Specifications

ManualsBrandsAllen-Bradley ManualsHome building and Decor1770-M10

1395, 1397, and FlexPak 3000 DC Drives to PowerFlex DC Drive

Catalog Numbers 1395, 1397, 20P

Migration Guide

Summary of content (194 pages)

PAGE 1
Migration Guide 1395, 1397, and FlexPak 3000 DC Drives to PowerFlex DC Drive Catalog Numbers 1395, 1397, 20P
PAGE 2
Important User Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-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.
PAGE 3
Table of Contents Preface Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pre-migration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Best Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 4
Table of Contents Chapter 3 Network Communication 4 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bulletin 1395 DC Drive Network Communication Options. . . . . . . . 1395 Node Adapter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-Communication Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ControlNet Adapter Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 5
Preface Overview Topic Page Overview 5 Pre-migration 5 Additional Resources 6 The purpose of this publication is to assist in migrating from a 1395, 1397, or FlexPak 3000 DC drive to a PowerFlex® DC drive. Please refer to the respective User Manual, Technical Data and/or Installation Instructions for more detail.
PAGE 6
Preface Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Description 1395 DC Drive, 800…1250 Hp, Firmware Versions 5.xx-9.30 User Manual, publication 1395-UM006 Provides the necessary information to install, program, start up and maintain the 1350 A and 2250 A version of the 1395 DC drive. 1395 Digital DC Drive Firmware Versions 5xx…10.10/9.
PAGE 7
Preface View All Publications for a Specific Drive You can view a list of all available publications for a specific drive on the Rockwell Automation Literature Library. For example, to view all publications for the 1397 drive, follow these steps: 1. On the Rockwell Automation Literature Library Home page, click Drives (Allen-Bradley). 2. Scroll down and click 1397. The list of available publications for the Bulletin 1397 DC drive are displayed.
PAGE 8
Preface Notes: 8 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012
PAGE 9
Chapter 1 Drive Comparisons This chapter provides comparisons of each drives specifications and features, catalog number explanations, ratings, dimensions, power and control wiring and options.
PAGE 10
Chapter 1 Drive Comparisons This section compares the specifications and features of your existing 1395, 1397, or FlexPak 3000 DC drive to the PowerFlex DC drive. Specifications and Features Table 1 - Drive Specification and Feature Comparisons Attributes 1395 1397 1395… 1397… 100…115V n/a n/a n/a n/a 200…240V 0.75…224 kW 1…300 Hp 1.1…111 kW 1.5…150 Hp 1.5…300 Hp 7…1000 A 1.5…300 Hp 7…1050 A 400…480V 1.5…500 Hp (400 VDC) 2…600 Hp (500 VDC) 2.
PAGE 11
Drive Comparisons Chapter 1 Table 1 - Drive Specification and Feature Comparisons (Continued) Attributes 1395 1397 FlexPak 3000 PowerFlex DC Programming/Control terminal Remote terminal DriveExecutive Local ScanPort HIMs Remote ScanPort HIMs DriveExplorer DriveExecutive Five-language graphical LCD Operator Interface Module (OIM) CS3000 Control/Configuration Software Local PowerFlex HIMs Remote PowerFlex HIMs DriveExplorer DriveExecutive Connected Components Workbench ControlNet Remote I/O DH+ Ser
PAGE 12
Chapter 1 Drive Comparisons Table 1 - Drive Specification and Feature Comparisons (Continued) Attributes 1395 1397 FlexPak 3000 PowerFlex DC n/a n/a n/a n/a 200…240V AC ±10% 47…63 Hz 48…62 Hz 47…63 Hz 47…63 Hz 380…480V AC ±10% 48…63 Hz 48…62 Hz 48…63 Hz 47…63 Hz 500…600V AC ±10% n/a n/a n/a 47…63 Hz Single Phase n/a n/a n/a n/a Three Phase All All All All Input Inductor 3% required 3% required 3% recommended 3% recommended Logic Ride-thru – – – 0.5…2.
PAGE 13
Drive Comparisons Chapter 1 Table 1 - Drive Specification and Feature Comparisons (Continued) Attributes 1395 1397 FlexPak 3000 PowerFlex DC U.L.
PAGE 14
Chapter 1 Drive Comparisons Table 1 - Drive Specification and Feature Comparisons (Continued) Attributes 1395 1397 FlexPak 3000 PowerFlex DC 51 32 32 48 Terminal Type Fixed, screw type Fixed, screw type Fixed, screw type Pull apart, screw type Control Inputs 24V DC or 115V AC 24V DC or 115V AC (opt) 24V DC or 115V AC (opt) 24V DC or 115V AC (opt) Programmable Control Inputs 5 0 1 standard, 5 optional 11 Jog Speeds (independent) 2 1 1 1 Yes Yes (optional) Yes (optional) 1 Y
PAGE 15
Drive Comparisons Chapter 1 Table 1 - Drive Specification and Feature Comparisons (Continued) Attributes 1395 1397 FlexPak 3000 PowerFlex DC Communication Drive Protocol SCANport Serial DPI Bluetooth Yes No Yes Remote I/O Yes Yes No Yes Serial Yes 232/422/485 232 232/485 DF1 Yes Yes No Yes DH485 No Yes No No DH+ Yes No No No BACNet No No No Yes DeviceNet No Yes Yes Yes ControlNet Yes Yes Yes Yes EtherNet/IP No Yes No Yes Profibus DP No No Yes Y
PAGE 16
Chapter 1 Drive Comparisons Table 1 - Drive Specification and Feature Comparisons (Continued) Attributes 1395 1397 FlexPak 3000 PowerFlex DC Control Modes Closed Loop Yes Yes Yes Yes Process Control Speed Speed Speed Speed Process Control Torque Torque Torque Torque Speed Profiles No No No Yes Position Control No No Yes Yes Droop Yes Yes Yes Yes Speed/Torque switch-over Yes No No Yes Speed/Torque MIN Yes No No Yes Speed/Torque MAX Yes No No Yes Speed/Torqu
PAGE 17
Drive Comparisons Chapter 1 Table 1 - Drive Specification and Feature Comparisons (Continued) Attributes 1395 1397 FlexPak 3000 PowerFlex DC 4 ms 20 ms 5 ms 2 ms (limited by analog input reference) Encoder PPR Encoder PPR Encoder PPR 0.5 RPM 150 140 140 170 Speed Regulation 0.00% 0.01% 0.01% 0.02% Operating Range 1:100 1:100 1:100 1:1000 10…32767 18…2500 18…2500 100…32770 12 bit A/D 12 bit A/D 12 bit A/D 1:2000 150 140 140 170 Speed Regulation 0.10% 1% 1% 0.
PAGE 18
Chapter 1 Drive Comparisons Bulletin 1395 Digital DC Drive Drive Catalog Number Explanations The following tables are an explanation of the catalog numbering system for the 1395 DC drive and options. Table 2 - 230V AC Input (1…100 Hp) 1395 - A61 - C1 - P10 - X1 First Position Second Position Third Position Fourth Position Bulletin No.
PAGE 19
Drive Comparisons Chapter 1 Table 3 - 460V AC Input (2…200 Hp) 1395 - B63 - C1 - P10 - X1 First Position Second Position Third Position Fourth Position Bulletin No. Horsepower Contactor Type Options 1395 Non-Regenerative Standard Standard Options (1)(2) Code Hp Code Hp Code Option B63N 2 Hp C1 2…30 Hp P10 Discrete adapter 115 VAC (Port A) B64N 3 Hp C2 40…60 Hp P11 Discrete adapter 24VDC (Port A) B65N 5 Hp C3 75…100 Hp P12 Digital reference adapter (Port A) B66N 7.
PAGE 20
Chapter 1 Drive Comparisons Table 4 - 230V AC Input (125…300 Hp) 1395 - A77 - E1 - P30 - P50 - X2 First Position Second Position Third Position Fourth Position Bulletin No.
PAGE 21
Drive Comparisons Chapter 1 Bulletin 1395 Digital DC Drive in Bulletin 2361 Motor Control Centers The following tables are an explanation of the catalog numbering system for the 1395 DC drive in a 2361 Motor Control Center (MCC) and the available options. Table 6 - Bulletin 2361 MCC Units Bulletin No.
PAGE 22
Chapter 1 Drive Comparisons Table 7 - Bulletin 1395 in Bulletin 2361 MCC Options Option Code Door-mounted Pilot Light (1) Door-mounted Push Buttons (1) Door-mounted Illuminated Push Buttons Door-mounted Switches (1)(4) Drive Port A Cards (2) Drive Port B Cards (2) Tachometer Feedback Scaling Boards (3) Configuration Terminals (4) Control Power Source (5) (1)(4) Description 4R Power-on 1B Drive stop (4) 1JF Jog forward (4) 1JR Jog reverse (4) 1ES Hard-wired stop interface 5G star
PAGE 23
Drive Comparisons Chapter 1 Table 7 - Bulletin 1395 in Bulletin 2361 MCC Options Option Blower Starters Code (4) Protection Description 14BN One NEMA size 1 full-voltage, non-reversing (FVNR) starter assembly with 30 A fuse blocks mounted within the drive unit 14B2N Two NEMA size 1 FVNR starter assemblies with 30 A fuse blocks mounted within the drive unit 14B2NX Two NEMA size 2 FVNR starter assemblies with 60 A fuse blocks mounted within the drive unit 14BI One IEC, 24 A starter assembly mount
PAGE 24
Chapter 1 Drive Comparisons Bulletin 1397 Digital DC Drive The following tables are an explanation of the catalog numbering system for the 1397 DC drive and options. Table 8 - Bulletin 1397 - All Drives 1397 - B 005 R - xxx First Position Second Position Third Position Fourth Position Fifth Position Bulletin No. Voltage Rating Type Options (2) 1397 24 Code AC Input Voltage Code Hp (kW) Rating Code Type A 230V 001 1.5 (1.1) N Non-Regenerative 002 2 (1.
PAGE 25
Drive Comparisons Chapter 1 Table 8 - Bulletin 1397 - All Drives 1397 - B 005 R - xxx First Position Second Position Third Position Fourth Position Fifth Position Bulletin No. Voltage Rating Type Options (2) 1397 Code AC Input Voltage Code Hp (kW) Rating Code Type B 460V 003 3 (2.2) N Non-Regenerative 005 5 (3.7) R Regenerative (1) 007 7.5 (5.6) 010 10 (7.
