Technical Data

PowerFlex Digital DC Drive

Table of Contents
Topic
Additional Resources Product Description Standard Drives Program Catalog Number Explanation Standard Drives Product Selection Factory Installed Options User Installed Options Installation Considerations Circuit Protection Mounting Approximate Dimensions PowerFlex DC Configured Drives Specifications Watts Loss and Fan Attributes

Page
3 3 4 6 7 9 10 20 51 67 68 74 79 82

PowerFlex Digital DC Drive

Rockwell Automation Publication 20P-TD001F-EN-P - February 2013

PowerFlex Digital DC Drive

Additional Resources
These documents contain additional information concerning related products from Rockwell Automation.
Resource PowerFlex Digital DC Drive User Manual, publication 20P-UM001 A Global Reference Guide for Reading Schematic Diagrams, publication 100-2.10 Guarding Against Electrostatic Damage, publication 8000-4.5.2 Preventive Maintenance of Industrial Control and Drive System Equipment, publication DRIVES-TD001 Safety Guidelines for the Application, Installation and Maintenance of Solid State Control, publication SGI-1.1 Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Product Certifications website, http://www.ab.com Description Provides basic information needed to install, start-up, and troubleshoot the PowerFlex DC drive. Provides a simple cross-reference of common schematic/wiring diagram symbols used throughout various parts of the world. Explains the causes of ESD and how to guard against its effects. Provides a checklist to use as a guide in performing preventive maintenance. Provides general guidelines for the application, installation, and maintenance of solid state control in the form of individual devices or packaged assemblies incorporating solid state components. Provides general guidelines for installing a Rockwell Automation industrial system. Provides declarations of conformity, certificates, and other certification details.

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

Product Description
The PowerFlex Digital DC drive provides digital control for precise speed and current regulation, easy programmability, extensive diagnostics, non-regenerative and regenerative operation, and is easily interfaced for integration into larger drive systems. PowerFlex DC drives are well suited to a variety of applications including extruding operations, finishing, drawing, and coating processes, applications exhibiting shock loads, high inertia, rapid accel/decel or continuous regeneration, and is an excellent choice for existing DC machinery upgrades. The compact design of this drive includes a fully contained power module and a common control structure for the entire range of horsepower. And, to make connectivity even easier, the PowerFlex DC drive provides a standard DPI interface that is compatible with all PowerFlex DPI communication products. The standard hardware offering consists of an open type enclosure, armature converter, regulated field converter for field weakening or economy applications, an advanced regulator with integrated DPI functionality, I/O, including eight digital inputs, four digital outputs, three analog inputs, and two analog outputs, a DC tachometer, and encoder capability. Note: Additional I/O and feedback options are available and are sold separately from the standard hardware offering. See I/O Option Kits and Feedback Option Kit on page 10.

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PowerFlex Digital DC Drive

Standard Drives Program

Packaging and Mounting
IP20, NEMA/UL Type Open - For conventional mounting inside or outside a control cabinet.

Easy to Use Communication Tools

The PowerFlex Digital DC drive 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 can be downloaded for free from http://ab.rockwellautomation.com/programmable-controllers/connectedcomponents-workbench-software. DriveTools SP (v4.01 or higher is required with a PowerFlex DC drive specific software patch. The patch can be downloaded from http://www.ab.com/support/abdrives/webupdate/). A suite of software tools which provide an intuitive means for programming, troubleshooting and maintaining Allen-Bradley drives, including the PowerFlex DC Drive Start-Up Wizard. DriveExplorer and DriveExplorer Lite (v5.02 or higher). A simple and flexible On-line tool for monitoring and configuring while connected to a drive. Internal Communications allow you to integrate the drive 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.

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PowerFlex Digital DC Drive

Drive Features
Fast-acting Current Limit and Voltage Regulation result in maximum accel/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 rotating loads, 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 can eliminate the need for a separate process loop controller. 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.

Unsurpassed Capability in Network Communications

PowerFlex drives are fully compatible with the wide variety of Allen-Bradley DPI communication adapters, offering the following benefits:
BACnet ControlNet DeviceNet EtherNet/IP PROFIBUS Remote I/O (1) RS485 DF1

Description

(Unconnected Messaging) permits other network devices (e.g. PanelView) to communicate directly to a drive without routing the communication through the network scanner. Adapter Routing - Plug PC 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. Very flexible configuration for each node (Example: reference must change by more than 5%). Peer Control provides master-slave type control between drives, where 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, by allowing the scanner to be configured to automatically detect a new drive and download the required parameter settings. Flexible Fault Configuration - Adapters can be programmed to take fault based actions as ramp to stop, coast-to-stop and hold last state, as well as send user configurable logic control and speed reference values. In addition, different actions can be taken based on whether the network experienced a serious problem (broken cable etc.) versus network idle condition (PLC set to Program).

(1) This item has Silver Series status. For information, refer to http://www.ab.com/silver.

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Catalog Number Explanation

Position 1-3 4 5 6 7 8-10 11 12 13 14 15 16

20P
a

4
b

1
c

A
d

D
e

4P1
f

R
g

A
h

0
i

N
j

N
k

N
l

a
Drive Code 20P Type PowerFlex DC 7P0 9P0 1.5 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 Code Hp

f1
230V, 60 Hz Input Armature Frame Amps 7 9 12 20 29 38 55 73 93 110 146 180 218 265 360 434 521 700 875 1050 A A A A A A A A A A B B B B B B C C D D Field Amps 10 10 10 10 10 10 10 14 14 14 20 20 20 20 20 20 20 20 40 40 Code 452 565 678 791 904 Field Amps 10 10 10 10 10 10 10 10 10 14 14 14 14 20 20 20 20 20 20 20 40 40 70 70 70 1K0 1K1 1K2 1K4 1K5 Code 067 101 135 270 405 540 675 810 1K0 1K2 1K3 1K6 Hp 50 75 100 200 300 400 500 600 800 900 1000 1250

f3
575V, 60 Hz Input Armature Frame Amps 67.5 101.3 135 270 405 504 675 810 1080 1215 1350 1668 B B B B B C C D D D D D Field Amps 20 20 20 20 20 20 20 40 40 40 40 40

b
Motor Operation Code 2 4 Type Two Quadrant Operation Four Quadrant Operation

012 020 029 038 055 073 093 110

Not available for 230V AC input drives.

c
Input Type Code 1 Type 6 Pulse

146 180 218 265 360 434

f4
690V, 60 Hz Input Hp 400 500 600 700 800 900 1000 1100 1250 1400 Armature Frame Amps 452 565 678 791 904 1017 1130 1243 1413 1582 C C D D D D D D D D Field Amps 20 20 40 40 40 40 70 70 70 70

d
Enclosure Code A Enclosure Rating IP20, NEMA/UL Type Open Conform. Coat Yes

521 700 875 1K0

f2 e
Input Voltage Code B D E Voltage 230V AC 460V AC 600V AC 460V, 60 Hz Input Code 4P1 6P0 010 014 019 027 035 045 052 073 086 100 129 167 207 250 330 412 495 667 830 996 1K1 1K3 1K4 Hp 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 400 500 600 700 800 900 Armature Frame Amps 4.1 6 10 14 19 27 35 45 52 73 86 100 129 167 207 250 330 412 495 667 830 996 1162 1328 1494 A A A A A A A A A A A A A B B B B B C C D D D D D

F 690V AC Use this code for 400V AC input applications.

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Catalog Number Explanation, continued

Position 1-3 4 5 6 7 8-10 11 12 13 14 15 16

20P
a

4
b

1
c

A
d

D
e

4P1
f

R
g

A
h

0
i

N
j

N
k

N
l

g
Field Supply Code R Type Single-Phase Regulated Code 0

i
HIM Operator Interface Blank Cover Code N

k
Communication Options Description None

h
Packaging/Documentation Code A Shipping Carton Yes User Manual Yes

Standard - for user installed options, see Human Interface and Wireless Interface Modules on page 9.

Standard - for user installed options, see Communication Option Kits on page 10.

j
I/O Options Code N Control None (8 - 24V DC Digital Inputs, 4 Digital Outputs, 3 Analog Inputs, and 2 Analog Outputs are Standard) Code N

l
Cabinet Options Type None

All I/O Options are purchased separately and are user installed. See I/O Options on page 9.

Standard Drives Product Selection

IP20, NEMA/UL Type Open (Position d = A)
All drives are rated 150% overload for 60 seconds, 200% for three seconds.

230V AC, Three-Phase

Drive Output Rating Normal Duty kW Normal Duty HP 1.2 1.5 1.5 2 2.2 3 3.7 5 5.5 7.5 7.5 10 11 15 15 20 18.5 25 22 30 30 40 37 50 45 60 56 75 75 100 Amps 7 9 12 20 29 38 55 73 93 110 146 180 218 265 360 Non-Regenerative Drives(1) Cat. No. 20P21AB7P0RA0NNN 20P21AB9P0RA0NNN 20P21AB012RA0NNN 20P21AB020RA0NNN 20P21AB029RA0NNN 20P21AB038RA0NNN 20P21AB055RA0NNN 20P21AB073RA0NNN 20P21AB093RA0NNN 20P21AB110RA0NNN 20P21AB146RA0NNN 20P21AB180RA0NNN 20P21AB218RA0NNN 20P21AB265RA0NNN 20P21AB360RA0NNN Regenerative Drives Cat. No. 20P41AB7P0RA0NNN 20P41AB9P0RA0NNN 20P41AB012RA0NNN 20P41AB020RA0NNN 20P41AB029RA0NNN 20P41AB038RA0NNN 20P41AB055RA0NNN 20P41AB073RA0NNN 20P41AB093RA0NNN 20P41AB110RA0NNN 20P41AB146RA0NNN 20P41AB180RA0NNN 20P41AB218RA0NNN 20P41AB265RA0NNN 20P41AB360RA0NNN Frame Size A A A A A A A A A A B B B B B

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PowerFlex Digital DC Drive

Drive Output Rating Normal Duty kW Normal Duty HP 93 125 112 150 149 200 186 250 224 300
(1) Currently not available for sale.

Amps 434 521 700 875 1050

Non-Regenerative Drives(1) Cat. No. 20P21AB434RA0NNN 20P21AB521RA0NNN 20P21AB700RA0NNN 20P21AB875RA0NNN 20P21AB1K0RA0NNN

Regenerative Drives Cat. No. 20P41AB434RA0NNN 20P41AB521RA0NNN 20P41AB700RA0NNN 20P41AB875RA0NNN 20P41AB1K0RA0NNN

Frame Size B C C D D

460V AC, Three-Phase

Drive Output Rating Normal Duty kW Normal Duty HP 1.5 2 2.2 3 3.7 5 5.5 7.5 7.5 10 11 15 15 20 18.5 25 22 30 30 40 37 50 45 60 56 75 75 100 93 125 112 150 149 200 187 250 224 300 298 400 373 500 447 600 552 700 597 800 671 900 Amps 4.1 6 10 14 19 27 35 45 52 73 86 100 129 167 207 250 330 412 495 667 830 996 1162 1328 1494 Non-Regenerative Drives Cat. No. 20P21AD4P1RA0NNN 20P21AD6P0RA0NNN 20P21AD010RA0NNN 20P21AD014RA0NNN 20P21AD019RA0NNN 20P21AD027RA0NNN 20P21AD035RA0NNN 20P21AD045RA0NNN 20P21AD052RA0NNN 20P21AD073RA0NNN 20P21AD086RA0NNN 20P21AD100RA0NNN 20P21AD129RA0NNN 20P21AD167RA0NNN 20P21AD207RA0NNN 20P21AD250RA0NNN 20P21AD330RA0NNN 20P21AD412RA0NNN 20P21AD495RA0NNN 20P21AD667RA0NNN 20P21AD830RA0NNN 20P21AD996RA0NNN 20P21AD1K1RA0NNN 20P21AD1K3RA0NNN 20P21AD1K4RA0NNN Regenerative Drives Cat. No. 20P41AD4P1RA0NNN 20P41AD6P0RA0NNN 20P41AD010RA0NNN 20P41AD014RA0NNN 20P41AD019RA0NNN 20P41AD027RA0NNN 20P41AD035RA0NNN 20P41AD045RA0NNN 20P41AD052RA0NNN 20P41AD073RA0NNN 20P41AD086RA0NNN 20P41AD100RA0NNN 20P41AD129RA0NNN 20P41AD167RA0NNN 20P41AD207RA0NNN 20P41AD250RA0NNN 20P41AD330RA0NNN 20P41AD412RA0NNN 20P41AD495RA0NNN 20P41AD667RA0NNN 20P41AD830RA0NNN 20P41AD996RA0NNN 20P41AD1K1RA0NNN 20P41AD1K3RA0NNN 20P41AD1K4RA0NNN Frame Size A A A A A A A A A A A A A B B B B B C C D D D D D

575V AC, Three-Phase

Drive Output Rating Normal Duty kW Normal Duty HP Amps Non-Regenerative Drives Cat. No. Regenerative Drives Cat. No. Frame Size

37 56 75 149 224 298 373 447 597 671 746 932 8

50 75 100 200 300 400 500 600 800 900 1000 1250

67.5 101.3 135 270 405 540 675 810 1080 1215 1350 1688

20P21AE067RA0NNN 20P21AE101RA0NNN 20P21AE135RA0NNN 20P21AE270RA0NNN 20P21AE405RA0NNN 20P21AE540RA0NNN 20P21AE675RA0NNN 20P21AE810RA0NNN 20P21AE1K0RA0NNN 20P21AE1K2RA0NNN 20P21AE1K3RA0NNN 20P21AE1K6RA0NNN

20P41AE067RA0NNN 20P41AE101RA0NNN 20P41AE135RA0NNN 20P41AE270RA0NNN 20P41AE405RA0NNN 20P41AE540RA0NNN 20P41AE675RA0NNN 20P41AE810RA0NNN 20P41AE1K0RA0NNN 20P41AE1K2RA0NNN 20P41AE1K3RA0NNN 20P41AE1K6RA0NNN

B B B B B C C D D D D D

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PowerFlex Digital DC Drive

690V AC, Three-Phase

Drive Output Rating Normal Duty kW Normal Duty HP 298 400 373 500 447 600 552 700 597 800 671 900 746 1000 820 1100 932 1250 1044 1400 Amps 452 565 678 791 904 1017 1130 1243 1413 1582 Non-Regenerative Drives Cat. No. 20P21AF452RA0NNN 20P21AF565RA0NNN 20P21AF678RA0NNN 20P21AF791RA0NNN 20P21AF904RA0NNN 20P21AF1K0RA0NNN 20P21AF1K1RA0NNN 20P21AF1K2RA0NNN 20P21AF1K4RA0NNN 20P21AF1K5RA0NNN Regenerative Drives Cat. No. 20P41AF452RA0NNN 20P41AF565RA0NNN 20P41AF678RA0NNN 20P41AF791RA0NNN 20P41AF904RA0NNN 20P41AF1K0RA0NNN 20P41AF1K1RA0NNN 20P41AF1K2RA0NNN 20P41AF1K4RA0NNN 20P41AF1K5RA0NNN Frame Size C C D D D D D D D D

Factory Installed Options

Each PowerFlex DC drive includes one encoder and DC analog tachometer input. No other factory installed options are available at this time.

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PowerFlex Digital DC Drive

User Installed Options

Human Interface Modules
Remote (Panel Mount) IP66, NEMA/UL Type 4x/12 Cat. No. 20-HIM-C3S 20-HIM-C5S

Human Interface Module Accessories

Description Bezel Kit for LCD HIMs, NEMA/UL Type 1 PowerFlex HIM Interface Cable, 1 m (39 in) Cable Kit (Male-Female) 0.33 Meters (1.1 Feet) 1 Meter (3.3 Feet) 3 Meter (9.8 Feet) 9 Meter (29.5 Feet) DPI/SCANport One to Two Port Splitter Cable 1202-H03 1202-H10 1202-H30 1202-H90 1203-S03 Cat. No. 20-HIM-B1 20-HIM-H10

Handheld/Local (Drive Mount) Description No HIM (Blank Plate) LCD Display, Full Numeric Keypad LCD Display, Programmer Only Enhanced, LCD, Full Numeric Cat. No. 20-HIM-A0 20-HIM-A3 20-HIM-A5 20-HIM-A6

For indoor use only. Includes a 1202-C30 interface cable (3 meters) for connection to drive.

Includes a 1202-C30 interface cable (3 meters) for connection to drive. Required only when HIM is used as handheld or remote. Required in addition to 20-HIM-H10 for distances up to a total maximum of 10 Meters (32.8 Feet).

