1395 Connection Guide Grounding and Power Connections Installation Objectives The following data will guide you in planning the installation of theBulletin 1395. Since most start-up difficulties are the result of incorrect wiring, every precaution must be taken to assure that the wiring is done asinstructed. IMPORTANT:The end user is responsible for completing theinstallation, wiring and grounding of the 1395 drive and for complyingwith all National and Local Electrical Codes. WARNING: The following information is merely a guide forproper installation. The National Electrical Code and any other governing regional or local code will overrule this information.The Allen-Bradley Companycannot assume responsibility forthe compliance or the noncompliance to any code, national, localor otherwise for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipmentdamage exists if codes are ignored during installation. Environment The drive must be mounted in a clean, dry, location. Contamination fromoils, corrosive vapors and abrasive debris must be kept out of the enclosure. Temperatures around the drive must be kept between 0°C and55°C (32°F and 131°F). Humidity must remain between 5% to 95%non-condensing. The drive can be applied at elevations of 3300 feet (1,000 meters) without derating. The drive current rating must be derated by 3%for each additional 1,000 feet (300 meters). Above 10,000 feet (3,000 meters), consult the local Allen-Bradley Sales Office. Mounting The 1395 drive is of the open type construction and is designed to be installed in a suitable enclosure. The selection of enclosure type is the responsibility of the user. The heat sink is electrically isolated and is usedas a mounting surface. WARNING: Shock hazard exists at motor armature terminals ifgravity drop out contactor does not open. The drivemust be mounted in the vertical position. Failure to observe thismounting practice can result in personal injury or death. CAUTION: The installation of the drive must be planned suchthat all cutting, drilling, tapping and welding can be accomplished with the drive removed from the enclosure. The drive isof the open type construction and any metal debris must be kept from falling into the drive. Metal debris or other foreign mattermay become lodged in the drive circuitry resulting in componentdamage. Cooling Airflow In order to maintain proper cooling, the drive must be mounted in a verticalposition (fuses in the upper right hand corner). The drive design produces up to a 10°C or 18°F air temperature rise whenthe drive is operated at full capacity. Precautions should be taken not to exceed the maximum inlet ambient air temperature of 55°C (131°F). If thedrive is in an enclosed cabinet, air circulation fans or a closed circuit heatexchanger may be required. NEMA Type 12 Enclosures When the drive is mounted in a NEMA Type 12 nonventilated sheet metalenclosure, the enclosure must be sized properly to allow adequate convection cooling. The drive will dissipate a heat loss that is proportionalto the amount of armature current being delivered. The following table lists the approximate wattage dissipation of each drivebased on its current rating. Table A. Drive Wattage Dissipation Drive HP Rating 230V AC 460V AC 1-5 2 - 10 7.5 - 15 15 - 30 20 40 25 - 30 50 - 60 40 - 50 75 - 100 60 - 75 125 - 150 100 200 125 - 200 250 - 400 250 - 300 500 - 600 Watts Dissipated 100 225 295 485 675 905 1265 2722 3456 The NEMA Type 12 enclosure should be sized such that 10 watts of power are dissipated for each 1 square foot of enclosure surface. This area should not include the enclosure bottom or surfaces of the enclosure mounted against a wall. The heat loss for additional equipment that is mounted in the enclosureshould be added to the heat loss of the drive. Wiring Clearance Although the minimum clearance should be maintained for proper cooling,this space may not always provide proper wiring clearance. The minimum allowable wire bending radius may necessitate that extra space be provided to accommodate power