Variador AF95 InstallationManual - Comm Version Rev2

Installation Manual
For Model AF95 Adjustable Frequency Drives
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Cutler-Hammer
Table of Contents
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
The Meaning of Safety Statements . . . . . . . . . . . . . . . . S-2
AF95 Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Handling of Drive After Delivery. . . . . . . . . . . . . . . . . . . . 2-2
Where to Locate Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Application Considerations . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Input Line Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Output Power Considerations . . . . . . . . . . . . . . . . . . . . 2-13
Analog and Digital Signal Considerations . . . . . . . . . 2-14
Arcnet® Network Considerations . . . . . . . . . . . . . . . . . . 2-15
Installation Check List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
AF95 Installation Manual

i
Table of Contents
Page
Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Dimensional Drawing for Mounting
NEMA Type 1 Enclosure . . . . . . . . . . . . . . . . . . . . . . . 4-2
Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Optional NEMA Enclosures . . . . . . . . . . . . . . . . . . . . 4-4
Ventilation Requirements for Chassis, NEMA
Type 1, and Optional NEMA Enclosures . . . . . . . . 4-5
Typical Terminal Block Assignments for
Typical AF95 Configurations . . . . . . . . . . . . . . . . . . . 4-6
Connection Diagram for
AF95 Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Identification of AF95 Keypad Assembly
Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Typical Cutler-Hammer AF95 Programmer
Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Typical Arcnet® Connection Diagram . . . . . . . . . . . . . 4-10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Nameplate Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Ratings Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Available Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

ii
Safety
Cutler-Hammer has made every effort to provide you with the
safest motor drives on the market but wishes to point out how to
safely operate and troubleshoot your drive.
After you review this section you will:
• Understand the meaning of the Safety Alert Symbol, Danger,

Warning, Caution, and Notice safety statements.
• Know the basic safety statements applicable to this entire

manual when performing any activity on or with your AF95
drive.

S-1
Safety
The Meaning of Safety Statements AF95 Safety Statements
You will find various types of safety information The safety statements contained in this manual
on the following pages and on the labels attached relate to the installation, operation and
to the equipment. This section explains their troubleshooting of Cutler-Hammer Solid State
meaning. Motor Control Equipment.
Notice - Make sure you read and understand

The Safety Alert Symbol means
ATTENTION! BECOME ALERT! the installation procedures in this guide before
! YOUR SAFETY IS INVOLVED! you attempt to operate or troubleshoot the
equipment.
! Danger ! Danger High Voltage

Motor control equipment and electronic
Danger means that failure to follow this safety controllers are connected to hazardous line
statement will result in serious personal injury voltage. When you install or service Cutler-
Hammer Solid State Motor Control Equipment,
or death.
there may be exposed components with their
cases and protrusions at or above line potential.
Take extreme care to protect yourself and others
! Warning against shock:
• Observe all shock hazard labels that may be

Warning means that failure to follow this located inside the drive.
safety statement might result in serious
• Stand on an insulating pad and make it a
personal injury or death. habit to use only one hand when installing or
checking components.
• Always work with another person in case an
! Caution emergency occurs.
• Always disconnect all power before you install
Caution means that failure to follow this or check controllers or perform maintenance.
safety statement might result in personal
• Be sure equipment is properly grounded
injury or property damage.
• Wear safety glasses whenever you are
working on electronic controllers or electrical
Notice - means that failure to follow these rotating equipment.
instructions could cause damage to the • Make sure that all electrical work conforms
equipment or cause it to operate improperly. with the National Electrical Codes and local
regulations.
• Installation should only be performed by
qualified personnel.

S-2
Safety
! Caution ! Caution
A hazard of potential damage to your drive due AF95 Adjustable Frequency Drives contain
to overheating exists if your drive is operated at components and sub-assemblies that are
a line impedance below 1%. sensitive to electrostatic discharge. Static
control precautions are required when installing,
You must ensure that the input line power has testing, servicing, or repairing your Adjustable
an impedance of at least 1% and less than or Frequency Drive. Component damage may
equal to 5% for proper drive operation. Damage result if you ignore electrostatic discharge
may occur if the source impedance is less than control procedures. Observe the following
1%. If the source impedance is more than 5%, precautions when you are working with electrical
the drive may not provide rated output voltage. subassemblies:
Install an AF95 1% input line reactor if your line • Before opening the enclosure, discharge
impedance measures below 1%. static electricity from your body by touching a
grounded metal object.
• When installing the equipment, connect the

equipment ground conductor as soon as
! Warning possible.
• Keep your hands and tools away from the

AF95 Adjustable Frequency Drives may require electronic circuitry as much as possible. Non-
more than one person or special material conductive materials such as paper, plastic
handling equipment to move from one location and Styrofoam must be kept away from the
to another. Refer to Section 4, Drawings in this electronic circuitry. Do not use tape in the
manual to estimate the weight of your drive. equipment enclosure. Pulling tape from a roll
Observe proper lifting techniques. Use generates a high static charge.
spreader bars for units over 75 pounds.
• When working on the electronic circuitry,
wear a high resistance grounded wrist strap
(sold by many consumer and industrial
electronic component suppliers.)
• When replacing a printed circuit board, do

not remove the board from its static shielding
bag until you are prepared to install it. While
wearing a grounded wrist strap, transfer the
board directly from the bag to the mounting
position.
• Printed circuit boards must be repaired by

technicians trained for working with
electrostatic sensitive components. Repair
must be performed at an electrostatic
protected workbench using appropriate tools.

S-3
Safety

S-4
SECTION 1
Introduction
About This Manual
Congratulations! You have purchased one of the most
sophisticated Adjustable Frequency Drives in the industry. Your
drive is part of a family of drives that provide AC motor speed
control in a wide variety of industrial and commercial applications.
Both constant and variable torque models are available from 15 to
200 Hp applications and variable torque models are available for
300 Hp applications.
This manual provides a check list, drawings, specifications and

pre-installation information to help you select the right equipment
and properly install your AF95 AC drive.
To assure successful installation, thoroughly read and understand

the material presented in each section before you attempt to
install the drive. If this is your first installation, we suggest that you
read each section in the sequence they are presented since they
assume you know the material presented previously. Once you
are an experienced installer, you can use the manual as a source
of reference and look up the information you need using the index
as a guide.
AF95 Adjustable Frequency Drives are designed to provide

adjustable speed control of three phase motors. The
microprocessor based pulse width modulated (PWM) drives have
standard features which can be programmed to tailor your drive’s
performance to suit your needs.

1-1
About This Manual
SECTION 1
AF95 features can be easily modified and/or enabled using the
Programmer’s Software that came with your drive. Using a personal
computer (PC) loaded with Microsoft® Windows 3.1, the Programmer’s
Software sets parameters such as acceleration, deceleration, and preset
speeds. Review the AF95 Programmer’s Manual for information on
enabling features and setting parameters.
Note that throughout the manual, titles of sections and other AF95
manuals are shown in italics. Items in bold italics are important. Items
in bold without italics are parameters or commands that appear on
your AF95 LCD or the names of buttons located on the keypad.
If you have any questions or comments, please feel free to contact us.
We at Cutler-Hammer are proud to have you as a customer and can
assure you that you will have many productive years from your new AF95
AC drive.
Every AF95 comes packed with these manuals:

• AF95 Operator’s Manual
• AF95 Installation Manual
The following manual is available from Cutler-Hammer:

• AF95 Programmer’s Manual
• AF95 Programmer’s Software

1-2
SECTION 2
Pre-Installation
This section of the Installation Manual provides guidelines to
consider before you install your drive:
• Handling of Drive After Delivery.
• Where to Locate Drive.
• Application Considerations.
• Input Line Considerations.
• Output Power Considerations.
• Analog and Digital Signal Considerations.
• Arcnet® Network Considerations.

2-1
Pre-Installation
SECTION 2
Handling of Drive After Delivery

Although every precaution is taken to ensure 3. If you are not installing the drive right away,
that the unit is delivered in good condition, take store the drive in a clean, dry area where the
a moment to inspect your drive after it arrives at ambient temperature is between -4 to 149°F
your plant: (-20 to 65°C) and less than or equal to 95%
humidity (non condensing).
1. Inspect the shipping container for evidence
of rough handling immediately after the unit Make sure the drive is not subject to a
arrives. Report all damage to the freight corrosive atmosphere (such as H2S).
carrier and your nearest Cutler-Hammer
customer support center.
2. Carefully unpack the drive, taking care to

save the shipping container and any packing
material should you need to return the unit at
a later date. Verify that the items on the
packing list or bill of lading agree with your
order.
! Warning
AF95 Adjustable Frequency Drives may require
more than one person or special material
handling equipment to move from one location
to another. Refer to Section 4, Drawings, in this
manual to estimate the weight of your drive.
Observe proper lifting techniques.

2-2
Pre-Installation
SECTION 2
Where to Locate Drive
Consider the following: 3. Refer to the illustrations in Section 4,

Drawings, for the mounting dimensions of
1. Locate the drive in an area consistent with each chassis and enclosure.
the environment specifications listed in
Section 5, Specifications in this manual. 4. Make sure there is plenty of ventilating
space surrounding the drive. Refer to the
Mount enclosures away from heavy and illustrations in Section 4, Drawings, for the
overhead construction. recommended ventilation space dimensions.
2. Select the type of enclosure that meets your

application. See your AF95 Catalog for the
appropriate enclosure.
Note: AF95 units are rated for a maximum of ! Danger

104°F (40°C). If your installation will impose
temperatures beyond these levels, the AF95
AF95 Adjustable Frequency Drives are not
must be derated 10% for every 9°F (5°C)
suitable for use in an explosive atmosphere or in
above the rated temperature, with a
a “Hazardous (Classified) Location.” See Article
maximum ambient of 140°F (60°C).
500 of the National Electric Code.
The AF95 drives are rated for a maximum
altitude of 3300 feet (1000 meters). For
every 1000 feet (300 meters), or portion
thereof above rated, you must derate by 2%.
See pages 5-4 and 5-5 for other

environmental considerations.

2-3
Pre-Installation
SECTION 2
Application Considerations
When you plan your AF95 Adjustable Frequency 2. Order a 3% or 5% input line reactor to
Drive installation, consider its application. correct input line harmonic distortion as
Different applications, such as industrial process required. Refer to the discussion on Input
control and HVAC system control, require Line Characteristics later in this section for
different drive options, motors and software more details on harmonic distortion.
configuration.
3. An AF95 input disconnect is a lockable
The following is a list of items you should keep in means for disconnecting the motor from the
mind when you plan the installation and order the power source. The drive and disconnect are
materials. It is important to note that some of the mounted in an optional NEMA enclosure or
options available for your drive must be installed MCC.
at the factory.
4. If your drive will be located near sources of
AF95 Options EMI, such as solenoid coils and relays, you
may need to install a “Quench Arc” across
1. Remember you must have an input line each coil to suppress the radiation. Refer to
impedance of at least 1% and not over 5% the Cutler-Hammer Catalog for ordering
for proper drive operation. You should information.
calculate the input line impedance to
determine whether a 1% input reactor is 5. Review the other options described in
required. Refer to the discussion on Input Section 5, Specifications, in this manual to
Line Considerations later in this section for determine whether they apply to your
more details on determining input line application.
impedance. Order a 1% line reactor if line
impedance, ratioed to drive size, is less than 1%. 6. Review Section 4, Drawings, in this manual
for typical pictorial representations of AF95
options.
! Caution
A hazard of potential damage to your drive due
to overheating exists if your drive is operated at
a line impedance below 1%.
You must ensure that the input line power has

an impedance of at least 1% and less than or
equal to 5% for proper drive operation. Damage
may occur if the source impedance is less than
1%. If the source impedance is more than 5%,
the drive may not provide rated output voltage.
Install an AF95 1% input line reactor if your line

impedance measures below 1%.