PAGE 26
Chapter 1 Drive Comparisons Table 9 - Bulletin 1397 Options Code Description Communication Options (Loose Kits) –1203–GD1 Single point remote I/O (RIO) – 115V AC –1203–GD2 RS–232/422/485, DF1 and DH485 protocol – 115VAC –1203–GK1 Single point remote I/O (RIO) – 24 VDC –1203–GK2 RS–232 interface board –1203–GK5 DeviceNet – 24 VDC Human Interface Options –HAB Blank – No functionality –HAP Programmer only –HA1 Programmer / Controller with analog pot –HA2 Programmer / Controller with digita
PAGE 27
Drive Comparisons Chapter 1 This table lists the option kits that broaden the application range of the FlexPak 3000 drive. Not all kits can be used with all drive model numbers. Table 11 - FlexPak 3000 Drive Options Option Name Description Model Number 115V AC Control Interface Converts customer-supplied 115V AC signals to 24V DC for operating a FlexPak 3000. Mounts separately on the panel or can be mounted in the bottom of a NEMA 1 enclosed drive.
PAGE 28
Chapter 1 Drive Comparisons PowerFlex Digital DC Drive Position 1-3 4 5 6 20P 4 1 A a b c d 7 8-10 D 4P1 e 11 R f 13 A g 0 h 15 N i Code Type 20P PowerFlex DC 16 N j N k l f3 230V, 60 Hz Input Field Amps Code Hp kW Armature Amps Frame Field Amps 7 A 10 067 50 37 67.5 B 20 9 A 10 101 75 56 101.3 B 20 2.2 12 A 10 135 100 75 135 B 20 5 3.7 20 A 10 270 200 149 270 B 20 029 7.5 5.
PAGE 29
Drive Comparisons Chapter 1 PowerFlex Digital DC Drive, Continued Position 1-3 4 5 6 7 8-10 11 12 13 14 15 16 20P 4 1 A D 4P1 R A 0 N N N a b c d e f g h i j k l i g Code R k HIM Field Supply Code Type Single-Phase Regulated 0 Operator Interface Code Blank Cover Standard - for additional selections, refer to the PowerFlex Digital DC Drive Technical Data, publication 20P-TD001. . .
PAGE 30
Chapter 1 Drive Comparisons Drive Conversion Guides The following tables compare rating codes, kilowatt and horsepower ratings, and armature DC output amps to assist you in migrating your 1395, 1397, or FlexPak 3000 drive to a comparable PowerFlex DC drive. See the table corresponding to your existing DC drive. IMPORTANT The tables below list the drives on a direct Amps-to-Amps comparison.
PAGE 31
Drive Comparisons Chapter 1 460V AC Input Drives 1395 PowerFlex DC Cat. No. Power Output kW (Hp) Armature DC Output (Amps) Cat. No. Power Output kW (Hp) Armature DC Output (Amps) B63 & B63N 1.5 (2) 4.1 D4P1 1.5 (2) 4.1 B64 & B64N 2.24 (3) 5.9 D6P0 2.24 (3) 6 B65 & B65N 3.75 (5) 9.6 D010 3.75 (5) 10 B66 & B66N 5.6 (7.5) 13.9 D014 5.6 (7.5) 14 B67 & B67N 7.5 (10) 18.3 D019 7.5 (10) 19 – – – D027 11.2 (15) 27 B68 & B68N 11.
PAGE 32
Chapter 1 Drive Comparisons Bulletin 1397 to PowerFlex DC Drive Conversions 230V AC Input Drives 1397 32 PowerFlex DC Cat. No. Power Output Hp (kW) Armature DC Output (Amps) Cat. No. Power Output kW (Hp) Armature DC Output (Amps) A001 1.5 (1.1) 7 B7P0 1.2 (1.5) 7 A002 2 (1.5) 9 B9P0 1.5 (2) 9 A003 3 (2.2) 12 B012 2.2 (3) 12 A005 5 (3.7) 20 B020 3.7 (5) 20 A007 7.5 (5.8) 29 B029 5.6 (7.5) 29 A010 10 (7.5) 38 B038 7.5 (10) 38 A015 15 (11) 55 B055 11.
PAGE 33
Drive Comparisons Chapter 1 460V AC Input Drives 1397 PowerFlex DC Cat. No. Power Output Hp (kW) Armature DC Output (Amps) Cat. No. Power Output kW (Hp) Armature DC Output (Amps) – – – D4P1 1.5 (2) 4.1 B003 3 (2.2) 6 D6P0 2.24 (3) 6 B005 5 (3.7) 10 D010 3.75 (5) 10 B007 7.5 (5.6) 14 D014 5.6 (7.5) 14 B010 10 (7.5) 19 D019 7.5 (10) 19 B015 15 (11) 27 D027 11.2 (15) 27 B020 20 (15) 35 D035 15 (20) 35 B025 25 (18) 45 D045 18.
PAGE 34
Chapter 1 Drive Comparisons FlexPak 3000 to PowerFlex DC Drive Conversions 230V AC Input Drives FlexPak 3000 PowerFlex DC Cat. No. Power Output Hp (kW) Armature DC Output (Amps) Cat. No. Power Output kW (Hp) Armature DC Output (Amps) 001**2 1.5 (1.1) 7 B7P0 1.2 (1.5) 7 002**2 2 (1.5) 9 B9P0 1.5 (2) 9 003**2 3 (2.2) 12 B012 2.2 (3) 12 005**2 5 (3.7) 20 B020 3.7 (5) 20 007**2 7.5 (5.8) 29 B029 5.6 (7.5) 29 010**2 10 (7.5) 38 B038 7.
PAGE 35
Drive Comparisons FlexPak 3000 Chapter 1 PowerFlex DC Cat. No. Power Output Hp (kW) Armature DC Output (Amps) Cat. No. Power Output kW (Hp) Armature DC Output (Amps) 050**4 50 (37) 86 D086 37.3 (50) 86 060**4 60 (44) 100 D100 44.8 (60) 100 075**4 75 (55) 129 D129 56 (75) 129 100**4 100 (74) 167 D167 74.6 (100) 167 125**4 125 (93) 207 D207 93.3 (125) 207 150**4 150 (111) 250 D250 112 (150) 250 200**4 200. (149) 330 D330 149.
PAGE 36
Chapter 1 Drive Comparisons Bulletin 1395 Drive Approximate Dimensions Drive Dimensions Figure 1 - 1395 Series B, 1…30 Hp, at 230VAC and 2…60 Hp at 460VAC A B E D C Side View Front View F Side View (with door open) 230V 1…30 Hp 36 460V 2…60 Hp A B C D E F mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 302.2 (11.9) 279.4 (11.0) 571.5 (22.5) 596.0 (23.5) 273.0 (10.75) 609.6 (24.
PAGE 37
Drive Comparisons Chapter 1 Figure 2 - 1395 Series A, 40…100 Hp at 230VAC and 75…200 Hp at 460VAC Dimensions in mm (in.) Top View 38 (1.5) Clearance for service 281 (11.05) Door swing Front B. Max 592 (23.3) max dimension for service 127 (5.0) Exhaust air 10 ° C rise 9.7 (0.38) diameter mounting holes and slots - four places for mounting with 7.9 (0.312) hardware C (max) Front View E Side View Rear View A Max 76 (3.0) 230V D Intake air 55 ° C (max) 460V 12.7 (0.
PAGE 38
Chapter 1 Drive Comparisons Figure 3 - 1395 MKVA Series B, 125…300 Hp at 230VAC and 250…600 Hp at 460VAC Dimensions in mm (in.) B E C Max 152 (6.0) Exhaust Air 10 ° C Rise 50.8 (2.0) Front View 152 (6.0) 230V 125…300 Hp 38 Side View A (A2) bus bar Intake air 55 ° C (max) 460V 250…600 Hp D A Rear View 158.8 (6.25) A B C D E mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 1168.0 (46.0) 813.0 (32.0) 470.0 (18.5) 1118.0 (44.0) 711.0 (28.
PAGE 39
Drive Comparisons Chapter 1 Bulletin 1397 Drive Approximate Dimensions Figure 4 - 1397 - 1.5…30 Hp at 230VAC, 7…110 A at 380/415VAC, 3…60 Hp at 460VAC 136.0 (5.35) 463.0 (18.23) 477.5 (18.80) 22.5 (0.89) 497.5 (19.59) 225.0 (8.86) 300.0 (11.81) 7.0 (0.28) Front View Side View 135 angle° Rec. hardware 3xM6 or 1/4 in. 270.5 (10.65) All dimensions are in mm (in.) Approximate shipping weight 30.
PAGE 40
Chapter 1 Drive Comparisons Figure 5 - 1397 - 40…75 Hp at 230VAC, 265 A at 380/415VAC, 75…150 Hp at 460 VAC 37.5 (1.48) 200.0 (7.87) 37.5 (1.48) 200.0 (7.87) 375.0 (14.76) 464.6 (18.29) 491.8 (19.36) 16.8 (0.66) 375.0 (14.76) 461.6 (18.17) Front View 300.0 (11.81) 334.3 (13.16) Side View 135 angle° 531.7 (20.93) 509.5 (20.06) Rec. hardware 3xM6 or 1/4 in. 461.6 (18.17) Top View 40 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 All dimensions are in mm (in.
PAGE 41
Drive Comparisons Chapter 1 Figure 6 - 1397 - 150 Hp at 230VAC, 200…300 Hp at 460VAC 67.5 (2.66) 230.0 (9.06) 240.0 (9.45) 67.5 (2.66) 230.0 (9.06) 240.0 (9.45) 424.7 (16.72) 822.8 (32.39) 850.0 (33.46) 12.7 (0.50) 470.0 (18.50) 599.0 (23.58) Front View 371.1 (14.61) 406.0 (15.99) Side View 135 angle° 598.4 (23.56) 578.9 (22.79) Rec. hardware 3xM6 or 1/4 in. 599.0 (23.58) All dimensions are in mm (in.) Approximate shipping weight 30.