I/O Option Kits

Description I/O Expansion board (4 24V DC Digital Inputs, 4 Digital Outputs, 2 Analog Outputs) Cat. No. 20P-S5V62 20P-S520L

20-HIM-A0

20-HIM-A3

20-HIM-A5

20-HIM-A6

115V AC to 24V DC 8 Channel I/O Converter Board (converts 8 Digital Inputs)

Feedback Option Kit

Description Resolver Feedback Option Module Cat. No. 20P-RES-A0

20-HIM-C3S

20-HIM-C5S

10

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User Installed Options, continued

Communication Option Kits
Description BACnet MS/TP RS485 Communication Adapter ControlNet Communication Adapter (Coax) DeviceNet Communication Adapter EtherNet/IP Communication Adapter HVAC Communication Adapter Modbus/TCP Communication Adapter PROFIBUS DP Communication Adapter ControlNet Communication Adapter (Fiber) Remote I/O Communication Adapter RS485 DF1 Communication Adapter External Communications Kit Power Supply DPI External Communications Kit External DPI I/O Option Board Compact I/O to DPI/SCANport Module Serial Null Modem Adapter Smart Self-powered Serial Converter (RS232) includes 1203-SFC and 1202-C10 Cables Universal Serial Bus (USB) Converter includes 2m USB, 20-HIM-H10 & 22-HIM-H10 Cables This item has Silver Series status. For information, refer to: http://www.ab.com/silver. For use only with External DPI Communications Kits 20-XCOMM-DC-BASE. Cat. No. 20-COMM-B 20-COMM-C 20-COMM-D 20-COMM-E 20-COMM-H 20-COMM-M 20-COMM-P 20-COMM-Q 20-COMM-R 20-COMM-S 20-XCOMMAC-PS1 20-XCOMMDC-BASE 20-XCOMMIO-OPT1 1769-SM1 1203-SNM 1203-SSS 1203-USB

PC Programming Software
Description Connected Components Workbench Software DriveTools SP Software DriveExplorer Software (Full) Connected Components Workbench is available for free download at: http://ab.rockwellautomation.com/Programmable-Controllers/ Connected-Components-Workbench-Software DriveTools SP is available for order using the Build This Catalog Number link at: http://ab.rockwellautomation.com/Drives/Software/9303-DriveTools-SP#/tab6 DriveExplorer Full is available for free download at: http://www.ab.com/support/abdrives/webupdate/software.html#

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.
Three Phase Primary Voltage Three Phase Secondary Voltage kVA kW (HP) Voltage 230V AC 460V AC Catalog Number Catalog Number 5 1.2 - 2.2 230 1321-3TW005-AA 1321-3TW005-AB (1.5 - 3) 460 1321-3TW005-BA 1321-3TW005-BB 575 1321-3TW005-CA 1321-3TW005-CB 7.5 3.7 (5) 230 1321-3TW007-AA 1321-3TW007-AB 460 1321-3TW007-BA 1321-3TW007-BB 575 1321-3TW007-CA 1321-3TW007-CB 11 5.5 (7.5) 230 1321-3TW011-AA 1321-3TW011-AB 460 1321-3TW011-BA 1321-3TW011-BB 575 1321-3TW011-CA 1321-3TW011-CB 14 7.5 (10) 230 1321-3TW014-AA 1321-3TW014-AB 460 1321-3TW014-BA 1321-3TW014-BB 575 1321-3TW014-CA 1321-3TW014-CB 20 11 (15) 230 1321-3TW020-AA 1321-3TW020-AB 460 1321-3TW020-BA 1321-3TW020-BB 575 1321-3TW020-CA 1321-3TW020-CB 27 15 (20) 230 1321-3TW027-AA 1321-3TW027-AB 460 1321-3TW027-BA 1321-3TW027-BB 575 1321-3TW027-CA 1321-3TW027-CB 575V AC Catalog Number N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

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PowerFlex Digital DC Drive

Three Phase Primary Voltage Three Phase Secondary Voltage kVA kW (HP) Voltage 230V AC 460V AC Catalog Number Catalog Number 34 18.5 (25) 230 1321-3TW034-AA 1321-3TW034-AB 460 1321-3TW034-BA 1321-3TW034-BB 575 1321-3TW034-CA 1321-3TW034-CB 40 22 (30) 230 1321-3TW040-AA 1321-3TW040-AB 460 1321-3TW040-BA 1321-3TW040-BB 575 1321-3TW040-CA 1321-3TW040-CB 51 30 (40) 230 1321-3TW051-AA 1321-3TW051-AB 460 1321-3TW051-BA 1321-3TW051-BB 575 1321-3TW051-CA 1321-3TW051-CB 63 37 (50) 230 1321-3TH063-AA 1321-3TH063-AB 460 1321-3TH063-BA 1321-3TH063-BB 575 1321-3TH063-CA 1321-3TH063-CB 75 45 (60) 230 1321-3TH075-AA 1321-3TH075-AB 460 1321-3TH075-BA 1321-3TH075-BB 575 1321-3TH075-CA 1321-3TH075-CB 93 56 (75) 230 1321-3TH093-AA 1321-3TH093-AB 460 1321-3TH093-BA 1321-3TH093-BB 575 1321-3TH093-CA 1321-3TH093-CB 118 75 (100) 230 1321-3TH118-AA 1321-3TH118-AB 460 1321-3TH118-BA 1321-3TH118-BB 575 1321-3TH118-CA 1321-3TH118-CB 145 93 (125) 230 1321-3TH145-AA 1321-3TH145-AB 460 1321-3TH145-BA 1321-3TH145-BB 575 1321-3TH145-CA 1321-3TH145-CB 175 112 (150) 230 1321-3TH175-AA 1321-3TH175-AB 460 1321-3TH175-BA 1321-3TH175-BB 575 1321-3TH175-CA 1321-3TH175-CB 220 145 (200) 230 1321-3TH220-AA 1321-3TH220-AB 460 1321-3TH220-BA 1321-3TH220-BB 575 1321-3TH220-CA 1321-3TH220-CB 275 187 (250) 230 1321-3TH275-AA 1321-3TH275-AB 460 1321-3TH275-BA 1321-3TH275-BB 575 1321-3TH275-CA 1321-3TH275-CB 330 224 (300) 230 1321-3TH330-AA 1321-3TH330-AB 460 1321-3TH330-BA 1321-3TH330-BB 575 1321-3TH330-CA 1321-3TH330-CB 440 298 (400) 230 N/A 1321-3TH440-AB 460 N/A 1321-3TH440-BB 575 N/A 1321-3TH440-CB 550 373 (500) 230 N/A 1321-3TH550-AB 460 N/A 1321-3TH550-BB 575 N/A 1321-3TH550-CB 660 448 (600) 230 N/A 1321-3TH660-AB 460 N/A 1321-3TH660-BB 575 N/A 1321-3TH660-CB 770 522 (700) 230 N/A 1321-3TH770-AB 460 N/A 1321-3TH770-BB 575 N/A 1321-3TH770-CB 880 597 (800) 230 N/A 1321-3TH880-AB 460 N/A 1321-3TH880-BB 575 N/A 1321-3TH880-CB

575V AC Catalog Number N/A N/A N/A N/A N/A N/A N/A N/A N/A 1321-3TH063-AC 1321-3TH063-BC 1321-3TH063-CC 1321-3TH075-AC 1321-3TH075-BC 1321-3TH075-CC 1321-3TH093-AC 1321-3TH093-BC 1321-3TH093-CC 1321-3TH118-AC 1321-3TH118-BC 1321-3TH118-CC 1321-3TH145-AC 1321-3TH145-BC 1321-3TH145-CC 1321-3TH175-AC 1321-3TH175-BC 1321-3TH175-CC 1321-3TH220-AC 1321-3TH220-BC 1321-3TH220-CC 1321-3TH275-AC 1321-3TH275-BC 1321-3TH275-CC 1321-3TH330-AC 1321-3TH330-BC 1321-3TH330-CC 1321-3TH440-AC 1321-3TH440-BC 1321-3TH440-CC 1321-3TH550-AC 1321-3TH550-BC 1321-3TH550-CC 1321-3TH660-AC 1321-3TH660-BC 1321-3TH660-CC 1321-3TH770-AC 1321-3TH770-BC 1321-3TH770-CC 1321-3TH880-AC 1321-3TH880-BC 1321-3TH880-CC

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PowerFlex Digital DC Drive

AC Input Line Reactors and Contactors

If a DC Contactor is used, an AC Input contactor is not needed.

230V AC Input Drives

Regenerative Drive Cat. No. 20P41AB7P0 20P41AB9P0 20P41AB012 20P41AB020 20P41AB029 20P41AB038 20P41AB055 20P41AB073 20P41AB093 20P41AB110 20P41AB146 20P41AB180 20P41AB218 20P41AB265 20P41AB360 20P41AB434 20P41AB521 20P41AB700 20P41AB875 20P41AB1K0 DC Amps 7 9 12 20 29 38 55 73 93 110 146 180 218 265 360 434 521 700 875 1050 AC Line HP Amps 5.7 7.4 9.8 16 24 31 45 60 76 90 119 147 178 217 294 355 426 572 715 858 1.5 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 IP00 (Open Style) Line Reactor Cat No. 1321-3R8-A 1321-3R12-A 1321-3R18-A 1321-3R18-A 1321-3R55-A 1321-3R55-A 1321-3R55-A 1321-3R80-A 1321-3R100-A 1321-3R100-A 1321-3R160-A 1321-3R160-A 1321-3RB250-A 1321-3RB250-A 1321-3RB320-A 1321-3RB400-A 1321-3R500-A 1321-3R600-A 1321-3R750-A 1321-3R850-A Line Reactor kW (HP) .75 (1) 1.49 (2) 0.75-3.7 (1-5) 0.75-3.7 (1-5) 5.5-11 (7.5-15) 5.5-11 (7.5-15) 5.5-11 (7.5-15) 15 (20) 18.5-22 (25-30) 18.5-22 (25-30) 30-37 (40-50) 30-37 (40-50) 45-56 (60-75) 45-56 (60-75) 75 (100) 93 (125) 112 (150) 149 (200) 186 (250) 224 (300) AC Input Contactor Cat. No. 100-C12D10 100-C12D10 100-C12D10 100-C23D10 100-C30D10 100-C37D10 100-C60D10 100-C60D10 100-C85D10 100-D110D11 100-D140D11 100-D180D11 100-D180D11 100-D250ED11 100-D300ED11 100-D420ED11 100-D630ED11 100-D630ED11 100-D860ED11 100-D860ED11

460V AC Input Drives

Non-Regenerative Regenerative Drive Cat. No. Drive Cat. No. 20P21AD4P1 20P21AD6P0 20P21AD010 20P21AD014 20P21AD019 20P21AD027 20P21AD035 20P21AD045 20P21AD052 20P21AD073 20P21AD086 20P21AD100 20P21AD129 20P21AD167 20P21AD207 20P21AD250 20P21AD330 20P21AD412 20P21AD495 20P21AD667 20P21AD830 20P41AD4P1 20P41AD6P0 20P41AD010 20P41AD014 20P41AD019 20P41AD027 20P41AD035 20P41AD045 20P41AD052 20P41AD073 20P41AD086 20P41AD100 20P41AD129 20P41AD167 20P41AD207 20P41AD250 20P41AD330 20P41AD412 20P41AD495 20P41AD667 20P41AD830 DC Amps 4.1 6 10 14 19 27 35 45 52 73 86 100 129 167 207 250 330 412 495 667 830 AC Line HP Amps 3.3 4.9 8.2 11.4 15.5 22.1 28.6 36.8 42.5 59.6 70.3 81.7 105.4 136.4 169.1 204.3 269.6 336.6 404.4 544.9 678.1 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 400 500 IP00 (Open Style) Line Reactor Cat No. 1321-3R4-A 1321-3R8-A 1321-3R18-B 1321-3R18-B 1321-3R18-B 1321-3R55-B 1321-3R55-B 1321-3R55-B 1321-3R55-B 1321-3R80-B 1321-3R100-B 1321-3R100-B 1321-3R160-B 1321-3R160-B 1321-3RB250-B 1321-3RB250-B 1321-3RB320-B 1321-3RB400-B 1321-3R500-B 1321-3R600-B 1321-3R750-B Line Reactor kW AC Input Contactor (HP) Cat. No. .55 (.75) .75 (1) 1.5-7.5 (2-10) 1.5-7.5 (2-10) 1.5-7.5 (2-10) 11-22 (15-30) 11-22 (15-30) 11-22 (15-30) 11-22 (15-30) 30 (40) 37-45 (50-60) 37-45 (50-60) 56-75 (75-100) 56-75 (75-100) 93-112 (125-150) 93-112 (125-150) 149 (200) 186.4 (250) 223.7 (300) 298.3 (400) 372.8 (500) 100-C12D10 100-C12D10 100-C12D10 100-C12D10 100-C23D10 100-C23D10 100-C30D10 100-C37D10 100-C43D10 100-C60D10 100-C85D10 100-C85D10 100-D110D11 100-D140D11 100-D180D11 100-D210ED11 100-D300ED11 100-D420ED11 100-D420ED11 100-D630ED11 100-D860ED11

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PowerFlex Digital DC Drive

Non-Regenerative Regenerative Drive Cat. No. Drive Cat. No. 20P21AD996 20P21AD1K1 20P21AD1K3 20P21AD1K4 20P41AD996 20P41AD1K1 20P41AD1K3 20P41AD1K4

DC Amps 996 1162 1328 1494

AC Line HP Amps 813.7 949.4 1085.0 1220.6 600 700 800 900

IP00 (Open Style) Line Reactor Cat No. 1321-3R850-B 1321-3R1000-B

(1) (2)

Line Reactor kW AC Input Contactor (HP) Cat. No. 447,4 (600) 552 (700) 100-D860ED11 100-G860KD22 100-G860KD22 100-G1200KD12

(1) No Line Reactor available for this drive rating. Use the recommended Isolation Transformer: 1321-3TH880-BB. (2) No Line Reactor or Isolation Transformer available for this drive rating - must be sourced locally.

575V AC Input Drives

Non-Regenerative Regenerative Drive Cat. No. Drive Cat. No. AC Line DC Amps Amps HP IP00 (Open Style) Line Reactor Line Reactor Cat No. kW (HP) AC Input Contactor Cat. No.

20P21AE067 20P21AE101 20P21AE135 20P21AE270 20P21AE405 20P21AE540 20P21AE675 20P21AE810 20P21AE1K0 20P21AE1K2 20P21AE1K3 20P21AE1K6

20P41AE067 20P41AE101 20P41AE135 20P41AE270 20P41AE405 20P41AE540 20P41AE675 20P41AE810 20P41AE1K0 20P41AE1K2 20P41AE1K3 20P41AE1K6

67.5 101.25 135 270 405 540 675 810 1080 1215 1350 1687.5

55.1 82.7 110.3 220.6 330.9 441.2 551.5 661.8 882.4 992.7 1103.0 1378.7

50 75 100 200 300 400 500 600 800 900 1000 1250

1321-3R55-B 1321-3R100-B 1321-3R130-B 1321-3RB250-B 1321-3RB320-B 1321-3RB500-B 1321-3R600-B 1321-3R750-B 1321-3R1000-B 1321-3R1000-B 2 x 1321-3R600-B 2 X 1321-3R750-B

37 (50) 56 (75) 75 (100) 149 (200) 224 (300) 298 (400) 373 (500) 447 (600) 597 (800) 671 (900) 746 (1000)

100-C60D10 100-C85D10 100-D110D11 100-D250ED11 100-D420ED11 100-D630ED11 100-D630ED11 100-D860ED11 100-G700KD22 100-G860KD22 100-G1000KD12
(1)

(1) No AC Input Contactor available for this drive rating - must be sourced locally.

690V AC Input Drives

Non-Regenerative Regenerative Drive Cat. No. Drive Cat. No. 20P21AF452 20P21AF565 20P21AF678 20P21AF791 20P21AF904 20P21AF1K0 20P21AF1K1 20P21AF1K2 20P21AF1K4 20P21AF1K5 20P41AF452 20P41AF565 20P41AF678 20P41AF791 20P41AF904 20P41AF1K0 20P41AF1K1 20P41AF1K2 20P41AF1K4 20P41AF1K5 DC Amps 452 565 678 791 904 1017 1130 1243 1412.5 1582 AC Line HP Amps 369 462 554 646 739 831 923 1016 1154 1292 400 500 600 700 800 900 1000 1100 1250 1400 Line Reactors or Isolation Transformers for 690V AC input voltage drives must be sourced locally. IP00 (Open Style) Line Reactor Cat No. 1321-3RB500-C 1321-3RB600-C Line Reactor kW AC Input Contactor (HP) Cat. No. 100-D420ED11 100-D630ED11 100-D630ED11 100-D860ED11 100-D860ED11 100-D860ED11 100-G700KD22 100-G860KD22 100-G1200KD12 100-G1200KD12

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PowerFlex Digital DC Drive

Dynamic Brake Resistor Kits and DC Output Contactors

See Alternate Dynamic Brake Resistor Kits and DC Output Contactors on page 17 for recommended alternate DC Output Contactors for 575V and 690V AC input drives, respectively.

