as you control, configure, and collect data.
Controller Features
• Programming flexibility allows parameters to be linked within the device.
• Field-flashable firmware through DPI interface.
• Reversing field supply standard on all frames.
• Control non-motor inductive loads, such as electromagnets
RS-485 DF1
ControlNet
DeviceNet
PROFIBUS
BACnet
Description
√ √ √ √ (Unconnected Messaging) permits other network devices (for example PanelView™) to communicate directly to a drive without routing the
communication through the network scanner.
√ √ √ √ √ Adapter Routing - Plug personal computer into one drive and talk to all other Allen-Bradley drives on same network, without being routed
through network scanner.
√ √ √ √ √ √ Access to 100% of all parameters over the network.
√ √ √ √ Autobaud capability makes initial connections less problematic.
√ Change of State significantly reduces network traffic by configuring control messages to be sent only upon customer defined states. Flexible
configuration for each node (Example: “reference must change by more than 5%”).
√ √ Peer Control provides master-slave type control between drives. With this feature, one or more slave drives (consumers) can run based on the
status of a master drive (producer), which can also significantly reduce network traffic.
√ ADR (Automatic Device Replacement) saves significant time and effort when replacing a drive. The scanner can be configured to detect a new
drive and download the required parameter settings.
√ √ √ √ √ √ Flexible Fault Configuration - Adapters can be programmed to take fault-based actions, such as ramp to stop, and send user-configurable logic
control and speed reference values. The drive can take different actions that are based on whether the network experienced a serious problem
(broken cable, etc.) versus network idle condition (PLC set to “Program”).
Factory-installed Options
Each PowerFlex DC drive includes one encoder and DC analog tachometer input. No other factory-installed options are currently available for
PowerFlex DC drives and field controllers.
User-installed Options
Unless otherwise specified, these user installed options are available for PowerFlex DC drives and field controllers.
Human Interface Modules I/O Option Kits
Remote Description Cat. No.
Handheld/ (Panel Mount)
Local Drive IP66, NEMA/UL I/O expansion board(1) 20P-S5V62
Mount Type 4x/12(1) 115V AC to 24V DC eight-channel I/O converter board (2)
20P-S520L
Description Cat. No. Cat. No. (1) Has four 24V DC digital inputs, four digital outputs, and two analog outputs.
(2) Converts eight digital inputs.
No HIM (blank plate) 20-HIM-A0 —
LCD display, full numeric keypad 20-HIM-A3 20-HIM-C3S(2) Feedback Option Kit (only for PowerFlex DC drives)
LCD display, programmer only 20-HIM-A5 20-HIM-C5S(2) Description Cat. No.
Enhanced LCD, full numeric keypad 20-HIM-A6 20-HIM-C6S(2) Resolver feedback option module 20P-RES-A0
(1) Only for indoor use.
(2) Includes a 1202-C30 interface cable (3 m) for connection to drive.
Isolation Transformers
Isolation transformers are available for installations that have specific types of AC supply configurations or require drive protection due to AC line
disturbances.
IMPORTANT An AC input contactor can only be used when the device is used in ‘standalone’ mode. An AC contactor for a device cannot be used when a PowerFlex DC
field controller is paired with and controlled by a PowerFlex DC drive.
ATTENTION: Do not remove AC power until the field controller output (load) current is zero. Equipment damage can occur.
Drive Current DC AC Line Dynamic Brake Voltage Resistance Drive without Drive with Crimp Lugs
Rating Code Amps Amps Hp Resistor Kit Cat. No. (Volts) (ohms) Dynamic Brake Dynamic Brake Cat. No.(3)
7P0 7 5.7 1.5 1370-DBL62
20
9P0 9 7.4 2 1370-DBL63
012 12 9.8 3 1370-DBL64 15
1370-LG40
020 20 16 5 1370-DBL65 8.6 1370-NC56 1370-DC56
029 29 24 7.5 1370-DBL66 6
A
038 38 31 10 1370-DBL67 5
055 55 45 15 1370-DBL68 3.5 1370-LG56
073 73 60 20 1370-DBL69 2.6
1370-LG92
093 93 76 25 1370-DBL70 1370-NC110 1370-DC110
2
110 110 90 30 1370-DBL71 1370-LG110
146 146 119 40 1370-DBL72 1.4 1370-LG160
1370-NC180 1370-DC180
180 180 147 50 1370-DBL73 240 1370-LG180
1
218 218 178 60 1370-DBL74 1370-LG228
1370-NC280 1370-DC280
265 265 217 75 1370-DBL75 0.67 1370-LG268
B 360 360 294 100 1370-DBL76 0.47 ABB_EHDB360C2P-1L2S ABB_EHDB360C-1L22SS
CUTLER-
HAMMER_G3AP50
434 434 355 125 0.4
(Qty 4 - two in series, ABB_EHDB520C2P-1L2S ABB_EHDB520C-1L22SS
two in parallel) (4)
521 521 426 150 HUBBELL_Y139W322GB 0.322
C
700 700 572 200 0.25 ABB_EHDB800C2P-1L2S ABB_EHDB800C-1L22SS
875 875 715 250 (1) ABB_EHDB960C2P-1L2S ABB_EHDB960C-1L22SS
D 0.2 SIEMENS-MFG_14-193- SIEMENS-MFG_14-193-
1K0 1050 858 300 101-58-2 (Qty 2) 101-58-2 (Qty 1)
(1) No dynamic brake resistor kit available for this drive rating—must be sourced locally.