2-4
Pre-Installation
SECTION 2
Application Considerations
Motor Selection 3. A motor as small as one third the nameplate
rating of the AF95 drive may be connected as
Careful consideration of the proper motor is a single load. In this situation the current
essential to obtain optimum performance from protection levels of the AF95 should be
your drive. Contact your Cutler-Hammer modified, with the AF95 Programmer
Distributor or Field Sales Office for additional Software, to match the rated current of the
assistance and/or literature regarding motor connected motor.
selection and other aspects of drive applications. 4. For motor lead lengths exceeding 100 feet,
see Output Filters on page 5-8.
1. Your AF95 drive is designed to be connected
directly to a single, NEMA design B, three
phase AC motor. The motor must be
selected and applied so that the average ! Warning
operating motor current and horsepower do
not exceed the continuous current and Carefully consider the application when you select
horsepower ratings of the drive. The and install AF95 Adjustable Frequency Drive
intermittent operating current must not components and options and associated drive motor.
exceed the intermittent current rating of the You must ensure that your application meets the
drive. restrictions stated in Section 4, Drawings and
Section 5, Specifications in this manual and the
Multiple motors may be connected to an nameplate of your drive.
AF95 drive if: Failure to observe these restrictions can cause
• Total current for all of the motors does not personal injury or damage to personal property and
exceed the current rating of the AF95. could void your warranty:
• Individual motor protection is supplied.
• All motors are to start/stop and change • Make sure selected equipment meets the
speeds together. requirements of, and are installed according to,
the NEC, NEMA, UL, cUL, IEC, IEEE, and local
2. Consider the effect of speed on the cooling codes.
capacity of the motor. As you slow down the • Pay particular attention to the requirements for
motor, its internal fan turns slower which motor and power disconnect devices, emergency
reduces air flow through the motor. Typically, stop pushbuttons, pre-start alarms and guards on
motors may overheat if you operate them for mechanical power transmission apparatus.
extended periods of time at their rated
torque and a reduced speed (less than 50% • Make sure motor selected is appropriately sized
of full speed). Choose a motor that matches for the application. Follow the recommendations
the expected duty, torque range and speed. in Section 2, Pre-Installation in this manual.
• If you configure the drive to operate above 60 Hz,
the motor will operate above its nameplate
! Warning speed. Personal injury or equipment damage
may exist when you operate the motor and
If you configure the drive to operate above 60 Hz, driven machines above their rated speed. Make
the motor may operate above its nameplate speed. certain that all guards and shields are in place
Personal injury or equipment damage may exist before operating at any speed. Refer to the motor
when you operate the motor and driven machines and driven machine manufacturers to verify safe
above their rated speed. Make certain that all operating speeds.
guards and shields are in place before operating at Before operating the equipment, make sure that
any speed. Refer to the motor and driven machine appropriate guards and safety devices are in
manufacturers to verify safe operating speeds. place.

2-5
Pre-Installation
SECTION 2
Input Line Considerations

All wiring must comply with the requirements of Grounding Connections
the National Electric Code (NEC) and/or other
codes as required by the authority having For personal safety and reliable equipment
jurisdiction over the installation. The installer operation, firmly connect each chassis to earth
must ensure that the electrical connections at ground as shown in the connection diagrams in
the site conform with the connection diagrams Section 4, Drawings, of this manual.
appropriate to the drive.
Two ground studs are provided on each chassis.
The one nearest the input terminals is for
Input Line Conductor and Branch Circuit grounding the AF95 drive chassis. The one
Overload Protection Selection nearest the motor (output) terminals is to be
used for grounding the frame of the motor.
Use a combination of the following guidelines to
choose the correct input line conductors and The AF95 chassis ground conductor should be
proper branch circuit overload protection: the same size as the input line conductors or
sized according to electrical code requirements.
Note: Select the input line conductor size and Use a copper or aluminum conductor.
branch circuit overload protection in
accordance with applicable code Connection to a grounded conduit does not
requirements. provide an adequate equipment ground.
• The input line and branch circuit overload Make sure that all operator’s control stations and
protection must be rated for the input voltage motor frames are adequately grounded.
and current stated on the nameplate of the
drive. The information is also listed in
Table 5-1. Input Line Impedance
• For runs over 300 feet, consider the You must ensure that the input line power
recommended minimum wire size listed in has an impedance of at least 1% and less
Table 2-1. than or equal to 5%, as ratioed to the drive
rating, for proper operation. Damage to the
• In addition, consider the wire size capacity of drive may occur if the source impedance is
the input line terminals. The size of the input less than 1%. If the source impedance is
line terminals varies depending upon the more than 5%, the drive may not provide
options supplied with the drive. Refer to the rated output voltage.
types of input connections listed on
Table 2-2. Actual input current varies considerably in
response to the efficiency and power factor of
• The input line conductors must be made of the motor connected to your drive and the
copper with a temperature rating of at least impedance of the power source.
167°F (75°C).
Since power source impedance has an effect on
the harmonic content of the input current, the
amount of impedance affects the value of the
input line current.

2-6
Pre-Installation
SECTION 2

The value of source impedance is expressed as
a percent of the effective impedance of the Since the design of a power distribution system
drive. often includes a short circuit capacity study,
power distribution system drawings or other
To determine the source impedance as a distribution system documentation may show
percent of the effective impedance of the drive, the short circuit capacity at various points. If this
you must know: data is not available, contact your Cutler-
Hammer Distributor or Field Sales Office for
• The short circuit capacity of the power help on estimating or calculating short circuit
source in symmetrical amperes at the drive’s current capacity.
input power terminals.
If you cannot calculate the short circuit capacity
• The full load (output) current rating of the before you purchase your drive, you can
drive (found on the nameplate or Table 5-1). estimate the input impedance by performing this
procedure:
The following calculation provides the source
impedance as a percent of the effective 1. With drive running and connected to the
impedance of the drive: motor, display the DC Bus Current on
your keypad LCD.
Full Load Current
100 = Source
Short Circuit Capacity * Review the instructions for using the
Impedance
Operation Display in your Operator’s
Manual.
The short circuit capacity must be at least 20 2. Use a clamp-on ammeter to measure the
times the full load current rating (5% impedance) Input Line Current (RMS) with the drive
and no more than 100 times the full load current running and connected to the motor.
rating (1% impedance).
3. Perform the following calculation:
For example, if the full load (output) current of an
AF95 drive is 22 amps and the short circuit Input Line Current (RMS)
= at most 1.00
current capacity of the power source is 2200 DC Bus Current
amps, the source impedance is:
22
4. If the calculation result is more than 1.00,
2200 * 100 = 1.00%
you must install a 1% input line reactor.

2-7
Pre-Installation
SECTION 2
Line Considerations
Typical Recommended Minimum Wire Size (AWG and MCM) To Prevent Excessive
Current Voltage Drop For Various Wire Run Distances (Feet)
per NEC
Hp (Amps) 300 Ft. 500 Ft. 700 Ft. 1,000 Ft.
15 22 10 8 6 6
20 28 8 8 6 4
25 36 8 6 4 3
30 42 8 6 4 2
40 55 6 4 3 1
50 68 4 3 2 1/0
60 81 3 3 1 2/0
75 101 1 1 2/0 4/0
100 130 2/0 2/0 3/0 250
125 164 3/0 3/0 4/0 400
150 189 4/0 4/0 250 500
200 252 350 350 500 2x250
250 300 350 350 2x4/0 2x350
300 380 500 2x3/0 2x300 2x600
Note: A dv/dt filter minimizes the possibility of motor damage due to peak voltages and dv/dt levels for
480 and 575 VAC AF95’s. Refer to page 5-8 for specific recommendations.
Note: The wire sizes noted above are based on voltage drop limitations. If the wire sizes used exceed
those allowed for in the AF95, the installer must provide the appropriate transition sections. The
AF95 wire capacities for various configurations are listed in Table 2-2.
Recommended Minimum Input Line and Output Power Wire Size

Table 2-1

2-8
Pre-Installation
SECTION 2
Line Considerations
HP (KW) Voltage/ Input/Output Input Disconnect Contactor Overload
Frequency Block, TB2* (See device for (Torque lb-in) (Torque lb-in)
(Torque lb-in) torque)
15 208/60 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
20 208/60 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
25 208/60 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #14 - #2/0 Ga. (200) #14 - #2/0 Ga. (200)
30 208/60 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #14 - #2/0 Ga. (200) #14 - #2/0 Ga. (200)
40 208/60 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #8 - #3/0 Ga. (200) #14 - #2/0 Ga. (200)
15 240/60 #18 - #2 Ga. (25) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (35)
20 240/60 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
25 240/60 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
30 240/60 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #14 - #2/0 Ga. (200) #14 - #2/0 Ga. (200)
40 240/60 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #8 - #3/0 Ga. (200) #14 - #2/0 Ga. (200)
50 240/60 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #8 - #3/0 Ga. (200) #14 - #2/0 Ga. (200)
15 (11) 380/50 #18 - #2 Ga. (25) #14 - #4 Ga. #16 - #8 Ga. (15) #14 - #6 Ga. (35)
20 (15) 380/50 #18 - #2 Ga. (25) #14 - #4 Ga. #16 - #8 Ga. (15) #14 - #6 Ga. (35)
25 (18.5) 380/50 #18 - #2 Ga. (25) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (35)
30 (22) 380/50 #18 - #2 Ga. (25) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (35)
35 (25) 380/50 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
45 (33) VT 380/50 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
50 (37) CT 380/50 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
54 (40) VT 380/50 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #14 - #2/0 Ga. (200) #14 - #2/0 Ga. (200)
60 (45) CT 380/50 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #14 - #2/0 Ga. (200) #14 - #2/0 Ga. (200)
75 (55) VT 380/50 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #14 - #2/0 Ga. (200) #14 - #2/0 Ga. (200)
75 (55) CT 380/50 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #8 - #3/0 Ga. (200) #14 - #2/0 Ga. (200)
85 (63) VT 380/50 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #8 - #3/0 Ga. (200) #14 - #2/0 Ga. (200)
15 (11) 415/50 #18 - #2 Ga. (25) #14 - #4 Ga. #16 - #8 Ga. (15) #14 - #6 Ga. (35)
20 (15) 415/50 #18 - #2 Ga. (25) #14 - #4 Ga. #16 - #8 Ga. (15) #14 - #6 Ga. (35)
25 (18.5) 415/50 #18 - #2 Ga. (25) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (35)
30 (22) CT 415/50 #18 - #2 Ga. (25) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (35)
35 (25) VT 415/50 #18 - #2 Ga. (25) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (35)
40 (30) 415/50 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
50 (37) 415/50 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
60 (45) VT 415/50 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #14 - #2/0 Ga. (200) #14 - #2/0 Ga. (200)
60 (45) CT 415/50 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #14 - #2/0 Ga. (200) #14 - #2/0 Ga. (200)
75 (55) VT 415/50 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #14 - #2/0 Ga. (200) #14 - #2/0 Ga. (200)
75 (55) CT 415/50 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #8 - #3/0 Ga. (200) #14 - #2/0 Ga. (200)
85 (63) VT 415/50 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #8 - #3/0 Ga. (200) #14 - #2/0 Ga. (200)
15 480/60 #18 - #2 Ga. (25) #14 - #4 Ga. #16 - #8 Ga. (15) #14 - #6 Ga. (35)
20 480/60 #18 - #2 Ga. (25) #14 - #4 Ga. #16 - #8 Ga. (15) #14 - #6 Ga. (35)
25 480/60 #18 - #2 Ga. (25) #6 - #1/0 Ga. #14 - #6 Ga. (15) #14 - #2 Ga. (35)
30 480/60 #18 - #2 Ga. (25) #6 - #1/0 Ga. #14 - #6 Ga. (15) #14 - #2 Ga. (35)
40 480/60 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
50 480/60 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
Wire Size Capacity of Input Line and Output Power Terminals for Various AF95 Configurations
Table 2-2 (Sheet 1 of 2)