PAGE 42
Chapter 1 Drive Comparisons Figure 7 - 1397 - 400…600 Hp at 460VAC 478.1 (18.82) 677.7 (26.68) 53.8 (2.12) 259.1 (10.20) 261.6 (10.30) 259.1 (10.20) 261.6 (10.30) 1149.2 (45.25) 1104.0 (43.47) 1076.3 (42.37) 53.8 (2.12) Front View 464.7 (18.30) Side View 135 angle° 650.5 (25.61) All dimensions are in mm (in.
PAGE 43
Drive Comparisons Chapter 1 FlexPak 3000 Drive Approximate Dimensions Figure 8 - FlexPak 3000 - 1.5…30 Hp at 230VAC, 3…60 Hp at 460VAC / 7…110 A Rated Output 7.9 (0.31) 477.3 (18.79) 463.0 (18.23) 112.4 (4.43) 22.4 (0.88) 224.9 (8.86) 270.5 (10.65) Weight = 26.4 kg (58.0 lb) Use M6 or 1/4 in. mounting hardware 310.6 (12.23) 135 angle° 498.8 (19.64) 485.2 (19.10) 257.0 (10.12) All dimensions are in mm (in.
PAGE 44
Chapter 1 Drive Comparisons Figure 9 - FlexPak 3000 - 40…75 Hp at 230VAC, 75…150 Hp at 460VAC / 265 A Rated Output 12.7 (0.50) 341.9 (13.46) 304.2 (11.98) 490.0 (19.29) 464.6 (18.29) 135 angle° 35.0 (1.38) 200.0 (7.87) 460.0 (18.11) 528.9 (20.82) 516.5 (20.33) Weight = 55.0 kg (122.0 lb) Use M8 or 5/16 in. mounting hardware All dimensions are in mm (in.) 44 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 175.0 (6.
PAGE 45
Drive Comparisons Chapter 1 Figure 10 - FlexPak 3000 - 100…150 Hp at 230VAC, 200…300 Hp at 460VAC 424.7 (16.72) 291.9 (11.49) 12.7 (0.50) 67.5 (2.66) 230.0 (9.06) 599.0 (23.58) 223.4 (8.80) A1 45 240.0 (9.45) 849.9 (33.46) 371.1 (14.6) 406.0 (16.0) 135 angle° Weight = 100.0 kg (220.5 lb) Use M10 or 3/8 in. mounting hardware The drive is shown with optional AC line disconnect kit 598.4 (23.56) 585.2 (23.04) All dimensions are in mm (in.
PAGE 46
Chapter 1 Drive Comparisons Figure 11 - FlexPak 3000 - 400…600 Hp at 460VAC 478.1 (18.82) 667.68 (26.68) 53.8 (2.12) 259.1 (10.20) 261.6 (10.30) 1149.2 (45.25) 1104.0 (43.47) 1076.3 (42.37) 53.8 (2.12) 259.1 (10.20) 261.6 (10.30) 464.7 (18.30) 135 angle° 650.5 (25.61) Weight = 204.5 kg (450.0 lb) Use M10 or 3/8 in. mounting hardware The drive is shown with optional AC line disconnect kit All dimensions are in mm (in.
PAGE 47
Drive Comparisons Chapter 1 Figure 12 - FlexPak 3000 Integrated Drive - 1.5…30 Hp at 230VAC, 3…60 Hp at 460VAC 7.9 (0.31) 402.2 (15.83) 388.9 (15.31) 22.4 (0.88) 112.4 (4.43) 224.9 (8.86) 312.7 (12.31) 270.5 (10.65) 135 angle° 484.9 (19.09) Weight = 16.4 kg (36.0 lb) Use M6 or 1/4 in. mounting hardware All dimensions are in mm (in.
PAGE 48
Chapter 1 Drive Comparisons Figure 13 - FlexPak 3000 Integrated Drive - 40…75 Hp at 230VAC, 75…150 Hp at 460VAC 35.0 (1.38) 270.5 (10.63) 200.0 (7.88) 328.4 (12.93) 50.8 (2.0) 12.7 (0.50) 490.29 (19.29) 464.6 (18.29) Mounting hole for M8x1.25 hardware or equivalent four places. 300.0 (11.81) 334.4 (13.16) 135 angle° 531.6 (20.93) 516.5 (20.33) Weight = 36.3 kg (80.0 lb) Use M8 or 5/16 in. mounting hardware All dimensions are in mm (in.
PAGE 49
Drive Comparisons Chapter 1 PowerFlex DC Drive Approximate Dimensions Figure 14 - PowerFlex DC Frame A, 1.5…30 Hp at 230VAC, 2…75 Hp at 460VAC A C A1 PORT MOD NET A NET B STS B1 B A2 A B C A1 A2 B1 mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 267 (10.5) 359 (14.0) 287 (11.3) 7 (0.3) 250 (9.8) 275 (10.
PAGE 50
Chapter 1 Drive Comparisons Figure 15 - PowerFlex DC Frame B, 40…125 Hp at 230VAC, 100…250 Hp at 460VAC, 50…300 Hp at 575VAC A A1 C PORT MOD NET A NET B STS B1 B A3 A2 45.2 (1.8) 53.1 (2.1) 98.5 (3.9) 48.5 (1.9) 147.0 (5.8) 53.1 (2.1) 200.1 (7.9) 48.5 (1.9) 248.6 (9.8) Terminal Details Dimensions in mm (in.) 50 A A1 A2 A3 B B1 C mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 311 (12.2) 275 (10.8) 16.5 (0.65) 7 (0.3) 388 (15.3) 375 (14.8) 350 (13.
PAGE 51
Drive Comparisons Chapter 1 Figure 16 - PowerFlex DC Frame C, 150…200 Hp at 230VAC, 300…400 Hp at 460VAC, 400…500 Hp at 575VAC, 400…500 Hp at 690VAC A1 C B4 PORT MOD NET A NET B B1 STS B B5 B2 B3 A 28.0 (1.1) 35.5 (1.4) 28.0 (1.1) 28.0 (1.1) 113.0 (4.5) 155.0 (6.1) 310.0 (12.2) Terminal Details Dimensions in mm (in.) A A1 B B1 B2 B3 B4 B5 C mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 521 (20.5) 499 (19.7) 511 (20.1) 400 (15.
PAGE 52
Chapter 1 Drive Comparisons Figure 17 - PowerFlex DC Frame D, 250…300 Hp at 230VAC, 500…900 Hp at 460VAC, 600…1250 Hp at 575VAC, 600…1400 Hp at 690VAC Right Side Front Dimensions of terminals U, V and W are the same. Lifting flange Dimensions are shown in mm and (in.) 174 (6.9) 436.5 (17.2) 80.5 (3.2) 359 (14.1) 704 (27.7) 544 (21.4) 25 (1.0) 15 (0.6) 44.5 (1.8) 60 (2.4) 30 (1.2) 42 (1.7) 792 (31.2) 1250 (49.2) 208 (8.2) 144 (5.7) 157.5 (6.2) 44.5 25 (1.8) (1.0) 15 (0.6) 30 146 60 (1.
PAGE 53
Drive Comparisons Chapter 1 Figure 18 - PowerFlex DC Frame D Dimensions are shown in mm and (in.) Left Side Back 94 (3.7) 103.25 (4.1) Lifting flange 127 (5.0) Ø 23 (0.9) 129 (5.1) 127 (5.0) 127 (5.0) 127 (5.0) 94 (3.7) 127 (5.0) 94 (3.7) 10.5 (0.4) 16 (0.6) 227.5 (9.0) Mounting holes 1435 MAX (56.5) 1230 (48.4) Mounting holes 157.5 (6.2) 129 (5.1) 215.225 (8.5) 531 (21.0) 10 (0.4) 10.5 (0.4) 94 (3.7) 127 (5.0) 127 (5.0) 127 (5.0) 541 (21.
PAGE 54
Chapter 1 Drive Comparisons Power Comparisons 1395 Power Connections - Standard Field Voltage ATTENTION: The motor field supply is phase sensitive. To guard against possible drive/motor damage, assure that the connections are properly made according to Figure 19, Figure 20 on page 55, Figure 21 on page 55, and Figure 22 on page 56.
PAGE 55
Drive Comparisons Chapter 1 Figure 20 - 1395 - 40…100 Hp, 230VAC / 75…200 Hp, 460VAC Series A F+ FDC motor shunt field* 1 Top view of drive 2 3 4 5 6 7 8 9 10 (Spare) TB2 TE PE F7 1 2 TB1 F4 DC contactor F8 L1 3 4 F5 5 A1 A2 Fuses L2 F6 L1 L2 L3 A1+ M A2 DC motor armature *Typical motor connection. Refer to motor data for specific motor connections.
PAGE 56
Chapter 1 Drive Comparisons 1395 External Field Transformer Connections Figure 22 - 1395 - All Drives TB1 (1) L1 Series B FU 1...30 Hp, 230 VAC 2...60 Hp, 460 VAC (1) FU Sized to load L3 1 Field transformer secondary 460V 230V 2 3 4 TB1 (2) 25 A Series A 1 (1) L1 FU 2 230V (1) 40...100 Hp, 230 VAC 75...200 Hp, 460 VAC L3 Field transformer secondary 460V 3 FU 4 (2) Sized to load 25 A 5 TB8 (1) L1 MKVA Series B 125...300 Hp, 230 VAC 250...
PAGE 57
Drive Comparisons Chapter 1 1397 AC Input Line Connections ATTENTION: If the AC input power system does not have a neutral or one phase referenced ground, an isolation transformer with the neutral of the secondary grounded is highly recommended. If the line-to-line voltages on any phase can exceed 125% of the nominal line-to-line voltage, an isolation transformer with the neutral of the secondary grounded, is always required.
PAGE 58
Chapter 1 Drive Comparisons Figure 24 - 1397 - 40…75 Hp at 230 VAC, 75…150 Hp at 460 VAC, 265 A at 380/415 VAC 45 Front view of drive without disconnect A1 GRD Blower motor (11FU) arm.