230V AC Input Drives

Frame Drive Current Rating Code A 7P0 9P0 012 020 029 038 055 073 093 110 146 180 218 265 360 434 521 700 875 1K0 DC AC Line Amps Amps 7 9 12 20 29 38 55 73 93 110 146 180 218 265 360 434 521 700 875 1050 5.7 7.4 9.8 16 24 31 45 60 76 90 119 147 178 217 294 355 426 572 715 858 HP Dynamic Brake Resistor Kit Cat. No. 1370-DBL62 1370-DBL63 1370-DBL64 1370-DBL65 1370-DBL66 1370-DBL67 1370-DBL68 1370-DBL69 1370-DBL70 1370-DBL71 1370-DBL72 1370-DBL73 1370-DBL74 1370-DBL75 1370-DBL76
(1)

C D
(1) (2) (3) (4) (5)

1.5 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300

(1)
(2)

(2) (2)

Armature Voltage (Volts) 240 240 240 240 240 240 240 240 240 240 240 240 240 240 240 240 240 240 240 240

DB Resistor Size (ohms) 20 20 15 8.6 6 5 3.5 2.6 2 2 0.7 0.5 0.5 2 1.4 0.5 0.322

DB Resistor Brake Amps DC Loop DC Contactor Size (Watts) Required Contactor Cat. Crimp Lugs Cat. No.(3) No.(4) 420 12.00 1370-DC56 1370-LG40 420 12.00 1370-DC56 1370-LG40 420 16.00 1370-DC56 1370-LG40 420 27.91 1370-DC56 1370-LG40 345 40.00 1370-DC56 1370-LG40 330 48.00 1370-DC56 1370-LG40 385 68.57 1370-DC56 1370-LG56 385 92.31 1370-DC110 1370-LG92 330 120.00 1370-DC110 1370-LG92 330 120.00 1370-DC110 1370-LG110 280 342.86 1370-DC180 1370-LG160 365 480.00 1370-DC180 1370-LG180 365 480.00 1370-DC280 1370-LG228 330 120.00 1370-DC280 1370-LG268 (5) 290 171.43 (1) 1458 651 (1) (5) 6221 781 (1) (5) (1) (5) (1) (5) (1) (5)

See Alternate Dynamic Brake Resistor Kits and DC Output Contactors Amp on page 17. No Dynamic Brake Resistor kit available for this drive rating - must be sourced locally. Coil voltage = 115V AC, 50/60Hz. See DC Contactor Crimp Lug Kit Specifications Amp on page 16 for more information. Wire and Lug size dependant on enclosure dimensions and local codes.

460V AC Input Drives

Frame Drive Current Rating Code A 4P1 6P0 010 014 019 027 035 045 052 073 086 100 129 DC Amps 4.1 6 10 14 19 27 35 45 52 73 86 100 129 AC Line Amps 3.3 4.9 8.2 11.4 15.5 22.1 28.6 36.8 42.5 59.6 70.3 81.7 105.4 HP Dynamic Brake Resistor Kit Cat. No. 1370-DBH63 1370-DBH64 1370-DBH65 1370-DBH66 1370-DBH67 1370-DBH68 1370-DBH69 1370-DBH70 1370-DBH71 1370-DBH72 1370-DBH73 1370-DBH74 1370-DBH75 Armature Voltage (Volts) 500 500 500 500 500 500 500 500 500 500 500 500 500 DB Resistor Size (ohms) 81 62 45 27 20 12 5 4.5 3.5 2.6 2 2 1 DB Resistor Size (Watts) 255 245 245 350 420 405 330 330 385 345 345 345 270 Brake DC Loop DC Contactor Amps Contactor Cat. Crimp Lugs Cat. Required No.(3) No.(4) 6.17 1370-DC56 1370-LG40 8.06 1370-DC56 1370-LG40 11.11 1370-DC56 1370-LG40 18.52 1370-DC56 1370-LG40 25.00 1370-DC56 1370-LG40 41.67 1370-DC56 1370-LG40 100.00 1370-DC56 1370-LG40 111.11 1370-DC56 1370-LG52 142.86 1370-DC56 1370-LG52 192.31 1370-DC110 1370-LG92 250.00 1370-DC110 1370-LG92 250.00 1370-DC110 1370-LG110 500.00 1370-DC180 1370-LG140

2 3 5 7.5 10 15 20 25 30 40 50 60 75

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PowerFlex Digital DC Drive

Frame Drive Current Rating Code B 167 207 250 330 412 495 667 800 960 1K1 1K3 1K4

DC Amps 167 207 250 330 412 495 667 830 996 1162 1328 1494

AC Line Amps 136.4 169.1 204.3 269.6 336.6 404.4 544.9 678.1 813.7 949.4 1085.0 1220.6

HP

C D

100 125 150 200 250 300 400 500 600 700 800 900

Dynamic Brake Resistor Kit Cat. No. 1370-DBH76 1370-DBH77 1370-DBH78 1370-DBH79
(1)

(1) (1)
(2)

(2) (2) (2) (2)

Armature Voltage (Volts) 500 500 500 500 500 500 500 500 500 500 500 500

DB Resistor Size (ohms) 0.7 0.7 0.5 0.7 0.808 0.595 0.542 0.463 0.322 0.322 0.255 0.255

DB Resistor Size (Watts) 280 280 365 280 7292 6069 6439 6338 6221 6221 5718 5718

Brake DC Loop DC Contactor Amps Contactor Cat. Crimp Lugs Cat. Required No.(3) No.(4) 714.29 1370-DC180 1370-LG180 714.29 1370-DC280 1370-LG228 1000.00 1370-DC280 1370-LG268 (5) 714.29 (1) (1) (5) (1) (5) (1) (5) (1) (5) (1) (5) (1) (5) (1) (5) (1) (5)

(1) (2) (3) (4) (5)

See Alternate Dynamic Brake Resistor Kits and DC Output Contactors Amp on page 17. No Dynamic Brake Resistor kit available for this drive rating - must be sourced locally. Coil voltage = 115V AC, 50/60Hz. See DC Contactor Crimp Lug Kit Specifications Amp on page 16for more information. Wire and Lug size dependant on enclosure dimensions and local codes.

DC Contactor Crimp Lug Kit Specifications

Use the information provided in the table below to assist you in ordering the correct Lug kit for your application.
Rated Motor Armature Current (1) A DC 4.135 4552 55 6086 100110 129 146 147167 207218 250265 266280 DC Contactor Rating A DC 56 56 56 110 110 180 180 180 280 280 280 Armature Conductor Size (2) AWG 8 6 4 2 1/0 2/0 3/0 4/0 300MCM 400MCM 500MCM DB Conductor Size (3) Armature Conductor Crimp AWG Lug Hole Size 8 8 8 6 4 2 2 2 1/0 2/0 3/0 #10 #10 #10 0.25 in. 0.25 in. 0.3125 in. 0.3125 in. 0.3125 in. 0.5 in. 0.5 in. 0.5 in. DB Conductor Crimp Lug Hole Size #10 #10 #10 0.25 in. 0.25 in. 0.3125 in. 0.3125 in. 0.3125 in. 0.375 in. 0.375 in. 0.375 in. Lug Kit Catalog Number 1370-LG40 1370-LG52 1370-LG56 1370-LG92 1370-LG110 1370-LG140 1370-LG160 1370-LG180 1370-LG228 1370-LG268 1370-LG280

(1) The Rated Motor Armature Current is taken directly from the motor nameplate or motor data. The current listed in this column is the maximum current allowed for the Armature Conductor Size (column 3) and the DC Contactor Rating (column 2). (2) The armature conductors are sized by multiplying the Rated Motor Armature Current by 1.25 as provided for in NEC 420-22 (1987). The DC lug ratings are determined from NEC Table 310-16 (1987) for copper conductors, insulation temperature rated at 75 C (167 F) at an ambient temperature of 30 C (86 F). If conditions are other than shown in NEC Table 310-16, then refer to application codes. (3) The dynamic braking (DB) conductors are sized as in footnote 2 above, but at half ampacity due to the short time duration of current flow in these conductors, and has been sized to satisfy NEMA Standard ICS 3-302.62 - Dynamic Braking. If the load inertia is larger than that of the motor, calculations must be made to determine correct conductor sizing and DB resistor wattage per NEMA Standard ICS 3302.62.

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PowerFlex Digital DC Drive

Alternate Dynamic Brake Resistor Kits and DC Output Contactors

The following alternate dynamic brake resistor kits and/or DC output contactors may be used with the corresponding PowerFlex DC drives but must be sourced separately from the drive.

230V AC Input Drives

Drive DC AC HP Current Amps Line Rating Amps Code B 360 360 294 100 434 434 355 125 Frame Dynamic Brake Resistor Kit Cat. No. Armature DB Resistor DB Brake DC Loop Contactor Cat. No.(2) Voltage Size (ohms) Resistor Amps Drive w/No Dynamic Brake Drive w Dynamic Brake (Volts) Size Required (Watts) 240 1.4 290 171.43 ABB_EHDB360C2P-1L2S ABB_EHDB360C-1L22SS 240 0.5 1458 651 ABB_EHDB520C2P-1L2S ABB_EHDB520C-1L22SS DC Contactor Crimp Lugs Cat. No.(3)
(4)

C D

521 700 875 1K0

521 700 875 1050

426 572 715 858

1370-DBL76 CUTLERHAMMER_G3AP50 (Qty 4 - two in series, two in parallel) 150 HUBBELL_Y139W322GB (1) 200 250 300

240 240 240 240

0.322

6221

781

ABB_EHDB800C2P-1L2S ABB_EHDB960C2P-1L2S SIEMENS-MFG_14-193-10158-2 (Qty 2)

ABB_EHDB800C-1L22SS ABB_EHDB960C-1L22SS SIEMENS-MFG_14-193-101-58-2 (Qty 1)

(1) (2) (3) (4)

No Dynamic Brake Resistor kit available for this drive rating - must be sourced locally. Coil voltage = 115V AC, 50/60Hz. See DC Contactor Crimp Lug Kit Specifications Amp on page 16 for more information. Wire and Lug size dependant on enclosure dimensions and local codes.

460V AC Input Drives

Drive Current Rating Code B 330 412 C 495 667 D 800 960 1K1 1K3 1K4 (1) (2) (3) (4) Frame DC AC HP Amps Line Amps 330 412 495 667 830 996 Armature DB Resistor DB Brake Voltage Size (ohms) Resistor Amps (Volts) Size Required (Watts) 269.6 200 1370-DBH79 500 0.7 280 714.29 336.6 250 HUBBELL_Y95W808GB 500 0.808 7292 404.4 300 HUBBELL_Y101W595GB 500 0.595 6069 544.9 400 HUBBELL_Y109W542GB 500 0.542 6439 (1) 678.1 500 500 0.463 6338 813.7 600 500 0.322 6221 500 500 500 0.322 0.255 0.255 6221 5718 5718 Dynamic Brake Resistor Kit Cat. No. DC Loop Contactor Cat. No.(2) Drive w/No Dynamic Brake Drive w Dynamic Brake ABB_EHDB360C2P-1L2S ABB_EHDB360C-1L22SS ABB_EHDB520C2P-1L2S ABB_EHDB520C-1L22SS ABB_EHDB520C2P-1L2S ABB_EHDB520C-1L22SS ABB_EHDB800C2P-1L2S ABB_EHDB800C-1L22SS ABB_EHDB960C2P-1L2S ABB_EHDB960C-1L22SS SIEMENS-MFG_14-193-101-58-2 SIEMENS-MFG_14-193-101-58(Qty 2) 2 (Qty 1) SIEMENS-MFG_14-193-101-58-2 SIEMENS-MFG_14-193-101-58(Qty 2) 2 (Qty 1) CUTLER-HAMMER_6702ED636-2 CUTLER-HAMMER_6702ED636(Qty 2) 2 (Qty 1) CUTLER-HAMMER_6702ED636-2 CUTLER-HAMMER_6702ED636(Qty 2) 2 (Qty 1) DC Contactor Crimp Lugs Cat. No.(3)
(4)

1162 949.4 700 1328 1085. 800 0 1494 1220. 900 6

No Dynamic Brake Resistor kit available for this drive rating - must be sourced locally. Coil voltage = 115V AC, 50/60Hz. See DC Contactor Crimp Lug Kit Specifications Amp on page 16 for more information. Wire and Lug size dependant on enclosure dimensions and local codes.

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PowerFlex Digital DC Drive

575V AC Input Drives

Drive Current Rating Code B 067 101 135 270 405 C 540 675 D 810 1K0 Frame 1K2 1K3 1K6 (1) (2) (3) (4) DC AC Hp Amps Line Amps 67.5 101 135 270 405 540 675 810 1080 1215 1350 1688 55.1 83 110 221 331 441 551 662 882 993 1103 1379 50 75 100 200 300 400 500 600 800 900 1000 1250 Dynamic Armature DB Resistor Brake Voltage Size (ohms) Resistor Kit (Volts) Cat. No. (1) 600 5.93 600 3.95 600 2.96 600 1.48 600 0.988 600 0.741 600 0.593 600 0.494 600 0.370 600 600 600 0.329 0.296 0.237 DB Resistor Size (Watts) Brake DC Loop Contactor Cat. No.(2) Amps Drive w/No Dynamic Brake Required ABB_EHDB220C2P-1L2S ABB_EHDB220C2P-1L2S ABB_EHDB220C2P-1L2S ABB_EHDB360C2P-1L2S ABB_EHDB520C2P-1L2S ABB_EHDB650C2P-1L2S ABB_EHDB800C2P-1L2S ABB_EHDB960C2P-1L2S SIEMENS-MFG_14-193-101-58-2 (Qty 2) SIEMENS-MFG_14-193-101-58-2 (Qty 2) CUTLER-HAMMER_6702ED636-2 (Qty 2) CUTLER-HAMMER_6702ED636-2 (Qty 2) Drive w Dynamic Brake ABB_EHDB220C-1L22SS ABB_EHDB220C-1L22SS ABB_EHDB220C-1L22SS ABB_EHDB360C-1L22SS ABB_EHDB520C-1L22SS ABB_EHDB650C-1L22SS ABB_EHDB800C-1L22SS ABB_EHDB960C-1L22SS SIEMENS-MFG_14-193-101-58-2 (Qty 1) SIEMENS-MFG_14-193-101-58-2 (Qty 1) CUTLER-HAMMER_6702ED636-2 (Qty 1) CUTLER-HAMMER_6702ED636-2 (Qty 1) DC Contactor Crimp Lugs Cat. No.(3)
(4)

No Dynamic Brake Resistor kit available for this drive rating - must be sourced locally. Coil voltage = 115V AC, 50/60Hz. See DC Contactor Crimp Lug Kit Specifications Amp on page 16 for more information. Wire and Lug size dependant on enclosure dimensions and local codes.

690V AC Input Drives

Drive DC Current Amps Rating Code C 452 452 Frame 565 D 678 791 904 1K0 1K1 1K2 1K4 1K5 (1) (2) (3) (4) 565 678 791 904 1017 1130 1243 1413 1582 AC Hp Line Amps 369 462 554 646 739 831 923 400 500 600 700 800 900 1000 Dynamic Armature DB Resistor Brake Voltage Size (ohms) Resistor Kit (Volts) Cat. No. (1) 700 1.03 700 700 700 700 700 700 700 700 700 0.826 0.688 0.590 0.516 0.459 0.413 0.375 0.330 0.295 DB Resistor Size (Watts) Brake DC Loop Contactor Cat. No.(2) Amps Drive w/No Dynamic Brake Required SIEMENS-MFG_14-193-101-58-2 (Qty 2) SIEMENS-MFG_14-193-101-58-2 (Qty 2) SIEMENS-MFG_14-193-101-58-2 (Qty 2) SIEMENS-MFG_14-193-101-58-2 (Qty 2) SIEMENS-MFG_14-193-101-58-2 (Qty 2) SIEMENS-MFG_14-193-101-58-2 (Qty 2) SIEMENS-MFG_14-193-101-58-2 (Qty 2) SIEMENS-MFG_14-193-101-58-2 (Qty 2) CUTLER-HAMMER_6702ED636-2 (Qty 2) CUTLER-HAMMER_6702ED636-2 (Qty 2) Drive w Dynamic Brake SIEMENS-MFG_14-193-101-58-2 (Qty 1) SIEMENS-MFG_14-193-101-58-2 (Qty 1) SIEMENS-MFG_14-193-101-58-2 (Qty 1) SIEMENS-MFG_14-193-101-58-2 (Qty 1) SIEMENS-MFG_14-193-101-58-2 (Qty 1) SIEMENS-MFG_14-193-101-58-2 (Qty 1) SIEMENS-MFG_14-193-101-58-2 (Qty 1) SIEMENS-MFG_14-193-101-58-2 (Qty 1) CUTLER-HAMMER_6702ED636-2 (Qty 1) CUTLER-HAMMER_6702ED636-2 (Qty 1) DC Contactor Crimp Lugs Cat. No.(3)
(4)

1016 1100 1154 1250 1292 1400

No Dynamic Brake Resistor kit available for this drive rating - must be sourced locally. Coil voltage = 115V AC, 50/60Hz. See DC Contactor Crimp Lug Kit Specifications Amp on page 16 for more information. Wire and Lug size dependant on enclosure dimensions and local codes.

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PowerFlex Digital DC Drive

Frame D Terminal Adapter Kits

The following frame D drives require the listed terminal adapter kits in order to meet UL installation requirements.
Voltage Class 230 460 Drive Current Rating Code 1K0 1K1 1K3 1K4 1K0 1K2 1K3 1K6 1K0 1K1 1K2 1K4 1K5 U, V, W Terminal Adapter Kit Number SK-20P-S726172 SK-20P-S726171 C, D Terminal Adapter Kit Number SK-20P-S726173

575

SK-20P-S726172 SK-20P-S726171

690

SK-20P-S726172 SK-20P-S726171

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PowerFlex Digital DC Drive

Installation Considerations
The PowerFlex Digital DC drive has the following built in protective features to help simplify installation: Ground fault protection during start up and running ensures reliable operation Electronic motor overload protection increases motor life There are many other factors that must be considered for optimal performance in any given application. The block diagram below highlights the primary installation considerations.