2-9
Pre-Installation
SECTION 2
Line Considerations
HP (KW) Voltage/ Input/Output Input Disconnect Contactor Overload
Frequency Block, TB2* (See device for (Torque lb-in) (Torque lb-in)
(Torque lb-in) torque)
60 480/60 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #14 - #2/0 Ga. (200) #14 - #2/0 Ga. (200)
75 480/60 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #14 - #2/0 Ga. (200) #14 - #2/0 Ga. (200)
100 480/60 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #8 - #3/0 Ga. (200) #14 - #2/0 Ga. (200)
125 480/60 #2 - #4/0 Ga. (144) (2) 3/0 Ga. - (2) 750 MCM or
(2) 250 MCM (2) 250 MCM & 3/0 —
Ga. (550)
150 VT 480/60 #2 - #4/0 Ga. (144) (2) 3/0 Ga. - (2) 750 MCM or
(2) 250 MCM (2) 250 MCM & 3/0 —
Ga. (550)
150 CT 480/60 #3/0 Ga. - 500 (2) 3/0 Ga. - (2) 750 MCM or
MCM (240) (2) 250 MCM (2) 250 MCM & 3/0 —
Ga. (550)
200 VT 480/60 #3/0 Ga. - 500 (2) 3/0 Ga. - (2) 750 MCM or
MCM (240) (2) 250 MCM (2) 250 MCM & 3/0 —
Ga. (550)
200 CT 480/60 #3/0 Ga. - 500 (2) 250 MCM - 500 - 750 MCM
—
MCM (240) (2) 350 MCM (500)
250 VT 480/60 #3/0 Ga. - 500 (2) 250 MCM - 500 - 750 MCM
—
MCM (240) (2) 350 MCM (500)
300 VT 480/60 #3/0 Ga. - 500 (2) 250 MCM - 500 - 750 MCM
—
MCM (240) (2) 350 MCM (500)
15 575/60 #18 - #2 Ga. (25) #14 - #4 Ga. #16 - #8 Ga. (15) #14 - #6 Ga. (35)
20 575/60 #18 - #2 Ga. (25) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (35)
25 VT 575/60 #18 - #2 Ga. (25) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (35)
25 CT 575/60 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
30 575/60 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
40 575/60 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
50 VT 575/60 #14 - #2/0 Ga. (45) #6 - #1/0 Ga. #14 - #6 Ga. (40) #14 - #2 Ga. (45)
50 CT 575/60 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #14 - #2/0 Ga. (200) #14 - #2 Ga. (45)
60 VT 575/60 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #14 - #2/0 Ga. (200) #14 - #2 Ga. (45)
75 VT 575/60 #14 - #2/0 Ga. (45) #2 - #4/0 Ga. #14 - #2/0 Ga. (200) #14 - #2 Ga. (45)
* Terminal block used for input line wiring when input disconnect and/or bypass contactor options are not installed.
Terminal block used for output wiring when output contactor and/or motor overload options are not installed.
Wire Size Capacity of Input Line and Output Power Terminals for Various AF95 Configurations
Table 2-2 (Sheet 2 of 2)

2-10
Pre-Installation
SECTION 2
Harmonic Distortion For example, if the source impedance

(expressed as a percent of the effective
As stated in the discussion on Input Line impedance of the drive) is 1%, you will cause
Impedance, source impedance can affect the less harmonic voltage distortion than if the
harmonic content of the input line current. As source impedance is 5%.
source impedance increases, line current
harmonic content decreases. Often harmonic distortion limits shown in, IEEE
519-1992, IEEE Recommended Practices and
The relationship between input line impedance Requirements for Harmonic Control in Electrical
and harmonic voltage distortion is just the Power Systems, are specified as maximum
opposite of the relationship between impedance levels for an installation. The point of common
and current distortion. As source impedance coupling, usually the utility feed to the
increases, so does harmonic voltage distortion. installation, is the location for the harmonic
calculations.
Contact your Cutler-Hammer Distributor or Field

Sales Office for assistance in estimating
harmonic distortion in multiple drive installations.
They can also provide assistance in selecting a
means of harmonic reduction such as line
reactors.

2-11
Pre-Installation
SECTION 2
Input Line Routing Isolation Transformers
• Use a separate conduit or cable tray for Isolation transformers can be used with AF95
input line conductors and output power Adjustable Frequency Drives. See the previous
conductors. Never route analog and digital discussion on Input Line Impedance.
wiring from any equipment in the same
conduit or cable tray as input or output
power wiring. Power Factor Correction
Multiple Conductor Wiring The displacement power factor at the input

terminals of an AF95 drive is approximately 0.95
If multiconductor wiring is used with more than at all operating speeds and loads. Therefore,
one drive, a separate multiconductor cable must power factor correction capacitors are not
be used for the input line wiring for each drive. required and should not be installed.
Line Fuses ! Caution

Line fuses are intended to remove input line If capacitors for correcting the power factor of
voltage from the drive in the event of internal other equipment are installed too close to the
component and drive failure. Optional line drive, drive and capacitor failure may result.
fuses installed in the drive must not be used
in place of branch circuit overload
protection. Standby Power Generation
AF95 Input Disconnect Three phase standby power generators can be

used with AF95 Adjustable Frequency Drives.
This option is used as a mechanical means of Consult your Cutler-Hammer Distributor or Field
disconnecting input power to the drive. AF95 Sales Office for elements to be considered if you
input disconnect installed in the drive must will be switching the AF95 input between
not be used in place of branch circuit generator and utility power.
overload protection.
Surge Protection
All AF95 Adjustable Frequency Drives are

equipped with a Metal Oxide Varistor (MOV)
circuit that provides voltage surge protection and
phase-to-phase plus phase-to-ground protection
which is designed to meet ANSI C62.41.

2-12
Pre-Installation
SECTION 2
Output Power Considerations

To comply with local and nationally recognized Output Power Conductor Routing
authorities, such as the NEC, you must consider
proper output power wiring when you plan your • Use a separate conduit or cable tray for
Adjustable Frequency Drive installation. input line conductors and output power
conductors. Never route analog and digital
Output Power Conductor Sizing wiring from any equipment in the same
conduit or cable tray as input or output
Use a combination of the following guidelines to power wiring.
choose the correct input line conductors and
proper branch circuit overload protection: Motor Overload Protection
Note: Select the output power conductor size in AF95 Adjustable Frequency Drives are designed
accordance with applicable code to automatically provide motor overload
requirements. protection only if one motor is connected to the
drive and the drive is properly configured for that
• The output power conductors must be rated motor.
for the output voltage and current stated on
the nameplate of the drive. The information If more than one motor is connected to the drive,
is also listed in Table 5-1. each motor must have its own overload
protection. In addition, the combined input
• For runs over 300 feet, consider the current rating on the nameplate of each motor
recommended minimum wire size listed in must not exceed the output current rating of the
Table 2-1 to minimize voltage drop. drive.
• In addition, consider the wire size capacity of

the output power terminals. The size of the Power Factor Correction
output power terminals varies depending
upon the options supplied with the drive. Power factor correction capacitors must never
Refer to the types of output power be connected to the output of the drive.
connections listed on Table 2-2.
• The output power conductors must be made ! Caution

of copper with a temperature rating of at
least 167°F (75°C).
If capacitors for correcting the motor power
factor are connected the AF95 output or the
dv/dt Filter
driven motor, drive and capacitor failure may
result.
A dv/dt filter minimizes the possibility of motor
damage due to peak voltages and dv/dt levels
for 480 and 575 VAC AF95’s. Refer to page 5-8
for specific recommendations.

2-13
Pre-Installation
SECTION 2
Analog and Digital Signal Considerations
To comply with the design of the drive and local • The analog and digital signal conductors
and nationally recognized authorities, follow must be made of copper with a temperature
proper analog and digital signal wiring when you rating of at least 167°F (75°C).
plan your Adjustable Frequency Drive
installation. Analog and Digital Conductor Routing
External Fault Signal
• If you use conduit:
Some configurations, such as an optional
overload interlock relay, provide an external fault Never route analog and digital wiring
signal to the drive so the drive will not start if the from any equipment in the same conduit
relay has tripped and not reset. If this or any as input or output power wiring.
other option that requires an external fault signal
is installed by the factory, the signal is factory Do not run AF95 Adjustable Frequency Drive
wired. If an option is not factory wired, this analog and digital signal conductors in the
input must be jumpered unless it will be used same conduit that has control wiring for
by an application installed by the customer. other equipment.
See the applicable logic schematic for details.
• If you use cable trays:
Analog and Digital Signal Wiring
Never route analog and digital wiring
• 18 AWG wire size is recommended. from any equipment in the same cable
Minimum wire size is 22 AWG. Maximum tray as input or output power wiring.
wire size is 14 AWG.
• One conductor per terminal for conductors Separate analog and digital wiring for your
14 and 16 AWG. Two conductors per AF95 drive from other control equipment
terminal at 18 AWG. Three conductors per wiring using a metal tray divider or keeping
terminal at 20 and 22 AWG. the conductors at least 2 inches apart.
• Maximum length is 500 feet; call Cutler- Trays containing analog and digital wiring
Hammer for longer runs. should be separated from trays containing
• Use shielded cable for the analog signal low voltage (up to 30 volts) power wiring by
conductors where indicated on the terminal at least 9 inches.
block connection diagram. Typically,
Trays containing analog and digital wiring
shielding is required for all analog input and
should be separated from trays containing
output runs. See Figure 4-6.
medium voltage (between 30 and 150 volts)
All digital signal runs over 75 feet long power wiring by at least 18 inches.
should be shielded.
• Only ground the shield conductor of shielded

cable at the terminal block of the drive. Do
not ground the other end of the shield
conductor.

2-14
Pre-Installation
SECTION 2
Arcnet® Network Considerations
An Arcnet® network communication system is Keypad Assembly or Terminal Block

used to provide communications between the Factory Mounted in AF95 Optional NEMA
AF95 logic board and keypad assembly(s) Enclosure Door
and/or terminal blocks. Power is also supplied to
the keypad assemblies and terminal blocks via If a keypad assembly or terminal block is factory
the Arcnet® cable in some configurations. mounted in the door of an oversized NEMA
enclosure, a factory installed, twisted pair
A keypad assembly provides a combination of Arcnet® cable, connects the keypad assembly to
an operation interface (which includes an LCD the logic board and another cable connects the
and keypad) and a terminal block (which keypad assembly to the terminal block (if any).
provides connection to analog and digital Arcnet® communications and power are supplied
discrete input and output signals). Terminal through this cable. See Section 4, Drawings, for
blocks with no operator interface are also details.
available for an AF95 drive. See Section 5,
Specifications, for more information on keypad
assemblies and terminal blocks. Keypad Assembly or Terminal Block
Mounted in a Custom Enclosure Door or
See the following discussions for specific
Remotely
configuration details.
If one or more devices (keypad assemblies or
terminal blocks) are mounted in the door of a
Keypad Assembly and Terminal Blocks
custom enclosure, you must purchase a twisted
Factory Mounted in AF95 Chassis pair Arcnet® cable, from Cutler-Hammer (various
or NEMA Type 1 Enclosure lengths of cable are available).
If a keypad assembly and terminal block are If the total length of cable from the logic board to
factory mounted in an AF95 chassis, a factory the last device exceeds 20 feet, an auxiliary
installed, twisted pair Arcnet® cable, connects power supply is required. The maximum
the keypad assembly to the logic board and distance must not exceed 400 feet.
another cable connects the keypad assembly to
the terminal block (if any). Arcnet®
communications and power are supplied through
this cable. See Section 4, Drawings, for details.

2-15
Pre-Installation
SECTION 2
Arcnet® Network Considerations
Arcnet® Address Setting
Each terminal block and keypad assembly has

its own Arcnet® address. The address is set
using the Arcnet® BCD Address Select switch on
the keypad assembly.
Arcnet® Terminating Resistor
Set both Arcnet® Terminating Resistor switches

(on keypad assembly they are SW3-1 and SW3-
2), to the closed position on the last device.
Set both Arcnet® Terminating Resistor switches

on all other devices to the open position.