wiring. Consult the governing code for the properwiring method. Main Disconnect IMPORTANT:The user is responsible for completing the installation ofthe drive system and to comply with all National and Local Electrical Codes. The following information is to be used as a reference only. WARNING: Hazard of electric shock or equipment damage existif drive is not installed correctly. The National Electrical Code (NEC) and local codes outline provisions for safely installingelectrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protectionand disconnect devices. Failure to do so may result in personalinjury and/or equipment damage. A main disconnect and lockout device with cabinet interlocks must be provided by the user. This device must be wired in the isolation transformer or reactor primary circuit. The device must be sized to handle115% of the primary current plus any additional loads that are connected tothe control system. Proper branch circuit protection for the drive andadditional devices must be provided according to NEC and local codes. IMPORTANT:Refer to Tables P and Q for drive current ratings toaid in properly sizing wire. Grounding Procedures The purpose of grounding is to: • Limit dangerous voltages on exposed parts to ground potential in theevent of an electrical fault. • To facilitate proper overcurrent device operation when ground faultconditions are incurred. • To provide for electrical interference suppression. The general grounding concept for the 1395 is explained below. Safety Ground (PE) - is the safety ground required by code. The groundbus can be connected to adjacent building steel (girder, joist) or a floorground loop, provided grounding points comply with NEC regulations. Multiple connections are permitted, but Do Not ground at the same point asthe Signal Ground (TE). The minimum distance between Signal andSafety Ground is 10 feet (3 meters). The ground bus requires a maximumof 1 ohm resistance to ground. Power Feeder - Each power feeder from the substation transformer to thedrive must be provided with properly sized ground cables. Simply utilizing the conduit or cable armor as a ground is not adequate. The conduit orcable armor and ground wires should be bonded to substation ground atboth ends. Each transformer enclosure and/or frame must be bonded toground at a minimum of two locations. Motor Connection- Each DC motor frame must be bonded to groundedbuilding steel within 20 feet (6 meters) of its location and tied to the drives PE via ground wires within the power cables and/or conduit. Bond theconduit or cable armor to ground at both ends. The ground wire size andinstallation must be per NEC Article 250. Signal Ground (TE)- must be connected to an earth ground by acontinuous separate lead (insulated #6 AWG or larger). The PLC I/O Communication Link must be run in grounded steel conduit.The conduit should be bonded to ground at both ends. Ground the cable shield at the drive end only. Encoder Connections- if required, must be routed in grounded steelconduit. The conduit must be grounded at both ends. Ground the cable shield at the motor only. Tachometer Connections- if required, must be routed in grounded steelconduit. The conduit must be grounded at both ends. Ground the cable shield at the drive end Only. Refer to the auxiliary device instruction manual for special groundingrecommendations. Figure 5 1395 Grounding Practices As previously explained, two different types of grounds are used in the 1395 drive. They are defined as follows: Safety Ground (PE) - A Safety Ground is normally required by theelectrical code and is defined externally as PE ground. Main PE is located at the contactor stud. TB-X connections are for jumpering TE to PE for stand alone only. Thesafety ground identified as PE ground is designated as follows: • TB2-5 • TB2-7 • TB5-11 1-30HP 230VAC 40-100 HP 230VAC 125-300 HP 230VAC 2-60 HP 460VAC 75-200 HP 460VAC 250-600 HP 460VAC Depending on the specific application, PE ground as defined above may be connected to a system ground bus when several drives