1395 1397 And Flexpak 3000 Dc Drives To Powerflex Dc

Summary

Migration Guide
1395, 1397, and FlexPak 3000 DC Drives to PowerFlex DC Drive
Catalog Numbers 1395, 1397, 20P
Important User Information
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from
your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/) describes some
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment

The examples and diagrams in this 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

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

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

IMPORTANT Identifies information that is critical for successful application and understanding of the product

Allen-Bradley, ControlLogix, MicroLogix, DriveExplorer, DriveExecutive, Encompass, PowerFlex, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc

Trademarks not belonging to Rockwell Automation are property of their respective companies

Table of Contents
Preface Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pre-migration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Best Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
View All Publications for a Specific Drive . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 1
Drive Comparisons Specifications and Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive Catalog Number Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Bulletin 1395 Digital DC Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Bulletin 1395 Digital DC Drive in Bulletin 2361 Motor Control
Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Bulletin 1397 Digital DC Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FlexPak 3000 Digital DC Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PowerFlex Digital DC Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PowerFlex Digital DC Drive, Continued . . . . . . . . . . . . . . . . . . . . . . 29
Drive Conversion Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Bulletin 1395 to PowerFlex DC Drive Conversions . . . . . . . . . . . . . 30
Bulletin 1397 to PowerFlex DC Drive Conversions . . . . . . . . . . . . . 32
FlexPak 3000 to PowerFlex DC Drive Conversions . . . . . . . . . . . . . 34
Drive Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Bulletin 1395 Drive Approximate Dimensions. . . . . . . . . . . . . . . . . . 36
Bulletin 1397 Drive Approximate Dimensions. . . . . . . . . . . . . . . . . . 39
FlexPak 3000 Drive Approximate Dimensions . . . . . . . . . . . . . . . . . . 43
PowerFlex DC Drive Approximate Dimensions. . . . . . . . . . . . . . . . . 49
Power Comparisons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1395 Power Connections - Standard Field Voltage . . . . . . . . . . . . . . 54
1395 External Field Transformer Connections. . . . . . . . . . . . . . . . . . 56
1397 AC Input Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1397 Field and Motor Armature Connections . . . . . . . . . . . . . . . . . . 61
FlexPak 3000 AC Input Line Connections . . . . . . . . . . . . . . . . . . . . . 65
FlexPak 3000 DC Motor Field and Armature Connections . . . . . . 68
PowerFlex DC Drive Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Control and Feedback Comparisons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Bulletin 1395 Digital DC Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Bulletin 1397 Digital DC Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
FlexPak 3000 DC Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
PowerFlex DC Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Chapter 2
Wiring Examples Bulletin 1395 to PowerFlex DC Drive Comparison . . . . . . . . . . . . . . . . 165
Bulletin 1397 to PowerFlex DC Drive Comparison . . . . . . . . . . . . . . . . 169
FlexPak 3000 to PowerFlex DC Drive Comparison . . . . . . . . . . . . . . . . 173
Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 3
Table of Contents
Chapter 3
Network Communication Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Bulletin 1395 DC Drive Network Communication Options. . . . . . . . 177
1395 Node Adapter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Multi-Communication Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
ControlNet Adapter Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Bulletin 1397 DC Drive Network Communication Options. . . . . . . . 179
FlexPak 3000 DC Drive Network Communication Options . . . . . . . . 180
ControlNet Network Communication Option Board . . . . . . . . . . 180
AutoMax Network Communication Option Board . . . . . . . . . . . . 180
DeviceNet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
PowerFlex DC Drive Network Communication Options. . . . . . . . . . . 181
Logic Command and Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Bulletin 1395 DC Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Bulletin 1397 DC Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
FlexPak 3000 DC Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
PowerFlex DC Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Rockwell Automation Encompass Partner Migration Offerings . . . . . 190
ProLinx 5210-DFNT-RIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
ProLinx 5201-DFNT-DH485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
AN-X-ABRIO-SCAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
AN-X-DHP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
AN-X-DCSNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
4 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012
Preface
Topic Page
Overview 5
Pre-migration 5
Additional Resources 6
Overview 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

This publication contains these chapters:
• Chapter 1: Drive Comparisons
Contains comparisons of the specifications, features, drive catalog
numbers, dimensions, power and control terminals, and feedback options
of the 1395, 1397, and FlexPak 3000 DC drives to the PowerFlex DC
drive. This chapter also provides information on the user-installed options,
contactors and recommended fuses for the PowerFlex DC drive