2-16
SECTION 3
Installation Check List
To help assure a safe and reliable drive installation, make
sure that the following tasks have been properly completed.
You can find complete information on the task by referring to
the Section(s) listed in the right column:
Installation Tasks Section(s)
❐ Pre-Installation 2
Application Considerations 2, 4 and 5

Input Line Considerations 2
Output Power Considerations 2
Analog and Digital Signal Considerations 2
Arcnet® Network Considerations 2
Where to Locate Drive 2
Handling of Drive After Delivery 2

3-1
SECTION 3
! Warning
To avoid an electrical shock, which can cause
serious personal injury or death, make sure
branch circuit AC power is disconnected before
you rough-in and connect the wiring.
Installation Tasks Sections
❐ Rough-In Enclosures
• Install options, if necessary, using the NA

instructions packed with each option.
• Mount enclosures, in location selected, 2

when job site is clear of heavy and
overhead construction.
• Use mounting dimensions shown in the 4

applicable enclosure illustration.
❐ Rough-In Wiring
• Refer to the pre-installation list and gather 2

wiring and materials necessary to install
input line, output power, and terminal block
wiring.
• Route all wiring through conduit or cable 2

trays as described.

3-2
SECTION 3
! Danger
The AF95 drive and motor must be properly
grounded to avoid electric shock which can
cause death or serious injury.
! Caution
AF95 Adjustable Frequency Drives contain
components and sub-assemblies that are
sensitive to electrostatic discharge. Static
control precautions are required when installing,
testing, servicing, or repairing your Adjustable
Frequency Drive. Component damage may
result if you ignore electrostatic discharge
control procedures.
Installation Tasks Sections
❐ Connect Wiring
• Connect input line and output power 4
conductors to locations shown in
applicable power connection drawing.
• Connect input and output ground 4

conductors to the chassis where
shown on the applicable power connection
drawing.
• Connect the analog and digital signal 4

wiring to locations shown on the applicable
logic schematic.
• Connect all shielded cables to terminal 4

block ground terminals where shown on
the applicable logic schematic. Only
ground the cable at the drive.
• Connect drive to PC that has the 4

Programmer’s Software installed, if needed.
• Connect Arcnet® cables, if needed. 4
• Check all wiring connections against all 4

connection diagrams that came packed
with the drive or in this manual.

3-3
SECTION 3
! Warning
To avoid an electrical shock, which can cause
serious personal injury or death, make sure AC
power is disconnected from drive before you
connect the output power to the motor.
! Caution
Read and heed all danger, warning, and caution
statements contained in the motor manual and
attached to the equipment. Refer to OSHA rules
and regulations, paragraph 1910.219 for guards
on mechanical power transmission apparatus.
Installation Tasks
❐ Install Motor and Related Equipment

• Mount motor and related equipment
according to manufacturer’s instructions.
Care should be taken to assure that the
motor is properly aligned with the driven
machinery to minimize motor loading.
• Connect output wiring to motor

according to the manufacturer’s
instructions. Make sure all phases are
properly connected and the motor frame
is grounded. Then connect the motor,
applying the proper voltage, according to
the diagram provided on the motor
nameplate.
• Check wiring connections to the motor.

3-4
SECTION 3
Installation Tasks
❐ Initial Startup
1. Apply AC power to the drive.
As shipped, the drive is ready to operate using the

keypad operator controls. We recommend that you use
the operator keypad for initial startup prior to using any
external circuitry. In some installations, the drive may
need to be configured prior to initial startup.
If the motor is designed for a non-standard voltage or

frequency, or if there are other unusual operating
requirements, we recommend that you contact the
Cutler-Hammer Solid State Motor Control Service
Department for startup assistance.
Refer to your AF95 Operator’s Manual for specific

operating instructions.
! Warning
Rotating mechanical equipment can cause
serious personal injury and property damage
unless you handle them carefully, especially
when the equipment is operating:
• Never wear loose fitting clothing, such as ties

and scarves, when you operate rotating
mechanical equipment.
• Always wear safety glasses when you

operate rotating mechanical equipment.
• Stand clear, and make sure all hands and

feet are clear, of rotating mechanical
equipment before you start the Adjustable
Frequency Drive.
• Refer to OSHA rules and regulations,

paragraph 1910.219 for the use of guards on
mechanical power transmission devices.

3-5
SECTION 3
2. Set a low operating speed.
3. Press the Start or Jog button.
Check to see that the motor is rotating in the correct

direction. Be prepared to stop the drive if the direction of
rotation is not correct. If the direction is not correct,
disconnect power from the drive and reverse the
connection of any two motor leads.
4. Check operation throughout the normal operating speed

range.
5. If you observe abnormal operation, refer to the AF95

Operator’s Manual.
6. Configure the drive per special requirements after you

verify basic operation. Refer to the AF95/IS905
Programmer’s Manual for configuration instructions.
! Danger High Voltage

The left side of the logic board is at bus potential
when connected to supply voltage. This voltage
is extremely dangerous and can cause death or
serious injury. When the supply is disconnected
from the input terminal block, it will take up to 10
minutes before the DC bus caps are discharged
to a safe voltage.
To ensure the voltage is safe, monitor the

capacitor discharge with a DC voltmeter
connected between the “+BUS” and “-BUS”
terminals on the input terminal block. Do not
work on the drive until the capacitors have
completely discharged. Do not attempt to
discharge the capacitors by short circuiting the
bus.
7. Check operation with external control circuitry.

3-6
SECTION 4
Drawings
This section of your AF95 Installation Manual presents the following
series of drawings:
• Cross reference between AF95 ratings and dimensional drawings.
• Dimensional drawings for AF95 configurations. These drawings

include special ventilation requirements as required.
• Terminal block assignments for typical AF95 configurations.
• Typical connection diagram for AF95 terminal block.
• Identification of AF95 keypad assembly elements including

terminal block pins, switches, AF95 Arcnet® and AF95 programmer
connections.
• Typical Cutler-Hammer AF95 Programmer connection diagram.
• Typical Arcnet® connection diagram.

4-1
480 Volt Dimensional Drawings
4-2
Horsepower Chassis NEMA 1 O/S NEMA 1 O/S NEMA 1 w/Floor Stand (V1) NEMA 12 NEMA 12 w/Floor Stand (V1) O/S NEMA 12*
15 and 20 Fig. 4-1 Fig. 4-7 Fig. 4-12 Fig. 4-16 Fig. 4-18 Fig. 4-23 NA
SECTION 4
60 and 75 Fig. 4-3 Fig. 4-9 Fig. 4-13 Fig. 4-17 Fig. 4-20 Fig. 4-24 Fig. 4-25
100 Fig. 4-4 Fig. 4-10 Fig. 4-14 NA Fig. 4-21 NA Fig. 4-26
125 to 200VT Fig. 4-5 Fig. 4-11 Fig. 4-15 NA Fig. 4-22 NA NA
200CT Fig. 4-6 NA Fig. 4-15 NA Fig. 4-22 NA NA
Drawings
250VT and Fig. 4-6 NA Fig. 4-15 NA Fig. 4-22 NA NA

300VT
* Required for line reactor, or EMI Filter, or bypass option.

15 Fig. 4-1 Fig. 4-7 Fig. 4-12 Fig. 4-16 Fig. 4-18 Fig. 4-23 NA
30 Fig. 4-3 Fig. 4-9 Fig. 4-13 Fig. 4-17 Fig. 4-20 Fig. 4-24 Fig. 4-25
40 and 50 Fig. 4-4 Fig. 4-10 Fig. 4-14 NA Fig. 4-21 NA Fig. 4-26


25 and 30 Fig. 4-3 Fig. 4-9 Fig. 4-13 Fig. 4-17 Fig. 4-20 Fig. 4-24 Fig. 4-25
40 Fig. 4-4 Fig. 4-10 Fig. 4-14 NA Fig. 4-21 NA Fig. 4-26
To find the correct dimensional diagram and ventilation requirements for your AF95 Adjustable Frequency Drive:
1. Tables 4-1 and 4-1a are sub-divided into voltage ratings for AF95 Adjustable Frequency Drives.
2. Find the input power voltage rating that matches your AF95 drive.
2. Use the horsepower or kilowatt rating and your configuration (such as chassis or NEMA 1)
to find the proper dimensional illustration (Figure 4-1 through 4-26).
4. Each illustration provides specifics for mounting the drive and special ventilation requirements (if any).
Cross Reference Between AF95 Ratings and Dimensional Drawings

480, 240 and 208 Volt
Table 4-1
15 and 20VT Fig. 4-1 Fig. 4-7 Fig. 4-12 Fig. 4-16 Fig. 4-18 Fig. 4-23 NA
20CT to 30VT Fig. 4-1 Fig. 4-7 Fig. 4-12 Fig. 4-16 Fig. 4-18 Fig. 4-23 NA
25CT to 50VT Fig. 4-2 Fig. 4-8 Fig. 4-13 Fig. 4-17 Fig. 4-19 Fig. 4-24 NA
50CT to 75VT Fig. 4-3 Fig. 4-9 Fig. 4-13 Fig. 4-17 Fig. 4-19 Fig. 4-24 Fig. 4-25

Kilowatt (HP) Chassis NEMA 1 O/S NEMA 1 O/S NEMA 1 w/Floor Stand (V1) NEMA 12 NEMA 12 w/Floor Stand (V1) O/S NEMA 12*
11 and 15 Fig. 4-1 Fig. 4-7 NA NA NA NA NA
(15 and 20)
18.5 and 22 Fig. 4-1 Fig. 4-7 NA NA NA NA NA
(25 and 30)
(35VT and 50)
40 and 55VT Fig. 4-3 Fig. 4-9 NA NA NA NA NA
(54 and 75VT)
55CT and 63VT Fig. 4-4 Fig. 4-10 NA NA NA NA NA
(75CT and 85)

Kilowatt (HP) Chassis NEMA 1 O/S NEMA 1 O/S NEMA 1 w/Floor Stand (V1) NEMA 12 NEMA 12 w/Floor Stand (V1) O/S NEMA 12*
(15 and 20)
18.5 and 25 Fig. 4-1 Fig. 4-7 NA NA NA NA NA
(25 and 35VT)
(40 and 50)
45 and 55VT Fig. 4-3 Fig. 4-9 NA NA NA NA NA
(60 and 75VT)
55CT and 63VT Fig. 4-4 Fig. 4-10 NA NA NA NA NA
(75CT and 85VT)
Cross Reference Between AF95 Ratings and Dimensional Drawings

575, 380 and 415 Volt
SECTION 4
4-3
Drawings

Table 4-1a
Drawings
SECTION 4
NOTE: LEAVE AT LEAST 6" (152 MM)

BETWEEN UNITS IF THEY
ARE PLACED SIDE-BY-SIDE.
AF95-01
Dimensional Drawing
Figure 4-1

4-4
Drawings
SECTION 4

AF95-02
Dimensional Drawing
Figure 4-2

4-5
Drawings
SECTION 4
AF95-03
Dimensional Drawing
Figure 4-3

4-6
Drawings
SECTION 4
AF95-04
Dimensional Drawing
Figure 4-4

4-7
Drawings
SECTION 4
FAN CUTOUT COVER PLATE

LEFT AND RIGHT SIDE
AF95-05
Dimensional Drawing
Figure 4-5

4-8
Drawings
SECTION 4
FAN CUTOUT COVER PLATE

LEFT AND RIGHT SIDE
WEIGHT: APPROXIMATELY 310 LB.