are configured as part of a system and mounted in the same cabinet. In other applications,this terminal may be connected directly to a PE ground point consisting ofadjacent building steel (girder, joist, floor ground loop, etc.), providedgrounding points comply with NEC regulations. Figures 6 and 7illustrate connection of PE for stand alone and system applications. PEshould be connected in a "Star" fashion, and not daisy chained. Figure 6 Stand Alone Drive Grounding Signal Ground (TE)- The Signal Ground point is used for all control signals internal to the drive. Depending on the application, TE may be connected to a system TE bus or connected to PE ground. Figure 6 and 7 illustrate the possible connections for TE. If the drive is configured as a stand alone unit, the TE and PE grounds may be run individually to the drive, or a jumper can be placed as shown in Table C and one ground lead run as indicated in Table D. Table C. Safety/Signal Ground Rating 1 - 30HP 230VAC 2 - 60HP 460VAC 60 - 100HP 230VAC 75 - 200HP 460VAC 125 - 300HP 230VAC 250 - 600HP 460VAC Wiring Connection TB2 - 4 & 5 TB2 - 6 & 7 TB5 - 10 & 11 Table D. Safety Ground Connections Rating 1 - 30HP 230VAC 2 - 60 HP 460VAC 60 - 100HP 230VAC 75 - 200 HP 460VAC 125 - 300HP 230VAC 250 - 600 HP 460VAC Ground Terminal TB2 - 5 TB2 - 7 TB2 - 11 Figure 7 System Grounding Procedures TB1 TB2 1-30 HP 230VAC 2-60 HP 460VAC TB 4 Terminals 4 & 5, TB2 40-100 HP 230VAC 75-200 HP 460VAC TB 4 Terminals 6 & 7, TB2 125-300 HP 230VAC 250-600 HP 460VAC TB 10 Terminals 10 & 11, TB5 On a multi drive system, assure that the Signal Ground (TE) of each drive is directly connected to the system TE bus. In addition, the Safety Ground (PE) of each drive must be directly connected to the system PE bus. IMPORTANT:PE must be connected in a "star" fashion and not daisy chained. Power Wiring It is the recommended that an Allen-Bradley DC Loop Contactor Lug Kit be ordered for proper wire terminations. Table E provides a listing and description of the available lug kits. Table E Allen-Bradley DC Loop Contactor Lug Kits Rated Motor Arm. Current1 A DC 40 52 56 68 92 104 110 120 140 160 180 204 228 248 268 280 DC Contactor Armature Rating Conductor A DC Size2 AWG 56 8 56 6 56 4 110 4 110 2 110 1 110 1/0 180 1/0 180 2/0 160 3/0 180 4/0 280 250MCM 280 300MCM 280 350MCM 280 400MCM 280 500MCM DB Conductor Size3 AWG 8 8 8 8 6 6 4 4 2 2 2 1 1/0 2/0 2/0 3/0 Arm. Conductor Crimp Lug Hole Size #10 #10 #10 1/4” 1/4” 1/4” 1/4” 5/16” 5/16” 5/16” 5/16” 1/2” 1/2” 1/2” 1/2” 1/2” DB Conductor Crimp Lug Hole Size Lug Kit Catalog Number #10 #10 #10 1/4” 1/4” 1/4” 1/4” 5/16” 5/16” 5/16” 5/16” 3/8” 3/8” 3/8” 3/8” 3/8” 1370-LG40 1370-LG52 1370-LG56 1370-LG68 1370-LG92 1370-LG104 1370-LG110 1370-LG120 1370-LG140 1370-LG160 1370-LG180 1370-LG204 1370-LG228 1370-LG248 1370-LG268 1370-LG280 1 The Rated Motor Armature Current is taken directly from the motor nameplate or motor data. The current listed in the table (column 1 ) is the maximum current allowed for the Armature Conductor Size (column 3) and the DC Contactor Rating (column 2). 2 The armature conductors are sized by multiplying the Rated Armature Current by 1 25 as provided for in NEC 430 -22 (1987). The DC lug ratings are determined from NEC Table 310-16 (1987) for copper conductors, insulation temperature rated at 75° C (167° F) at an ambient temperature of 30° C (86° F). If conditions are other than shown in NEC Table 310 -16 then refer to applicable codes. 