Input Fuses - See page 51

Input Power Conditioning - See page 11

LCD HIM - See page 10

DC Drive Accessories - See page 15

Motor Overload Protection - See page 42

Motor Recommendations -See http://ab.rockwellautomation.com/Motors

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PowerFlex Digital DC Drive

Power Wiring AC Input Voltages

PowerFlex DC drives are rated for the following AC input voltages @ 50/60 Hz 5%:

Mains Circuit (Terminals U, V, W)

230V 10%, 3Ph 400V 10%, 3Ph 440V 10%, 3Ph 460V 10%, 3Ph 480V 10%, 3Ph 575V 10%, 3Ph 690V 10%, 3Ph

Field Circuit (Terminals U1, V1)

230V 10%, 1Ph 400V 10%, 1Ph 460V 10%, 1Ph

Control Circuit (Terminals U2, V2)

115V 15% or 230V 15%, 1Ph

Note: For frame B and C drives only, 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. Refer to Frame B drives SA-SB Terminal Block Location on page 37 and Frame C Drives SA-SB Terminal Block Location on page 38 for terminal block locations.

DC Output Voltages
The output voltages below 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 (Terminals U, V, W) 230V 10 %, 3Ph 400V 10 %, 3Ph 440V 10 %, 3Ph 460V 10 %, 3Ph 480V 10 %, 3Ph 575V 10 %, 3Ph 690V 10 %, 3Ph DC Output Armature Voltage (Terminals C & D) Two Quadrant Drive Four Quadrant Drive 260V 240V 470V 420V 530V 460V 560V 480V 580V 500V 680V 600V 810V 720V

Field Circuit
AC Input Voltage (Terminals U1 & V1) 230V 10 %, 1Ph 400V 10 %, 1Ph 460V 10%, 1Ph DC Output Field Voltage(1) (Terminals C1 & D1) Fixed Field Adjustable Field 200V 200V 310V 310V 360V 360V

(1) The max field voltage is equal to 0.85 x AC input line voltage

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22
PE 34 (on I/O TB4) (N.O. Relay) M1 AC Contactor C Aux Line Reactor L1 L2 L3 W A2 FS2 D C1 FU1 FV1 AC Input Voltage SA (1) SB U2 V2 35 36 U3 V3
(9)

(4)

FS2

(6)

PowerFlex Digital DC Drive

Lockable Installation Disconnect Isolation (2) Transformer

(2)

13 T1 T2 T3 A2 A2
(6)

14 FS1 FS1 FS1

(3) (3) (3)

19 (+24V on I/O TB2) U V 1A2

Armature Volt. (7) Fdbk. Term.

(5)

L1 A1

1A1

A1

L2

Typical Power Wiring Diagrams

L3 Safety Ground FU A1

Power Wiring with AC Input Contactor

3 Phase AC line
Field Power Terminal Block U1 F1 These connections must be taken from the primary side of the Isolation Transformer or Line Reactor (clean power). 460 VAC Max. or 230 VAC (10) Min. V1
(1)

FU

FU

FU

PowerFlex DC Drive

D1

F2

Control Board P/S Control Power / Relay Outputs Terminal Block

AC Input Voltage
(8) (8)

The following diagram represents recommended power wiring configurations:

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230V Fan Power Terminal Block

115V or (1) 230V

AC Input Voltage

(1) For frame B and C drives only, a jumper is required between terminals SA and SB for 115V AC control input power. See Control Circuit Input Power on page 34 for more information. (2) An Isolation Transformer and/or 35% impedance Line Reactor is required. If the Isolation Transformer provides the required 35% impedance, a Line Reactor is not required. See AC Input Line Reactors and Contactors on page 13 and Isolation Transformers on page 11 for recommendations. (3) AC input fuses for the armature converter are customer supplied for frame A and B drives and are internally mounted on frame C and D drives. See Circuit Protection on page 51 for fuse recommendations. (4) Par 140 [Digital In8 Sel] set to 31 Contactor (5) If using the +24V internal power supply, terminal 18 (24V common) must be jumpered to terminal 35 (digital input common). (6) Customer supplied armature output fuses are required on four quadrant and are recommended on two quadrant Frame A and B drives. See Circuit Protection on page 51 for fuse recommendations. (7) Optional armature voltage feedback sensing not required with AC contactor. (8) 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 Terminal block, NOT the I/O terminal blocks. See Relay Outputs on page 42 for locations. (9) Frame C & D drives only require an external power supply for the heatsink cooling fan. See Frame C Heatsink Cooling Fans Power Supply Terminals on page 39 and Frame D Heatsink Cooling Fan Power Supply Terminals on page 40 for more information. (10) See Field Converter Connections on page 31.

PE
Aux

34 (on I/O TB4) 19 (+24V on I/O TB2)

FS2 L1 L2 A1 A2 T2 A1 T1
(6)

(4)

(5)

13

14

Lockable Installation Disconnect Isolation (2) Transformer Line Reactor FS1 FS1 FS1 W Safety Ground FU A2 Field Power Terminal Block U1 FU1 FV1 V1 SA (1) SB U2 V2 35 36 U3 V3
(8)

(2)

C D
(N.O. Relay) M1 DC Contactor

(3) (3) (3)

L1 V 1A1
Armature Volt. Fdbk. Term.

PowerFlex DC Drive
A1 1A2
(6)

L2

L3

M
A2 FS2

Power Wiring with DC Output Contactor

3 Phase AC line
460 VAC Max. or 230 VAC (9) Min.

FU

FU

FU

These connections must be taken from the primary side of the Isolation Transformer or Line Reactor (clean power). C1 F1
AC Input Voltage
(1)

D1

F2

Control Board P/S Control Power / Relay Outputs Terminal Block

AC Input Voltage
(7) (7)

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230V Fan Power Terminal Block

115V or (1) 230V

AC Input Voltage

(1) For frame B and C drives only, a jumper is required between terminals SA and SB for 115V AC control input power. See Control Circuit Input Power on page 34 for more information. (2) An Isolation Transformer and/or 35% impedance Line Reactor is required. If the Isolation Transformer provides the required 35% impedance, a Line Reactor is not required. See AC Input Line Reactors and Contactors on page 13 and Isolation Transformers on page 11 for recommendations. (3) AC input fuses for the armature converter are customer supplied for frame A and B drives and are internally mounted on frame C and D drives. See Circuit Protection on page 51 for fuse recommendations. (4) Par 140 [Digital In8 Sel] set to 31 Contactor (5) If using the +24V internal power supply, terminal 18 (24V common) must be jumpered to terminal 35 (digital input common). (6) Customer supplied armature output fuses are required on four quadrant and are recommended on two quadrant Frame A and B drives. See Circuit Protection on page 51 for fuse recommendations. (7) Par 1391 [ContactorControl] = 3 DC Cntctr and Par 1392 [Relay Out 1 Sel] = 25 Contactor. Important: Terminal 35 and 36 are on the Control Power / Relay Terminal block, NOT the I/O terminal blocks. See Relay Outputs on page 42 for locations. (8) Frame C & D drives only require an external power supply for the heatsink cooling fan. See Frame C Heatsink Cooling Fans Power Supply Terminals on page 39 and Frame D Heatsink Cooling Fan Power Supply Terminals on page 40 for more information. (9) See Field Converter Connections on page 31.

PowerFlex Digital DC Drive

23

24
PE
Aux

34 (on I/O TB4) 19 (+24V - on I/O TB2)

(5)

(4)

13 L1 L2 L3 T3 A2 T2 T1
(6)

14

PowerFlex Digital DC Drive

Lockable Installation Disconnect Isolation (2) Transformer Line Reactor FS1 FS1 FS1 W Safety Ground FU A2 Field Power Terminal Block U1 FU1 FV1
AC Input Voltage
A2
Armature Volt. Fdbk. Term.
(3) (3) (3) (2)

C D

L1 V 1A1 A1 1A2
(N.O. Relay) M1 DC Cntctr A1

PowerFlex DC Drive
A1

FS2

L2

L3

3 Phase AC line
460 VAC Max. or 230 VAC (10) Min.

FU

FU

FU

M
F1
DB (7) Res.

These connections must be taken from the primary side of the Isolation Transformer or Line Reactor (clean power). C1 V1 SA (1) SB V2 U2 35 36 U3 V3
(9)

D1

F2

FS2

(6)

(1)

Control Board P/S Control Power / Relay Ouputs Terminal Block

AC Input Voltage
(8) (8)

Power Wiring with DC Output/Dynamic Braking Contactor and a Dynamic Brake

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230V Fan Power Terminal Block

115V or (1) 230V

AC Input Voltage

(1) For frame B and C drives only, a jumper is required between terminals SA and SB for 115V AC control input power. See Control Circuit Input Power on page 34 for more information. (2) An Isolation Transformer and/or 35% impedance Line Reactor is required. If the Isolation Transformer provides the required 35% impedance, a Line Reactor is not required. See AC Input Line Reactors and Contactors on page 13 and Isolation Transformers on page 11 for recommendations. (3) AC input fuses for the armature converter are customer supplied for frame A and B drives and are internally mounted on frame C and D drives. See Circuit Protection on page 51 for fuse recommendations. (4) Par 140 [Digital In8 Sel] set to 31 Contactor (5) If using the +24V internal power supply, terminal 18 (24V common) must be jumpered to terminal 35 (digital input common). (6) Customer supplied armature output fuses are required on four quadrant and are recommended on two quadrant Frame A and B drives. See Circuit Protection on page 51 for fuse recommendations. (7) The Enable input must be removed in order to perform a dynamic braking stop. (8) Par 1391 [ContactorControl] = 3 DC Cntctr and Par 1392 [Relay Out 1 Sel] = 24 ContactorDB. Important: Terminal 35 and 36 are on the Control Power / Relay Terminal block, NOT the I/O terminal blocks. See Relay Outputs on page 42 for locations. (9) Frame C & D drives only require an external power supply for the heatsink cooling fan. See Frame C Heatsink Cooling Fans Power Supply Terminals on page 39 and Frame D Heatsink Cooling Fan Power Supply Terminals on page 40 for more information. (10) See Field Converter Connections on page 31.

PowerFlex Digital DC Drive

Armature Power Terminal Connections

Terminals U, V, W C, D PE Description Three phase AC input to the armature converter DC output to the motor armature Safety ground

Frame A Armature Terminal Block Locations

Bottom View

Loosen the two screws that secure the power terminal cover to the drive chassis and remove the terminal cover in order to connect the armature power wiring. Front View Note: Front view of drive shown with bottom protective and power terminal covers removed.

PE

ATTENTION: Do not operate the drive with the power terminal cover removed. Operating the drive with the power terminal cover removed may result in a hazardous condition that could cause personal injury and/or equipment damage.

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PowerFlex Digital DC Drive

Frame B Armature Terminal Block Locations

PE

Frame C Armature Terminal Block Locations

Front View

PE

Bottom View

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PowerFlex Digital DC Drive

Frame D Armature Terminal Block Locations

Important: Certain frame D drives require the use of a terminal adapter kit(s) for terminals U, V, W, C and D. Refer to Frame D Terminal Adapter Kits on page 19 for details.

Top of Drive

Bottom of Drive

PE

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PowerFlex Digital DC Drive

Armature Power Terminal and Ground (PE) Wire Sizes

Frame Drive Current Rating Code(1) 230V 460V 575 A 7P0055 4P1052 073110 073129 B All All C D All All All All All Terminals 690 U, V, W, C, D, PE U, V, W, C, D PE U, V, W, C, D PE All U, V, W, C, D, PE Wire Size and Type See Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001. Terminal Bolt Size (mm) 5 Terminal Block 10 8 10 8 12 Tightening Torque Nm (lbin) 6 (53) 12 (106) 25 (221) 15 (132.75) 25 (221) 15 (132.75) 45 (398.2)

(1) See Catalog Number Explanation on page 6, positions 8, 9 and 10 for corresponding drive HP rating, armature amp rating and field amp rating.

IMPORTANT

Certain frame D drives require the use of a terminal adapter kit(s) for terminals U, V, W, C, and D. Refer to Frame D Terminal Adapter Kits on page 19 for details.

Armature Voltage Feedback Connections

When a DC output contactor or inverting fault breaker/fuse is used with the drive, and a speed feedback device (tachometer or encoder) is used, the Armature Voltage Feedback terminals can be used to monitor the armature voltage at the motor regardless of the state of the contactor or inverting fault device. When this terminal block is not connected to the motor armature terminals, the terminals must be jumpered (as described in the table below) and the armature voltage feedback is monitored internally within the drive. In this case, when a DC contactor is used with the drive, a speed feedback device is not used, and the contactor opens, the drive will no longer receive the armature voltage feedback signal. 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.

Note that this terminal block is not present on drives shipped from the factory prior to those with v3.001 firmware installed. However, new Pulse Transformer boards shipped as replacement parts from the factory will contain this terminal block and can be used with any version of firmware.
Terminal 1A1 A1 1A2 A2 Description Jumpered to A1 when internal armature voltage feedback is used. Not used when A1 is connected to motor terminal A1. Voltage feedback from motor terminal A1. Jumpered to A2 when internal armature voltage feedback is used. Not used when A2 is connected to motor terminal A2. Voltage feedback from motor terminal A2.

Armature Voltage Feedback Circuit Wire Sizes and Terminal Specifications

Frame A, B & C D Terminals 1A1, A1, 1A2, A2 Wire Size and Type(1) 2410 AWG/kcmils 228 AWG/kcmils Tightening Torque Nm (lbin) 0.50.6 (4.45.3) 0.81.6 (7.114.2)

(1) Wire with an insulation rating of 600V or greater is recommended. See Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for cable spacing information.

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PowerFlex Digital DC Drive

Frame A Armature Voltage Feedback Circuit Terminal Block Location

Bottom of View of Drives Drive with no fan Drive with fan

Shown with terminals jumpered for internal armature voltage feedback.

Frame B Armature Voltage Feedback Circuit Terminal Block Location

Top of Drive

Shown with terminals jumpered for internal armature voltage feedback.

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PowerFlex Digital DC Drive

Frame C Armature Voltage Feedback Circuit Terminal Block Location

Bottom of Drive

Frame D Armature Voltage Feedback Circuit Terminal Block Location

Shown with terminals jumpered for internal armature voltage feedback.

Bottom of Drive, Left Side

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1A1(C) A1 1A2 (D) A2

1A1(C) A1 1A2 (D) A2

1A1(C) A1 1A2 (D) A2

1A1(C) A1 1A2 (D) A2

PowerFlex Digital DC Drive

Field Converter Connections

For 575V or 690V AC input drives only, a step down transformer with either a 230 VAC secondary, for a 150V motor field, or 460 VAC, for a 300V motor field, is required before the input to the field control circuit (terminals U1, V1). Also, If the rated voltage of the DC motor field is not compatible with the field DC output voltage of the drive, an external field control transformer must be used. Refer to the following example for transformer selection information. Example: 10 Hp, 240V Armature, 17.2A, 240V Field, 2.0 A motor a. The field control transformer must have a 230V primary, a 460V secondary, and be single-phase, 60 Hz b. kVA = 2 A x 460VAC x 1.5 = 1.38 kVA (1.5 kVA is closest) In addition, the following configuration must be completed in the PowerFlex DC drive: c. Control board DIP switch S14 must be set to select a value of 2 A. d. Parameter 374 [Drv Fld Brdg Cur] must be programmed to match DIP switch S14 = 2. e. Parameter 280 [Nom Mtr Fld Amps] must be programmed to the rated motor nameplate field current 2.

Field Converter Terminal Designations

Terminal Description U1, V1 Single-phase AC line input power to the field circuit. C1, D1 DC output power to the motor field.

Frame A Field Circuit Terminal Block Location

Bottom View of Drive

U1

V1

C1

D1

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PowerFlex Digital DC Drive

Frame B Field Circuit Terminal Block Location

U1 V

1C 1D 1

Top View of Drive

Frame C Field Circuit Terminal Block Location

Front View of Drive

D1 C1 U1 V1

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PowerFlex Digital DC Drive

Frames AC Field Circuit Wire Sizes and Terminal Specifications

Terminals U1, V1, C1, D1 Wire Size and Type(1) 2410 AWG/kcmils Tightening Torque Nm (lbin) 0.50.8 (4.47.1)

(1) See Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for cable spacing information.

Frame D Field Circuit Terminal Block Location

Wire routing hole Cable clamp Top of Drive, Left Side AC input for field is at top of fuse holder (marked FU1, FV1)

Shown with control cover removed. Remove control cover to access terminals.

C1

D1

Bottom of Drive, Left Side

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PowerFlex Digital DC Drive

Frame D Field Circuit Wire Sizes and Terminal Specifications

Drive Current Rating Code(1) 230V 460V 575V 690V 875 830 810 678 1K0 996 1K0 791 1K2 904 1K3 1K0 1K6 1K1 1K1 1K3 1K2 1K4 1K4 1K5 Terminals U1, V1, C1, D1 Wire Size(2) 6 AWG Tightening Torque Nm (lbin) 4.0 (35.4)

2 AWG

(1) See Catalog Number Explanation on page 6, positions 8, 9 and 10 for corresponding drive HP rating, armature amp rating and field amp rating. (2) See Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for cable spacing information.

Control Circuit Input Power

The control circuit must be powered by an external 230V AC or 115V AC single phase power supply. For frame B and C drives only, a jumper is required between terminals SA and SB for 115V AC control input power. Refer to Frame B drives SA-SB Terminal Block Location on page 37 and Frame C Drives SA-SB Terminal Block Location on page 38 for terminal block locations.

