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PowerFlex 750-Series Products with TotalFORCE Control Installation Instructions

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PowerFlex 750-Series Products with TotalFORCE ControlCatalog Numbers 20G , 20JInstallation InstructionsOriginal InstructionsImportant User InformationRead this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibitedThroughout this manual, when necessary, we use notes to make you aware of safety considerations.Labels may also be on or inside the equipment to provide specific precautions. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.IMPORTANTIdentifies information that is critical for successful application and understanding of the product.SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).Rockwell Automation Publication 750-IN100A-EN-P - May 20173Table of ContentsPrefaceAdditional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Chapter 1Product OverviewGeneral Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Product Rating Cross-references. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Commonly Used Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Hardware Installation Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Fastener Torque Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Chapter 2Receiving, Handling, and StorageReceiving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Shipment Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Chapter 3Prepare for InstallationCE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Location Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Minimum Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Recommended Cabinet Mounting Hardware. . . . . . . . . . . . . . . . . . . . 39Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Installation Site Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Chapter 4Mechanical and Electrical InstallationPrepare Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Component Removal Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Remove Protective Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Remove Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Remove LCL Filter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Place the Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Join Enclosures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Affix the Enclosures to the Floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Electrical Interconnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Fiber-optic Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Chapter 5Power WiringGrounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Power Cable Types Acceptable for 400…690 Volt Installations. . . 101Motor Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Bus Bar Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1024Rockwell Automation Publication 750-IN100A-EN-P - May 2017Table of ContentsField Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Recommended Cable Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Short Circuit Current Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Input Contactor Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Output Contactor Precaution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Bypass Contactor Precaution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Applying and Removing Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Drive Power Jumper Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Chapter 6I/O WiringI/O Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136Access Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138Device Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140Main Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141Hardware Enable Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142Safety Enable Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143Fiber Optic Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Option Module Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14511-Series I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14611-Series I/O Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14922-Series I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15522-Series I/O Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158Safe Torque Off Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Safe Speed Monitor Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 164Integrated Safety - Safe Torque Off Option Module. . . . . . . . . . . . . 166DeviceNet Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167ControlNet Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168Dual-Port EtherNet/IP Option Module . . . . . . . . . . . . . . . . . . . . . . . 169Profibus Option Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170BACnet/IP Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Single Incremental Encoder Option Module. . . . . . . . . . . . . . . . . . . . 172Dual Incremental Encoder Option Module. . . . . . . . . . . . . . . . . . . . . 174Universal Feedback Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 178Motor Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181Feedback Device Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181Motor Feedback Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181Rockwell Automation Publication 750-IN100A-EN-P - May 20175PrefaceThis manual provides procedures for the mechanical and electrical installation of PowerFlex® 750-Series products with TotalFORCE™ control. This manual includes the basic steps to transport, position, and join the product enclosures, to make internal electrical connections, to connect power and the motor, and to wire basic I/O.This manual provides instructions for an initial product installation. Assembly procedures in chapters 1...4 assume that supply power is not connected. Once the product is connected to a power supply, always verify that system power is not present before performing any work on the product. See safety-related practices that are contained in publication NFPA 70E, Standard for Electrical Safety in the Work Place.This manual is intended for two types of personnel:•Qualified personnel familiar with handling heavy equipment.•Qualified electricians or other personnel who have experience with electrical terminology, equipment, methods, and safety precautions.The Additional Resources section is a directory of Rockwell Automation publications that provide detailed drive information from wiring and grounding recommendations to troubleshooting and repair.Additional ResourcesThe following table lists publications that provide general drive-related information.ResourceDescriptionPowerFlex Drives with TotalFORCE Control Programming Manual, publication 750-PM100Provides detailed information on:•I/O, control, and feedback options•Parameters and programming•Faults, alarms, and troubleshootingPowerFlex 750-Series Products with TotalFORCE Control Technical Data, publication 750-TD100Provides detailed information on:•Drive and bus supply specifications•Option specifications•Fuse and circuit breaker ratingsPowerFlex 20-HIM-A6 / -C6S HIM (Human Interface Module) User Manual, publication 20HIM-UM001Provides detailed information on HIM components, operation, features.PowerFlex 750-Series Products with TotalFORCE Control Hardware Service Manual, publication 750-TG100Provides detailed information on:•Preventive maintenance•Component testing•Hardware replacement proceduresPowerFlex Drives with TotalFORCE Control Built-in EtherNet/IP Adapter User Manual, publication 750COM-UM009Provides information on how to install, configure, and troubleshoot applications for the PowerFlex drives with the built-in EtherNet/IP adapter.PowerFlex 750-Series Drive DeviceNet Option Module User Manual, publication 750COM-UM002These publications provide detailed information on to configure, use, and troubleshoot PowerFlex 750-Series communication option modules and adapters.PowerFlex 7-Class Network Communication Adapter User Manuals, publications 750COM-UMxxxAC Drives Common Bus Application Techniques, publication 750-AT004Provides basic information to properly wire and ground common bus PWM AC drives.

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