• Chapter 2: Wiring Examples
Contains comparisons of the drive configuration, control wiring and
parameters of the 1395, 1397, and FlexPak 3000 DC drives to the
PowerFlex DC drive

• Chapter 3: Network Communication
Identifies the 1395, 1397, and FlexPak 3000 drives network options that
can be migrated to networks used by the PowerFlex DC drive. This
chapter also provides overview information for the velocity reference/
feedback, I/O adaptors, 16 bit-based processors (PLC 5) and provides
information for Quest (a Rockwell Automation Encompass™ partner), that
offers a remote I/O to EtherNet/IP communication convertor migration
solution

Pre-migration Best Practices
• Upload and save the drive parameters via DriveExplorer™ or
DriveExecutive™. If you cannot connect to the drive online, manually
record the drive parameter values

• Record the motor nameplate data, record and label all power, motor, and
digital and analog I/O control wiring

• Upload and save any network files and Programmable Logic Controller
(PLC) programs

• Update and/or markup any changes to hardware prints

Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 5
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 Provides the necessary information to install, program,
User Manual, publication 1395-UM006 start up and maintain the 1350 A and 2250 A version of
the 1395 DC drive

1395 Digital DC Drive Firmware Versions 5xx…10.10/9.30 Provides the necessary information to install, program,
User Manual, publication 1395-UM003 start up, and maintain the1395 DC drive

Bulletin 1395 Digital DC Drive in Bulletin 2361 MCCs User Provides instructions for installing and operating a
Manual, publication 2361-5.01. high-horsepower 1395 drive

1397 DC Drive Firmware 2.xx User Manual, publication Provides information necessary to install, program,
1397-UM000 start up, and maintain the 1397 DC drive

FlexPak 3000 Digital DC Drive Hardware Reference, Provides information necessary to install, start up, and
Installation and Troubleshooting Version 4.3, publication troubleshoot the FlexPak 3000 DC drive

FP3-UM012
FlexPak 3000 Digital DC Drive Software Reference Manual Describes the software of the FlexPak 3000 DC drive

Version 4.3, publication FP3-UM013
PowerFlex Digital DC Drive User Manual, publication Provides the basic information needed to install, start
20P-UM001 up, program, and troubleshoot the PowerFlex DC drive

PowerFlex Digital DC Drive Technical Data, publication Provides information on drive specifications and
20P-TD001 features

Industrial Automation Wiring and Grounding Guidelines, Provides general guidelines for installing a Rockwell
publication 1770-4.1 Automation industrial system

Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and
other certification details

You can view or download publications at
http:/www.rockwellautomation.com/literature/. To order paper copies of
technical documentation, contact your local Allen-Bradley® distributor or
Rockwell Automation sales representative

6 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012
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

Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 7
Preface
Notes:
8 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012
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

Topic Page
Specifications and Features 10
Drive Catalog Number Explanations 18
Bulletin 1395 Digital DC Drive 18
Bulletin 1395 Digital DC Drive in Bulletin 2361 Motor 21
Control Centers
Bulletin 1397 Digital DC Drive 24
FlexPak 3000 Digital DC Drive 26
PowerFlex Digital DC Drive 28
Drive Conversion Guides 30
Bulletin 1395 to PowerFlex DC Drive Conversions 30
Bulletin 1397 to PowerFlex DC Drive Conversions 32
FlexPak 3000 to PowerFlex DC Drive Conversions 34
Drive Dimensions 36
Bulletin 1395 Drive Approximate Dimensions 36
Bulletin 1397 Drive Approximate Dimensions 39
FlexPak 3000 Drive Approximate Dimensions 43
PowerFlex DC Drive Approximate Dimensions 49
Power Comparisons 54
1395 Power Connections - Standard Field Voltage 54
1395 External Field Transformer Connections 56
1397 AC Input Line Connections 57
1397 Field and Motor Armature Connections 61
FlexPak 3000 AC Input Line Connections 65
FlexPak 3000 DC Motor Field and Armature 68
Connections
PowerFlex DC Drive Power Wiring 73
Control and Feedback Comparisons 94
Bulletin 1395 Digital DC Drive 94
Bulletin 1397 Digital DC Drive 101
FlexPak 3000 DC Drive 108
PowerFlex DC Drive 118
Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 9
Chapter 1 Drive Comparisons
Specifications and Features This section compares the specifications and features of your existing 1395, 1397,
or FlexPak 3000 DC drive to the PowerFlex DC drive