Control Circuit Terminal Designations

Terminal Description U2 Single-phase AC power for the control circuits. V2

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PowerFlex Digital DC Drive

Frame A Control Circuit Terminal Block Location

U2

V2

Frame B Control Circuit Terminal Block Location

U2

V2

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PowerFlex Digital DC Drive

Frame C Control Circuit Terminal Block Location

U2

V2

Frame D Control Circuit Terminal Block Location

U2 V2

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PowerFlex Digital DC Drive

Control Circuit Wire Sizes

Terminals Wire Size and Type(1) Flexible Multi-core AWG (mm2) (mm2) 0.141.5 0.142.5 2614 2.510 2.510 128 Tightening Torque Nm (lbin) 0.5 (4.4) 2.0 (18.0)

U2, V2 PE

(1) See Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for cable spacing information.

Frame B drives SA-SB Terminal Block Location

SA-SB terminals

Top of drive Front of drive

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PowerFlex Digital DC Drive

Frame C Drives SA-SB Terminal Block Location

Switching Power Supply board (located on the back of the Control EMI shield) SA-SB terminals Control EMI Shield (Shown in the open position)

Front of drive shown with top protective cover removed.

Control EMI shield

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PowerFlex Digital DC Drive

Frame C Heatsink Cooling Fans Power Supply Terminals

Frame C drives require an external 230V AC power supply for the heatsink cooling fans. The power supply connections must be taken from the primary side of the installed Isolation Transformer or Line Reactor (clean power). Refer to Typical Power Wiring Diagrams on page 22. In addition, the fan power input terminals U3 and V3 are required to be short circuit protected. This protection can be provided by using a circuit breaker. The circuit breaker must be selected to survive the short circuit available current of the feeder source for this circuit and the inrush current of the fan. The rating of the circuit breaker should be sized mainly to protect the wiring from the circuit breaker connections to terminals U3 and V3, and not nuisance trip or blow from the inrush current.

Frame C Heatsink Cooling Fans Terminal Designations

Terminal Description U3 Single-phase AC input power for cooling fans. V3 Maximum Voltage 230V AC Maximum Current 1A

Frame C Heatsink Cooling Fans Wire Sizes and Terminal Specifications

Terminals Wire Size and Type(1) Tightening Torque Multi-core AWG Nm (lbin) Flexible (mm2) (mm2) 0.141.5 0.142.5 2616 0.4 (3.5)

U3, V3

(1) See Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for cable spacing information.

Frame C Heatsink Cooling Fan Terminal Block Location

U3

V3

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PowerFlex Digital DC Drive

Frame D Heatsink Cooling Fan Power Supply Terminals

Frame D drives require an external 230V AC power supply for the heatsink cooling fan. The power supply connections must be taken from the primary side of the installed Isolation Transformer or Line Reactor (clean power). Refer to Typical Power Wiring Diagrams on page 22. The fan power input terminals U3 and V3 are required to be short circuit protected. This protection can be provided by using a circuit breaker. The circuit breaker must be selected to survive the short circuit available current of the feeder source for this circuit and the inrush current of the fan. The rating of the circuit breaker should be sized mainly to protect the wiring from the circuit breaker connections to terminals U3 and V3, and not nuisance trip or blow from the inrush current. In addition, a N.C. contact (at terminals 31 and 32) can be connected to an external device to provide indication of a fan supply failure or can be wired to drive digital input terminals configured for 14 Aux Fault (via Pars133144).

Frame D Heatsink Cooling Fan Terminal Designations

Terminal U3 V3 31 32 PE Description Single-phase AC input power for cooling fans. Normally closed contact. Safety ground Maximum Voltage 230V AC 250V AC Maximum Current 2.43.3 A (50/60 Hz) 1A

Frame D Heatsink Cooling Fan Signal Wire Sizes and Terminal Specifications
Terminals Wire Size and Type(1) Tightening Torque Multi-core AWG Nm (lbin) Flexible (mm2) (mm2) 0.141.5 0.142.5 2812 0.50.6 (4.45.3)

U3, V3, 31, 32, PE

(1) See Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for cable spacing information.

Frame D Heatsink Cooling Fan Terminal Block Location

Top of Drive, Left Side

32

31

PE

V3

U3

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PowerFlex Digital DC Drive

Frame C and D Armature Fuse Signal Terminals

Terminals 81 and 82 on frame C and D drives are connected to the internal armature circuit protection fuses and can be connected to an external device to provide indication that the fuses have opened. Alternatively, terminals 81 and 82 can be wired to drive digital input terminals configured for 64 Invert Flt (via Pars 133144).

Armature Fuse Signal Terminal Designations

Terminal Description 81 Internal armature fuse intervention signal. 82 Maximum Voltage 250V AC Maximum Current 1A

Armature Fuse Signal Wire Size and Terminal Specifications

Terminals Wire Size and Type(1) Tightening Torque Nm (lbin) Flexible Multi-core AWG (mm2) (mm2) 0.141.5 0.142.5 2616 0.4 (3.5)

81, 82

(1) See Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for cable spacing information.

Frame C Internal Armature Fuse Signal Terminal Block Location

81

82

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PowerFlex Digital DC Drive

Frame D Internal Armature Fuse Signal Terminal Block Location

81

82

Relay Outputs
Terminals 35 and 36 and 75 and 76 are N.O. relay outputs. The relay output between terminals 35 and 36 is configured with parameter 1392 [Relay Out 1 Sel]. The relay output between terminals 75 and 76 is configured with parameter 629 [Relay Out 2 Sel]. Refer to Using Contactors in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for more information.

Thermistors and Thermal Switches

To detect motor overheating and protect the motor from overloading, an external, user-supplied thermistor (PTC) or thermal switch must be connected to terminals 78 and 79. The drives response to a motor over temperature fault is configured in parameter 365 [OverTemp Flt Cfg]. If a temperature sensor is not used, a 1k ohm resistor must be connected between terminals 78 and 79 (installed at the factory). The instructions for installing a thermal sensor are detailed below.

Thermistors (PTC)
PTC thermistors fitted in the motor can be connected directly to the drive via terminals 78 and 79. In this case the 1k ohm resistor is not required between terminals 78 and 79.

Thermal Switches (Klixon) in the Motor Windings

Klixon type temperature-dependent contacts can disconnect the drive from the motor 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 in order to indicate a drive Motor Over Temp fault (F16), though this is not recommended due to the noise sensitivity of the current threshold circuitry. If a thermal switch is used a 1k ohm resistor must be placed in series between the switch and one of the terminals.
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PowerFlex Digital DC Drive

Contact Relay and Thermistor Terminal Designations

Terminal 35 36 75 76 78 79 Description Normally open contact. Configured with parameter 1392 [Relay Out 1 Sel] set to 25 Contactor by default. Normally open contact. Configured with parameter 629 [Relay Out 2 Sel] - set to 5 Ready by default. Motor thermistor connections (PTC)

Frame A Contact Relay and Thermistor Terminal Block Locations

Note: Terminals 78 and 79 shown with 1k ohm resistor in place of temperature sensor.

78 79 35 36 75 76

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PowerFlex Digital DC Drive

Frame B Contact Relay and Thermistor Terminal Block Locations

78 79 35 36 75 76

Frame C Contact Relay and Thermistor Terminal Block Locations

35 36 75 76 78 79

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PowerFlex Digital DC Drive

Frame D Contact Relay and Thermistor Terminal Block Locations

78 79 35 36 75 76

Located on control pan to the left of the HIM cradle.

Recommended Signal Wire Size for Relay Outputs and Thermistor/Thermal Switch Terminals
Signal Type Terminals Wire Size and Type(1) Flexible (mm2) Multi-core (mm2) 0.1401.500 0.1401.500 AWG 2614 Tightening Torque Nm (lbin) 0.5 (4.4)

Relay Outputs Thermistor and Thermal Switches

35 & 36, 75 & 76 78 & 79

(1) See Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for cable spacing information.

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PowerFlex Digital DC Drive

I/O Signal and Control Wiring

Eight (8) digital inputs, four (4) digital outputs, three (3) analog inputs, and two (2) analog outputs are available on the standard I/O terminal blocks provided with the drive. One digital input (1-8) must be configured for Enable. Additional digital and analog I/O is available when using the optional I/O Expansion circuit board. Refer to 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. Also, you can use the optional 115V AC Converter circuit board to convert 115V AC digital input signals to 24V DC digital inputs signals to interface with the digital inputs on the standard I/O terminal blocks. Refer to 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 located on the control board.

I/O Terminal Block Locations

Terminal Block 3 Terminal Block 1

Terminal Block 4 Terminal Block 2

I/O Terminal Block 1 Designations

No. 1 2 3 4 5 6 Signal Analog Input 1 (+) Analog Input 1 () Analog Input 2 (+) Analog Input 2 () Analog Input 3 (+) Analog Input 3 () Description Isolated (1), bipolar, differential, 10V / 020mA, or 420mA. Important: 020mA or 420mA operation requires that switch S9, S10, and S11 on the Control board be in the Off position. Drive damage may occur if the switch is not in the correct position based on the type of input signal. Refer to DIP Switch and Jumper Settings in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001. Max 10V, Max 0.25mA. 25k ohm load. Max 10V, Max 10mA. For (+) and () 10V pot references. PE ground to drive chassis. Factory Default 1 Speed Ref A 0 Off 0 Off Related Parameter 70 [Anlg In1 Sel] 75 [Anlg In2 Sel] 80 [Anlg In3 Sel]

10

7 8 9 10

+10V Pot Reference 10V Pot Reference Pot Common PE ground

(1) Differential Isolation - External source must be maintained at less than 160V with respect to PE. Input provides high common mode immunity.

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I/O Terminal Block 2 Designations

No. 11 12 13 14 15 16 Signal Internal 0V Digital Input 1 Digital Input 2 Digital Input 3 Digital Input 4 Digital Input Common Factory Default Max Volt. +30V, Max Cur. 15V/3.2mA, 24V/5mA, and 2 Stop/CF 30V/6.4mA. 3 Start A digital input (18) must be configured for 11 Jog Enable. 1 Enable Important: When using the internal +24V DC supply (terminal 19) for digital inputs 14, you must connect the digital input common (terminal 16) to the +24V supply common (terminal 18). Common for the internal power supply. Drive supplied +24V DC I/O power. Max. +2030V, 200mA Note: The total current draw is the sum of encoder power, digital outputs and any other loads connected to terminal 19. PE ground to drive chassis. Description Related Parameter 133 [Digital In1 Sel] 134 [Digital In2 Sel] 135 [Digital In3 Sel] 136 [Digital In4 Sel]

11

12

13

14

15

16

17

18

19

20

17 18 19

Not Used 24V Supply Common Internal +24V DC Supply

20

PE ground

I/O Terminal Block 3 Designations

No. Signal 21 22 23 24 25 26 27 28 29 30 Description Analog Output 1 (+) Max. 10V, Max. 5 mA. Analog Output 1 () Analog Output 2 (+) Analog Output 2 () Digital Output Common Digital Output 1 Max. +30V, Max 50mA Digital Output 2 Digital Output 3 Digital Output 4 Digital Output +24VDC Source Tie point for the internal supply or customer supplied voltage for the digital outputs. Max. +30V DC, 80 mA. Important: When using the internal +24V DC supply (terminal 19) for digital outputs 14, you must connect terminal 19 to terminal 30 and the digital output common (terminal 25) to the +24V supply common (terminal 18). Factory Default 12 Motor Speed 13 Motor Curr 5 Ready 9 Fault 2 Spd Thresh 4 CurrentLimit Related Parameter 66 [Anlg Out1 Sel] 67 [Anlg Out2 Sel] 145 [Digital Out1 Sel] 146 [Digital Out2 Sel] 147 [Digital Out3 Sel] 148 [Digital Out4 Sel]

21

22

23

24

25

26

27

28

29

30

I/O Terminal Block 4 Designations

No. 31 32 33 34 35
38 39 40

31

32

33

34

35

36

37

Signal Digital Input 5 Digital Input 6 Digital Input 7 Digital Input 8 Digital Input Common

Description Max Volt. +30V, Max Cur. 15V/3.2mA, 24V/5mA, and 30V/6.4mA. A digital input (18) must be configured for Enable. Important: When using the internal +24V DC supply (terminal 19) for digital inputs 58, you must connect the digital input common (terminal 35) to the +24V supply common (terminal 18).

Factory Default 17 Speed Sel 1 18 Speed Sel 2 19 Speed Sel 3 31 Contactor

Related Parameter 137 [Digital In5 Sel] 138 [Digital In6 Sel] 139 [Digital In7 Sel] 140 [Digital In8 Sel]

36 40

Not Used

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Recommended Signal Wire Size for Analog I/O and Digital I/O
Signal Type Analog and Digital I/O Terminal Block (Terminals) TB14 (140) Wire Size and Type(1) Flexible (mm2) Multi-core (mm2) AWG 0.1401.500 0.1401.500 2616 Tightening Torque Nm (lbin) 0.4 (3.5)

(1) See Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for cable spacing information.

Digital Encoder Terminal Block

The encoder connection cables should always be connected directly to the terminals on the encoder terminal block. The encoder cable must be made up of twisted pairs with the shield connected to the shield ground on the drive side. Do not connect the shield to ground on the motor side. In some cases (i.e., cable lengths that exceed 100 meters), it may be necessary to ground the shield of each twisted pair on the power supply. Refer to Appendix A of the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for Digital Encoder specifications.

Digital Encoder Terminal Designations

Terminal Block Label A+ AB+ BZ+ ZCOM +V Signal Encoder A Encoder A (NOT) Encoder B Encoder B (NOT) Encoder Z Encoder Z (NOT) +5/1215V (1) DC Return +5/1215V (1) DC Power Description Single channel or quadrature A input Dual channel quadrature B input Pulse, marker or registration input (2) Internal power common Internal power source 200 mA

A+

A-

B+

B-

Z+

ZCO M

+V

(1) Selectable via switch S21 on the Control board. Refer to DIP Switch and Jumper Settings in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for more information. (2) Selectable via switch S20 on the Control board. Refer to DIP Switch and Jumper Settings in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for more information.

Digital Encoder Terminal Block Location

Digital Encoder terminal block

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Sample Encoder Power Wiring

Power Source Internal Drive Power (1) Internal (drive) +5/1215V DC, 200 mA Connection Example
+5/12-15V DC (200 mA)

+V COM ZZ+ BB+ AA+

Common

to Shield (1)

External Power Source

+V COM ZZ+ BB+ AA+

+ Common

to Shield (1)

External Power Supply

(1) Shield connection is on the drive Control EMI Shield. Refer to Digital Encoder Terminal Block Location on page 48.

Sample Encoder Signal Wiring

Encoder Signal Single-Ended, Dual Channel Connection Example
+V COM ZZ+ BB+ AA+
A NOT A B NOT B Z NOT Z

Supply Common

to Shield (1)

Differential, Dual Channel

+V COM ZZ+ BB+ AA+

Z NOT Z B NOT B A NOT A

to Shield (1)

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DC Analog Tachometer Terminal Block

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.

DC Analog Tachometer Terminal Designations

No. A B C + Signal Negative input (Not Used) Description

22.7 / 45.4 / 90.7 / 181.6 / 302.9V(1) Positive input Feedback polarity is determined during the max voltage start up routine. 8 mA max. current

(1) Maximum voltage depends on the configuration of DIP switch S4. Refer to the PowerFlex Digital DC Drive User Manual, publication 20P-UM001 for information on jumper settings.

Analog Tachometer Terminal Block Location

Analog Tachometer terminal block

Recommended Signal Wire Size for DC Analog Tachometer

Signal Type Terminal Block (Terminals) M3 (+ and ) Wire Type and Size(1) Flexible multi-core AWG (mm2) (mm2) 0.1401.500 0.1401.500 2616 Tightening Torque Nm (lbin) 0.4 (3.5)

DC Analog Tach

(1) See Cable and Wiring Recommendations in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001.

Resolver Feedback Module

The resolver feedback module (catalog number 20P-RES-A0), which provides a drive interface to a selection of compatible resolvers, must be ordered and purchased separately from the drive. The resolver option module includes the PowerFlex DC Drive Resolver Feedback Module Installation Instructions, publication 20P-IN071, which provides installation and wiring information. See Resolver Type Selection in the PowerFlex Digital DC Drive User Manual, publication 20PUM001, for more information on compatible resolvers.
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Circuit Protection
The tables on the following pages provide drive ratings and the recommended fuses for protecting the armature and field circuits. Externally mounted fuses (as indicated in the figures below) must be sourced separately when installing the drive. Internally mounted fuses are provided with the drive. See page 57 for frames C and D fuse information.

Frame A and B Fuse Designations

FS1 = Externally mounted fuses for the armature converter on the AC input side.

FS1

U1 FS3 C1

V1

FS3 = Internally mounted fuses for the field circuit on the AC input side.

C
FS2 = Externally mounted fuses for the armature circuit on the DC side.

D1

FS2

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Frame A and B Recommended AC Input Line Fuses

AC input line fuses are externally mounted for frame A and B drives and must be sourced separately. See Fuse Code FS1 in Frame A and B Fuse Designations on page 51.