(2) Coil voltage = 115V AC, 50/60Hz.
(3) For more information, see DC Contactor Crimp Lug Kit Specifications on page 18.
(4) Wire and lug size dependent on enclosure dimensions and local codes.
Drive Current DC AC Line Dynamic Brake Resistor Voltage Resistance Drive without Drive with Crimp Lugs
Rating Code Amps Amps Hp Kit Cat. No. (Volts) (ohms) Dynamic Brake Dynamic Brake Cat. No.(3)
4P1 4.1 3.3 2 1370-DBH63 81
6P0 6 4.9 3 1370-DBH64 62
010 10 8.2 5 1370-DBH65 45
1370-DC56 1370-LG40
014 14 11.4 7.5 1370-DBH66 27
019 19 15.5 10 1370-DBH67 20 1370-NC56
027 27 22.1 15 1370-DBH68 12
A 035 35 28.6 20 1370-DBH69 10 1370-LG40
045 45 36.8 25 1370-DBH70 9 1370-DC56
1370-LG52
052 52 42.5 30 1370-DBH71 7
073 73 59.6 40 1370-DBH72 5.2
1370-LG92
086 86 70.3 50 1370-DBH73 4 1370-NC110 1370-DC110
100 100 81.7 60 1370-DBH74 4 1370-LG110
129 129 105.4 75 1370-DBH75 500 3 1370-LG140
1370-NC180 1370-DC180
167 167 136.4 100 1370-DBH76 1370-LG180
2.1
207 207 169.1 125 1370-DBH77 1370-DC280 1370-LG228
1370-NC280
B 250 250 204.3 150 1370-DBH78 1.5 1370-DC280 1370-LG268
330 330 269.6 200 1370-DBH79 1.05 ABB_EHDB360C2P-1L2S ABB_EHDB360C-1L22SS
412 412 336.6 250 HUBBELL_Y95W808GB 1
ABB_EHDB520C2P-1L2S ABB_EHDB520C-1L22SS
495 495 404.4 300 HUBBELL_Y101W595GB 0.8
C
667 667 544.9 400 HUBBELL_Y109W542GB 0.625 ABB_EHDB800C2P-1L2S ABB_EHDB800C-1L22SS
800 830 678.1 500 0.463 ABB_EHDB960C2P-1L2S ABB_EHDB960C-1L22SS (4)
960 996 813.7 600 SIEMENS-MFG_14-193- SIEMENS-MFG_14-193-
0.322
D 1K1 1162 949.4 700 (1) 101-58-2 (Qty 2) 101-58-2 (Qty 1)
1K3 1328 1085.0 800 CUTLER- CUTLER-
0.255 HAMMER_6702ED636-2 HAMMER_6702ED636-2
1K4 1494 1220.6 900 (Qty 2) (Qty 1)
(1) No dynamic brake resistor kit available for this drive rating—must be sourced locally.
(2) Coil voltage = 115V AC, 50/60Hz.
(3) For more information, see DC Contactor Crimp Lug Kit Specifications on page 18.
(4) Wire and lug size dependent on enclosure dimensions and local codes.
Installation Considerations
PowerFlex DC Drive
The PowerFlex DC drive has the following built in protective features to help simplify installation:
• Ground fault protection during startup and operation to help provide excellent reliability
• Electronic motor overload protection increases motor life
There are many other factors that must be considered for optimal performance in any given application. This block diagram highlights the primary
installation considerations.
DC Motor
PORT
MOD
NET A
NET B
DC Motor Field
OR
Inductive Load
IMPORTANT For only frame B and C drives, a jumper must be placed between terminals SA-SB when 115V AC input power is used for the control circuit. See Frame B
Drives SA-SB Terminal Block Location on page 37 and Frame C Drives SA-SB Terminal Block Location on page 37 for terminal block locations.
DC Output Voltages
The output voltages listed in these two tables take into account an AC input undervoltage within the stated tolerance limits and a voltage drop of
4% due to an AC input line reactor. It is the same as the rated armature voltage suggested for the connected motor.
Armature Circuit
AC Input Voltage DC Output Armature Voltage (Terminals C & D)
(Terminals U, V, W) Two Quadrant Drive Four Quadrant Drive
230V ±10%, 3Ph 260V 240V
400V ±10%, 3Ph 470V 420V
440V ±10%, 3Ph 530V 460V
460V ±10%, 3Ph 560V 480V
480V ±10%, 3Ph 580V 500V
575V ±10%, 3Ph 680V 600V
690V ±10%, 3Ph 810V 720V
Field Circuit
AC Input Voltage DC Output Field Voltage(1) (Terminals C1 & D1)
(Terminals U1 & V1) Fixed Field Adjustable Field
230V ±10%, 1Ph 200V 200V
400V ±10%, 1Ph 310V 310V
460V ±10%, 1Ph 360V 360V
(1) The maximum field voltage is equal to 0.85 x AC input line voltage
IMPORTANT For only frame B field controllers, a jumper must be placed between terminals SA-SB on the switching power supply circuit board for the control circuits to
work with 115V AC input. See Frame B Drives SA-SB Terminal Block Location on page 25 for terminal block locations.