PAGE 59
Drive Comparisons Chapter 1 Figure 25 - 1397 - 100…150 Hp at 230 VAC, 200…300 Hp at 460 VAC Shown without AC line disconnect AC line connections Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 59
PAGE 60
Chapter 1 Drive Comparisons Figure 26 - 1397 - 400…600 Hp at 460 VAC AC line connections 81 82 83 AC line connections 181 182 183 1FU 2FU 3FU 1FU 2FU 3FU 281 282 283 281 282 283 Blower motor starter kits Without AC line disconnect 60 Blower motor starter kits With AC line disconnect Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012
PAGE 61
Drive Comparisons Chapter 1 1397 Field and Motor Armature Connections Figure 27 - 1397 - 1.
PAGE 62
Chapter 1 Drive Comparisons Figure 28 - 1397 - 40…75 Hp at 230 VAC, 75…150 Hp at 460 VAC, 265 A at 380/415 VAC DC motor armature connections 45 A1 Ground point GRD (11FU) arm.
PAGE 63
Drive Comparisons Chapter 1 Figure 29 - 1397 - 100…150 Hp at 230 VAC, 200…300 Hp at 460 VAC 45 A1 DC motor armature connections Side View Front View 1 2 3 4 F1 F2 DB connections for optional kit only DC motor field connections Top View Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 63
PAGE 64
Chapter 1 Drive Comparisons Figure 30 - 1397 - 400…600 Hp at 460 VAC A1 S2 DBR A2/S1 Removable link 64 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012
PAGE 65
Drive Comparisons Chapter 1 FlexPak 3000 AC Input Line Connections Figure 31 - FlexPak 3000 - 1.
PAGE 66
Chapter 1 Drive Comparisons Figure 33 - FlexPak 3000 - 100…150 Hp at 230 VAC, 200…300 Hp at 460 VAC AC line Connections 81 A1 A1 45 45 AC line Connections 181/ L1 182/ L2 Drive without optional AC line disconnect 66 183/ L3 Drive with optional AC line disconnect Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 82 83
PAGE 67
Drive Comparisons Chapter 1 Figure 34 - FlexPak 3000 - 400…600 Hp at 460 VAC AC line Connections 81 82 83 AC line Connections 181 182 Drive without optional AC line disconnect 183 Drive with optional AC line disconnect Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 67
PAGE 68
Chapter 1 Drive Comparisons FlexPak 3000 DC Motor Field and Armature Connections Figure 35 - FlexPak 3000 - 1.
PAGE 69
Drive Comparisons Chapter 1 Figure 36 - FlexPak 3000 - 4…75 Hp at 230 VAC, 75…150 Hp at 460 VAC, 265 A at 380/415 VAC 1 2 3 4 F1 F2 Dynamic braking DC motor field connections connections DC motor armature connections 45 A1 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 69
PAGE 70
Chapter 1 Drive Comparisons Figure 37 - FlexPak 3000 (S6) - 100…150 Hp at 230 VAC, 200…300 Hp at 460 VAC DC motor armature connections A1 See Detail A 45 A1 45 Top View Detail A 1 2 3 4 F1 F2 Dynamic braking DC motor field connections for connections optional kit only 70 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012
PAGE 71
Drive Comparisons Chapter 1 Figure 38 - FlexPak 3000 (S6R) - 100…150 Hp at 230 VAC, 200…300 Hp at 460 VAC 45 A1 DC motor armature connections See Detail A 45 A1 Top View Detail A 1 2 3 4 F1 F2 Dynamic braking DC motor field connections for connections optional kit only Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 71
PAGE 72
Chapter 1 Drive Comparisons Figure 39 - 400…600 Hp at 460 VAC A1 S2 DBR A1 A2/S1 S2 DBR See Detail A See Detail A Top View Detail A 1 2 3 4 F1 F2 DC motor field connections 72 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 A2/S1
PAGE 73
Drive Comparisons Chapter 1 PowerFlex 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 mu
PAGE 74
Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 FU FU FU These connections must be taken from the primary side of the Isolation Transformer or Line Reactor (clean power). AC Input 230V Voltage AC Input 115V Voltage or (1) 230V FU Safety Ground AC Input Voltage Isolation (2) (2) Transformer Line Reactor T1 T2 T3 A2 L2 L3 A1 Aux 14 L1 13 460 VAC Max. or 230 VAC (10) Min.
PAGE 75
Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 FU FU FU AC Input 230V Voltage AC Input 115V Voltage or (1) 230V FU These connections must be taken from the primary side of the Isolation Transformer or Line Reactor (clean power). Safety Ground Isolation (2) (2) Transformer Line Reactor AC Input Voltage FS1 (3) FS1 (3) (3) FS1 460 VAC Max. or 230 VAC (9) Min.
PAGE 76
Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 FU FU FU AC Input 230V Voltage AC Input 115V Voltage or (1) 230V FU These connections must be taken from the primary side of the Isolation Transformer or Line Reactor (clean power). Safety Ground Isolation (2) (2) Transformer Line Reactor AC Input Voltage (3) FS1 FS1 (3) FS1 (3) 460 VAC Max. or 230 VAC (10) Min.
PAGE 77
Drive Comparisons Chapter 1 PowerFlex DC - Armature Power Connections Terminals Description U, V, W Three phase AC input to the armature converter C, D DC output to the motor armature PE Safety ground PowerFlex DC Armature Power Terminal and Ground (PE) Wire Sizes Frame A B Drive Current Rating Code(1) 230V 460V 575 690 7P0…055 4P1…052 – – 073…110 073…129 – – All All – – Terminals Wire Size and Type U, V, W, C, D, PE See “Cable and Wiring Recommendations” in the PowerFlex Dig
PAGE 78
Chapter 1 Drive Comparisons Figure 44 - PowerFlex DC - Frame B Armature Terminal Block Locations Front View U PE U C V C V D D Shown with lower protective cover removed.
PAGE 79
Drive Comparisons Chapter 1 Figure 45 - PowerFlex DC - Frame C Armature Terminal Block Locations Front View PORT MOD NET A NET B STS FU1 FV1 D C U PE U V C V W D W Shown with lower protective cover removed.
PAGE 80
Chapter 1 Drive Comparisons Figure 46 - PowerFlex DC - Frame D Armature Terminals Locations Front View U V W IMPORTANT: Certain frame D drives require the use of terminal adapter kits for terminals U, V, W, C, and D. Refer to Frame D Terminal Adapter Kits on page 161 for details.
PAGE 81
Drive Comparisons Chapter 1 PowerFlex DC - 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 not 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.
PAGE 82
Chapter 1 Drive Comparisons Figure 47 - PowerFlex DC - Frame A Armature 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. Figure 48 - PowerFlex DC - Frame B Armature Voltage Feedback Circuit Terminal Block Location Top of Drive Shown with terminals jumpered for internal armature voltage feedback.
PAGE 83
Drive Comparisons Chapter 1 Figure 49 - PowerFlex DC - Frame C Armature Voltage Feedback Circuit Terminal Block Location 1A1(C) A1 1A2 (D) A2 1A1(C) A1 1A2 (D) A2 1A1(C) A1 1A2 (D) A2 1A1(C) A1 1A2 (D) A2 Bottom of Drive Figure 50 - PowerFlex DC - Frame D Armature Voltage Feedback Circuit Terminal Block Location Shown with terminals jumpered for internal armature voltage feedback.
PAGE 84
Chapter 1 Drive Comparisons PowerFlex DC 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.
PAGE 85
Drive Comparisons Chapter 1 Figure 51 - PowerFlex DC - Frame A Field Circuit Terminal Block Location U1 V1 C1 D1 Bottom View of Drive Figure 52 - PowerFlex DC - Frame B Field Circuit Terminal Block Location U1 V 1C 1D 1 Top View of Drive Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 85
PAGE 86
Chapter 1 Drive Comparisons Figure 53 - PowerFlex DC - Frame C Field Circuit Terminal Block Location Front View of Drive D1 C1 U1 V1 86 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012
PAGE 87
Drive Comparisons Chapter 1 Figure 54 - PowerFlex DC - 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 PowerFlex DC Control Circuit Power Connections The control circuit must be powered by an external 230V AC or 115V AC single phase power supply.
PAGE 88
Chapter 1 Drive Comparisons Control Circuit Wire Sizes Terminals U2, V2 PE Wire Size and Type(1) Multi-core AWG Flexible (mm2) (mm2) 0.14…1.5 0.14…2.5 26…14 2.5…10 2.5…10 12…8 Tightening Torque N•m (lb•in) 0.5 (4.4) 2.0 (18.0) (1) See “Cable and Wiring Recommendations” in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for cable spacing information.
PAGE 89
Drive Comparisons Chapter 1 Figure 57 - PowerFlex DC - Frame C Control Circuit Terminal Block Location U2 V2 Figure 58 - PowerFlex DC - Frame D Control Circuit Terminal Block Location U2 V2 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 89
PAGE 90
Chapter 1 Drive Comparisons Figure 59 - PowerFlex DC - Frame B drives SA-SB Terminal Block Location SA-SB terminals Top of drive Front of drive Figure 60 - PowerFlex DC - Frame C Drives SA-SB Terminal Block Location Switching Power Supply board (located on the back of the Control EMI shield) 90 SA-SB terminals Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 Control EMI Shield (Shown in the open position)
PAGE 91
Drive Comparisons Chapter 1 PowerFlex DC 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). See PowerFlex DC Drive Typical Power Wiring Diagrams on page 74. In addition, the fan power input terminals U3 and V3 are required to be short circuit protected.
PAGE 92
Chapter 1 Drive Comparisons PowerFlex DC Frame D Heatsink Cooling Fans 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). See PowerFlex DC Drive Typical Power Wiring Diagrams on page 74. The fan power input terminals U3 and V3 are required to be short circuit protected.
PAGE 93
Drive Comparisons Chapter 1 PowerFlex DC 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 133…144).
PAGE 94
Chapter 1 Drive Comparisons Figure 64 - Frame D Internal Armature Fuse Signal Terminal Block Location 81 Control and Feedback Comparisons 82 Bulletin 1395 Digital DC Drive Input and output signals can be 24V DC, but require a separate 24V DC power supply in addition to basic 115V AC control circuit requirement. All control wiring to external devices except for contactor control is terminated in the drive at terminal block TB3.