140.6 KILOGRAMS
DIMENSIONS IN BRACKETS ARE IN MILLIMETERS AF95-06
Dimensional Drawing
Figure 4-6

4-9
Drawings
SECTION 4

AF95-07
Dimensional Drawing
Figure 4-7

4-10
Drawings
SECTION 4

AF95-08
Dimensional Drawing
Figure 4-8

4-11
Drawings
SECTION 4
AF95-09
Dimensional Drawing
Figure 4-9

4-12
Drawings
SECTION 4
AF95-10
Dimensional Drawing
Figure 4-10

4-13
Drawings
SECTION 4
AF95-11
Dimensional Drawing
Figure 4-11

4-14
Drawings
SECTION 4

AF95-12
Dimensional Drawing
Figure 4-12

4-15
Drawings
SECTION 4
AF95-13
Dimensional Drawing
Figure 4-13

4-16
Drawings
SECTION 4
AF95-14
Dimensional Drawing
Figure 4-14

4-17
Drawings
SECTION 4
AF95-15
Dimensional Drawing
Figure 4-15

4-18
Drawings
SECTION 4
AF95-16
Dimensional Drawing
Figure 4-16

4-19
Drawings
SECTION 4
AF95-17
Dimensional Drawing
Figure 4-17

4-20
Drawings
SECTION 4

AF95-18
Dimensional Drawing
Figure 4-18

4-21
Drawings
SECTION 4
AF95-19
Dimensional Drawing
Figure 4-19

4-22
Drawings
SECTION 4
AF95-20
Dimensional Drawing
Figure 4-20

4-23
Drawings
SECTION 4
AF95-21
Dimensional Drawing
Figure 4-21

4-24
Drawings
SECTION 4
AF95-22
Dimensional Drawing
Figure 4-22

4-25
Drawings
SECTION 4
AF95-23
Dimensional Drawing
Figure 4-23

4-26
Drawings
SECTION 4
AF95-24
Dimensional Drawing
Figure 4-24

4-27
Drawings
SECTION 4
AF95-25
Dimensional Drawing
Figure 4-25

4-28
Drawings
SECTION 4
AF95-26
Dimensional Drawing
Figure 4-26

4-29
Drawings
SECTION 4
Terminal Block Configuration Number Options.

Select The Desired Configuration Number By Using The Keypad.
#1 #2 #3 #4 #5
1 AUTO FOLLOWER AUTO FOLLOWER AUTO FOLLOWER AUTO FOLLOWER AUTO FOLLOWER
2 AUTO FOLLOWER AUTO FOLLOWER AUTO FOLLOWER AUTO FOLLOWER AUTO FOLLOWER
3 COMMON COMMON COMMON COMMON COMMON
4 SPEED SPEED SPEED SPEED SPEED
5 LOAD LOAD LOAD LOAD LOAD
6 SHIELD COMMON SHIELD COMMON SHIELD COMMON SHIELD COMMON SHIELD COMMON
7
8 SPEED SET SPEED SET SPEED SET SPEED SET SPEED SET
9
10
Keypad 11 STATUS RUN ENABLE/STOP RUN ENABLE/STOP RUN ENABLE/STOP RUN ENABLE/STOP
Assembly 12 STATUS START 1 START 1 START 1 START 1
Terminal 13 STATUS PLC RUN 2 PLC RUN 2 PLC RUN 2 PLC RUN 2
Block 14 STATUS FORWARD/REVERSE FORWARD/REVERSE FORWARD/REVERSE MANUAL/AUTO
15 STATUS JOG 3 JOG 3 PRESET INPUT #1 PRESET INPUT #1
16 STATUS MANUAL/AUTO MANUAL/AUTO PRESET INPUT #2 PRESET INPUT #2
17 STATUS PRESET INPUT #1 CONTACTOR INTLK PRESET INPUT #3 PRESET INPUT #3
18 STATUS EXTERNAL FAULT EXTERNAL FAULT EXTERNAL FAULT EXTERNAL FAULT
19 RUN RUN CONTACTOR DRIVER RUN RUN
22 FAULT FAULT FAULT FAULT FAULT
Terminal Block Configuration Number Options.

Select The Desired Configuration Number By Using The Keypad.
#6 #7 #8 #9 # 10
1 AUTO FOLLOWER AUTO FOLLOWER AUTO FOLLOWER AUTO FOLLOWER PID FEEDBACK
2 AUTO FOLLOWER AUTO FOLLOWER AUTO FOLLOWER AUTO FOLLOWER PID FEEDBACK
3 COMMON COMMON COMMON COMMON COMMON
4 SPEED SPEED SPEED SPEED SPEED
5 LOAD LOAD LOAD LOAD LOAD
6 SHIELD COMMON SHIELD COMMON SHIELD COMMON SHIELD COMMON SHIELD COMMON
7
8 SPEED SET SPEED SET SPEED SET SPEED SET PID SETPOINT
9
10
Keypad 11 RUN ENABLE/STOP RUN ENABLE/STOP RUN ENABLE/STOP RUN ENABLE/STOP RUN ENABLE/STOP
Assembly 12 START 1 START 1 START 1 START 1 START 1
Terminal 13 PLC RUN 2 PLC RUN 2 PLC RUN 2 PLC RUN 2 PLC RUN 2
Block 14 FORWARD/REVERSE MANUAL/AUTO SMOKE PURGE SMOKE PURGE SMOKE PURGE
15 PRESET INPUT #1 PRESET INPUT #1 PM SETBACK PM SETBACK PM SETBACK
16 PRESET INPUT #2 PRESET INPUT #2 MANUAL/AUTO MANUAL/AUTO MANUAL/AUTO
17 CONTACTOR INTLK CONTACTOR INTLK EXTERNAL INTLK CONTACTOR INTLK CONTACTOR INTLK
18 EXTERNAL FAULT EXTERNAL FAULT EXTERNAL FAULT EXTERNAL FAULT EXTERNAL FAULT
19 CONTACTOR DRIVER CONTACTOR DRIVER RUN CONTACTOR DRIVER CONTACTOR DRIVER
1 Not in configurations 2a thru 10a
2 Start/Stop replaces PLC Run for configurations 2a thru 10a
3 Not in configurations 2a or 3a
ETN-Term Blk Opt
Typical Terminal Block Assignments for Typical AF95 Configurations

Figure 4-27

4-30
Drawings
SECTION 4
TB-COM - Serial Communication Port
5 4 3 2 1
Removable Terminal Block
See TB-COM Table
SW2 NOTE 1: When terminal #18 (DIN8) is configured for
external fault, it must be jumpered unless
2 TB1 - 24 Position Removable
1 Terminal Block it is connected to an external fault contact.
1 (+) Analog Signal Input Terminal #18 (DIN8) may be factory wired -
2 (–) See Notes 2 and 3 see below.
3 COM
Analog Output Signals
4 CH 1 (+)
See Note 3.
5 CH 2 (+)
6
+ Speed Pot
7 NOTE 2: If pneumatic signal follower
8
1K is supplied, analog signal is
9
(See Note 3) factory wired and is not
COM available.
10
11
12
13 Digital Inputs
14 (DIN1-DIN8)
15
For Customer Use Optional Overload Interlock
16
See Fig. 4-5 (Factory Wired)
17
OL
18 18 10
Relay 1 19
20
Optional Dual Overload Interlock
21
Programmable Relays (Factory Wired)
22 For Customer Use
23 See Fig. 4-5 OL1 OL2
18 10
24
Relay 2
Keypad TB-COM Table

Assembly Terminal Two Wire Description SW2
PCB TB-COM-1 RXTX – Receiver and Transmitter –
TB-COM-2 RXTX + Receiver and Transmitter + Position 1 Closed
TB-COM-3 GND Signal Ground Position 2 Open
TB-COM-4 Jumper To TB-COM-1
NOTE 3: Analog input 1 can be configured for 4-20ma or TB-COM-5 Jumper To TB-COM-2
0-10VDC. Analog input 2 can be configured for
a potentiometer or 0-10VDC. Analog output 1 Terminal Four Wire Description SW2
and 2 can be configured for a 4-20ma or TB-COM-1 RXD – Receiver –
0-10VDC. The default setup for terminals 7 to 9 TB-COM-2 RXD + Receiver + Position 1 Closed
is a speed potentiometer input and terminals 1 TB-COM-3 GND Signal Ground Position 2 Closed
to 2 as a 4-20ma input. The two analog outputs TB-COM-4 TXD – Transmitter –
on terminals 4 to 3 and 5 to 3 are defaulted to TB-COM-5 TXD + Transmitter +
4-20ma. When analog output 2 is configured for
0-10VDC, the signal input terminals are 8(+) to RS-485 Communications Port
6(-). To reconfigure the analog I/O from the RS-485 Operates from the CPU's SCI (Serial Communications
default value, refer to the Analog Signal Interface). Both two wire (half duplex) and four wire (full duplex)
Configuration section of the AF95 Operator's RS-485 Operation are supported. Consult factory for RS-232
Manual. or 422 designations. ETN-Term Blk Conn
Typical Connection Diagram for AF95 Terminal Block

Figure 4-28

4-31
Drawings
SECTION 4
RUN
FAULT
Setup/Display Control
Forward/Reverse
Scroll Parameters
Change Settings
SETUP F/R
INCREASE
Operation Display
Diagnostic Display DECREASE
DISPLAY
JOG
Speed Control Start/Stop Control

Keypad Keypad
START
FASTER
Remote Remote
SLOWER
SELECT SELECT
STOP
TB-COM
1
2
Front View
3
SW2
4
RS232 Programmer Port
5
(9 Pin Sub-D Male Connector) Pry Slot
2 TB1
Bottom View 1
1
2
1
2
TB-COM 3
3
Removable 4
4
Terminal Block LCD Backlight Adjust

5
5
2
1 6
1 SW2 Serial 7
2 Communication +5V Power Status LED 8
3 Terminating Resistor
4 9
5 10
6 11
7
8
Terminal 12
9
Block 13
10 8 Digital Input Status LEDS 14
11 (DIN1 to DIN8) 15
Front 12
16
Face 13 TB1
17
14 Removable
67 89
5 0
15 Terminal Block 18
43 1
2 16 19
17
20
18 2 Output Relay Status LEDS
19 21
20 22
1 7 8
2 6 9
21 5
4 1
0 SW4 Arcnet® BCD Address Select 23
22 3 2
24
23
24
Arcnet® Connector (P-ARC2) Pry Slot
1 SW3 Arcnet® Remove terminal block

2
Terminating Resistor by prying up, using a
screwdriver blade in slots
Detail A Detail B at each end.
Arcnet® Connector (P-ARC1)
Detail A Detail B
ETN-Combo Views
Identification of AF95 Keypad Assembly Elements

Figure 4-29

4-32
Drawings
SECTION 4
RUN
FAULT
Setup/Display Control
Forward/Reverse
Scroll Parameters
Change Settings
SETUP F/R
INCREASE
Operation Display
Diagnostic Display DECREASE
DISPLAY
JOG
Speed Control Start/Stop Control

Keypad Keypad
START
FASTER
Remote Remote
SLOWER
SELECT SELECT
STOP Keypad Assembly
RS232 Programmer Port

(9 Pin Sub-D Male Connector)
Bottom View
9 Pin Sub-D Female Connector 9 or 25 Pin Sub-D

Female Connector
Maximum 50 ft.
Serial Port
on back of
PC
Minimum Required Connections
9-Pin Female 9-Pin Female 25-Pin Female

Connector Connector Connector 386 Based Computer or Better
(Programmer Port) (PC Port) (PC Port) Loaded with Windows 3.1 and
AF95 Programmer
Pin 3 - Txd Pin 2 - Rxd Pin 3 - Rxd
Pin 2 - Rxd Pin 3 - Txd Pin 2 - Txd
Pin 5 - Gnd Pin 5 - Gnd Pin 7 - Gnd
Connections to pins other than those listed are not required. ETN-CONFIGCONN
Typical Cutler-Hammer AF95 Programmer Connection Diagram

Figure 4-30

4-33
Drawings
SECTION 4
4 3 2 1
4 3 2 1
5
2 2
1 1
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
P-ARC2 11
12
11
12
13
14
13
14
P-ARC2
67 89 15 P-ARC1 67 89 15
P-ARC
5 0 5 0
43 1
2 16 43 1
2 16
17 17
18 18
19 19
20 20
1 1
2 21 2 21
22 22
23 23
24 24 Logic Board
Arcnet® Terminating
Resistor Switch
Keypad Assembly Keypad Assembly

Terminal Block Terminal Block
Typical Chassis
1. For factory mounted board/terminal block, cable is factory installed.