DC Output Voltages
The output voltages that are shown here include an AC input undervoltage within the stated tolerance limits and a voltage drop of 4% due to an AC
input line reactor. It is the same as the rated armature voltage suggested for the connected load.
FV1
AC Input V1 D1 F2
Voltage
(14) (14)
K1 K1 (1)
SA
(1)
SB
25
26
PE
(4) (6)
34 (on I/O TB4) FS2
(N.O. Relay) C
M1 AC Contactor
Lockable Aux
Installation Isolation EMC Filter
(2) (2) 13 14 (5)
Transformer (if used) Line Reactor 19 (+24V on I/O TB2)
Disconnect (3)
PowerFlex DC Drive and Field Controller
FS1 1A1 A1
L1 T1
L1 U
(3)
FS1 Armature Volt. A1
3 Phase L2 T2 (7)
L2 V Fdbk. Term. Blk. 1A2
AC line (3) M
FS1
L3 T3
L3 W A2
A1 A2 A2
Safety Ground PowerFlex DC
(6)
460 VAC Drive FS2
Max. or D
PowerFlex DC Drive Power Wiring with DC Output Contactor
FV1
AC Input V1 D1 F2
Voltage
(14) (14)
K1 K1 (1)
SA
(1)
SB
FU
PowerFlex DC Drive and Field Controller
27
PowerFlex DC Drive and Field Controller
1. For frame B and C drives only, a jumper is required between terminals SA and SB for 115V AC control input power. See PowerFlex DC
Drives and Field Controller Control Circuit Input Power on page 35 for more information.
2. An isolation transformer and/or 3…5% impedance line reactor is required. If the isolation transformer provides the required 3…5%
impedance, a line reactor is not required. For recommendations, see Isolation Transformers on page 10 and AC Input Line Reactors and
Contactors on page 13. We recommend that the isolation transformer has a grounded wye secondary neutral. If the PowerFlex DC drive is
installed in a system with an ungrounded wye neutral or with an impedance ground connection, see Grounding for Installations in an
Ungrounded or High-Impedance Neutral Ground or System in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001,
for more information.
3. AC input fuses for the armature converter are not provided for frame A and B drives (the customer must purchase). AC input fuses for the
armature converter are internally mounted on frame C and D drives. For fuse recommendations, see PowerFlex DC Drives and Field
Controller Circuit Protection on page 48.
4. Par 140 [Digital In8 Sel] set to 31 ‘Contactor.’
5. If the +24V internal power supply is used, terminal 18 (24V common) must be jumpered to terminal 35 (digital input common).
6. For four quadrant frame A and B drives, armature output fuses are required (the customer must purchase). For two quadrant frame A and B
drives, armature output fuses are recommended (the customer must purchase). For fuse recommendations, see PowerFlex DC Drives and
Field Controller Circuit Protection on page 48.
7. When you use an AC input contactor, armature voltage feedback is not required.
8. The ‘Enable’ input must be removed to perform a dynamic braking stop.
9. Par 1391 [ContactorControl] = 1 ‘AC Cntctr’ and Par 1392 [Relay Out 1 Sel] = 25 ‘Contactor.’ Important: Terminal 35 and 36 are on the
Control Power / Relay Outputs Terminal block, NOT the I/O terminal blocks. See Frames A and B Contact Relay and Thermistor
Terminal Block Locations on page 41, and Frame D Contact Relay and Thermistor Terminal Block Locations (only for PowerFlex DC
Drives) on page 42.
10. Frame C and D drives require only an external power supply for the heat sink cooling fans. For more information, see Frame C Heat Sink
Cooling Fan Specifications on page 38 and Frame D, Series B and C Heat Sink Cooling Fan Specifications on page 39.
11. See PowerFlex DC Drive Field Converter Connections on page 34.
12. If sourced from the main three-phase AC input, the connections must be taken from the primary side of the Isolation Transformer or Line
Reactor (clean power).
13. Fuses or a circuit breaker. For more information, see Frame C Heat Sink Cooling Fan Specifications on page 38 and Frame D, Series B and
C Heat Sink Cooling Fan Specifications on page 39.
14. For frames B, C, and D drives, a pilot relay is required for the contactor coil.
Inductive
PE
Load
IMPORTANT An AC input contactor can only be used when the device is used in
‘standalone’ mode. An AC contactor for a device cannot be used when a
Voltage
drive.