230V AC Input Drives

Frame Drive Current Rating Code 7P0 9P0 012 020 029 038 055 073 093 110 146 180 218 265 360 434 DC Amps AC Line Bussmann Amps Ferrule FWP Type 5.7 7.4 9.8 16 24 31 45 60 76 90 119 147 178 217 294 355 FWP-10A14F FWP-15A14F FWP-20A14F FWP-25A14F FWP-40A22F FWP-63A22F FWP-80A22F Ferraz Shawmut (Gould Shawmut) Ferrule Fuse North American North American Ferrule A70QS North American A70P / Block FWP Type Fuse Block Type A70QS Type CH143D FWP-10B FWP-15B FWP-20B FWP-25B FWP-40B FWP-60B FWP-80B FWP-100A FWP-150A FWP-175A FWP-250A FWP-300A FWP-350A FWP-400 FWP-600A FWP-600A BH-1133 A70QS10-14F A70QS16-14F A70QS20-14F A70QS25-14F A70QS40-22F A70QS63-22F A70QS80-22F A70P10-4 A70P15-4 A70P20-4 A70P25-4 A70QS40-4 A70QS60-4 A70QS80-4 A70QS100-4K A70QS150-4K A70QS175-4K A70QS250-4 A70QS300-4 A70QS350-4 A70QS400-4 A70QS600-4K A70QS600-4

7 9 12 20 29 38 55 73 93 110 146 180 218 265 360 434

CH223D

BH-3144

460V AC Input Drives

Frame Drive DC AC Line Bussmann Current Amps Amps Ferrule FWP Rating Code Type 4P1 4.1 3.3 FWP-10A14F 6P0 6 4.9 FWP-10A14F 010 10 8.2 FWP-20A14F 014 14 11.4 FWP-25A14F 019 19 15.5 FWP-25A14F 027 27 22.1 FWP-40A22F 035 35 28.6 FWP-63A22F 045 45 36.8 FWP-80A22F 052 52 42.5 FWP-80A22F 073 73 59.6 086 86 70.3 100 100 81.7 129 129 105.4 167 167 136.4 207 207 169.1 250 250 204.3 330 330 269.6 412 412 336.6 Ferrule Fuse North American Block FWP Type CH143D FWP-10B FWP-10B FWP-20B FWP-25B FWP-25B CH223D FWP-40B FWP-60B FWP-80B FWP-80B FWP-100A FWP-150A FWP-175A FWP-175A FWP-300A FWP-350A FWP-400A FWP-600A FWP-600A North American Fuse Block BH-1133 Ferraz Shawmut (Gould Shawmut) Ferrule A70QS North American A70P Type / A70QS Type A70QS10-14F A70P10-4 A70QS10-14F A70P10-4 A70QS20-14F A70P25-4 A70QS25-14F A70P25-4 A70QS25-14F A70P25-4 A70QS40-22F A70QS40-4 A70QS63-22F A70QS60-4 A70QS80-22F A70QS80-4 A70QS80-22F A70QS80-4 A70QS100-4K A70QS150-4K A70QS175-4K A70QS175-4K A70QS300-4 A70QS350-4 A70QS400-4 A70QS600-4K A70QS600-4

BH-3144

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575V AC Input Drives

Frame Drive Current DC Amps Rating Code 067 101 135 270 405 67.5 101.3 135 270 405 AC Line Bussmann Amps 55.1 82.7 110.3 220.6 330.9 Ferraz Shawmut (Gould Shawmut) North American FWP Type North American FWP Fuse Block North American A70QS Type FWP-100A A70QS100-4 FWP-175A BH-1133 A70QS175-4K FWP-225A A70QS225-4 FWP-450A BH-3144 A70QS450-4 FWP-600A A70QS600-4K

Frame A and B Recommended Armature DC Output Fuses

Armature DC output fuses are externally mounted for frame A and B drives and must be sourced separately. These fuses are required on four quadrant drives only, but highly recommended on two quadrant drives. See Fuse Code FS2 in Frame A and B Fuse Designations on page 51.

230V AC Input Drives

Frame Drive Current Rating Code A 7P0 9P0 012 020 029 038 055 073 093 110 146 180 218 265 360 434 DC AC Line Bussmann Amps Amps Ferrule FWP Type 7 5.7 FWP-15A14F 9 7.4 FWP-20A14F 12 9.8 FWP-25A14F 20 16 FWP-40A14F 29 24 FWP-63A22F 38 31 FWP-80A22F 55 45 73 60 93 76 110 90 146 119 180 147 218 178 265 217 360 294 434 355 Ferrule Fuse North American Block FWP Type CH142D FWP-15B FWP-20B FWP-25B FWP-40B CH222D FWP-60B FWP-80B FWP-125A FWP-150A FWP-200A FWP-225A FWP-300A FWP-350A FWP-450A FWP-600A FWP-700A FWP-900A North American Fuse Block BH-1133 Ferraz Shawmut (Gould Shawmut) Ferrule A70QS North American A70P Type / A70QS Type A70QS16-14F A70P15-4 A70QS20-14F A70P20-4 A70QS25-14F A70P25-4 A70QS40-14F A70QS40-4 A70QS63-22F A70QS60-4 A70QS80-22F A70QS80-4 A70QS125-4K A70QS150-4K A70QS200-4K A70QS250-4 A70QS300-4 A70QS350-4 A70QS450-4 A70QS600-4K A70QS700-4 A70P900-4

BH-3144

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460V AC Input Drives

Frame Drive DC AC Line Bussmann Current Amps Amps Ferrule FWP Rating Code Type A 4P1 4.1 3.3 FWP-10A14F 6P0 6 4.9 FWP-15A14F 010 10 8.2 FWP-20A14F 014 14 11.4 FWP-30A14F 019 19 15.5 FWP-40A14F 027 27 22.1 FWP-63A22F 035 35 28.6 FWP-80A22F 045 45 36.8 FWP-100A22F 052 52 42.5 FWP-100A22F 073 73 59.6 086 86 70.3 100 100 81.7 129 129 105.4 B 167 167 136.4 207 207 169.1 250 250 204.3 330 330 269.6 412 412 336.6 Ferrule Fuse North American Block FWP Type CH142D FWP-10B FWP-15B FWP-20B FWP-30B FWP-40B CH222D FWP-60B FWP-70B FWP-90B FWP-100B FWP-150A FWP-175A FWP-200A FWP-250A FWP-350A FWP-400A FWP-500A FWP-700A FWP-800A North American Fuse Block BH-1133 Ferraz Shawmut (Gould Shawmut) Ferrule A70QS North American A70P Type / A70QS Type A70QS10-14F A70P10-4 A70QS16-14F A70P15-4 A70QS20-14F A70P20-4 A70QS32-14F A70P30-4 A70QS40-14F A70QS40-4 A70QS63-22F A70QS60-4 A70QS80-22F A70QS70-4 A70QS90-4 A70QS100-4 A70QS150-4K A70QS175-4K A70QS200-4K A70QS250-4 A70QS350-4 A70QS400-4 A70QS500-4K A70QS700-4 A70QS800-4

BH-3144

575V AC Input Drives

Frame Drive Current Rating Code 067 101 135 270 405 DC Amps AC Line Amps Bussmann North American FWP Type 67.5 101.3 135 270 405 55.1 82.7 110.3 220.6 330.9 FWP-125A FWP-200A FWP-250A FWP-600A FWP-800A Ferraz Shawmut (Gould Shawmut) North American FWP Fuse Block North American A70P / A70QS Type BH-1133 A70QS125-4K A70QS200-4K A70QS250-4 A70QS600-4K A70QS800-4

BH-3144

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Frame A and B Recommended Field Circuit Fuses

Field circuit fuses are internally mounted and provided with the drive. See Fuse Code FS3 in Frame A and B Fuse Designations on page 51. Also, see Frame A Field AC Input Line Fuses Location on page 56 and Frame B Field AC Input Line Fuses Location on page 57 for fuse locations.

230V AC Input Drives

Frame Drive Current Rating Code A 7P0 9P0 012 020 029 038 055 073 093 110 146 180 218 265 360 434 Field Amps 10 Type 6 x 32 mm Quantity Bussmann 2 FWH-016A6F Ferraz Shawmut (Gould Shawmut) E085449 SIBA 70 125 40.16

14

20

10 x 38 mm

FWC-25A10F

A60Q25-2

60 033 05.25

460V AC Input Drives

Frame Drive Current Rating Code A 4P1 6P0 010 014 019 027 035 045 052 073 086 100 129 167 207 250 330 412 Field Amps 10 Type 6 x 32 mm Quantity 2 Bussmann FWH-016A6F Ferraz Shawmut (Gould Shawmut) E085449 SIBA 70 125 40.16

14

20

10 x 38 mm

FWC-25A10F

A60Q25-2

60 033 05.25

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575V AC Input Drives

Frame B Drive Current Field Rating Code Amps 067 101 135 270 405 20 Quantity Type 2 10 x 38 mm Bussmann FWC-25A10F Ferraz Shawmut (Gould Shawmut) A60Q25-2 SIBA 60 033 05.25

Frame A Field AC Input Line Fuses Location

Bottom View of Drive with Fan Bottom View of Drive without Fan

Field circuit fuses

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Frame B Field AC Input Line Fuses Location

Top View of Drive

Field circuit fuses

Frame C and D Fuse Designations

All fuses for armature and field circuit protection are internally mounted and provided with frame C and D drives.

FS4 = Internally mounted fuses for the armature converter on the AC input side.

U FS4 C

U1 FS3 C1

V1

FS3 = Internally mounted fuses for the field circuit on the AC input side.

D1

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Frame C and D Recommended Field Circuit Fuses

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 Frame C and D Fuse Designations on page 57. Also, see Frame C Field Circuit Fuse Location on page 59 and Frame D Field Circuit Fuse Location on page 59 for locations.

230V AC Input Drives

Frame C D Drive Current Rating Code 521 875 1K0 Field Amps 20 40 Type 10 x 38 mm 22 x 58 mm Qty Bussmann 2 FWC-25A10F FWP-50A22F Ferraz Shawmut (Gould SIBA Shawmut) A60Q25-2 6003305.25 A70QS50-22F 5014006.50

460V AC Input Drives

Frame C D Drive Current Rating Code 495 667 830 996 1K1 1K3 1K4 Field Amps 20 40 70 Type 10 x 38 mm 22 x 58 mm Qty Bussmann 2 FWC-25A10F FWP-50A22F FWP-100A22F Ferraz Shawmut (Gould Shawmut) A60Q25-2 A60Q25-8 A70QS50-22F A70QS100-22F SIBA 6003305.25 5014006.50 5014006.100

575V AC Input Drives

Frame C D Drive Current Rating Code 540 675 810 1K0 1K2 1K3 1K6 Field Amps 20 40 Type 10 x 38 mm 22 x 58 mm Qty Bussmann 2 FWC-25A10F FWP-50A22F Ferraz Shawmut (Gould Shawmut) A60Q25-2 A60Q25-8 A70QS50-22F SIBA 6003305.25 5014006.50

690V AC Input Drives

Frame C D Drive Current Rating Code 452 565 678 791 904 1K0 1K1 1K2 1K4 1K5 Field Amps 20 40 Type 10 x 38 mm 22 x 58 mm Qty Bussmann 2 FWC-25A10F FWP-50A22F Ferraz Shawmut (Gould Shawmut) A60Q25-2 A60Q25-8 A70QS50-22F SIBA 6003305.25 5014006.50

70

FWP-100A22F

A70QS100-22F

5014006.100

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Frame C Field Circuit Fuse Location

Field AC input fuses are located on the Control EMI shield, which holds the Control board.

Frame D Field Circuit Fuse Location

Top, left side of drive control panel.

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Fuses for Regenerative Frame C and D Drives

Leg fuses are internally mounted and provided with frames C and D drives. See Fuse Code FS4 in Frame C and D Fuse Designations on page 57. Also, see Frame C Regenerative Drive - Leg Fuse Location on page 61 and Frame D Regenerative Drive - Leg Fuse Location on page 62.

Recommended Leg Fuses - 230V AC Input Frame C Drives

Frame Drive Current DC Rating Code Amps C 521 700 521 700 AC Line Qty Bussmann Ferraz Shawmut (Gould Shawmut) Amps Square Body - Flush End Contact 426 6 170M5464 + switch 170H0069 6,9 URD 32 TTF 800 + switch MS 3-V1-5 BS 571 6 170M5464 + switch 170H0069 6,9 URD 32 TTF 800 + switch MS 3V 1-5 BS SIBA 20 671 32.800 + switch 28 001 04 20 671 32.800 + switch 28 001 04

Recommended Leg Fuses - 230V AC Input Frame D Drives

Frame Drive Current DC Rating Code Amps D 875 1K0 875 1050 AC Line Qty Bussmann Ferraz Shawmut (Gould Shawmut) Amps Square Body - DIN 43653 Stud-Mount 715 6 170M6263 + switch 170H0069 Y300263 + switch MS 3V 1-5 UR 858 6 170M6264 + switch 170H0069 Z300264 + switch MS 3V 1-5 UR SIBA 20 635 32.900 + switch 28 001 04 20 635 32.1000 + switch 28 001 04

Recommended Leg Fuses - 460V AC Input Frame C Drives

Frame Drive Current DC AC Qty Bussmann Ferraz Shawmut (Gould Shawmut) Rating Code Amps Line Square Body - Flush End Contact Amps C 495 495 404.4 6 170M5462 + switch 170H0069 6,9 URD 32 TTF 630 + switch MS 3-V1-5 BS 667 667 544.9 6 170M5464 + switch 170H0069 6,9 URD 32 TTF 800 + switch MS 3-V1-5 BS SIBA

20 671 32.630 + switch 28 001 04 20 671 32.800 + switch 28 001 04

Recommended Leg Fuses - 460V AC Input Frame D Drives

Frame Drive Current DC AC Line Qty Bussmann Ferraz Shawmut (Gould Shawmut) Rating Code Amps Amps Square Body - DIN 43653 Stud-Mount D 830 830 678.1 6 170M6262 + switch 170H0069 X300262 + switch MS 3V 1-5 UR 996 996 813.7 6 170M6264 + switch 170H0069 Z300264 + switch MS 3V 1-5 UR 1K1 1162 949.4 6 170M6265 + switch 170H0069 A300262 + switch MS 3V 1-5 UR 1K3 1328 1085.0 6 170M6266 + switch 170H0069 B300266 + switch MS 3V 1-5 UR 1K4 1494 1220.6 6 170M6267 + switch 170H0069 C300267 + switch MS 3V 1-5 UR SIBA 20 635 32.800 + switch 28 001 04 20 635 32.1000 + switch 28 001 04 20 635 32.1100 + switch 28 001 04 20 635 32.1250 + switch 28 001 04 20 635 32.1400 + switch 28 001 04

Recommended Leg Fuses - 575V AC Input Frame C Drives

Frame Drive Current DC AC Qty Bussmann Ferraz Shawmut (Gould Shawmut) Rating Code Amps Line Square Body - Flush End Contact Amps C 540 540 441 6 11 URD 72 TTF 0800 + switch MS 3V 1-5 BS 675 675 551 6 11 URD 72 TTF 0800 + switch MS 3V 1-5 BS SIBA

20 771 32.800 + switch 28 001 04 20 771 32.800 + switch 28 001 04

Recommended Leg Fuses - 575V AC Input Frame D Drives

Frame Drive Current DC AC Line Qty Bussmann Ferraz Shawmut (Gould Shawmut) Rating Code Amps Amps Square Body - DIN 43653 Stud-Mount D 810 810 661 6 170M6246 + switch 170H0069 J300572 + switch MS 3V 1-5 UR 1K0 1080 881 6 170M6248 + switch 170H0069 L300574 + switch MS 3V 1-5 UR 1K2 1215 991 12 170M6244 + switch 170H0069 G300570 + switch MS 3V 1-5 UR 1K3 1350 1102 12 170M6245 + switch 170H0069 H300571 + switch MS 3V 1-5 UR 1K6 1688 1377 12 170M6246 + switch 170H0069 J300572 + switch MS 3V 1-5 UR SIBA 20 735 32.800 + switch 28 001 04 20 735 32.1000 + switch 28 001 04 20 735 32.630 + switch 28 001 04 20 735 32.700 + switch 28 001 04 20 735 32.800 + switch 28 001 04

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Recommended Leg Fuses - 690V AC Input Frame C Drives

Frame Drive Current DC AC Qty Bussmann Ferraz Shawmut (Gould Shawmut) Rating Code Amps Line Square Body - Flush End Contact Amps C 452 452 369 6 170M5394 + switch 170H0069 12,5 URD 72 TTF 0500 + switch MS 3V 1-5 BS 565 565 461 6 12,5 URD 72 TTF 0630 + switch MS 3V 1-5 BS SIBA

20 771 32.500 + switch 28 001 04 20 771 32.630 + switch 28 001 04

Recommended Leg Fuses - 690V AC Input Frame D Drives

Frame Drive Current DC Rating Code Amps D 678 791 904 1K0 1K1 1K2 1K4 1K5 678 791 904 1017 1130 1243 1413 1582 AC Line Amps 553 645 738 830 922 1014 1153 1291 Qty 6 6 6 6 12 12 12 12 Bussmann Ferraz Shawmut (Gould Shawmut) Square Body - DIN 43653 Stud-Mount 170M6244 + switch 170H0069 G300570 + switch MS 3V 1-5 UR 170M6246 + switch 170H0069 J300572 + switch MS 3V 1-5 UR 170M6247 + switch 170H0069 K300573 + switch MS 3V 1-5 UR 170M6248 + switch 170H0069 L300574 + switch MS 3V 1-5 UR 170M6244 + switch 170H0069 G300570 + switch MS 3V 1-5 UR 170M6244 + switch 170H0069 G300570 + switch MS 3V 1-5 UR 170M6245 + switch 170H0069 H300571 + switch MS 3V 1-5 UR 170M6246 + switch 170H0069 J300572 + switch MS 3V 1-5 UR SIBA 20 735 32.630 + switch 28 001 04 20 735 32.800 + switch 28 001 04 20 735 32.900 + switch 28 001 04 20 735 32.1000 + switch 28 001 04 20 735 32.630 + switch 28 001 04 20 735 32.630 + switch 28 001 04 20 735 32.700 + switch 28 001 04 20 735 32.800 + switch 28 001 04

Frame C Regenerative Drive - Leg Fuse Location

Note: Drive shown with front covers removed and Control EMI shield lowered. Leg fuses and switches are located on the bus bars behind the Control EMI shield, which holds the Control board.