®
2. Arcnet cable available in various lengths from Cutler-Hammer for custom
mounted keypad assembly/terminal blocks. If the total cable length from
the logic board to the last device exceeds 20 feet, an auxiliary power
supply is required. The maximum cable length is limited to 400 feet.
Consult your Cutler-Hammer Distributor or Field Sales Office.
ETN-ARCCONN
Typical Arcnet® Connection Diagram

Figure 4-31

4-34
SECTION 5
Specifications
This section of the Installation Manual provides the following
AF95 specifications:
• Nameplate Identification
• General Specifications
• Ratings Table
• Available Options

5-1
Specifications
SECTION 5
Nameplate Identification
Cutler-Hammer 11
! Caution
Adjustable Frequency A C Drive
Cat No: 1 The equipment warranty covers
Part No: 2 Gen. Order No.: 3 only the original nameplate
Schem: 4 Conn: 5 rating. If the equipment is applied
Software Code No: 6 contrary to the nameplate rating,
Input: 7 V 3PH HZ A RMS or if unauthorized equipment
Output: 8 To V 3PH To HZ A RMS modifications are made, the
Max Ambient 9 Deg. C
warranty becomes invalid.
Nominal HP: 10 @ Volts Overload 12
Enclosure Type: 13
Grounding Required
Cutler Hammer
Solid State Motor Control
Oldsmar, Florida USA 34677 42-160-20
ETN-AF95NAME
Legend:
1. Cat. No: - AF95 drives are available in various models 8. Output: - Rated output voltage, frequency and current.
with different ratings, specifications and features as
required for different applications. Table 5-1 and Fig. 9. Max. Ambient: - Maximum allowable ambient
5-2 summarize the information coded into the catalog temperature for continuous operation at rated
number. operating conditions.
2. Part No: - Assigned to identify the specific variations 10. Nominal HP: - Maximum brake horsepower load
of a particular model. subject to any limitation imposed by the output current
and voltage ratings.
3. Gen. Order No: - Number assigned to identify each
individual unit furnished on an individual customer 11. Independent Testing Laboratory Logo: - Only
order. certified or listed products are marked with a testing
laboratory logo.
4. Schem: - Schematic diagram drawing number for this
specific equipment. 12. Overload: - Maximum one minute output current
overload rating - typically 110% for variable torque
5. Conn: - Connection diagram drawing number for this models and 150% for constant torque models.
specific equipment.
13. Enclosure Type: - The specific type of enclosure
6. Software Code No: - Identifies the software loaded (such as “Chassis” or “NEMA Type 1”) for this AF95
into non-volatile memory. drive is listed here. For the complete list of enclosure
types available for AF95 drives, see Fig. 5-2.
7. Input: - Rated input line voltage, frequency and
current.
Typical AF95 Nameplate

Figure 5-1

5-2
Specifications
SECTION 5
General Specifications
• Drive insensitive to line phase sequence.
! Caution
Input Line Transients
It is your responsibility to check your installation • Drive protected and operational for line
to make sure it meets the conditions stated in transients to ANSI C62.41 (formerly IEEE 587)
these specifications before you install your and IEC 801.
Adjustable Frequency Drive. Operation of the
drive outside of these specifications will void • Drive protected (but may trip) for severe or
your warranty. prolonged transients per IEEE 446.
Frequency Range Keypad Assembly

1 to 133 Hz A combination of an operator interface and
You must make certain that the motor and terminal block. The operator interface consists of:
associated equipment is capable of
operating safely, and that protective guards • An LCD display (two rows of 16 characters
are in place, before you operate your drive per row) and keypad.
above 60 Hz.
• Operator can display operating conditions,
parameter settings, or English language
Input Line Conditions diagnostic messages on the LCD.
• Nameplate voltage ±10%, and nameplate • Operator can change the settings of a pre-
frequency ± 2 Hz; nominal. Drive safely defined list of parameters.
shuts down if voltage exceeds 110% or falls
below 70%. • Operator can issue Start, Stop, Forward,
• Input line impedance - 1% to 5%. You must Reverse and Jog commands and change
purchase a 1% input line reactor if you speeds using the keypad. Keypad can also be
calculate or measure input line set for remote Start and speed change.
impedance less than 1% as ratioed to the
drive rating. The terminal block (a board that provides analog
and discrete digital inputs and outputs) consists
• Line Distortion - The harmonic voltage of:
distortion of the input power line should be
limited to 10% or less including distortion • Two analog follower inputs.
caused by the drive(s). (See IEEE 519.)
• Two analog outputs.
• Three phase line input.
• Input phase voltage unbalance less than 3% • Eight digital inputs.
(per IEEE Standard 446).
• Two digital outputs.
• Single phase input protection - drive safely
shuts down if any of the phases open up.

5-3
Specifications
SECTION 5
Digital Inputs Analog and Digital Input and Output

Signal Transient Protection
2-24 VDC, non isolated. Voltage below 2 VDC is
considered active. Current from terminal to Inputs and outputs protected to IEC 801
ground will be at least 10 ma when shorted. transients.
Protected from voltages -5 to 25 VDC to ground.
Operating Environment
Digital Outputs
Isolated Form C contact closure, 1 amp resistive • Ambient Operating Conditions
at 230 VAC or 24 VDC. Separate common per 32 to 104°F (0 to 40°C). Less than or equal
pair. Max switch voltage: 30 VDC/250VAC. to 95% humidity (non condensing).
Max switch current: 8A @30 VDC, 8A @250
VAC. • Cooling Air
The cooling air must be free of conductive
Analog Inputs dust, oil mist and condensation. If the
cooling air contains dust and oil, clean the
• Potentiometer - High (5 VDC), low and heat sink surface of the unit regularly. If it is
shield connections provided. Pot input is not cleaned, the unit may overheat. The
ratiometric and needs minimum of 1 K ohm AF95 drive contains thermal protection,
resistance. All lines checked for open which will cause a fault and stop the drive.
connection. Sampling less than or equal to
50 ms with a bandwidth of better than 5 Hz. Temperature range is 32 to 104°F (0 to 40°C).
• Follower - 4 to 20 madc. Refer to the AF95
Operator’s Manual, Analog Signal Humidity, less than or equal to 95%, non
Configuration section, for setup for 0 to 10 condensing.
VDC. Common mode rejection at least 60
dB at 60 Hz and above. Protected from 3300 feet (1000 meters) maximum altitude.
common mode differential voltages ± 50
VDC. See page 2-3 for temperature and altitude
derating information.
• Both inputs - Non isolated. Resolution is 12
bits with an accuracy of ± 5% full scale. • Storage Conditions
-4 to 149°F (-20 to 65°C). Less than or equal
Analog Outputs
to 95% humidity (non condensing).
• Two analog output signals, 4 to 20 madc.
Refer to the AF95 Operator’s Manual,
Analog Signal Configuration section, to
setup 0 to 10 VDC.
• Resolution - Analog outputs are 12 bit

resolution, 5% full scale, D/A updated at a
50 ms maximum interval with 10 outputs
selected.
• Isolation and Protection- Analog outputs

are non-isolated, non differential. Protected
from voltages -5 to 25 VDC to ground.

5-4
Specifications
SECTION 5
• Heat Dissipation • Solvent Withstand

Keypad will withstand common industrial
The following table provides heat dissipation solvents, such as alcohols and acids, per
in watts for standard AF95 chassis units at ASTM-896.
rated current, 60 Hz. Certain optional
features, such as input reactors and output • Surge Protection
dv/dt reactors, add significantly to heat All AF95 Adjustable Frequency Drives are
dissipation. These estimates are for the equipped with a Metal Oxide Varistor (MOV)
standard carrier frequency setting (12 KHz circuit that provides voltage surge protection
for 15 and 20 Hp models, 6 KHz for models and phase-to-phase plus phase-to-ground
25 to 100 Hp, and 3 KHz for models 125 Hp protection which is designed to meet ANSI
and above). Higher carrier frequency C62.41.
settings result in increased heat dissipation.
Shock and Vibration
Hp VT Models CT Models
(480V, 60Hz)* (in Watts) (in Watts)
Drive will withstand shock and vibration
encountered during shipping, installation and
15 410 445
20 477 518 operation per ASTM D999.
25 540 566
30 595 628 EMI Radiation
40 902 733
50 1017 902 Drive complies with FCC part 15B of federal
60 1435 1246 regulation #47 as a class A digital device when
75 1621 1406
operated in an optional EMI enclosure installed
100 1640 1715
125 2178 2299 per the required procedures.
150 2406 2758
200 3358 2484 EMI Susceptibility
250 4402 —
300 4869 — Drive will operate without fault or disturbance in
* Consult factory for loss information at other compliance with IEC 801-3, Class 2
input voltages. (Performance Criteria 1).
• Hazardous Environment
Agency Standards
Must not be subject to explosive atmosphere
or “Hazardous (Classified) Location” per
In addition to standards previously listed, AF95
National Electrical Code Article 500.
drives comply with the following agency
standards:
• Corrosive Environment
Must not be exposed to corrosive
• UL - Standard 508C and cUL
atmosphere, such as H2S.
• NEMA - ICS 7.1

5-5
Specifications
SECTION 5
Enclosures • Optional NEMA Enclosures

These enclosures provide standalone,
The following types of enclosures are available NEMA Type 1 (General Purpose) or Type 12
for AF95 drives: (Dust Tight) mounting. A chassis and a wide
variety of options are mounted inside the
• Chassis enclosure. A keypad assembly and circuit
This type of enclosure is available for custom breaker may also be mounted in the door
mounting. All internal drive components, one (see AF95 catalog for complete details).
keypad assembly, one terminal block, and a
limited variety of options can be mounted in • Motor Control Center (MCC) Mounting
a chassis (see AF95 catalog for complete AF95 drives are available in Cutler-Hammer
details). Freedom 2100 motor control center
structures. For additional information,
• NEMA Type 1 contact your Cutler-Hammer Distributor or
This is similar to the previously listed chassis Field Sales Office.
but includes covers that enclose the
openings in the chassis. A conduit box
extension encloses the top of the chassis
and provides for conduit connection and
wiring space. The keypad assembly can be
installed on the front surface of the cover for
the logic option space. For dimensional
comparison to a chassis, see Section 4,
Drawings.