C
Terminal Block
Board P/S
Control
19 (+24V on I/O TB2)
34 (on I/O TB4)
(4)
(6)
(6)
(5)
(1)
(1)
PE
35
36
U2
W
V2
SA
SB
U
V
(3)
(3)
(3)
FS1
FS1
FS1
(7)
K1
M1 AC Contactor
(N.O. Relay)
14
A2
T1
T2
T3
(7)
K1
Aux
(7)
A1
L1
L2
L3
K1
13 (3)
Line Reactor
EMC Filter
(if used)
(1)(12)
115V or 230V AC
Safety Ground
Input Source
(2)
Transformer
Isolation
Installation
Disconnect
Lockable
L1
L2
L3
3 Phase
AC Line
PE U C V D W
Loosen the two screws that secure the power terminal cover to the drive chassis. Front view of drive is shown with bottom protective and power terminal covers removed.
Remove the power terminal cover to connect the armature power wiring.
ATTENTION: Do not operate the drive with the power terminal cover removed. Operating the drive with the power terminal cover removed can result in a
hazardous condition that can cause personal injury and/or equipment damage.
PE U C V D W
PE U C V D W
Bottom View
IMPORTANT Certain frame D drives require the use of a terminal adapter kits for terminals U, V, W, C and D. See Frame D Terminal Adapter Kits on page 20 for details.
PE C D
U V W
IMPORTANT Certain frame D drives require the use of a terminal adapter kit for terminals U, V, W, C, and D. For details, see Frame D Terminal Adapter Kits on page 20.
IMPORTANT By default, these terminals are jumpered - 1A1 to A1 and 1A2 to A2. If these terminals are not wired to the motor terminals, the jumpers must be installed.
This terminal block is not present on drives that were shipped from the factory prior to drives with version 3.001 firmware installed. However, new
pulse transformer boards that are shipped as replacement parts from the factory contain this terminal block and can be used with any version of
firmware.
Terminal Description
Jumpered to A1 when internal armature voltage feedback is used.
1A1
Not used when A1 is connected to motor terminal A1.
A1 Voltage feedback from motor terminal A1.
Jumpered to A2 when internal armature voltage feedback is used.
1A2
Not used when A2 is connected to motor terminal A2.
A2 Voltage feedback from motor terminal A2.
Tightening Torque
Frame Terminals Wire Size and Type(1)
N•m (lb•in)
A, B & C 24…10 AWG/kcmils 0.5…0.6 (4.4…5.3)
1A1, A1, 1A2, A2
D 22…8 AWG/kcmils 0.8…1.6 (7.1…14.2)
(1) Wire with an insulation rating of 600V or greater is recommended. For more information, see Cable and Wiring
Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001.
Bottom of Drive
A2
A2
(C)
(C)
A1 1A2
A1 1A2
(C)
(C)
1A1
1A1
Cable clamp
Frames A and B Control Circuit Terminal Block Location (on all PowerFlex DC Drives and Field Controllers)
Frame A Drive Frame B
Frame B SA-SB Terminal Block Location (on all PowerFlex DC Drives and Field Controllers)
SA-SB terminals
Top of drive
Front of drive
Frame C Heat Sink Cooling Fans Wire Sizes and Terminal Specifications
Wire Size and Type(1)
Flexible Multi-core Tightening Torque
Terminals (mm2) (mm2) AWG N•m (lb•in)
U3, V3 0.14…1.5 0.14…2.5 26…16 0.4 (3.5)
(1) For more information, see Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual,
publication 20P-UM001.
IMPORTANT When connecting the fan power wiring, verify that the airflow enters through the bottom and exits through the top of the
drive. If the airflow is incorrect, switch the leads on terminals U3 and V3.
The cooling fan power input terminals U3, V3, and W3 are required to be short circuit protected. This protection can be
provided by using a circuit breaker or fuses.
• If a circuit breaker is used, it must be rated for the short circuit available current of the feeder source for this circuit
and the inrush current of the fan. Size the circuit breaker to protect the wiring from the circuit breaker connections
to terminals U3, V3, and W3, and not spurious trip or blow from the inrush current.
• If fuses are used, they must be rated for either 400V AC, 2.5 amps (slow blow), or 460V AC, 3.15 amps (slow blow). Airflow
A normally closed (N.C.) contact wired to terminals 31 and 32 of the fan terminal block can be connected to an external device to provide
indication of a fan supply failure or can be wired to drive digital input terminals that are configured for 14 “Aux Fault” (via Pars 133…144).
Frame D, Series B and C Heat Sink Cooling Fan Signal Wire Sizes and Terminal Specifications
Wire Size and Type(1) Tightening Torque
Terminals Flexible (mm2) Multi-core (mm2) AWG N•m (lb•in)
U3, V3, W3, 31, 32, PE 0.14…1.5 0.14…2.5 28…12 0.5…0.6 (4.4…5.3)
(1) For more information, see Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001.
Frame D, Series B and C Heat Sink Cooling Fan Terminal Block Location
Top View
of Drive
U3 V3 W3 PE 31 32
U3 V3 W3 PE 31 32
Thermistors (PTC)
PTC thermistors that are fitted in the load can be connected directly to the drive via terminals 78 and 79. In this case, the 1 kΩ resistor is not
required between terminals 78 and 79.