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Frame D Regenerative Drive - Leg Fuse Location

Note: Drive shown with Control EMI shield in open position. Leg fuses and switches are located on the bus bars behind the Control EMI shield, which holds the Control board.

Fuses for Non-Regenerative Frame C and D Drives

AC input line and/or leg fuses are internally mounted and provided with frames C and D drives. See Fuse Code FS4 in Frame C and D Fuse Designations on page 57. Also, see Frame C Non-Regenerative Drive - AC Input Line Fuse Location on page 64.

Recommended AC Input Line Fuses - 230V AC Input Frame C

Frame Drive Current DC Rating Code Amps C 521 700 521 700 AC Line Qty Bussmann Ferraz Shawmut (Gould Shawmut) Amps Square Body - Flush End Contact 426 3 170M5466 + switch 170H0069 6,9 URD 32 TTF 1000 + switch MS 3-V1-5 BS 571 3 170M5466 + switch 170H0069 6,9 URD 32 TTF 1000 + switch MS 3V 1-5 BS SIBA 20 671 32.1000 + switch 28 001 04 20 671 32.1000 + switch 28 001 04

Recommended Leg Fuses - 230V AC Input Frame D Drives

Frame Drive Current DC AC Line Qty Bussmann Ferraz Shawmut (Gould Shawmut) Rating Code Amps Amps Square Body - DIN 43653 Stud-Mount D 875 875 715 6 170M6263 + switch 170H0069 Y300263 + switch MS 3V 1-5 UR 1K0 1050 858 6 170M6264 + switch 170H0069 Z300264 + switch MS 3V 1-5 UR SIBA 20 635 32.900 + switch 28 001 04 20 635 32.1000 + switch 28 001 04

Recommended AC Input Line Fuses - 460V AC Input Frame C

Frame Drive Current DC Rating Code Amps C 495 667 495 667 AC Line Qty Bussmann Ferraz Shawmut (Gould Shawmut) Amps Square Body - Flush End Contact 404.4 3 170M5464 + switch 170H0069 6,9 URD 32 TTF 800 + switch MS 3-V1-5 BS 544.9 3 170M5466 + switch 170H0069 6,9 URD 32 TTF 1000 + switch MS 3-V1-5 BS SIBA 20 671 32.800 + switch 28 001 04 20 671 32.1000 + switch 28 001 04

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Recommended Leg Fuses - 460V AC Input Frame D Drives

Frame Drive Current DC AC Line Qty Bussmann Ferraz Shawmut (Gould Shawmut) Rating Code Amps Amps Square Body - DIN 43653 Stud-Mount D 830 830 678.1 6 170M6262 + switch 170H0069 X300262 + switch MS 3V 1-5 UR 996 996 813.7 6 170M6264 + switch 170H0069 Z300264 + switch MS 3V 1-5 UR 1K1 1162 949.4 6 170M6265 + switch 170H0069 A300262 + switch MS 3V 1-5 UR 1K3 1328 1085.0 6 170M6266 + switch 170H0069 B300266 + switch MS 3V 1-5 UR 1K4 1494 1220.6 6 170M6267 + switch 170H0069 C300267 + switch MS 3V 1-5 UR SIBA 20 635 32.800 + switch 28 001 04 20 635 32.1000 + switch 28 001 04 20 635 32.1100 + switch 28 001 04 20 635 32.1250 + switch 28 001 04 20 635 32.1400 + switch 28 001 04

Recommended AC Input Line Fuses - 575V AC Input Frame C Drives

Frame Drive Current DC AC Line Qty Bussmann Ferraz Shawmut (Gould Shawmut) Rating Code Amps Amps Square Body - Flush End Contact C 540 540 441 3 170M5466 + switch 170H0069 6,9 URD 32 TTF 1000 + switch MS 3V 1-5 BS 675 675 551 3 170M5466 + switch 170H0069 6,9 URD 32 TTF 1000 + switch MS 3V 1-5 BS SIBA 20 671 32.1000 + switch 28 001 04 20 671 32.1000 + switch 28 001 04

Recommended Leg Fuses - 575V AC Input Frame D Drives

Frame Drive Current DC AC Line Qty Bussmann Ferraz Shawmut (Gould Shawmut) Rating Code Amps Amps Square Body - DIN 43653 Stud-Mount D 810 810 661 6 170M6262 + switch 170H0069 X300262 + switch MS 3V 1-5 UR 1K0 1080 881 6 170M6264 + switch 170H0069 Z300264 + switch MS 3V 1-5 UR 1K2 1215 991 6 170M6265 + switch 170H0069 A300262 + switch MS 3V 1-5 UR 1K3 1350 1102 6 170M6266 + switch 170H0069 B300266 + switch MS 3V 1-5 UR 1K6 1688 1377 12 170M6262 + switch 170H0069 X300262 + switch MS 3V 1-5 UR SIBA 20 635 32.800 + switch 28 001 04 20 635 32.1000 + switch 28 001 04 20 635 32.1100 + switch 28 001 04 20 635 32.1250 + switch 28 001 04 20 635 32.800 + switch 28 001 04

Recommended AC Input Line Fuses - 690V AC Input Frame C Drives

Frame Drive Current DC AC Line Rating Code Amps Amps C 452 565 452 565 369 461 Qty Bussmann Ferraz Shawmut (Gould Shawmut) Square Body - Flush End Contact 6 170M5463 + switch 170H0069 6,9 URD 32 TTF 0700 + switch MS 3V 1-5 BS 6 170M5465 + switch 170H0069 6,9 URD 32 TTF 0900 + switch MS 3V 1-5 BS SIBA 20 671 32.700 + switch 28 001 04 20 671 32.900 + switch 28 001 04

Recommended Leg Fuses - 690V AC Input Frame D Drives

Frame D Drive Current DC Rating Code Amps 678 791 904 1K0 1K1 1K2 1K4 1K5 678 791 904 1017 1130 1243 1413 1582 AC Line Qty Amps 553 645 738 830 922 1014 1153 1291 6 6 6 6 6 6 6 12 Bussmann Ferraz Shawmut (Gould Shawmut) Square Body - DIN 43653 Stud-Mount 170M6260 + switch 170H0069 V300260 + switch MS 3V 1-5 UR 170M6262 + switch 170H0069 X300262 + switch MS 3V 1-5 UR 170M6263 + switch 170H0069 Y300263 + switch MS 3V 1-5 UR 170M6264 + switch 170H0069 Z300264 + switch MS 3V 1-5 UR 170M6265 + switch 170H0069 A300262 + switch MS 3V 1-5 UR 170M6266 + switch 170H0069 B300266 + switch MS 3V 1-5 UR 170M6267 + switch 170H0069 C300267 + switch MS 3V 1-5 UR 170M6262 + switch 170H0069 X300262 + switch MS 3V 1-5 UR SIBA 20 635 32.630 + switch 28 001 04 20 635 32.800 + switch 28 001 04 20 635 32.900 + switch 28 001 04 20 635 32.1000 + switch 28 001 04 20 635 32.1100 + switch 28 001 04 20 635 32.1250 + switch 28 001 04 20 635 32.1400 + switch 28 001 04 20 635 32.800 + switch 28 001 04

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Frame C Non-Regenerative Drive - AC Input Line Fuse Location

AC Input fuses and switches are located on the bus bars behind the Control EMI shield, which holds the Control board.

Note: Drive shown with front covers removed and Control EMI shield lowered.

Control Power Circuit Protection Fuses

The following fuses are used to protect the Switching Power Supply circuit. IMPORTANT Verify the circuit board revision prior to ordering and installing fuses.

Frame A B

Circuit Board ID / Revision SW1-31 / H & below SW1-31 / I & above SW2-32 / H & below SW2-32 / I & above

SW3-32 / H & below SW3-32 / I & above

SW1-31 / I & above

Designation F1 F1 F1 F2 F1 F2 F1 F2 F1 F2 F1

Fuse (5 x 20 mm) 1 A, 250V, slow 2.5 A, 250V, slow 3.15 A, 250V fast 2.5 A, 250V slow 2.5 A, 250V slow 3.15 A, 250V fast 2.5 A, 250V slow 2.5 A, 250V slow 2.5 A, 250V, slow

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Frame A Switching Power Supply Fuse Location

Switching Power Supply fuse Top View of Drive

Frame B Switching Power Supply Fuse Location

Top View of Drive F1 = 3.15A fuse (Board Rev. H and below only) F2 = 2.5A fuse (Board Rev. H and below only)

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Frame C Switching Power Supply Fuse Location

F1 = 3.15A fuse (Board Rev. H and below only)

F2 = 2.5A fuse (Board Rev. H and below only)

Fuses are located on the Switching Power Supply circuit board (SW-2) on the back of the Control EMI shield, which holds the Control board.

Frame D Switching Power Supply Circuit Board Fuse Location

Switching Power Supply fuse holder The Switching Power Supply circuit board is located on the Control EMI shield.

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Mounting
Operating Conditions and Temperatures
PowerFlex DC drives are designed to operate at 050 C (32122 F) surrounding air temperature without derating. The drive 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 Mounting Clearances

Minimum clearance requirements are intended to be from drive to drive. Other objects can occupy this space; however, reduced airflow may cause protection circuits to fault the drive. See Drive Enclosure Minimum Mounting Clearances below. The drive must be mounted in a vertical orientation as shown below and must not be mounted at an angle greater than 30 from vertical. In addition, inlet air temperature must not exceed the product specification.

Drive Enclosure Minimum Mounting Clearances

150 mm (6.0 in.)

150 mm (6.0 in.)

PORT MOD NET A NET B

PORT MOD NET A NET B STS

STS

10 mm (0.4 in.)

10 mm (0.4 in.)

150 mm (6.0 in.)

10 mm (0.4 in.)

50 mm (2.0 in.)

Airflow through the drive must not be impeded.

IMPORTANT

Verify that all mounting screws are properly tightened before and after operation.

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Approximate Dimensions
Frame A Dimensions
A mm (in.) 267 (10.5) B mm (in.) 359 (14.0) C mm (in.) 287 (11.3) A1 mm (in.) 7 (0.3) A2 mm (in.) 250 (9.8) B1 mm (in.) 275 (10.8)

A A1
PORT MOD NET A NET B

STS

B1

A2

Frame A Weights
Drive w/ND Rating Code 230V 7P0 9P0 012 020 029 038 055 073 093 110 460V 4P1 6P0 010 014 019 027 035 045 052 073 086 100 129 Weight Drive kg (lb) Drive & Packaging kg (lb)

8.4 (19.5)

10.5 (23.1)

8.8 (19.4)

11 (24.3)

10.8 (23.8)

13 (28.7)

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Frame B Dimensions
A mm (in.) 311 (12.2) A1 mm (in.) 275 (10.8) A2 mm (in.) 16.5 (0.65) A3 mm (in.) 7 (0.3) B mm (in.) 388 (15.3) B1 mm (in.) 375 (14.8) C mm (in.) 350 (13.8)

A A1

PORT MOD NET A NET B

STS

B1

A2

A3
Terminal Details Dimensions in mm (in.)

45.2 (1.8)

53.1 (2.1) 98.5 (3.9) 48.5 (1.9) 53.1 (2.1) 48.5 (1.9) 200.1 (7.9) 248.6 (9.8)

147.0 (5.8)

Frame B Weights
Drive w/ND Rating Code 230V 146 180 218 265 360 434 460V 167 207 250 330 412 575V 067 101 135 270 405 Weight Drive kg (lb) 25.5 (56.2) 29.5 (65.0) 32 (70.5) Drive & Packaging kg (lb) 27.5 (60.6) 31.5 (69.5) 34 (75)

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Frame C Dimensions
A mm (in.) 521 (20.5) A1 mm (in.) 499 (19.7) B mm (in.) 511 (20.1) B1 mm (in.) 400 (15.7) B2 mm (in.) 200 (7.9) B3 mm (in.) 55 (2.2) B4 mm (in.) 56 (2.2) B5 mm (in.) 10.5 (0.4) C mm (in.) 416 (16.4)

A1 B4

PORT MOD NET A NET B

B1 B B2

STS

B5

B3

Terminal Details Dimensions in mm (in.)

35.5 (1.4)

28.0 (1.1)

28.0 (1.1) 113.0 (4.5)

28.0 (1.1)

155.0 (6.1) 310.0 (12.2)

Frame C Weights
Drive w/ND Rating Code Weight - Regenerative Drives Drive Drive & Packaging 230V 460V 575V 690V kg (lb) kg (lb) 495 61 (134.5) 83 (183.0) 521 667 65 (143.3) 87 (191.8) 700 540 452 72 (158.7) 94 (207.2) 675 565 Weight - Non-regenerative Drives Drive Drive & Packaging kg (lb) kg (lb) 57 (125.7) 79 (174.2) 62 (136.7) 68 (150.0) 84 (185.2) 90 (198.4)

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Frame D Dimensions - Right Side and Front Views

Dimensions are shown in mm and (in.) Dimensions of terminals U, V and W are the same.
359 (14.1) 544 (21.4) 704 (27.7) 60 (2.4) 30 (1.2) 42 (1.7)

80.5 (3.2)

Lifting flange

436.5 (17.2)

174 (6.9)

25 (1.0)

15 (0.6) 44.5 (1.8)

792 (31.2)

1250 (49.2)

208 (8.2)

144 (5.7)

157.5 (6.2)

44.5 25 (1.8) (1.0)

32 (1.3) 15 (0.6) 30 60 (1.2) (2.4)

PE

146 (5.7)

PE

10.5 (0.4) 252.5 (10.0) 134 (5.3) 22.6 (0.9) 44.5 (1.8) 44.5 (1.8) 134 (5.3)

10 (0.4)

269.5 (10.6) 454.5 (18.0)

100 (4.0)

44.5 (1.8) 27.8 (1.1) 100 (4.0)

437.5 (17.2)

Note: 134 mm (5.3 in.) C and D terminals are installed on 460V AC input, 800 and 900 Hp, 575V AC input, 1000 Hp, and 690V AC input, 1100, 1200, 1250, and 1400 Hp drives only. All other frame D ratings have 100 mm (4.0 in.) C and D terminals.

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Frame D Dimensions - Left Side and Back Views

Dimensions are shown in mm and (in.)
103.25 (4.1) 94 (3.7) 127 (5.0) 23 (0.9) 16 (0.6) 227.5 (9.0) 127 (5.0) 10.5 (0.4) 127 (5.0) 127 (5.0) 94 (3.7)

Lifting flange

129 (5.1)

Mounting holes

1435 MAX (56.5)

1230 (48.4)

157.5 (6.2)

Mounting holes

129 (5.1) 215.225 (8.5) 531 (21.0) 541 (21.3)

10 (0.4)

10.5 (0.4)

94 (3.7)

127 (5.0)

127 (5.0)

127 (5.0)

127 (5.0)

94 (3.7)

Frame D - 230V AC Input Drive Weights

Drive w/ND Rating Code Weight - Regenerative Drives Drive Drive & Packaging
kg (lb) kg (lb)

Weight - Non-regenerative Drives Drive Drive & Packaging

kg (lb) kg (lb)

875 1K0

203 (447.5)

281 (619.5)

152 (335.1)

230 (507.1)

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Frame D - 460V AC Input Drive Weights

Drive w/ND Rating Code Weight - Regenerative Drives Drive Drive & Packaging kg (lb) kg (lb) 202 (445.3) 215 (474.0) 280 (617.3) 293 (646.0) Weight - Non-regenerative Drives Drive Drive & Packaging kg (lb) kg (lb) 152 (335.1) 165 (363.8) 230 (507.1) 243 (535.7)

830 996 1K1 1K3 1K4

Frame D - 575V AC Input Drive Weights

Drive w/ND Rating Code Weight - Regenerative Drives Drive Drive & Packaging kg (lb) kg (lb) 198 (436.5) 215 (474.0) 222 (489.4) 241 (531.3) 276 (608.5) 293 (646.0) 300 (661.4) 319 (703.3) Weight - Non-regenerative Drives Drive Drive & Packaging kg (lb) kg (lb) 148 (326.3) 165 (363.8) 172 (379.2) 191 (421.1) 226 (498.2) 243 (535.7) 250 (551.2) 269 (593.0)

810 1K0 1K2 1K3 1K6

Frame D - 690V AC Input Drive Weights

Drive w/ND Rating Code Weight - Regenerative Drives Drive Drive & Packaging kg (lb) kg (lb) 198 (436.5) 200 (440.9) 202 (445.3) 215 (474.0) 241 (531.3) 276 (608.5) 278 (612.9) 280 (617.3) 293 (646.0) 319 (703.3) Weight - Non-regenerative Drives Drive Drive & Packaging kg (lb) kg (lb) 148 (326.3) 150 (330.7) 152 (335.1) 165 (363.8) 172 (379.2) 191 (421.1) 226 (498.2) 228 (502.7) 230 (507.1) 243 (535.7) 250 (551.2) 269 (593.0)

678 791 904 1K0 1K1 1K2 1K4 1K5

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PowerFlex DC Configured Drives

Overview
The PowerFlex DC Configured Drives allow users to create drive packages based on their specific needs. This program enhances stand-alone drive functionality through additional control, power and packaging options, which are ideal for Original Equipment Manufacturers (OEM) and end users with special installation needs. This program consists of: Standard Configured Drives Engineer To Order Configured Drives

Standard Configured Drives

The Standard Configured Drives Program allows users to create drive packages based on their specific needs. A complete drive package may be specified by assembling a single catalog number string that includes a base drive and all required options. Packaging is available for 230 and 460V AC requirements in IP20, NEMA/UL Type 1 MCC style enclosures or rigid-panel mounted for installation in an existing enclosure. The program consists of a fully defined catalog string identified within this publication. Focused on higher volume, repeat business, the standard designs provide consistent manufacturing and minimizes customer resources by reducing engineering, manufacturing and installation time. Products can be ordered by contacting your Local Solution Center / Fastrac team.