PAGE 95
Drive Comparisons Chapter 1 Figure 65 - 1395 - TB3 Terminal Descriptions TB3 Encoder Channel A ENCA1 20 Channel A 19 Channel B 18 Channel B 17 ENCA1 Main Control Board ENCB1 ENCB1 16 15 + Supply Voltage 14 - Supply Voltage 13 ENCPWR +12V ENCGND 12V –24V OUT 12 +24V OUT 11 24V DC E-Coast –24V ECOAST 10 +24V ECOAST 9 FLT 2 8 Closed when the drive is not faulted Drive FLT Output FLT 1 7 115V AC Common 115V COMMON OUT 6 115V ECOAST2 5 115V AC E-Coast 24V DC or 115V AC Voltage
PAGE 96
Chapter 1 Drive Comparisons 1395 Discrete Adapter Board External wiring is connected to the terminal block at the bottom of the 1395 drive enclosure. Terminals 23 through 52 are reserved for wiring the Discrete Adapter board to external I/O devices. See the 1395 Digital DC Drive, User Manual, publication 1395-UM003, or Bulletin 1395 Discrete Adapter Board Installation and Operation Manual, publication 1395-IN001, for more details.
PAGE 97
Drive Comparisons Chapter 1 Figure 67 - 1395 Discrete Adapter Block Diagram TB3 Terminal Block Numbers Digital Inputs Digital Input Common 47 Bit # Specifier Digital Input #1 48 PB/PA 533/583 Digital Input #2 49 534/584 Digital Input #3 50 535/585 Digital Input #4 51 356/586 Analog Input #4 Analog Input #3 Analog Input #2 Analog Input #1 + 30 – 29 + 28 – 27 + 26 – 25 + 24 – 23 PB/PA 300/400 PB/PA 500/550 501/551 ADC1 Scale Offset PB/PA 502/552 503/553 ADC2 Scale Offs
PAGE 98
Chapter 1 Drive Comparisons 1395 Digital Reference Adapter Board External wiring is connected to the terminal block at the bottom of the 1395 enclosure. Terminals 23 through 62 are reserved for wiring the Digital Reference Adapter Board to external I/O devices. See the 1395 Digital DC Drive, User Manual, publication 1395-UM003, or Bulletin 1395 Digital Reference Adapter Board Hardware/Software Reference Manual, publication 1395-RM001, for more details.
PAGE 99
Drive Comparisons Chapter 1 Figure 69 - 1395 Digital Reference Adapter Board Block Diagram TB3 Terminal Block Numbers Digital Inputs Digital Input Common 53 Bit # Select Digital Input #1 43 583 Digital Input #2 44 584 Digital Input #3 45 585 Digital Input #4 46 586 Digital Input #5 47 587 Digital Input #6 48 588 Digital Input #7 49 589 Digital Input #8 50 590 Digital Input #9 51 591 Digital Input #10 52 592 + 31 – 32 + 33 – 34 Encoder In Ch B 26 Ch B 25 Encod
PAGE 100
Chapter 1 Drive Comparisons 1395 Encoder Driver Interface Module The Encoder Driver Interface module is a multi-purpose pulse amplifier primarily used for generating 15 mA, double-ended, sink and source output signals. These signals are acceptable as inputs to digital reference and/or digital feedbacks into opto-isolated circuits of Bulletin 1395, 1336 PLUS, 1336 FORCE and 1399 drives.
PAGE 101
Drive Comparisons Chapter 1 Bulletin 1397 Digital DC Drive Most control connections on the 1397 drive are made at the Regulator board terminal strip which is located at the bottom of the drive as shown here. See the Bulletin 1397 DC Drive Firmware 2.xx User Manual, publication 1397-UM000, for more details.
PAGE 102
Chapter 1 Drive Comparisons Figure 71 - 1397 Regulator Board Terminal Strip Inputs 102 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012
PAGE 103
Drive Comparisons Chapter 1 1397 - 115VAC Control Interface Card The 115V AC Control Interface card is a remote mounted option that provides a means of interfacing signals and commands to the 1397 drive using 115V AC signals. A 115V AC power source must be supplied by the user for the card to operate. See the 115V AC Control Interface Card Installation Instructions, publication 1397-IN007, for more details.
PAGE 104
Chapter 1 Drive Comparisons 1397 I/O Expansion Card The I/O Expansion card is a drive mounted board that provides additional I/O signals, including five digital inputs, two digital outputs, 2 analog inputs, 2 analog outputs, one frequency input, and one frequency output. See the 1397–L11 I/O Expansion Card Installation Instructions, publication 1397-IN008, for more details.
PAGE 105
Drive Comparisons Chapter 1 Figure 75 - I/O Expansion Card Digital Output Terminal Block Figure 76 - I/O Expansion Card Analog Input Terminal Block Figure 77 - I/O Expansion Card Analog Output Terminal Block Figure 78 - I/O Expansion Card Frequency Input Terminal Block Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 105
PAGE 106
Chapter 1 Drive Comparisons Figure 79 - I/O Expansion Card Frequency Output Terminal Block 1397 AC Tachometer Interface Card The AC Tachometer Interface card is designed for use with the following Reliance Electric tachometers; RE-045F, RE-045R, or RE-050. IMPORTANT The card provides feedback signals for non-regenerative 1397 drives and cannot be used in conjunction with the Pulse Encoder Interface card.
PAGE 107
Drive Comparisons Chapter 1 1397 Pulse Encoder Interface Card The Pulse Encoder Interface card is a drive mounted board that provides terminals and an interface to differential encoder feedback signals for both regenerative and non-regenerative 1397 drives. For additional information on encoder signal requirements, wire recommendations, encoder parameters and related function blocks, see the Bulletin 1397 DC Drive Firmware 2.
PAGE 108
Chapter 1 Drive Comparisons FlexPak 3000 DC Drive Figure 83 - Regulator Board Terminal Strip Location Shown with Standard Cover Removed RS-232 Connector Terminal Strip 108 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012
PAGE 109
Drive Comparisons Chapter 1 Figure 84 - Regulator Board Terminal Strip Wiring Diagram Optional Jog Selector Switch 1 Start 2 Run 2 Stop 3 Run 4 Jog Run Jog Jog 3 () = Terminal Number Start/Stop by User Contact (1) (2) (1) (3) (4) (2) Rev (5) (3) Fwd Auto Man (7) (6) (7) (8) (8) [2] [1] (9) 1 (9) (10) (10) (11) (11) Optional Jog with Maintained Contact Stop/Stop 4 +24V Run Stop (24) (25) Jog Reverse/Forward Auto/Man (26) (28) (29) Customer Interlock (30) +24V Motor Th
PAGE 110
Chapter 1 Drive Comparisons Table 12 - User Device Connections to the Regulator Board Terminal Strip User Device Regulator Board Terminal Number Run 1 (+24V), 2 Stop 1 (+24V), 3 Jog 1 (+24V), 4 Reverse/Forward 1 (+24V), 5 Auto/Manual 1 (+24V), 6 Interlock 9, 11 (+24V) Fault/Alarm Reset 10, 11 (+24V) Digital Input 0 12, 11 (+24V) Motor Thermostat 13, 11 (+24V) Speed Reference Potentiometer • High Side (+10 ISOL) • Wiper (+ Man. Ref.) • Low Side (– Man. Ref.
PAGE 111
Drive Comparisons Chapter 1 Flexpak 3000 115V AC Control Option Board See the Installing the 115V AC Control Option Board Installation Instructions, publication GV3000-IN004, for more details.
PAGE 112
Chapter 1 Drive Comparisons Table 13 - Control Option Board Wiring to a FlexPak 3000 Drive Control Option Board Control Device AC Input Terminal DC Output Terminal FlexPak 3000 Regulator Board Terminal Run 2 (IN1) 1 2 Stop 3 (IN2) 2 3 Jog 4 (IN3) 3 4 Reverse/Forward 5 (IN4) 4 5 Auto/Manual 6 (IN5) 5 6 Coast/Stop 8 (IN6) 6 8 Interlock 9 (IN7) 7 9 Fault/Alarm Reset 10 (IN8) 8 10 Brush Wear 12 (IN9) 9 12 Motor Thermostat 13 (IN10) 10 13 11 (+V) 1, 7, 11, or 14 12
PAGE 113
Drive Comparisons Chapter 1 FlexPak 3000 I/O Expansion Kit This kit provides additional input/output capabilities for FlexPak 3000 drives, including five digital inputs, two digital outputs, two analog inputs, two analog outputs, one frequency input, and one frequency output. See the FlexPak 3000 Drive I/O Expansion Kit Installation Instructions, publication FP3-IN007, for more details.
PAGE 114
Chapter 1 Drive Comparisons Figure 87 - I/O Expansion Kit Jumper Settings Figure 88 - I/O Expansion Kit Terminal Block Designations 114 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012
PAGE 115
Drive Comparisons Chapter 1 FlexPak 3000 AC Tachometer Interface Kit See the FlexPak 3000 Drive AC Tachometer Interface Kit Installation Instructions, publication FP3-IN003, for more details. Figure 89 - FlexPak 3000 Regulator Board Jumper Locations Note: See Table 14 below for jumper J11 and J14 settings.
PAGE 116
Chapter 1 Drive Comparisons Figure 90 - AC Tachometer Interface Kit Terminal Block Locations AC Tachometer Interface Board Output leads from the AC tachometer Orange and black output leads to the Regulator board terminals The orange and black wires from the AC Tachometer Interface board are connected to the terminals on the drive’s Regulator board. See Figure 83 on page 108 for the Regulator board terminal strip locations and Figure 84 on page 109 for terminal strip descriptions.
PAGE 117
Drive Comparisons Chapter 1 FlexPak 3000 Pulse Encoder Interface Kit See the FlexPak 3000 Pulse Encoder Interface Kit Installation Instructions, publication FP3-IN008, for details. ATTENTION: Do not route pulse encoder wiring with AC and DC power or logic control wiring in the same conduit. This may cause interference with drive operation. Failure to observe this precaution could result in damage to or destructions of the equipment. ATTENTION: Do not ground any pulse encoder wiring connection.
PAGE 118
Chapter 1 Drive Comparisons PowerFlex DC Drive PowerFlex DC 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.
PAGE 119
Drive Comparisons Chapter 1 Table 18 - I/O Terminal Block 2 Designations No.