5-6
Specifications
SECTION 5
Current Current
Rating Maximum Rating Maximum
Current One Input Current One Input
Voltage/ Rating Minute Current Voltage/ Rating Minute Current
HP (KW) Frequency Continuous VT/CT Note 1 HP (KW) Frequency Continuous VT/CT Note 1
15 208/60 49 54/74 49 40 (30) 415/50 58 64/87 58
20 208/60 63 69/95 63 50 (37) 415/50 66 73/99 66
25 208/60 79 87/119 79 60 (45) 415/50 84 92/126 84
30 208/60 93 102/140 93 75 (55) 415/50 100 110/158 100
40 208/60 120 132/180 120 85 (63) VT 415/50 115 127 115
15 240/60 44 48/66 44 15 480/60 22 24/33 22
20 240/60 57 63/86 57 20 480/60 28 31/42 28
25 240/60 71 78/107 71 25 480/60 36 40/54 36
30 240/60 84 92/126 84 30 480/60 42 46/63 42
40 240/60 109 120/164 109 40 480/60 55 61/83 55
50 240/60 137 151/206 137 50 480/60 68 75/102 68
15 (11) 380/50 23 25/35 23 60 480/60 81 89/122 81
20 (15) 380/50 31 34/47 31 75 480/60 101 111/152 101
25 (18.5) 380/50 39 43/59 39 100 480/60 130 143/195 130
30 (22) 380/50 46 51/69 46 125 480/60 164 180/246 164
35 (25) 380/50 55 61/83 55 150 480/60 189 208/284 189
50 (37) VT 380/50 66 73 66 200 480/60 252 277/378 252
50 (37) CT 380/50 72 108 72 250 480/60 315 347/473 315
54 (40) VT 380/50 83 91 83 300 480/60 380 418/570 380
60 (45) CT 380/50 85 128 85 15 575/60 18 20/27 18
75 (55) 380/50 105 116/158 105 20 575/60 23 25/35 23
85 (63) VT 380/50 117 129 117 25 575/60 29 32/44 29
15 (11) 415/50 22 24/33 22 30 575/60 34 37/51 34
20 (15) 415/50 29 32/44 29 40 575/60 44 48/66 44
25 (18.5) 415/50 37 41/56 37 50 575/60 55 61/83 55
30 (22) CT 415/50 42 63 42 60 575/60 65 72/98 65
35 (25) VT 415/50 49 54 49 75 VT 575/60 77 85 77
Note 1: Currents specified with 1% input impedance as scaled to the AF95 rating and nominal input line voltage
Ratings for AF95 Adjustable Frequency Drives

Table 5-1
Legend AF95 AN0C 015V ABCD
Enclosure Style Horsepower (Examples)
N - Chassis 0xx - xx Horsepower
S - NEMA Type 1 F25 - 1/4 (0.25) Horsepower A B C D E F G H
G - NEMA 1 Oversize G12 - 1200 Horsepower
(General Purpose) Catalog Number Codes
D - NEMA 12 (Dust Tight) Application Rating
A - Base Catalog Number
V - Variable Torque
Voltage C - Constant Torque B - Series
E- 208 V, 60 Hz D - Dual Rated
C - Enclosure
B- 240 V, 60 Hz
L- 380 V, 50 Hz D - Special
K- 415 V, 50 Hz E- Voltage
C- 480 V, 60 Hz
D- 575 V, 60 Hz F- Horsepower
G- Application Rating
H- Modification Codes (See AF95 Catalog)
Catalog Number Decoding

Figure 5-2
5-7
Specifications
SECTION 5
Available Options
The following is a brief description of some of 1% Input Line Reactor - This option provides a
the options available on an AF95. For more 1% input impedance if the line impedance
information, see the AF95 Options Manual. measures less than 1% with the drive in
Bypass Contactors - This option consists of 3 operation. You must ensure that the input line
to 4 definite purpose rated contactors and a power has an impedance of at least 1% and
three-position switch (located on the enclosure less than 5% for proper drive operation.
door) that allows you to operate the motor if your Refer to the discussion on input impedance in
AF95 drive is out of service. Space is available Section 2, Pre-Installation.
for up to 2 output motor overloads. This is a 3% and 5% Input LIne Reactors - These options
factory installed option that is not available for can be mounted in an enclosure (not open
installation in a chassis. chassis) to correct input line harmonic distortions.
AF95 Input Disconnect - This option provides a Line Fuses - This option opens the input line in
lockable disconnect that can be mounted in the the event the drive fails catastrophically, or the
drive. This qualifies as a disconnecting means electronic protection fails. Line fuses, located
for the AF95 input. Lock the input disconnect in at the drive, must not be used in place of
the Off position when you service the drive. The branch circuit overload protection.
disconnect also forces you to manually
disconnect line current when you open the Output Contactor - This option provides a
enclosure door. AF95 input disconnects, positive mechanical disconnect for the output
located in the drive, must not be used in power to your motor. A definite purpose
place of branch circuit overload protection. contactor, controlled by the Start/Stop buttons,
An input disconnect is not available for connects the motor prior to the beginning of the
installation in a chassis. acceleration ramp and disconnects the motor
after the completion of the deceleration ramp.
Output Filters - 1000 V/µsec and 1500 V/µsec
! Danger High Voltage dv/dt output filters are available to minimize the
possibility of damage to motor insulation from
Defeating the input disconnect door interlock high dv/dt and peak voltage levels. The 1500
allows access to exposed components with V/µsec filter is recommended for cable runs of
cases and protrusions at or above line potential. 100 feet and up to 300 feet. The 1000 V/µsec
Take extreme care to protect yourself and others filter for cable runs of 300 to 500 feet. Exceeding
against electric shock. Refer to Section S, these distances is allowable (up to 1000 feet for
Safety in this manual. the 1000 V/µsec filter), although an inverter duty
motor (in accordance with NEMA MG 1-1993,
Dynamic Braking - This option uses active
Rev 1, Part 31, Definite Purpose Inverter-Fed
components and resistors to provide controlled
Motors) is also recommended beyond 500 feet.
braking torque to slow down or stop the load
If output filters are not used, and if an inverter
more rapidly or to retard an overhauling load.
duty motor (as described above) is not used,
Dynamic braking is capable of decelerating 2
measurements should be taken at the motor
times motor inertia at the one minute overload
terminals to determine dv/dt and peak voltage
rating of the drive (150%). The active
levels. Consult the motor manufacturer to
components are installed in the drive chassis
determine the motor’s capability of withstanding
and the braking resistors are installed in a
the measured dv/dt and peak voltage levels.
separate enclosure. Dynamic breaking is only
Special considerations exist for multiple motor
available with the following AF95 ratings: 15 to
applications.
50 Hp, 208 and 240 VAC; 15 to 100 Hp, 480
VAC; and 15 to 75 Hp, 575 VAC.
5-8
SECTION 6
Index
1 Analog and Digital Conductor Routing; 2-14
Input Line Routing and; 2-14
1% Input Line Reactor; S-3, 2-7, 5-3, 5-8
Using Cable Trays; 2-14
1500 V/µsec Output Limiting Reactor; 5-8
Using Conduit; 2-14
Analog and Digital Conductor Wiring
3 Output Power Conductor Routing and; 2-14
Analog and Digital Signal Considerations; 2-1, 2-14, 3-1
3% and 5% Input Line Reactors; 5-8
Analog and Digital Conductor Wiring and; 2-14
Analog and Digital Signal Wiring and; 2-14
1000 Analog and Digital Signal Wiring; 2-14, 3-3
Grounding Requirements and; 2-14
1000 and 1500 V/µsec Output Limiting Reactor; 5-8
Materials and; 2-14
Shielded Cable and; 2-14
A Wire Size and; 2-14
Analog I/O Signal Transient Protection; 5-4
AF95; S-1, S-3, 2-4, 2-5
Analog Inputs; 5-4
Associated Drive Motor; 2-5
Follower and; 5-4
Drive Components; S-3
Speed Pot and; 5-4
Options; 2-4
Analog Outputs; 5-3 to 5-4
AF95 Configuration Manual; 1-2, 3-5
Isolation and Protection; 5-4
AF95 Configuration Program; 1-2, 3-3
Resolution; 5-4
AF95 Help System; 1-2
ANSI C62.41; 2-12, 5-3
AF95 Input Disconnect; 2-4, 2-12, 5-6, 5-8
Application; 2-1, 2-3 to 2-5, 3-1
Input Line Considerations and; 2-12
AF95 Drive Components and; 2-5
Lockable Motor Disconnect; 2-4, 5-8
AF95 Motor Selection and; 2-5
AF95 Operator’s Manual; 1-2, 3-5
AF95 Options and; 2-4, 2-5
AF95 Options Manual; 1-2, 5-8
Application Considerations; 2-4, 2-5
AF95 Programmer; 1-2, 3-3
AF95 Adjustable Frequency Drive Options and; 2-4
AF95 Troubleshooting and Repair Manual; 1-2, 3-5
Motor Selection and; 2-5
Agency Standards; 5-5
Applying AC Power; 3-5
NEMA-ICS 7.1; 5-5
Arcnet® Address Setting; 2-16
UL Standard 508C; 5-5
Arcnet® Network Communications
UL Standard cUL; 5-5
AF95 Chassis and; 2-15
Alert Symbol; S-1 to S-2
Arcnet® Network Considerations; 2-1, 2-15, 2-16, 3-1
Align Motor; 3-4
Arcnet® Cable and; 2-15
Align Motor and Machinery and; 3-4
Custom Enclosure Door and; 2-15
Altitude; 2-3, 5-4
Keypad Assembly and; 2-15, 2-16
Ambient Operating Conditions; 2-3, 5-4
Optional NEMA Enclosure Door and; 2-15
Terminal Block and; 2-15
Arcnet® Terminating Resistor; 2-16

6-1
Index
SECTION 6
Article 500; 2-3, 5-5 Conn; 5-2
National Electric Code and; 2-3, 5-5 Connect Wiring; 3-3
ASTM D999; 5-5 Connection Diagrams; 2-6, 3-3
ASTM-896; 5-5 Continuous Current Rating; 2-5, 2-12
Authority Having Jurisdiction; 2-6 Control Wiring; 2-14
Available Options; 5-1, 5-8 Analog and Digital Conductor Routing and; 2-14
1%, 3 % and 5% Input Line Reactors; 5-8 Cooling Air; 5-4
AF95 Input Disconnect; 5-8 Cooling Capacity of Motor; 2-5
Bypass Contactors; 5-8 Corrosive Atmosphere, Protection From; 2-2, 5-5
Dynamic Breaking; 5-8 Corrosive Environment; 5-5
Extended Transient Protection; 5-8 Custom Enclosure Door; 2-14
Line Fuses; 5-8 Arcnet® Network Communications and; 2-15, 2-16
Output Contactor; 5-8 Cutler-Hammer Freedom 2100 Motor Control Centers; 5-6
Output Filters; 5-8
Average Operating Motor Current; 2-5 D
Danger; S-2, 2-3, 3-3
B
Explosive Atmosphere; 2-3
Branch Circuit Overload Protection Selection; 2-6 Meaning of; S-2
Bus Voltage; 3-6 Danger High Voltage; S-2, 3-6, 5-8
Buttons; 1-2, 5-8 Bus Voltage; 3-6
Bypass Contactors; 5-8 General Precautions; S-2
DC Bus Capacitors; 3-6
C High Voltage Danger and; 3-6
DC Voltmeter; 3-6
Cable; 2-12 to 2-15, 3-3 Measuring Bus Voltage and; 3-6
Arcnet® Communications Cable and; 2-16 Diagnostic Messages; 5-3
Length of Arcnet® Cable; 2-15 Digital I/O Signal Transient Protection; 5-4
Cable Trays; 2-12 to 2-14, 3-2 Digital Inputs; 5-3 to 5-4
Analog and Digital Conductor Routing and; 2-12 to 2-14 Digital Outputs; 5-3 to 5-4
Input Line Routing and; 2-11, 2-14 Disconnect Device; 2-5
Output Power Conductor Routing and; 2-13 and 2-14 Disconnecting Means; 5-8
Cat. No; 5-2 Drawings; S-3, 1-1 to 1-2, 2-2 to 2-4, 2-6 to 2-7,
Catalog Number Decoding; 5-7 2-14, 4-4 to 4-34, 5-6
Caution; S-1, S-2, S-3, 2-4, 2-13, 3-3, 3-4, 5-2, 5-3 Arcnet® Connections; 4-34
Electrostatic Discharge; 3-3 Chassis Dimensions; 4-2 and 4-3, 4-4 to 4-29
Heed All Safety Statements; 3-4 Keypad Assembly Item Identification; 4-32
Meaning of; S-2 NEMA Type 1 Enclosure Dimensions; 4-2 and 4-3,
OSHA 1910.219; 3-4, 3-5 4-4 to 4-29
Chassis; 2-3, 2-14, 4-1 to 4-29, 5-2, 5-4, 5-6, 5-8 Optional NEMA Dimensions; 4-2 and 4-3, 4-4 to 4-29
Arcnet® Network Considerations and; 2-15, 2-16 Programmer Connection; 4-33
Check List; 1-1 Terminal Block Assignments; 4-30
Class A Digital Device; 5-5 Terminal Block Connections; 4-31
Code Requirements; 2-6, 2-12 Ventilation Requirements; 4-2 and 4-3, 4-4 to 4-29
Branch Circuit Overload Protection and; 2-6 Drive Components; 2-5, 5-6
Input Line Conductor Selection and; 2-6 Drive Motor; 2-5
Output Power Conductor Sizing and; 2-13 Dynamic Braking; 5-8
Codes; S-2, 2-6, 2-12 to 2-14, 3-4, 5-5
Article 500 NEC; 2-3, 5-5
E
OSHA 1910.219; 3-4, 3-5
Commands; 1-2, 5-3 Electrostatic Discharge; S-3, 3-3
Conduit; 2-6, 2-12, 2-13, 2-14, 3-2, 5-6 Caution; S-3, 3-3
Analog and Digital Conductor Routing and; 2-14 Emergency Stop Requirements; 2-5
Ground Connections and; 2-6 EMI; 2-4, 5-5
Input Line Routing and; 2-12 Built-In Protection and; 5-5
Output Power Conductor Routing and; 2-13 External Sources and; 2-4
Quench Arc, Need for; 2-4