Engineer To Order Configured Drives (ETO)

The Engineer To Order Configured Drives Program offers users the ability to create drive packages beyond the Standard Configured Drives offering. Options may or may not be defined within this publication. Products can be ordered by contacting your FasTrac representative or one of the Local Drive Solution Centers. Our engineering experts will assist in defining the specific requirements of your application. The Standard Configured Drive designs may be modified to meet the design criteria or a complete custom package can be designed for any application. The typical lead time of an ETO order is 812 weeks based on the lead time and availability of unique components of the design.

Benefits
Simplified installation and start-up by use of common options assembled at the factory. Drive functionality exceeds options offered with a standard drive. Multiple packaging options specific to customer needs. Pre-engineered options for easy order entry, consistent manufacturing, high quality and reduced delivery time. Selectable configurations to meet application requirements.

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Features
Standard PowerFlex DC Digital drives and drive-related options. 6 pulse. Enclosure options: IP20 MCC, IP42 Filter, IP00 (mounted on a panel), either conformal coated circuit boards or without. Pre-engineered options. Custom/engineered solutions. UL panel recognition from the factory for pre-engineered options.

Factory Installed Options Enclosure Options

The PowerFlex Configured DC drives can be ordered in a IP20, NEMA/UL Type 1 MCC style enclosure or a IP43, NEMA/UL Type 1 with Fan & Filter MCC style enclosure. For both of these enclosures the drive, incoming disconnect and any specified operator devices will be mounted and wired in the cabinet or on the door as required. If a cabinet mounted input line reactor is specified, it will be mounted in the cabinet for drives ratings of 200 Hp or less. The drive may also be ordered on a rigid panel for installation in a users existing cabinet. For these designs the drive and all panel mounted parts will be mounted and wired. The incoming disconnect, operator devices and input line reactor will be shipped loose for customer mounting and wiring per local codes. All MCC cabinets are 2286 mm H x 635 mm D (90 in. H x 25 in. D) with the width determined by the size of the drive and the options requested. The standard width enclosures are 508, 635, 889 mm (20, 25 and 35 in.) wide. The rigid panel mount designs are shipped on a 1981 mm H x 508 mm W or 813 mm W (78 in. H x 20 in. W or 32 in. W) panel to fit a standard 610 mm W X 914 mm W (24 in. W or 36 in. W) enclosure.

Human Interface Module (HIM) Options

The PowerFlex Configured DC drives can be ordered with a variety of HIM modules to meet the needs of each drive. The HIMs are installed on the door of the enclosures or shipped loose on the Open Panel designs. All designs have the door mounted bezel and interconnect cable to the drive. HIMs can be installed or updated in the field.

No HIM (Blank Plate) Catalog Code: 0

LCD Display, Full Numeric Keypad Catalog Code: C

LCD Display, Programmer Only Catalog Code: E

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I/O Options
The PowerFlex Configured DC drive has built-in configurable digital and analog I/O. The digital I/O is 24V DC and the analog I/O can be configured for voltage or current operation. Additional 24V DC and analog I/O can be added or an I/O conversion card can be added to accommodate 115V AC digital I/O.
I/O Options Control I/O Expansion Card (4 Additional 24V DC Digital Inputs & Outputs, 2 Analog Outputs) 115V AC Conversion Card (8 Digital Inputs) 8 - 24V DC Digital Inputs, 4 Digital Outputs, 3 Analog Inputs, & 2 Analog Outputs Code A B N

Communication Options
The PowerFlex Configured DC drives are fully compatible with Allen-Bradley drives wide variety of DPI communication adapters, offering the following options.
Description ControlNet Communication Adapter (Coax) DeviceNet Communication Adapter EtherNet/IP Communication Adapter Lonworks Communication Adapter PROFIBUS DP Communication Adapter ControlNet Communication Adapter (Fiber) Remote I/O Communication Adapter None Catalog No. C D E L P Q R N

This item has Silver Series status. For information, refer to: http://www.ab.com/silver.

Cabinet Options
The Configured Drive enclosure can be equipped with a variety of standard user option. These options are predefined as described below. Other options can be ordered through the ETO program.
Description None Start and Stop PBs Local/Remote SS E-Stop PB Jog Blower Motor Starter Options 1 & 2 Options 1 & 3 Options 1 & 4 Options 1 - 3 Options 1 - 4 Options 1 - 5 Options A & 4 Options A & 5 Options B & 4 Options B & 5 Catalog No. N 1 2 3 4 5 A B C D E F G H J K

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Certifications
The PowerFlex DC Drive is a UL/cUL certified product. The Configured Drive enclosure can also be built to UL/cUL certification and to CSA certification.
Description None (Drive unit is UL/cUL UL/cUL CSA Inspection & certification Code N 1 2

Please contact your local distributor or sales office for product availability. Configured Drives offers Quick Ship and PreEngineered Programs.

Configured Drive Enclosure Dimensions

Frame 1
150 mm (5.91 in.)

Frame 2

150 mm (5.91 in.)

JOG
PORT MOD NET A NET B

START

JOG
PORT MOD NET A NET B

START

STS
STS

LOCAL-REMOTE

STOP

LOCAL-REMOTE

STOP

SPEED

EMERG STOP

SPEED

EMERG STOP

1986 mm (78.25 in.)

1986 mm (78.25 in.)

150 mm (5.91 in.) 508 mm (20.0 in.)

150 mm (5.91 in.) 635 mm (25.0 in.)

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Configured Drive Enclosure Dimensions, continued

Frame 3
150 mm (5.91 in.)

JOG
PORT MOD NET A NET B

START

STS

LOCAL-REMOTE

STOP

SPEED

EMERG STOP

1986 mm (78.25 in.)

150 mm (5.91 in.) 889 mm (35.0 in.)

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Specifications
Category Agency Certification Specification According to file E59272 for the series of the approved devices. In conformity with the following European Directives: EMC Directive (2004/108/EC) Low Voltage Directive (2006/95/EC) Standards applied: EN 50178: 1997 EN 61800-3: 2004 Australian Communications and Media Authority In conformity with the following: Radio communications Act: 1992 Radio communications Standard: 2008 Radio communications Labelling Notice: 2008 Standards applied: EN 61800-3:2004 The drive is also designed to meet the following specifications: NFPA 70 - US National Electrical Code Category Drive Type Protection Specification Full Wave Regen, 6 Pulse, Regulated Field Supply Heat Sink Thermistor: Monitored by microprocessor overtemp trip Drive Overcurrent Trip Software Overcurrent Trip: Programmable, 0250% of rated current (175% default) Hardware Overcurrent Trip: Based on armature circuit fusing Line transients: Up to 2000 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 Ground Fault Trip: Phase-to-ground on drive output Short Circuit Trip: Phase-to-phase on drive output Altitude: 1000 m (3300 ft) max. without derating. De-rate output power by 1.2% for every 100 meters (328ft) above 1000 meters (3300ft). 050 C (32122 F), typical. Maximum Surrounding Air Temperature IP20, NEMA Type De-rate 1.25% for every 1 C over 50 C (122 F), to 55 C (131 F). Open: Additional cooling is required for temps. above 55 C. Storage Temp. (all const.): 2555 C (13131 F) Atmosphere: Important: Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas, vapors or dust. If the drive is not going to be installed for a period of time, it must be stored in an area where it will not be exposed to a corrosive atmosphere. Relative Humidity: Operating: 585% non-condensing Storage: 595% non-condensing Shock: 15G peak for 11ms duration (1.0 ms) Vibration: 0.152 mm (0.006 in.) displacement, 1G peak

Environment(1)

(1) PowerFlex DC drives must be installed in a Pollution Degree 2 environment.

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Category Drive Type Electrical

Specification Full Wave Regen, 6 Pulse, Regulated Field Supply Input Voltages: Armature: 230 to 690V AC +/- 10%, 3 Phase Field: 230 to 460V AC +/- 10%, 1 Phase Control: 115V AC or 230V AC +/- 15%, 1 Phase (115V AC input control power requires a jumper between terminals SA and SB for frame B and C drives only.) (See AC Input Voltages on page 21 for details.) Input Frequency: 50/60 Hz +/- 5% Max. Rate of Change of Input 2 Hz/Sec. Frequency: Armature Output Voltage: Two Quadrant Drives Four Quadrant Drives 240V DC @ 230V AC 260V DC @ 230V AC 420V DC @ 400V AC 470V DC @ 400V AC 460V DC @ 440V AC 530V DC @ 440V AC 480V DC @ 460V AC 560V DC @ 460V AC 500V DC @ 480V AC 580V DC @ 480V AC 600V DC @ 575V AC 680V DC @ 575V AC 720V DC @ 690V AC 810V DC @ 690V AC Output Horsepower (Cont.) 1.5300 HP @ 230V AC 2900 HP @ 460V AC 501250 HP @ 575V AC 4001400 HP @ 690V AC Output Current: 71050 A @ 230V AC 4.11494 A @ 400V AC 67.51688 A @ 575V AC 4521582 A @ 690V AC Overload Capability: 100% rated continuous current 150% rated current for one minute then fault 200% rated current for three seconds then fault Field Output Voltage 200V DC @ 230V AC 310V DC @ 400V AC 360V DC @ 460V AC Maximum field output voltage is 0.85 x AC input line voltage. Controller Current Overload: 150% rated current for one minute 200% rated current for three seconds Max. Short Circuit Rating: 100,000 A

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Category Control

Specification Speed Regulation:*

Torque Regulation

Feedback Devices

Encoder

Resolver DC Analog Tachometer

Inputs

Analog Inputs

Digital Inputs

Outputs

Analog Outputs

Digital Outputs

Relay Outputs

All operating modes: Max. speed: 8000 rpm Digital reference resolution: 0.1 rpm Analog reference resolution: 0.25 rpm with Digital Incremental Encoder/Resolver Speed feedback resolution better than 0.5 rpm (based on encoder PPR or resolver resolution) Operating range better than 1000:1 rpm, bi-directional Performance Accuracy 0.02% typical 170 rad/sec bandwidth with DC Analog Tachometer Speed feedback resolution better than 2000:1 rpm Operating range better than 1000:1 rpm, bi-directional Performance accuracy 0.1% 170 rad/sec bandwidth with Armature Voltage Feedback Voltage feedback resolution better than 2000:1 rpm Operating range better than 100:1 rpm, bi-directional Performance accuracy: 2.0% typical 80 rad/sec bandwidth *Subject to motor specs. and current loop tuning. Current feedback resolution better than 2000:1 Performance accuracy: 1.0% typical 500 rad/sec bandwidth Type: Incremental, dual channel, two channel optional (with jumper), differential (recommended) or single-ended Input Voltage: Configurable for +2.55.2V (switch S21 in ENC_5 position) or +5.415.2V (switch S21 in ENC_12 position) Input Current: 4.5 mA / 6.810.9 mA each channel Quadrature: 90 27 @ 25 C Duty cycle: 50% 10% Source/Sink capable Pulses Per Revolution: 10032770 Maximum Frequency: 150 kHz Maximum Cable Length: Shielded, 150m (0.75 mm2), 125m (0.5 mm2), 55m (0.22 mm2) See the PowerFlex DC Drive Resolver Feedback Option Module Installation Instructions, publication 20P-IN071 for details. Input Voltage: 22.7, 45.4, 90.7, 181.6, & 302.9V max. Input Current: 8 mA full scale Maximum Cable Length: Shielded, depends on the installation, typical 150m. Three configurable, isolated, differential 10V, 010V, 020 mA or 420 mA. Resolution: 11 Bit + sign Eight standard configurable, four additional configurable with the I/O Expansion circuit board. Max Voltage +30V DC input, 200 mA (total current draw is the sum of encoder power, digital outputs and any other loads connected to terminal 19) Two standard configurable, two additional configurable with the I/O Expansion circuit board. Sampling rate 2 ms. 10V, 5 mA, bipolar (current is not bipolar) Resolution: 11 Bit + sign Four standard configurable, four additional configurable with the I/O Expansion circuit board. + 30V, 50 mA Two configurable, N.O. contacts Max. 250V AC, 1A AC1

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Watts Loss and Fan Attributes

Watts loss and fan attributes data shown below is based on the rated current of the drive.

Frame A Drives
Drive Current Rating Code(1) @ 230 VAC @ 460 VAC 7P0 9P0 012 020 029 038 055 073 093 110 4P1 6P0 010 014 019 027 035 045 052 073 086 100 129 Total Watts Loss Total Value for Fan (none or 1) AC Input Rated Current Voltage (A) Max. Air Flow Noise Level

131

(no fan)

186 254 408 476 553 (Internal power supply) 80 m3/h 37 dB(A)

160 m3/h 45 dB(A)

(1) Refer to Catalog Number Explanation on page 6, positions 810 for corresponding drive Hp rating, armature amp rating and field amp rating.

Frame B Drives
Drive Current Rating Code(1) 146 180 218 265 360 434 167 207 250 330 412 067 101 135 270 405 AC Input Voltage 230 Total Watts Loss 781 939 1038 1693 460 781 939 1038 1248 1693 400 553 700 1038 1693 Total Value for All Fans (2) AC Input Rated Current Voltage Max. Air Flow Noise Level 320 m3/h 48 dB(A) 680 m3/h 53 dB(A) 320 m3/h 48 dB(A) 680 m3/h 53 dB(A) 320 m3/h 48 dB(A) 680 m3/h 53 dB(A)

(Internal power supply)

575

(1) Refer to Catalog Number Explanation on page 6, positions 810 for corresponding drive Hp rating, armature amp rating and field amp rating.

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Frame C Drives
Drive Current Rating Code(1) 521 700 495 667 540 675 452 565 AC Input Voltage 230 460 575 690 Total Watts Loss 2143 2700 2143 2590 2300 2620 1700 2300 Total Value for All Fans (3) (2) AC Input Rated Current Voltage Max. Air Flow Noise Level

230 VAC

0.75 Amps

1050 m3/h 62.5 dB(A)

(1) Refer to Catalog Number Explanation on page 6, positions 810 for corresponding drive Hp rating, armature amp rating and field amp rating. (2) Fans on frames C drives must be powered by an external 230 V AC, 50/60 Hz power supply, connected to terminals U3 and V3.

Frame D Drives
Drive Current Rating Code(1) 875 1K0 830 996 1K1 1K3 1K4 810 1K0 1K2 1K3 1K6 678 791 904 1K0 1K1 1K2 1K4 1K5 AC Input Voltage 230 480 Total Watts Loss 2694 3284 3200 3568 4189 5229 5117 3122 3819 4679 4879 5720 3174 3582 4028 4064 4509 5368 5543 5886 Total Value for Fan (1) (2) AC Input Rated Current Voltage Max. Air Flow Noise Level

575

230 VAC

2.4A@50Hz and 3.3A@60Hz

2400 m3/h 80 dB(A)

690

(1) Refer to Catalog Number Explanation on page 6, positions 810 for corresponding drive Hp rating, armature amp rating and field amp rating. (2) Fans on frames D drives must be powered by an external 230 V AC, 50/60 Hz power supply, connected to terminals U3 and V3.

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PowerFlex Digital DC Drive

PowerFlex DC Stand-Alone Regulator

Catalog Number (1) 23PMD4 23PMD7 23PMF4 23PMF7 Total Watts Loss Total Value for Fans (2) [W] AC Input Voltage Rated Current 303 357 374 428 Max. Air Flow Noise Level 160 m3/h 40 dB(A)

(Internal power supply)

(1) Refer to Stand-Alone Regulator Catalog Numbers in the PowerFlex DC Stand-Alone Regulator and Gate Amplifier User Manual, publication 23P-UM001, for a description of ratings.

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Important User Information

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this publication 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.

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Publication 20P-TD001F-EN-P - February 2013

Supersedes Publication Supersedes Publication 20P-TD001D-EN-P - January 2010 Copyright 2013 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.