Klixon type temperature-dependent contacts can disconnect the drive from the load via an external control or can be configured as an external fault
using a digital input on drive. They can also be connected to terminals 78 and 79 to indicate the following:
• For a PowerFlex DC drive, to indicate a drive “Motor Over Temp” fault (F16)
• For a PowerFlex DC field controller, to indicate a field controller “PTC Over Temp” fault (F16)
However, this configuration is not recommended due to the noise sensitivity of the current threshold circuitry. If a thermal switch is used, a 1 kΩ
resistor must be placed in series between the switch and one of the terminals.
Frame C Contact Relay and Thermistor Terminal Block Locations (only for PowerFlex DC Drives)
230V/460V AC Input Frame C 575V/690V AC Input Frame C
Frame D Contact Relay and Thermistor Terminal Block Locations (only for PowerFlex DC Drives)
Recommended Signal Wire Size for Relay Outputs and Thermistor/Thermal Switch Terminals
Wire Size and Type(1) Tightening Torque
Signal Type Terminals Flexible (mm2) Multi-core (mm2) AWG N•m (lb•in)
Relay Outputs 35 & 36, 75 & 76
Thermistor and 0.140…1.500 0.140…2.500 26…14 0.5 (4.4)
78 & 79
Thermal Switches
(1) For more information, see Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001.
PowerFlex DC Drives and Field Controller I/O Signal and Control Wiring
Eight digital inputs, four digital outputs, three analog inputs, and two analog outputs are available on the standard I/O terminal blocks that are
provided with the drive. One digital input (1…8) must be configured for “Enable”.
More digital and analog I/O is available when using the optional I/O expansion circuit board. See Appendix F - ‘Optional Analog and Digital I/O
Expansion Circuit Board,’ in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for more information. You can also use the
optional 115V AC converter circuit board to convert 115V AC to 24V DC digital inputs signals to interface with the digital inputs on the standard
I/O terminal blocks. See Appendix G Optional 115V AC to 24V DC I/O Converter Circuit Board in the PowerFlex Digital DC Drive User
Manual, publication 20P-UM001, for more information. All I/O terminal blocks are on the control board.
Recommended Signal Wire Size for Analog I/O and Digital I/O
Terminal Block Wire Size and Type(1) Tightening Torque
Signal Type (Terminals) Flexible (mm2) Multi-core (mm2) AWG N•m (lb•in)
Analog and Digital I/O TB1…4 (1…40) 0.140…1.500 0.140…1.500 26…16 0.4 (3.5)
(1) For more information, see Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001.
+5/12-15V DC
(200 mA)
+V
COM Common
+V
COM
Z-
Common
Z+ to
+
to Shield (1)
+V
COM
Z NOT
Z-
Z
Z+
B NOT
Differential, Dual Channel B-
B
B+
A NOT
A-
A
A+
to Shield (1)
ATTENTION: The drive can overspeed if DIP switch S4 is set incorrectly, or the tachometer is wired incorrectly. Failure to do so could result in damage to, or
destruction of, the equipment.
FS1 = Externally
mounted fuses for the
FS1
armature converter on
the AC input side.
U V W U1 V1 FS3 = Internally
mounted fuses for the
FS3 field circuit on the AC
input side.
C D C1 D1
Rating DC Line Ferrule FWP North American Ferrule A70QS North American
Code Amps Amps Type FWP Type Type A70P / A70QS Type
7P0 7 5.7 FWP-10A14F FWP-10B A70QS10-14F A70P10-4
9P0 9 7.4 FWP-15A14F FWP-15B A70QS16-14F A70P15-4
012 12 9.8 FWP-20A14F FWP-20B A70QS20-14F A70P20-4
020 20 16 FWP-25A14F FWP-25B A70QS25-14F A70P25-4
029 29 24 FWP-40A22F FWP-40B A70QS40-22F A70QS40-4
A
038 38 31 FWP-63A22F FWP-60B A70QS63-22F A70QS60-4
055 55 45 FWP-80A22F FWP-80B A70QS80-22F A70QS80-4
073 73 60 FWP-100A A70QS100-4K
093 93 76 — FWP-150A — A70QS150-4K
110 110 90 FWP-175A A70QS175-4K
146 146 119 FWP-250A A70QS250-4
180 180 147 FWP-300A A70QS300-4
218 218 178 FWP-350A A70QS350-4
B — —
265 265 217 FWP-400A A70QS400-4
360 360 294 FWP-600A A70QS600-4K
434 434 355 FWP-600A A70QS600-4
Rating DC Line Ferrule FWP North American Ferrule A70QS North American
Code Amps Amps Type FWP Type Type A70P / A70QS Type
4P1 4.1 3.3 FWP-10A14F FWP-10B A70QS10-14F A70P10-4
6P0 6 4.9 FWP-10A14F FWP-10B A70QS10-14F A70P10-4
010 10 8.2 FWP-20A14F FWP-20B A70QS20-14F A70P25-4
014 14 11.4 FWP-25A14F FWP-25B A70QS25-14F A70P25-4
019 19 15.5 FWP-25A14F FWP-25B A70QS25-14F A70P25-4
027 27 22.1 FWP-40A22F FWP-40B A70QS40-22F A70QS40-4
A 035 35 28.6 FWP-63A22F FWP-60B A70QS63-22F A70QS60-4
045 45 36.8 FWP-80A22F FWP-80B A70QS80-22F A70QS80-4
052 52 42.5 FWP-80A22F FWP-80B A70QS80-22F A70QS80-4
073 73 59.6 FWP-100A A70QS100-4K
086 86 70.3 FWP-150A A70QS150-4K
100 100 81.7 FWP-175A A70QS175-4K
129 129 105.4 FWP-175A A70QS175-4K
167 167 136.4 — FWP-300A — A70QS300-4
207 207 169.1 FWP-350A A70QS350-4
B 250 250 204.3 FWP-400A A70QS400-4
330 330 269.6 FWP-600A A70QS600-4K
412 412 336.6 FWP-600A A70QS600-4
AC input line fuses are externally mounted for frame A and B drives and must be sourced separately.