Table 1 - Drive Specification and Feature Comparisons
Attributes 1395 1397 FlexPak 3000 PowerFlex DC
Catalog Reference 1395… 1397… 20P…
AC Input Ratings
100…115V n/a n/a n/a n/a
200…240V 0.75…224 kW 1.1…111 kW 1.5…300 Hp 1.5…300 Hp
1…300 Hp 1.5…150 Hp 7…1000 A 7…1050 A
400…480V 1.5…500 Hp (400 VDC) 2.2…448 kW 3…600 Hp 2…900 Hp
2…600 Hp (500 VDC) 3…600 Hp 6…960 A 4.1…1494 A
500…600V n/a n/a n/a n/a
690V n/a n/a n/a n/a
Ambient Temperature Limit IP00 / Open = 55 °C IP00 / Open = 55 °C IP00 / Open = 55 °C IP20 / Open = 50 °C
(55°C with derating)
Field Supply Single phase internal or external Single phase internal Single phase internal 150V and 300V, current reg

single phase internal or external
EMC Filters n/a External External External
Armature Input Type 6-pulse 6-pulse 6-pulse 6-pulse standard
Performance
Overload Capability Heavy Duty Application Heavy Duty Application Heavy Duty Application Heavy Duty Application
150% - 60 s 150% - 60 s 150% - 60 s 150% - 60 s
200% - 10 s 200% - 5 s 200% - 5 s 200% - 3 s
260% - 5 s
Control Performance Full wave, full control, 6-SCR Full wave, full control, 6-SCR Full wave, full control, 6-SCR Full wave, full control, 6-SCR
Control Features Drive overload protection Drive overtemp. protection Drive overtemp. protection Drive overload protection
PI control (Spd or Trq) PI control (Spd or Trq) PI control (Spd or Trq) PID control (Spd or Trq)
Spd/Trq/Min/Max/Sum Inertia compensation Inertia compensation Adaptive gain
Droop Droop Droop Droop
Feedback loss switchover PI outer control loop / Process PI outer control loop / Process Feedback loss switchover
trim trim Winder control
WebPak 3000 (winder app.)
Operating Speed Range 100:1 encoder 200:1 encoder 200:1 encoder 1000:1 DC tachometer
100:1 armature feedback
1000:1 encoder
Field Control Field economize Fixed field - standard Fixed field - standard Field economize
Field weakening Regulated - optional, provides Regulated - optional, provides Field weakening
field economize and weakening field economize and weakening
10 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012
Drive Comparisons Chapter 1
Table 1 - Drive Specification and Feature Comparisons (Continued)
Attributes 1395 1397 FlexPak 3000 PowerFlex DC
Interface
User Interface Programming/Control terminal Local ScanPort HIMs Five-language graphical LCD Local PowerFlex HIMs
Remote terminal Remote ScanPort HIMs Operator Interface Module (OIM) Remote PowerFlex HIMs
DriveExecutive DriveExplorer CS3000 Control/Configuration DriveExplorer
DriveExecutive Software DriveExecutive
Connected Components
Workbench
Communications Options ControlNet Internal - ScanPort Internal - Serial Internal - DPI
Remote I/O DeviceNet AutoMax network BACnet
DH+ ControlNet DeviceNet DeviceNet
Serial Remote I/O ControlNet ControlNet
Node adapter board (PLC3/5) DF1/DH485 Profibus EtherNet/IP
Multi-communication board Interbus - S Remote I/O (1)
RS485 DF-1
RS485 HVAC
Modbus RTU
Modbus/TCP)
PROFIBUS DP
Interbus - S
Preset Speeds 5 3 (with I/O expansion) 3 (with I/O expansion) 7
Standard Analog Inputs 0 2 fixed 2 fixed 3 configurable
(12 bit + sign, ±1V or mA, ±1V) (12 bit + sign, ±1V or mA, ±1V) (11 bit + sign, each ±V or mA)
Standard Digital Inputs 4 fixed 10 - Fixed 10 - Fixed 8 - Configurable
24V DC 24V DC 24V DC 24V DC
Standard Analog Outputs 0 2 - Configurable 2 - Configurable 2 - Configurable
(12 bit + sign, each ±V) (12 bit + sign, each ±V) (11 Bit + sign, each ±V)
Standard Digital Outputs 1 fixed 3 fixed 3 fixed 4 configurable (24V DC)