3 The dynamic braking (DB) conductors are sized as in Note 2, but at half ampacity due to the short time duration of current flow in these conductors, and has been sized to satisfy NEMA Standard ICS -302.62 3 - Dynamic Braking. If the load inertia is larger than that of the motor, calculations must be made to determine correct conductor sizing and DB resistor wattage per NEMA Standard ICS 3-302.62. If the wire size of the DB conductor does not fit on the DB grid connection, install a terminal block near the DB resistors and use multiple wire nuns between the resistors and the terminal block. Power Wiring Procedure The following procedure provides the steps needed to properly perform the power wiring connections to the 1395 drive. Using Table F, verify that the motor field is compatible with the DC field voltage output of the drive. Table F. Standard Field Voltage Output AC Incoming Voltage to Drive 230V AC 380V AC 415V AC 460V AC DC Supply Output Voltage to Field 120-150V DC 200-250V DC 220-270V DC 240-300V DC 1. Connect the motor armature and field leads to produce proper direction of motor rotation. Table G lists the connections required to produce counterclockwise rotation of the motor when viewed from the commutator end with a positive speed reference input to the drive. Table G. Motor Connections for CCW Rotation Connection Motor Field Motor Armature Drive 1 - 30 HP, 230V AC 2 - 60 HP, 460V AC 40 - 100 HP, 230V AC 75 - 200 HP, 460V AC 125 - 300 HP, 230V AC 250 - 600 HP, 460V AC 1 - 100 HP, 230V AC 2 - 200 HP, 460V AC 125 - 300 HP, 230V AC 250 - 600 HP, 460V AC Drive Terminal Connection TB1-3 TB1-4 TB2-1 TB2-2 TB7-1 TB7-3 A1 A2 A1 A2 Motor Lead F1(+) F2(-) F1(+) F2(-) F1(+) F2(-) A1(+) A2(-) A1(+) A2(-) Refer to Figures 9 & 10 for power wiring with a standard field voltage. Note that 125 -600 HP construction requires field voltage semiconductor fuses rated at 50A (use KTK-R Fuses). ATTENTION: The motor field supply is phase sensitive. To guard against possible drive/motor damage, assure that the connections are properly made according to Figures 9 & 10. 2. The 1395 is supplied with semi conductor fuses for line protection. A line reactor must be used between the main distribution system and the drive. An isolation transformer can also be used. Refer to Figures 9 and 10 for AC input wiring at the main fuses. Connect incoming three-phase AC line power to the AC line fuses or to the bus bar on the 125 - 600 HP drive The fuses supplied are designed to provide protection against short circuits for the drive semiconductors and associated output wiring. They are not to be considered a substitute for the user supplied motor branch circuit protective devices that are required by the National Electrical Code. Refer to Tables P and Q for proper sizing of the AC power and branch fuses. Figure 9 Power Connections - Standard Field Voltage Figure 10 Power Connections - Standard Field Voltage 3. If the DC motor field is not compatible with the field DC output of the drive, an external field control transformer must be used. Refer to the following example for trans former selection information. EXAMPLE: 10 HP, 240 Volt Armature, 17.2A, 240 Volt Field, @ 2.0A a) The Field Control Transformer - will have 230V primary, 460V secondary, single phase 60 Hz. b) kVA = 2A x 460V AC x 1.5 = 1.38 kVA (1.5 kVA is closest) c) J1 - Field jumper selection is in location 3 as the motor field is 2A. d) Rated Field Motor Current (parameter - 612) to be programmed “2” as stamped on the motor nameplate. e) Rated Field Bridge Current (parameter 616) to be programmed “2.1”. SeeTable H (1395 Connection Guide: Circuit Boards, Jumper Connections and Control Connections ), Jumper Selection 3 Max Field Current Rating. f) Refer to Figure 11 and both NEC code and local codes for fusing requirements. g) On 1-30 HP 230 volt and 2-60 HP 460 volt, remove factory installed wires at TB1-1 and TB2-2 on the power board and remove these same wires at TB1-1 and TB1-2 on the power board and remove these same wires at the other end at 1L1 and 1L3 on the drive side of the main fuses. Wirethe transformer as shown in figure 11. 4. Typical external field transformer connections are shown in Figure 11 for a motor rated 240 volt armature, 240V field. Figure 11 External Field Transformer Connections 1. The primary of the external field transformer requires branch circuit protection, to be fused with FRN or FRS style fuses. Refer to NEC Code (and local codes) for sizing. 2. As noted, the secondary of the external field transformer must be fused with semi conductor type fuses; type KTK-R. For correct value, refer to Figure 11.