Bussman Mersen
Frame DC AC Line Ferrule North American Ferrule North American
Cat. No. Size Amps Amps FWP Type FWP Type A70QS Type A70P / A70QS Type
23PFCx017 17 14 FWP-25A14F FWP-25B A70QS25-14F A70P25-4
23PFCx060 A 60 49 FWP-80A22F FWP-80B A70QS80-22F A70QS80-4
23PFCx120 120 98 FWP-150A A70QS150-4K
23PFCx245 245 201 FWP-300A A70QS300-4
— —
23PFCx365 B 365 299 FWP-400A A70QS400-4
23PFCx570 570 467 FWP-600A A70QS600-4
Field circuit fuses are internally mounted and provided with the drive. See Fuse Code FS3 in PowerFlex DC Drives Frame A and B Fuse Information
on page 48. Also, see PowerFlex DC Drive Frame A Field AC Input Line Fuses Location on page 52 and PowerFlex DC Drive Frame B Field AC
Input Line Fuses Location on page 52 for fuse locations.
Rating Field
Code Amps Type Quantity Bussmann Mersen SIBA
7P0
9P0
012
020 10
029
A 6 x 32 mm 2 FWH-016A6F E085449 70 125 40.16
038
055
073
093 14
110
146
180
218
B 20 10 x 38 mm 2 FWC-25A10F A60Q25-2 60 033 05.25
265
360
434
Rating Field
Code Amps Type Quantity Bussmann Mersen SIBA
4P1
6P0
010
014
019 10
027
A 035 6 x 32 mm 2 FWH-016A6F E085449 70 125 40.16
045
052
073
086
14
100
129
167
207
B 250 20 10 x 38 mm 2 FWC-25A10F A60Q25-2 60 033 05.25
330
412
Rating Field
Code Amps Type Quantity Bussmann Mersen SIBA
067
101
B 135 20 10 x 38 mm 2 FWC-25A10F A60Q25-2 60 033 05.25
270
405
U V W U1 V1
FS4 FS3
FS4 = Internally FS3 = Internally
mounted fuses for the mounted fuses for the
armature converter on C D C1 D1 field circuit on the AC
the AC input side. input side.
Field circuit fuses for frames C and D drives are internally mounted (labeled FU1 and FV1) and provided with the drive. See Fuse Code FS3 in
PowerFlex DC Drive Frame C and D Fuse Information on page 53. Also, see PowerFlex DC Frame C and D Drives Field Circuit Fuse Locations on
page 54 and Fuses for Regenerative Frame C and D Drives on page 54 for locations.
Leg fuses are internally mounted and provided with frames C and D drives. See Fuse Code FS4 in PowerFlex DC Drive
Frame C and D Fuse Information on page 53. Also, see Frame C Regenerative Drive - Leg Fuse Location and Frame D
Regenerative Drive - Leg Fuse Location on page 56.
AC input line and/or leg fuses are internally mounted and provided with frames C and D drives. See Fuse Code FS4 in PowerFlex DC Drive Frame
C and D Fuse Information on page 53. Also, see Frame C Non-Regenerative Drive - AC Input Line Fuse Location on page 58.
Note: Drive shown with front covers removed and Control EMI shield lowered.
Bussman Mersen
Ferrule North American Ferrule A70QS North American
Cat. No. Frame Size DC Amps AC Line Amps FWP Type FWP Type Type A70P / A70QS Type
23PFCx017 17 14 FWP-25A14F FWP-25B A70QS25-14F A70P25-4
23PFCx060 A 60 49 FWP-80A22F FWP-80B A70QS80-22F A70QS80-4
23PFCx120 120 98 FWP-150A A70QS150-4K
23PFCx245 245 201 FWP-300A A70QS300-4
— —
23PFCx365 B 365 299 FWP-400A A70QS400-4
23PFCx570 570 467 FWP-600A A70QS600-4
PowerFlex DC Drive and Field Controller Control Power Circuit Protection Fuses
The following fuses are used to protect the switching power supply circuit.
IMPORTANT Before you order and install fuses, verify the circuit board revision.