PAGE 120
Chapter 1 Drive Comparisons Table 21 - Recommended Signal Wire Size for Analog I/O and Digital I/O Signal Type Terminal Block (Terminals) Analog and Digital I/O Wire Size and Type(1) Flexible (mm2) Multi-core (mm2) TB1…4 (1…40) 0.140…1.500 0.140…1.500 AWG 26…16 Tightening Torque N•m (lb•in) 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.
PAGE 121
Drive Comparisons Chapter 1 Table 23 - Sample Encoder Wiring I/O Connection Example (1) Encoder Power – Internal Drive Power Internal (drive) +5/12-15V DC, 200 mA +V COM +5/12-15V DC (200 mA) Common ZZ+ to Shield (1) BB+ AA+ Encoder Power –External Power Source +V Z+ BB+ + Z- Common COM to Shield (1) External Power Supply AA+ Encoder Signal –Single-Ended, Dual Channel +V to Power Supply Common COM Z- Z NOT Z Z+ B- B NOT B B+ A- A NOT A A+ to Shield (1) Encoder Signal –Different
PAGE 122
Chapter 1 Drive Comparisons PowerFlex DC 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 observe this precaution could result in damage to, or destruction of, the equipment. Table 24 - DC Analog Tachometer Terminal Designations − A B C No. – A B C + + Signal Negative input (Not Used) Description – Positive input 22.7 / 45.4 / 90.7 / 181.6 / 302.
PAGE 123
Drive Comparisons Chapter 1 Resolver Type Selection The following table provides a description and related attributes for the resolver types compatible with the PowerFlex DC drive and resolver feedback module. Where possible, specific compatible resolver models have been identified. Additional options are available for this parameter when a resolver with matching attributes is used (identified by the option “Resolver xx”).
PAGE 124
Chapter 1 Drive Comparisons PowerFlex DC Analog and Digital I/O Expansion Circuit Board The I/O expansion board is a drive mounted option module that provides these additional I/O signals. • Four Digital Inputs • Four Digital Outputs • Two Analog Outputs Table 27 - Recommended Signal Wire Size Wire Type and Size Tightening Torque N•m (lb•in) 2 2 Flexible (mm ) multi-core (mm ) AWG 0.14…1.5 0.14…1.5 28…16 0.4 (3.5) A 75 x 2.5 x 0.4 mm (3.0 x 0.1 x 0.02 in.
PAGE 125
Drive Comparisons Chapter 1 Figure 95 - I/O Expansion Board Wiring Diagram 1 4 2 3 5 4 5 6 6 7 7 8 8 9 9 10 11 12 19 11 10 12 13 14 0 V 24 3 Digital Inputs Digital Outputs + 24 V Analog Outputs Supply I/O Expansion Board Control Board 18 15 + 24 V 0V PowerFlex DC 115V AC to 24V DC I/O Converter Circuit Board The 115V AC to 24V DC I/O converter board allows you to convert 115V AC digital input signals to 24V DC digital input signals to interface with the standard digital
PAGE 126
Chapter 1 Drive Comparisons Figure 96 - I/O Converter Board M_IN Terminal Block Designations 1 2 3 4 5 6 7 8C OM No. Signal Description 1 Digital Input 1 2 Digital Input 2 3 Digital Input 3 Rated input voltage:115V AC ±10% 50 60Hz. ON input voltage: 115V AC ±10% OFF input voltage: 0 - 70V AC ON input current: 4 - 5.
PAGE 127
Drive Comparisons Chapter 1 115V AC to 24V DC I/O Board Main Control Board Figure 97 - I/O Converter Board with Internal Supply OPTO OPTO 15k 15k DC OUTPUT 24V 1 2 3 4 5 AC INPUT 6 7 8 0V 1 2 3 4 5 6 7 8 COM M_OUT M_IN To Digital Inputs (Terminals 12-15, 31-34) on Control Board To Drive Supplied +24V DC (Terminal 19) on Control Board To Digital Input Common (Terminal 16 or 35) and 24V Supply Common (Terminal 18) on Control Board External 115V AC Internal Wiring Customer Wiring
PAGE 128
Chapter 1 Drive Comparisons Installation Considerations for PowerFlex DC Drives 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.
PAGE 129
Drive Comparisons Chapter 1 PowerFlex DC 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. PowerFlex DC User-installed Options The options listed below cannot be ordered via the drive catalog number and must be ordered separately.
PAGE 130
Chapter 1 Drive Comparisons I/O Option Kit Description Cat. No. I/O Expansion board 20P-S5V62 115V AC to 24V DC 8 Channel I/O Converter Board 20P-S520L Feedback Option Kit Description Cat. No. Resolver Feedback Option Module 20P-RES-A0 Communication Option Kits Description Cat. No.
PAGE 131
Drive Comparisons Chapter 1 Grounding PowerFlex DC Drives The drive Safety Ground - PE must be connected to system ground. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked. For installations within a cabinet, a single safety ground point or ground bus bar connected directly to building steel should be used.
PAGE 132
Chapter 1 Drive Comparisons Safety Ground (PE) This is the safety ground for the drive that is required by code. This point must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar (see above). Grounding points must comply with national and local industrial safety regulations and/or electrical codes. Power Feeder Each power feeder from the substation transformer to the drive must be provided with properly sized ground cables.
PAGE 133
Drive Comparisons Three Phase Primary Voltage Three Phase Secondary Voltage kVA kW (Hp) 230V AC Cat. No. 14 7.5 (10) 20 27 34 40 51 63 75 93 118 145 175 220 11 (15) 15 (20) 18.5 (25) 22 (30) 30 (40) 37 (50) 45 (60) 56 (75) 75 (100) 93 (125) 112 (150) 145 (200) Voltage 460V AC Cat. No. Chapter 1 575V AC Cat. No.
PAGE 134
Chapter 1 Drive Comparisons Three Phase Primary Voltage Three Phase Secondary Voltage kVA kW (Hp) 230V AC Cat. No. 275 187 (250) 330 440 550 660 770 880 134 224 (300) 298 (400) 373 (500) 448 (600) 522 (700) 597 (800) Voltage 460V AC Cat. No. 575V AC Cat. No.
PAGE 135
Drive Comparisons Chapter 1 AC Input Line Reactors and Contactors If a DC output contactor is used, an AC input contactor is not needed. Table 32 - 230V AC Input Drives Regenerative Drive Cat. No. DC Amps AC Line Amps Hp IP00 (Open Style) Line Reactor Cat No. Line Reactor kW (Hp) AC Input Contactor Cat. No. 20P41AB7P0 7 5.7 1.5 1321-3R8-A .75 (1) 100-C12D10 20P41AB9P0 9 7.4 2 1321-3R12-A 1.49 (2) 100-C12D10 20P41AB012 12 9.8 3 1321-3R18-A 0.75…3.
PAGE 136
Chapter 1 Drive Comparisons NonRegenerative Drive Cat. No. Regenerative Drive Cat. No. DC Amps AC Line Amps Hp IP00 (Open Style) Line Reactor Line Reactor Cat No. kW (Hp) 20P21AD019 20P41AD019 19 15.5 10 1321-3R18-B 1.5…7.5 (2…10) 100-C23D10 20P21AD027 20P41AD027 27 22.1 15 1321-3R55-B 11…22 (15…30) 100-C23D10 20P21AD035 20P41AD035 35 28.6 20 1321-3R55-B 11…22 (15…30) 100-C30D10 20P21AD045 20P41AD045 45 36.
PAGE 137
Drive Comparisons Chapter 1 Table 34 - 575V AC Input Drives NonRegenerative Drive Cat. No. Regenerative Drive Cat. No. DC Amps AC Line Amps Hp IP00 (Open Style) Line Reactor Line Reactor Cat No. kW (Hp) AC Input Contactor Cat. No. 20P21AE067 20P41AE067 67.5 55.1 50 1321-3R55-B 37 (50) 100-C60D10 20P21AE101 20P41AE101 101.25 82.7 75 1321-3R100-B 56 (75) 100-C85D10 20P21AE135 20P41AE135 135 110.3 100 1321-3R130-B 75 (100) 100-D110D11 20P21AE270 20P41AE270 270 220.
PAGE 138
Chapter 1 Drive Comparisons EMC Filters PowerFlex DC drives require the use of an external EMC filter in order to comply with the EMC directive (2004/109/EC) and emission limits of EN 61800-3: 2004.
PAGE 139
Drive Comparisons Chapter 1 PowerFlex DC Drives Circuit Protection Drive Power 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 146 for frames C and D fuse information.
PAGE 140
Chapter 1 Drive Comparisons 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 Figure 100 on page 139.
PAGE 141
Drive Comparisons Chapter 1 Table 37 - 460V AC Input Drives Frame Drive Current Rating Code A B DC Amps AC Line Amps Bussmann 4P1 4.1 3.3 FWP-10A14F 6P0 6 4.9 010 10 014 019 Ferrule FWP Type Ferraz Shawmut (Gould Shawmut) Ferrule Fuse Block North American FWP Type North American Fuse Block CH143D FWP-10B – A70QS10-14F A70P10-4 FWP-10A14F FWP-10B – A70QS10-14F A70P10-4 8.2 FWP-20A14F FWP-20B – A70QS20-14F A70P25-4 14 11.
PAGE 142
Chapter 1 Drive Comparisons 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 Figure 100 on page 139.
PAGE 143
Drive Comparisons Chapter 1 Table 40 - 460V AC Input Drives Frame Drive Current Rating Code DC Amps AC Bussmann Line Amps Ferrule FWP Type Ferrule Fuse Block North American FWP Type North American Fuse Block Ferrule A70QS Type North American A70P / A70QS Type A 4P1 4.1 3.3 FWP-10A14F CH142D FWP-10B – A70QS10-14F A70P10-4 6P0 6 4.9 FWP-15A14F FWP-15B – A70QS16-14F A70P15-4 010 10 8.2 FWP-20A14F FWP-20B – A70QS20-14F A70P20-4 B Ferraz Shawmut (Gould Shawmut) 014 14 11.
PAGE 144
Chapter 1 Drive Comparisons 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 139. Also, see Frame A Field AC Input Line Fuses Location on page 145 and Frame B Field AC Input Line Fuses Location on page 146 for fuse locations.