24V DC 24V DC 24V DC 2 configurable relay (N.O.)
Optional I/O Discrete Adapter 2 analog outputs 2 analog outputs 2 configurable analog outputs
(4 digital inputs, 2 digital 2 analog inputs 2 analog inputs 4 configurable digital inputs
outputs, 4 analog inputs, 4 5 fixed digital inputs 5 fixed digital inputs 4 configurable digital outputs
analog outputs)
2 configurable digital outputs 2 configurable digital outputs 115V AC interface
Digital Ref
(1 fixed input, 10 digital inputs, 1 pulse train input 1 pulse train input
5 digital outputs, 2 analog inputs, 1 pulse train output 1 pulse train output
2 analog outputs) 120V AC external interface
Protection
Motor OL Protection Yes Yes Yes Yes
Field Loss Yes Yes Yes Yes
Feedback Loss Yes Yes Yes Yes
Under & Over Voltage Protection – Yes Yes Yes
Dynamic Braking Armature regen or dynamic Armature regen or dynamic Armature regen or dynamic Armature regen or dynamic
braking resistor braking resistor braking resistor braking resistor
Over Current Yes Yes Yes Yes
MOVs Field bridge only – – –
Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012 11
Chapter 1 Drive Comparisons
Table 1 - Drive Specification and Feature Comparisons (Continued)
Attributes 1395 1397 FlexPak 3000 PowerFlex DC
Input Power
120V AC ±10% 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…2.0 s
Power Ride-thru None None None 15 ms at full load
Extended Power Ride-thru No No No No
Transient Protection MOV – – –
Dynamic Braking Optional Optional Optional Optional
Output Power
120V DC n/a n/a n/a n/a
240V DC 1…300 Hp 1.5…300 Hp 1.5…300 Hp 1.5…300 Hp
500V DC 2…600 Hp 3…600 Hp 3…600 Hp 2…900 Hp
600V DC n/a n/a n/a 50…1250 Hp
700V DC n/a n/a n/a 400…1400 Hp
Efficiency (100% Speed & Load) – 99.30% 99.30% –
Power Factor 88% @ max speed 88% @ max speed 88% @ max speed Speed dependent
Output Power Device SCR SCR SCR SCR
Protection
Ground Fault – No No Yes
Ground Warning – No No No
Current Limit Yes Yes Yes Yes
Over Current Yes Yes Yes Yes
Electronic Overload Yes No – –
Overload Meets NEC per UL – No – –
Speed Sensitive Overload – No – –
Enclosure
Open / IP20 Yes Yes Yes Yes
12 Rockwell Automation Publication PFLEX-AP009A-EN-P - September 2012

1395, 1397, and FlexPak 3000 DC Drives to PowerFlex DC Drive Catalog Numbers 1395, 1397, 20P Migration Guide. catalog number explanations, ratings, dimensions, power and control …

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Frequently Asked Questions

What is the power output on a powerflex 1395 drive?

NOTE: If your 1395 drive utilizes 115 VAC Inputs, refer to the PowerFlex DC user manual, Appendix G for details on the 115V AC to 24V DC I/O Converter Circuit Board. ( User Supplied )Neutral / Common Stop/CF Run +24V ( User Supplied ) Neutral / Common • Configuration: P624 [Maintained Start] = 1 “Maintained”.

What is the flexpak 3000 control processor option?

This option allows a FlexPak 3000 DC drive to send and receive data via a control processor over the ControlNet network. FlexPak 3000 drives (version 4.2 or later) are compatible with all versions of the network option board.

What version of rockwell flexpak 3000 is in the manual?

FlexPak 3000 Digital DC Drive Hardware Reference, Installation and Troubleshooting Version 4.3 D2-3404-2 ©2004 Rockwell Automation. All rights reserved. The information in this manual is subject to change without notice.

What power supply do i need for a 1395 digital drive?

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.