Frame A Switching Power Supply Fuse Location (on all PowerFlex DC Drives and Field Controllers)
Top View of Drive Switching power supply fuse
Frame B Switching Power Supply Fuse Location (on all PowerFlex DC Drives and Field Controllers)
Top View of Drive F1 = 3.15A fuse F2 = 2.5A fuse
(Board Rev. “H” and below only) (Board Rev. “H” and below only)
Frame D Switching Power Supply Circuit Board Fuse Location (only on PowerFlex DC Drives)
Mounting
Maximum Surrounding Air Temperature Specifications
• 0…50 °C (32…122 °F), typical
• De-rate 1.25% for every 1 °C (°F) over 50 °C (122 °F), to 55 °C (131 °F)
• Additional cooling is required for temperatures above 55 °C (131 °F)
Operating Conditions
The drive and/or field controller must be mounted in a clean, dry location. Contaminants such as oils, corrosive vapors,
and abrasive debris must be kept out of the enclosure. NEMA/UL Type Open, IP20 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 clearance requirements (shown here) are intended to be from device to device. Other objects can occupy this
space; however, reduced airflow can cause protection circuits to fault the drive. The device must be mounted in a vertical
orientation (as shown in the illustration) and must not be mounted at an angle greater than 30° from vertical. In addition,
inlet air temperature must not exceed the product specification.
150 (6)
150 (6)
10 10 10 50 (2)
(0.4) (0.4) (0.4) Airflow through the drive
150 (6)
must not be impeded.
IMPORTANT Verify that all mounting screws are properly tightened before and after operation.
A C
A1
B1
B
A2
Frame A Weights
Drive w/ND Rating Code Weight, kg (lb)
230V 460V Drive Drive and Packaging
7P0 4P1
9P0 6P0
012 010
11 (24.25) 13 (28.7)
020 014
— 019
029 027
038 035
055 045 11.5 (25.4) 13.5 (29.8)
– 052
073 073
093 086
110 — 12 (26.5) 14 (30.9)
100
—
129
Frame B Dimensions
mm (in.)
A A1 A2 A3 B B1 C1 C2(1)
311 (12.2) 275 (10.8) 16.5 (0.65) 7 (0.3) 388 (15.3) 375 (14.8) 350 (13.8) 380 (15.0)
(1) Only frame B drive catalog numbers 20P21AD330, 20P21AD412, 20P21AE405, 20P41AB360, 20P41AB434, 20P41AD330, 20P41AD412, and 20P41AE405.
A C
A1
B
B1
A2 A3
45.2 (1.8)
53.1 (2.1)
98.5 (3.9)
48.5 (1.9)
147.0 (5.8)
53.1 (2.1)
200.1 (7.9)
48.5 (1.9)
248.6 (9.8)
Frame B Weights
Drive w/ND Rating Code Weight, kg (lb)
230V 460V 575V Drive Drive and Packaging
146 167 067
180 207 101 25.5 (56.2) 27.5 (60.6)
218 — 135
265 250 270 29.5 (65.0) 31.5 (69.5)
360 330 405
32 (70.5) 34 (75)
434 412 —
Frame C Dimensions
mm (in.)
A A1 B B1 B2 B3 B4 B5 C
521 (20.5) 499 (19.7) 511 (20.1) 400 (15.7) 200 (7.9) 55 (2.2) 56 (2.2) 10.5 (0.4) 416 (16.4)
A1 C
B4
B1
B
B5
B2
B3
Frame C Weights
Weight, kg (lb)
Drive w/ND Rating Code Regenerative Drives Non-regenerative Drives
230V 460V 575V 690V Drive Drive and Packaging Drive Drive and Packaging
— 495 61 (134.5) 83 (183.0) 57 (125.7) 79 (174.2)
521 667 —
65 (143.3) 87 (191.8) 62 (136.7) 84 (185.2)
700
— 540 452
— 72 (158.7) 94 (207.2) 68 (150.0) 90 (198.4)
675 565
792 1250
(31.2) (49.2)
208
(8.2)
144
(5.7)
157.5
(6.2)
32
(1.3)
PE C D PE C D
44.5 10.5
(1.8) 10
(0.4) (0.4)
22.6 44.5
25 30 (1.8)
(1.0) (1.2) (0.9)
44.5 269.5 100
146 60 (1.8) 44.5 (10.6) (4.0) 27.8
(5.7) (2.4) (1.8) (1.1)
454.5 100
252.5 134 (18.0) (4.0)
(10.0) (5.3)
437.5
(17.2)
Note: 134 mm (5.3 in.) C and D terminals are installed on 460V AC input, 800 Hp and 900 Hp, 575V AC input, 1000 Hp, and 690V AC input,
1100, 1200, 1250, and 1,400 Hp drives only. All other frame D ratings have 100 mm (4.0 in.) C and D terminals.
1435, max
(56.5)
1230
(48.4)
157.5
Mounting Slots (5)
(6.2)
10.5 (0.4)
129
(5.1) 10
(0.4)
215.225
(8.5) 94 127 127 127 127 94
531 (3.7) (5.0) (5.0) (5.0) (5.0) (3.7)
(21.0)
541
(21.3)
A C
A1
B1
B
A2
Frame A Weights
Weight, kg (lb)
Cat. No. Drive Drive and Packaging
23PFCB017 and23PFCD017 10.8 (23.8) 12.8 (28.2)
23PFCB060 and 23PFCD060 11.3 (24.9) 13.3 (29.3)
23PFCB120 and 23PFCD120 11.8 (26.0) 13.8 (30.4)
Frame B Dimensions
mm (in.)