PAGE 145
Drive Comparisons Chapter 1 Frame Drive Current Rating Code Field Amps Type Quantity Bussmann Ferraz Shawmut (Gould Shawmut) SIBA B 167 20 10 x 38 mm 2 FWC-25A10F A60Q25-2 60 033 05.25 207 250 330 412 Table 44 - 575V AC Input Drives Frame Drive Current Rating Code Field Amps Quantity Type Bussmann Ferraz Shawmut (Gould Shawmut) SIBA B 067 20 2 10 x 38 mm FWC-25A10F A60Q25-2 60 033 05.
PAGE 146
Chapter 1 Drive Comparisons Figure 102 - 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.
PAGE 147
Drive Comparisons Chapter 1 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 146. Also, see Frame C Field Circuit Fuse Location on page 148 and Frame D Field Circuit Fuse Location on page 149 for locations.
PAGE 148
Chapter 1 Drive Comparisons Table 48 - 690V AC Input Drives Frame C Drive Current Rating Code Field Amps Type Qty Bussmann 452 20 10 x 38 mm 2 FWC-25A10F 565 D 678 Ferraz Shawmut (Gould Shawmut) SIBA A60Q25-2 6003305.25 A60Q25-8 40 22 x 58 mm FWP-50A22F A70QS50-22F 5014006.50 FWP-100A22F A70QS100-22F 5014006.
PAGE 149
Drive Comparisons Chapter 1 Figure 104 - Frame D Field Circuit Fuse Location Top, left side of drive control panel. 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 146. Also, see Frame C Regenerative Drive - Leg Fuse Location on page 151 and Frame D Regenerative Drive - Leg Fuse Location on page 151.
PAGE 150
Chapter 1 Drive Comparisons Table 52 - Recommended Leg Fuses - 460V AC Input Frame D Drives Frame Drive Current Rating Code DC Amp s AC Line Amps Qty Bussmann D Ferraz Shawmut (Gould Shawmut) SIBA Square Body - DIN 43653 Stud-Mount 830 830 678.1 6 170M6262 + switch 170H0069 X300262 + switch MS 3V 1-5 UR 20 635 32.800 + switch 28 001 04 996 996 813.7 6 170M6264 + switch 170H0069 Z300264 + switch MS 3V 1-5 UR 20 635 32.1000 + switch 28 001 04 1K1 1162 949.
PAGE 151
Drive Comparisons Chapter 1 Figure 105 - 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. Figure 106 - Frame D Regenerative Drive - Leg Fuse Location Note: Drive shown with Control EMI shield in open position.
PAGE 152
Chapter 1 Drive Comparisons Table 58 - Recommended Leg Fuses - 230V AC Input Frame D Drives Frame Drive Current Rating Code DC Amps AC Qty Bussmann Ferraz Shawmut (Gould Shawmut) Line Square Body - DIN 43653 Stud-Mount Amps SIBA D 875 875 715 6 170M6263 + switch 170H0069 Y300263 + switch MS 3V 1-5 UR 20 635 32.900 + switch 28 001 04 1K0 1050 858 6 170M6264 + switch 170H0069 Z300264 + switch MS 3V 1-5 UR 20 635 32.
PAGE 153
Drive Comparisons Chapter 1 Table 64 - Recommended Leg Fuses - 690V AC Input Frame D Drives Frame D Drive DC Current Amps Rating Code AC Line Amps Qty Bussmann Ferraz Shawmut (Gould Shawmut) SIBA Square Body - DIN 43653 Stud-Mount 678 678 553 6 170M6260 + switch 170H0069 V300260 + switch MS 3V 1-5 UR 20 635 32.630 + switch 28 001 04 791 791 645 6 170M6262 + switch 170H0069 X300262 + switch MS 3V 1-5 UR 20 635 32.
PAGE 154
Chapter 1 Drive Comparisons Control Power The following fuses are used to protect the Switching Power Supply circuit. IMPORTANT Verify the circuit board revision prior to ordering and installing fuses. Table 65 - Control Power Fuses Frame Circuit Board ID / Revision Designation Fuse (5 x 20 mm) A SW1-31 / H & below F1 1 A, 250V, slow SW1-31 / I & above F1 2.5 A, 250V, slow SW2-32 / H & below F1 3.15 A, 250V fast F2 2.5 A, 250V slow F1 2.
PAGE 155
Drive Comparisons Chapter 1 Figure 109 - 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) Figure 110 - 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.
PAGE 156
Chapter 1 Drive Comparisons Figure 111 - 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.
PAGE 157
Drive Comparisons Chapter 1 PowerFlex DC Drive Accessories Dynamic Brake Resistor Kits and DC Output Contactors See Alternate Dynamic Brake Resistor Kits and DC Output Contactors on page 159 for recommended alternate DC Output Contactors for 575V and 690V AC input drives, respectively. Table 66 - 230V AC Input Drives Frame Drive Current Rating Code DC Amps AC Line Amps A 7P0 7 5.7 1.5 1370-DBL62 9P0 9 7.4 2 012 12 9.
PAGE 158
Chapter 1 Drive Comparisons Table 67 - 460V AC Input Drives Frame Drive Current DC Rating Code Amps A B (1) (2) (3) (4) (5) 158 AC Line Amps Hp Dynamic Brake Resistor Kit Cat. No. Armature Voltage (Volts) DB Resistor Size (ohms) DB Resistor Size (Watts) Brake Amps Required DC Loop Contactor Cat. No.(3) DC Contactor Crimp Lugs Cat. No.(4) 4P1 4.1 3.3 2 1370-DBH63 500 81 255 6.17 1370-DC56 1370-LG40 6P0 6 4.9 3 1370-DBH64 500 62 245 8.06 1370-DC56 1370-LG40 010 10 8.
PAGE 159
Drive Comparisons Chapter 1 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 DC Contactor Rating A DC Armature DB Conductor Conductor Size (2) Size (3) AWG AWG Armature Conductor Crimp Lug Hole Size DB Conductor Crimp Lug Hole Size Lug Kit Catalog Number 4.
PAGE 160
Chapter 1 Drive Comparisons Frame Table 69 - 460V AC Input Drives Drive Current Rating Code DC Amps B 330 C D (1) (2) (3) (4) AC Line Amps Hp 330 269.6 200 412 412 336.6 495 495 667 667 Dynamic Brake Resistor Kit Cat. No. Armature Voltage (Volts) DB Resistor Size (ohms) 1370-DBH79 500 250 HUBBELL_Y95W808GB 404.4 300 544.9 400 (1) DC Loop Contactor Cat. No.(2) DB Resistor Size (Watts) Brake Amps Required 0.7 280 714.29 ABB_EHDB360C2P-1L2S ABB_EHDB360C-1L22SS 500 0.
PAGE 161
Drive Comparisons Chapter 1 Frame Table 71 - 690V AC Input Drives Drive Current Rating Code DC Amps C 452 D (1) (2) (3) (4) AC Line Amps Hp 452 369 400 565 565 462 678 678 791 Dynamic Brake Resistor Kit Cat. No. Armature Voltage (Volts) DB Resistor Size (ohms) (1) 700 500 554 791 904 DC Loop Contactor Cat. No.(2) DB Resistor Size (Watts) Brake Amps Required 1.03 – – SIEMENS-MFG_14-193-101-58-2 (Qty 2) SIEMENS-MFG_14-193-101-58-2 (Qty 1) 700 0.
PAGE 162
Chapter 1 Drive Comparisons PowerFlex DC Motor Overload Protection 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 drive’s 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).
PAGE 163
Drive Comparisons Chapter 1 Figure 112 - Frame A Contact Relay and Thermistor Terminal Block Locations Note: Terminals 78 and 79 shown with 1k ohm resistor in place of temperature sensor.
PAGE 164
Chapter 1 Drive Comparisons Figure 113 - Frame C Contact Relay and Thermistor Terminal Block Locations 35 36 75 76 78 79 Figure 114 - 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.
PAGE 165
Chapter 2 Wiring Examples Bulletin 1395 to PowerFlex DC Drive Comparison Topic Page Bulletin 1395 to PowerFlex DC Drive Comparison 165 Bulletin 1397 to PowerFlex DC Drive Comparison 165 FlexPak 3000 to PowerFlex DC Drive Comparison 173 See the Bulletin 1395 Digital DC Drive User Manual, publication 1395-UM003, the Bulletin 1395 Discrete Adapter Board Installation & Operation Manual, publication 1395-IN001, or the Bulletin 1395 Digital Reference Adapter Board, publication 1395-RM001 for more deta
PAGE 166
Analog Input 1 (+) -10 VDC +10 VDC 30 31 32 41 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 +24V ( User Supplied ) Neutral / Common Clear Fault Start Stop Digital Input 4 Not Used 51 52 Digital Input 3 Digital Input 2 50 Digital Input 1 49 Digital Input Common Digital Output 1 Digital Output 2 Not Used Analog Output 1 (Common) 48 47 46 • Scaling: 0 to +10 VDC = +/- 100% Base Speed 42 P551 [A>ADC Offset 1] = -5V P550 [A>ADC Scale 1] = 4 43 - Refer to the 139
PAGE 167
Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 +24V ( User Supplied ) Neutral / Common Clear Fault Start Stop • Scaling: +/- 10 VDC = +/- 100% Base Speed P551 [A>ADC Offset 1] = 0 P550 [A>ADC Scale 1] = 2 - Refer to the 1395 Discrete Adapter Board Installation & Operation Manual, Publication 1395-in001, Chapter 5: Start-Up, for more details on scaling examples.
PAGE 168
Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 +24V ( User Supplied ) Neutral / Common Run Reference Select B Start Run Reference Select A Stop Note: If Digital Input 2 & 4 are open, the drive uses P154 [Vel Ref Whole] as it’s speed reference.
PAGE 169
Wiring Examples Bulletin 1397 to PowerFlex DC Drive Comparison Chapter 2 See the 1397 D Drive User Manual, publication 1397-UM000, for more details. See the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for details on example wiring diagrams.
