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PowerFlex Digital DC Drive User Manual

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PowerFlex Digital DC DrivePowerFlex DC Drive V1.006…6.004, PowerFlex DC Standalone Regulator V1.006…6.004User ManualImportant 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 prohibited.Throughout this manual, when necessary, we use notes to make you aware of safety considerations.Labels may also be on or inside the equipment to provide specific precautions.Allen-Bradley, Connected Components Workbench, DriveExecutive, DriveExplorer, DriveTools, PowerFlex, and Rockwell Automation are trademarks of Rockwell Automation, Inc.Trademarks not belonging to Rockwell Automation are property of their respective companies.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 20P-UM001L-EN-P - July 20153Summary of ChangesThis manual contains new and updated information.New and Updated InformationThis table contains the changes made to this revision.Changes to this manual for previous revisions are included in AppendixI History of Changes on page 383.TopicPageAdded the Maximum Surrounding Air Temperature Specifications.18Updated the frame B drive dimensions to include another depth dimension for certain catalog numbers.20Updated the Typical Power Wiring Diagrams to illustrate connections for frame D, series A, B, and C fans.45Updated the Frame D, Series B and C Heatsink Cooling Fan Specifications to include information on fan air-flow verification after wiring.71Updated the description for the DIP switch S20 to identify Z channel monitoring in software versus hardware.76Changed the name of parameter 467 from [Max Fld Curr Pct] to [Max Fld Flux Pct].The parameter name was only incorrect in this manual.Throughout manualAdded a note to parameter 232 [Inertia Comp Out].126Updated the description for parameter 652 [Encoder Err Chk].139Added a note to parameters 87 [Spd Reg Kp] and 88 [Spd Reg Ki], 459 [SpdReg Kp Bypass], and 460 [SpdReg Ki Bypass] that refers to the Manual Tuning the Speed Regulator procedures for firmware version 6.001 and later.146 and 150Changed 920 ms to 960 ms to reflect the correct amount of time after which a Main Contactor fault occurs when the main and/or dynamic brake (DB) contactor fails to open or close.221Added new values to the Testpoint Codes and Functions table.231Removed the Certifications and Specifications information. See the PowerFlex Digital DC Drive Technical Data, publication 20P-TD001, for certification and specification information.234Added a new table for frame D drive watts loss and series B fan capacity data.236Added a new table for frame D drive watts loss and series C fan capacity data.236Added a summary of the basic relationships between Speed Regulator gains, bandwidth, and tuning for firmware version 6.001 and later to the Manually Tuning the Speed Regulator for Firmware Revision 6.001 and Later procedure.3044Rockwell Automation Publication 20P-UM001L-EN-P - July 2015Summary of ChangesNotes:Rockwell Automation Publication 20P-UM001L-EN-P - July 20155Table of ContentsPrefaceDrive Storage Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Drive Nameplate Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Drive Series Letter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Drive Firmware Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Standard Drive Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . 15Standard Drive Catalog Number Explanation, Cont.. . . . . . . . . . . . . . . . 16Standalone-Alone Regulator Catalog Numbers . . . . . . . . . . . . . . . . . . . . . 16Chapter 1Installation and WiringMount the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Operating Conditions and Temperatures. . . . . . . . . . . . . . . . . . . . . . . 18Minimum Mounting Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Maximum Surrounding Air Temperature Specifications. . . . . . . . . 18Approximate Drive Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . 19Lifting PowerFlex DC Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Mount Frame C and D Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Remove the Drive Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Frame A Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Frame B and C Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Frame D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Isolation Transformers / Line Reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30AC Input Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31DC Output Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Dynamic Brake Resistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31General Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Safety Ground (PE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Power Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Encoder/Resolver Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . 33Tachometer Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Grounding for Installations in an Ungrounded or High-Impedance, Neutral Ground, or System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Power Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34CE Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39EMC Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Installation Requirements Related to the Low Voltage Directive. . 40

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