A A1 A2 A3 B B1 C1 C2(1)
311 (12.2) 275 (10.8) 16.5 (0.65) 7 (0.3) 388 (15.3) 375 (14.8) 350 (13.8) 380 (15.0)
(1) Only frame B drive catalog numbers 23PFCB570 and 23PFCD570.
A C
A1
B1 B
A2 A3
Frame B Weights
Weight, kg (lb)
Cat. No. Drive Drive and Packaging
23PFCB245 and 23PFCD245 25.3 (55.8) 27.3 (60.2)
23PFCB365 and 23PFCD365 29.3 (64.6) 31.3 (69.0)
23PFCB570 and 23PFCD570 31.8 (70.1) 33.8 (74.5)
Category Specification
Drive Type Full Wave Regen, 6 Pulse, Regulated Field Supply
Protection Heat sink Thermistor: Monitored by microprocessor overtemp trip
Drive Overcurrent Trip
• Software Overcurrent Trip: • Programmable, 0…250% of rated current (175% default)
• Hardware Overcurrent Trip: • Based on armature circuit fusing
Line transients: Up to 2,000 volts peak per IEC 6100-4-5
Control Logic Noise Immunity: Showering arc transients up to 1500V peak
Power Ride-Thru: 15 milliseconds at full load
Logic Control Ride-Thru: 0.5 seconds minimum, 2 seconds typical
Environment(1) Altitude: 1,000 m (3,300 ft) max. without derating.
De-rate output power by 1.2% for every 100 meters (328 ft) above 1,000 meters (3,300 ft).
Maximum Surrounding Air 0…50 °C (32…122 °F), typical.
Temperature IP20, NEMA Type De-rate 1.25% for every 1 °C over 50 °C (122 °F), to 55 °C (131 °F).
Open: More cooling is required for temps. above 55 °C.
Storage Temp. (all const.): –25…55 °C (–13…131 °F)
Atmosphere: Important: Drive must not be installed in an area where the ambient atmosphere
contains volatile or corrosive gas, vapors, or dust. If the drive is not going to be immediately
installed, it must be stored in an area where it is not exposed to a corrosive atmosphere.
Relative Humidity: Operating: 5…85% noncondensing
Storage: 5…95% noncondensing
Shock: 15G peak for 11 ms duration (±1.0 ms)
Vibration: 0.152 mm (0.006 in.) displacement, 1G peak
(1) PowerFlex DC drives must be installed in a Pollution Degree 2 environment.
Category Specification
Drive Type Full Wave Regen, 6 Pulse, Regulated Field Supply
Protection Heat sink Thermistor: Monitored by microprocessor overtemp trip
Drive Overcurrent Trip Programmable, 0…250% of rated current (175% default)
Line transients Up to 2,000 volts peak per IEC 6100-4-5
Control Logic Noise Immunity Showering arc transients up to 1500V peak
Power Ride-Thru 15 milliseconds at full load
Logic Control Ride-Thru 0.5 seconds minimum, 2 seconds typical
Environment(1) Altitude: 1,000 m (3,300 ft) max. without derating.
De-rate output power by 1.2% for every 100 meters (328 ft) above 1,000 meters (3,300 ft).
Maximum Surrounding Air 0…50 °C (32…122 °F), typical.
Temperature IP20, NEMA Type De-rate 1.25% for every 1 °C over 50 °C (122 °F), to 55 °C (131 °F).
Open: More cooling is required for temps. above 55 °C.
Storage Temp. (all const.) –25…+55 °C (–13…+131 °F)
Atmosphere Important: The field controller must not be installed in an area where the ambient atmosphere contains volatile
or corrosive gas, vapors, or dust. If the drive is not going to be immediately installed, it must be stored in an area
where it is not exposed to a corrosive atmosphere.
Relative Humidity Operating: 5…85% noncondensing
Storage: 5…95% noncondensing
Shock 15G peak for 11 ms duration (°1.0 ms)
Vibration 0.152 mm (0.006 in.) displacement, 1G peak
Electrical Input Voltages: Control: 115V AC or 230V AC +/- 15%, 1 Phase
(For details, see AC Input Voltages on page 23.)
Input Frequency: 50/60 Hz +/- 5%
Max. Rate of Change of Input 2 Hz/Sec.
Frequency:
Output Current: 17…570 A
Drive Overload Capability: 100% rated continuous current
Field Output Voltage Maximum field output voltage is 1.16 x AC input line voltage.
Max. Short Circuit Rating: 100,000 A
(1) Field controllers must be installed in a Pollution Degree 2 environment.
(2) 115V AC input control power requires a jumper between terminals SA and SB for frame B field controllers only. For more information, see PowerFlex DC Drives and Field Controller Control Circuit Input Power on page 35.
Notes:
Notes:
Notes:
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