PAGE 170
Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 (2) RUN – Edge sensitive signal that initiates a Run command (0 1 = Run). If the Drive is Run, voltage may be applied to the armature causing the motor to reach the desired speed. The Run input is latched and therefore does not have to be maintained to keep the drive Running. (1) Require for initial startup and operational checks. Voltage must be present at these points during operation. In other words, these terminals must be made.
PAGE 171
Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 (2) RUN – Edge sensitive signal that initiates a Run command (0 1 = Run). If the Drive is Run, voltage may be applied to the armature causing the motor to reach the desired speed. (1) Require for initial startup and operational checks. Voltage must be present at these points during operation. In other words, these terminals must be made. If open, the drive will be ‘Not Ready’.
PAGE 172
Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 (2) RUN – Edge sensitive signal that initiates a Run command (0 1 = Run). If the Drive is Run, voltage may be applied to the armature causing the motor to reach the desired speed. (1) Require for initial startup and operational checks. Voltage must be present at these points during operation. In other words, these terminals must be made. If open, the drive will be ‘Not Ready’.
PAGE 173
Wiring Examples FlexPak 3000 to PowerFlex DC Drive Comparison Chapter 2 See the FlexPak 3000 Hardware Reference, Installation and Troubleshooting Manual, publication FP3-UM012, for more details. See the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for details on example wiring diagrams.
PAGE 174
Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 (2) RUN – Edge sensitive signal that initiates a Run command (0 1 = Run). If the Drive is Run, voltage may be applied to the armature causing the motor to reach the desired speed. The Run input is latched and therefore does not have to be maintained to keep the drive Running. (1) Require for initial startup and operational checks. Voltage must be present at these points during operation. In other words, these terminals must be made.
PAGE 175
Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 (2) RUN – Edge sensitive signal that initiates a Run command (0 1 = Run). If the Drive is Run, voltage may be applied to the armature causing the motor to reach the desired speed. (1) Require for initial startup and operational checks. Voltage must be present at these points during operation. In other words, these terminals must be made. If open, the drive will be ‘Not Ready’.
PAGE 176
Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 (2) RUN – Edge sensitive signal that initiates a Run command (0 1 = Run). If the Drive is Run, voltage may be applied to the armature causing the motor to reach the desired speed. (1) Require for initial startup and operational checks. Voltage must be present at these points during operation. In other words, these terminals must be made. If open, the drive will be ‘Not Ready’.
PAGE 177
Chapter 3 Network Communication Overview Topic Page Overview 177 Bulletin 1395 DC Drive Network Communication Options 177 Bulletin 1397 DC Drive Network Communication Options 179 FlexPak 3000 DC Drive Network Communication Options 180 PowerFlex DC Drive Network Communication Options 181 Logic Command and Status 182 Rockwell Automation Encompass Partner Migration Offerings 190 The process of migrating from a 1395, 1397, and FlexPak 3000 to a PowerFlex DC drive can vary significantly depen
PAGE 178
Chapter 3 Network Communication The 1395 Node Adapter Board Installation and Operation Manual, publication 1395-IN017, contains the information necessary to perform the following functions: • Install and set-up the Node Adapter board • Configure the drive for control by a PLC • Maintain and troubleshoot the board Multi-Communication Board The Multi-communication Adapter (MCA) board provides a sophisticated interface to an Allen-Bradley PLC and other equipment capable of communicating over serial communic
PAGE 179
Network Communication Bulletin 1397 DC Drive Network Communication Options Chapter 3 The 1397 drive uses the SCANPort communication protocol with the following network communication options: • Remote I/O (RIO) • RS-232/422/485, DF1 and DH485 Protocol • DeviceNet - 24 VDC • ControlNet • Ethernet/IP • Profibus DP (ProSoft) • Modbus Plus (ProSoft) • Modbus RTU (ProSoft) • Metasys N2 (ProSoft) • LonWorks (ProSoft) See Appendix D, Using SCANPort Capabilities, in the 1397 DC Drive User Manual, publication 1397
PAGE 180
Chapter 3 Network Communication FlexPak 3000 DC Drive Network Communication Options A DeviceNet Interface board, AutoMax Network Communication board, or ControlNet Network Communication board may be installed in the drive. See Chapter 10, Configuring a Network, in the The FlexPak 300 Digital DC Drive Software Reference Manual, publication FP3-UM013, for a description of the parameters used to configure for these networks.
PAGE 181
Network Communication PowerFlex DC Drive Network Communication Options Chapter 3 The PowerFlex DC drive supports the following network communication protocols: • BACnet MS/TP RS485 Communication Adapter: 20-COMM-B • ControlNet Communication Adapter (Coax): 20-COMM-C • DeviceNet Communication Adapter: 20-COMM-D • EtherNet/IP Communication Adapter: 20-COMM-E • HVAC Communication Adapter: 20-COMM-H • Interbus Communication Adapter: 20-COMM-I • PROFIBUS DP Communication Adapter: 20-COMM-P • ControlNet Commun
PAGE 182
Chapter 3 Network Communication Logic Command and Status Summaries of the Logic Command and Status words for each drive are included below. Bulletin 1395 DC Drive Parameter 150: Logic Command 1 [Logic Cmd 1] Internal units: None Programming Terminal units: Bit Field Description: This is a word of fast data used to control drive logic operation. The information is contained in binary (boolean) form. If a bit is set, the associated function is enabled, otherwise the function is disabled (inactive).
PAGE 183
Network Communication Chapter 3 Table 75 - Logic Command Word Bits 0, 1, 2 Bit 2 1 1 Definition Selected Parameters 0 0 0 External Speed Reference 154 0 0 1 Preset Speed 1 633 0 1 0 Preset Speed 2 634 0 1 1 Preset Speed 3 635 1 0 0 Preset Speed 4 636 1 0 1 Preset Speed 5 637 1 1 0 MOP Forward Speed MOP 1 1 1 MOP Reverse Speed MOP Table 76 - Logic Command Word Bits 6, 7 Bit 7 6 Definition Selected Parameters 0 0 MOP 1 Accel, Decel 641, 645 0 1 MOP 2 Ac
PAGE 184
Chapter 3 Network Communication Parameter 100: Logic Status [Logic Status] Internal Units: None Programming Terminal units: Bit Field Description: This is a word of status data that indicates conditions within the Drive in boolean logic. Where a bit is set to 1, the corresponding condition in the drive is true, otherwise the condition is false. The bits in the Logic Status word are defined as: Fault Field 0, 1 (Bits 0, 1): This 2-bit field denotes the fault status of the drive as follows: Flt. Fld.
PAGE 185
Network Communication Chapter 3 Bulletin 1397 DC Drive Logic Status Format Logic Command Format See Appendix D, Using SCANport Capabilities, of the 1397 DC Drive Firmware 2.xx User Manual, publication 1397-UM000. for more details. Rockwell Automation Publication XXXX-X.X.
PAGE 186
Chapter 3 Network Communication FlexPak 3000 DC Drive Logic Status Format 186 Name Description (Drive to PLC) Word 0 Drive Status Word 1 Indicates drive status Bit 00 Ready 0 = Not ready, 1 = Ready Bit 01 Running 0 = Stopped, 1 = Running Bit 02 Fault 0 = No Fault, 1 = Fault Bit 03 Jogging 0 = Not jogging, 1 = Jogging Bit 04 Actual direction 0 = Forward, 1 = Reverse Bit 05 Stopping 0 = Not stopping, 1 = Stopping Bit 06 Mode 0 = Manual, 1 = Auto Bit 07 At speed reference 0 = Not at refe
PAGE 187
Network Communication Chapter 3 Logic Command Format Name Description (PLC to Drive) Word 0 Drive Control Word This word consists of a set of bits written to by the PLC to control the state of the drive (only when CONTROL SOURCE SELECT = NETWORK). Bit 00 Run Starts the drive in run mode. A 0-to-1 transition causes the drive to start (if ready). Setting this bit to zero (0) does not stop the drive. Bit 01 Stop A value of 0 stops the drive. A value of 1 allows the drive to become ready.
PAGE 188
Chapter 3 Network Communication PowerFlex DC Drive Typical Programmable Controller Configurations If block transfers are programmed to continuously write information to the drive, care must be taken to properly format the block transfer. If attribute 10 is selected for the block transfer, values will be written only to RAM and will not be saved by the drive. This is the preferred attribute for continuous transfers.
PAGE 189
Network Communication Chapter 3 Figure 125 - Logic Status Word Logic Bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Status x Ready x x x x x x x x x x x x x x x Active Command Direction Actual Direction Accel Decel Alarm Fault At Speed Local Control (1) Reference Source Description 0 = Not Ready 1 = Ready 0 = Not Active 1 = Active 0 = Reverse 1 = Forward 0 = Reverse 1 = Forward 0 = Not Accelerating 1 = Accelerating 0 = Not Decelerating 1 = Decelerating 0 = No Alarm 1 = Alarm 0 = No Fault 1 = Fault 0
PAGE 190
Chapter 3 Network Communication Rockwell Automation Encompass Partner Migration Offerings The Rockwell Automation Encompass program creates a path for critical information exchange and improved product solutions by linking the technical and commercial resources of Rockwell Automation and the best suited Encompass partner. Encompass partners are companies that have a range of product capabilities which extend and enhance Rockwell Automation solutions.
PAGE 191
Network Communication Chapter 3 ProLinx 5210-DFNT-RIO • ProLinx 5210-DFNT-RIO from ProSoft Technologies • Stand-alone, DIN-rail mountable protocol gateway creates a powerful connection between devices on EtherNet/IP and Remote I/O networks • EtherNet/IP port supports Explicit Messaging and user-configurable as both a Client and a Server • Remote I/O port connects to a scanner (master) that controls the data transfer and supports limited high speed data transfer via the Input and Output images • Enables ea
PAGE 192
Chapter 3 Network Communication AN-X-DHP The AN-X Data Highway+ product line allows virtually transparent access from any Ethernet-enabled device to any Data Highway+ PLC or device Use the power of Ethernet connectivity to upgrade your Data Highway+ networks for programming/monitoring, HMI applications or remote network capture and diagnostics Website: http://www.qtsusa.com/dhp.
PAGE 193
PAGE 194
Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. At http://www.rockwellautomation.com/support, you can find technical manuals, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. You can also visit our Knowledgebase at http://www.rockwellautomation.