6-2
Index
SECTION 6
EMI Susceptibility; 5-5 H
Enclosure Selection; 2-3, 5-2, 5-3, 5-4 to 5-6, 5-8
H2S; 2-2, 5-5
Enclosure Type; 5-2
Handling of Drive After Delivery; 2-1 to 2-2, 3-1
Enclosures; 2-3, 3-2, 4-1 to 4-29, 5-6
Harmonic Content of Input Current; 2-11
Chassis; 5-6
Typical Values; 2-11
Optional NEMA Enclosures; 5-6
Harmonic Current Content (See Line Current Harmonic
Motor Control Center (MCC); 5-6
Content)
NEMA Type 1; 5-6
Harmonic Distortion; 2-4, 2-11, 5-8
Environment Specifications; 2-3, 5-4, 5-5
Harmonic Voltage Distortion; 2-11
Explosive Atmosphere; 2-3, 5-5
Input Line Impedance and; 2-11
Extended NEMA Enclosures; 4-1 to 4-29, 5-6
Line Current Harmonic Content and; 2-11
Extended Temperature Range; 2-3
Harmonic Voltage Distortion; 2-11, 5-3
External Control Circuitry; 3-5
Examples of; 2-11
External Fault Signal; 2-14
Relationship to Input Line Impedance and; 2-11
Jumper Required in Some Applications and; 2-14
Hazardous Environment; 5-5
Provided by Factory in Some Configurations and; 2-14
Hazardous Line Voltage; S-2
Warning of; S-2
F Heat Dissipation; 5-5
Factory; 2-4, 2-14, 2-15, 5-8 Heavy Equipment Handling; 2-2, 3-5
Factory Wired Signal; 2-4, 2-14 Heavy Equipment Handling, Warning of; 2-2, 3-5
External Fault Signal in Some Applications and; 2-4, 2-14 Help System; 1-2
FCC Part 15B; 5-5 Horsepower; 2-5, 5-2
Follower; 5-3 to 5-4 Horsepower Rating; 2-5, 5-2
Frequency Range; 5-3 HVAC System Control; 2-4
G I
Gen. Order No; 5-2 IEC; 2-5, 5-3 to 5-5

General Specifications; 5-1, 5-3, 5-4, 5-5, 5-6 IEC - 22G; 5-5
Agency Standards; 5-5 IEC 801; 5-4, 5-5
Analog Inputs; 5-4 IEEE; 2-5, 5-3, 5-8
Analog Outputs; 5-4 IEEE Standard 446; 5-3
Analog/Digital Transient Protection; 5-4 Independent Testing Laboratory Logo; 5-2
Digital Inputs; 5-4 Industrial Process Control; 2-4
Digital Outputs; 5-4 Initial Startup; 3-5
EMI Susceptibility; 5-5 Input; S-3, 2-1, 2-4, 2-6 to 2-15, 3-1 to 3-3, 5-2 to 5-4, 5-8
Enclosures; 5-6 Input Current; 2-5, 2-6 to 2-7, 2-11, 2-12 to 2-13, 5-2, 5-4,
Frequency Range; 5-3 5-8
Input Line Conditions; 5-3 Input Disconnect; 2-4, 2-11, 5-6, 5-8
Input Line Transients; 5-3 Lockable Motor Disconnect; 2-4, 5-8
Keypad Assembly; 5-3 Input Line Conditions; 5-3
Operating Environment; 5-4 Input Line Conductor Selection; 2-6, 2-11, 2-12
Shock and Vibration; 5-5 Code Requirements and; 2-6
Terminal Block; 5-4 Input Current and; 2-6
Ground Conductor Size; 2-6 Input Terminal Wire Size Capacity and; 2-6
Ground Studs, Located On Drive; 2-6 Input Voltage and; 2-6
Grounding; S-2, S-3, 2-6, 3-4 Material Requirements and; 2-6
High Voltage Danger and; S-2 Runs Over 300 Feet and; 2-6
Grounding Connections; 2-6 Input Line Current; 2-6, 2-11, 2-12
Ground Conductor Sizing and; 2-6 Input Line Impedance and; 2-6
Ground Studs Provided and; 2-6 Motor Efficiency and; 2-6
Material Selection and; 2-6 Motor Power Factor and; 2-6
Motor Frames and Operator Control Stations; 2-6
Guards; 2-5, 3-4, 5-3
Warning of; 2-5

6-3
Index
SECTION 6
Input Line Impedance; S-3, 2-4, 2-6, 2-7, 2-11 and 2-12, L
5-3, 5-8
LCD; 1-2, 2-7, 2-15, 5-3
Harmonic Content of Input Current and; 2-6, 2-11
Line Considerations; 2-4, 2-6, 2-7, 2-8 to 2-9, 2-12, 3-1
Harmonic Voltage Distortion and; 2-11
AF95 Input Disconnect; 2-12, 5-8
Input Current and; 2-6
Branch Circuit Overload Protection and; 2-6
Input Line Reactor and; S-3, 2-4, 2-6, 2-7
Grounding Connections and; 2-6
Need For Calculation of; 2-4, 2-6
Harmonic Distortion and; 2-11
Range of; S-3, 2-4, 2-6, 2-7
Input Line Conductor Sizing and; 2-6
Rated Output Voltage and; 2-6
Input Line Impedance and; 2-6, 2-7, 2-11
Warning of; S-3
Input Line Routing and; 2-12
Input Line Reactor; S-3, 2-4, 2-7, 5-3, 5-8
Isolation Transformers and; 2-12
Input Line Impedance and; S-3, 2-4, 2-7, 5-3, 5-8
Line Fuses and; 2-12
Need for; S-3, 2-4, 2-7, 5-3, 5-8
Multiple Conductor Wiring and; 2-12
Input Line Routing; 2-12
Power Factor Correction and; 2-12
Analog and Digital Wiring and; 2-12
Standby Power Generation and; 2-12
Output Power Wiring and; 2-12
Line Current Harmonic Content; 2-11
With Cable Trays; 2-12
Input Line Impedance and; 2-11
With Conduit; 2-12
Line Distortion; 5-3
Input Line Transients; 5-3
Line Fuses; 2-12, 5-8
Input Reactors; 5-5
Input Voltage; 2-6
Line Impedance (See Input Line Impedance)
Install Motor and Related Equipment; 3-4
Line Sags; 2-4
Installation Check List; 3-1 to 3-5
Line Surges; 2-4
Pre-Installation and; 3-1
Line Swell; 5-8
Rough-In Enclosures and; 3-2
Local Codes; 2-5
Rough-In Wiring and; 3-2
Local Regulations; S-2
Connect Wiring; 3-3
Logic Board; 2-15, 3-6
Install Motor and Related Equipment; 3-4
Logic Schematic; 2-14, 3-3
Initial Startup; 3-5
Installation Tasks; 3-1 to 3-5
Instruction Manual; 2-5 M
Motor Instruction Manual; 2-5
Manufacturer’s Instructions; 3-4
Intermittent Current Rating; 2-5
Installing Motor and; 3-4
Intermittent Operating Motor Current; 2-5
Max. Ambient; 5-2
Isolation Transformers; 2-12
Metal Oxide Varistor (MOV); 2-12
Microprocessor Control; 1-1
Microsoft® Windows 3.1; 1-2
J Monitoring DC Capacitor Discharge; 3-6
High Voltage Danger and; 3-6
Jumpered; 2-14
Motor Efficiency; 2-6
External Fault Signal and; 2-14
Motor Frames, Grounding Requirement and; 2-6
Motor Loading; 3-4
K Motor Power Factor; 2-6
Keypad; 1-2, 2-7, 2-15, 3-5, 5-3, 5-5 to 5-6 Motor Rotation; 3-5
During Initial Startup; 3-5 During Initial Startup; 3-5
Keypad Assembly; 2-14, 2-15, 4-1, 4-32, 5-3, 5-6 Motor Selection (See Motors)
Arcnet® Considerations and; 2-15, 2-16, 5-3 Motor Speed; S-3, 1-1, 2-5, 3-5, 5-3 to 5-4
Description and; 5-3 During Initial Startup; 3-5
Keypad and; 5-3 Motor Speed Control; 1-1
LCD and; 5-3 Motor Voltage Diagram; 3-4
Operator Interface and; 5-3 Motors; S-2, 1-1, 2-4, 2-5, 2-6, 2-7, 2-12, 2-13, 3-4, 3-5, 5-
Terminal Block and; 5-3 3, 5-6, 5-8

6-4
Index
SECTION 6
Average Operating Motor Current and; 2-5 Output Dv/Dt Reactors; 5-8
Cooling Requirements and; 2-5 Output Power Circuit; 2-13
Horsepower Requirements and; 2-5 Overcurrent Protection and; 2-13
Installation Requirements and; 2-5, 2-13, 3-4 Output Power Conductor Routing; 2-13
Manufacturer’s Ratings and; S-3, 2-5, 2-13, 3-4 Analog and Digital Wiring and; 2-14
NEMA Design B and; 2-5 Input Power Wiring and; 2-13
Operation Above 60 Hz and; 2-5 Using Cable Trays; 2-13
Operation at Reduced Speed and; 2-5 Using Conduit; 2-13
Selection of; S-3, 2-5, 2-6, 2-13 Output Power Conductor Sizing; 2-13, 2-14, 3-3
Three Phase and; 2-5 Code Requirements and; 2-13
Torque Rating and; 2-5 Material Requirements and; 2-13
Mounting Dimensions; 2-3, 3-2 Output Current and; 2-13
MOV; 2-12 Output Terminal Wire Sizing Capacity and; 2-13
Definition; 2-12 Output Voltage and; 2-13
Ratings; 2-12 Runs Over 300 Feet and; 2-13
Surge Protection; 2-12 Output Power Considerations; 2-1, 2-13, 3-1
Multiple Conductor Wiring; 2-12 Output Power Conductor Routing and; 2-13
Output Power Conductor Sizing and; 2-13
N Overcurrent Protection and; 2-13
Power Factor Correction and; 2-13
Nameplate; S-3, 2-5, 2-6 to 2-7, 2-13, 3-4, 5-2 Output Filters; 5-8
Nameplate Identification; 5-1 Overcurrent Protection; 2-13
Nameplate Speed; S-3 Multiple Motors and; 2-13
Nameplate Speed One Motor and; 2-13
Rated Operating Speed of Motor and; S-3 Output Power Circuit and; 2-13
National Electric Code (NEC); S-2, 2-3, 2-5, 2-6 Overhead Construction, Drive Location and; 2-3, 3-2
Article 500 and; 2-3 Overload; 2-6, 2-11 to 2-14, 5-2, 5-8
NEC; 2-3, 2-5, 2-6 Overload Interlock Relay; 2-14
NEMA; 2-3 to 2-5, 2-15, 4-1 to 4-29, 5-2, 5-4 to 5-6 External Fault Signal and; 2-14
NEMA Type 1 Enclosure; 5-6
NEMA - ICS 7.1; 5-5
P
Nominal HP; 5-2
Non-Standard Frequency; 3-5 Parameters; 1-2, 5-3
Non-Standard Voltage; 3-5 Part No; 5-2
Notice; S-1 to S-2 Percent of the Effective Impedance; 2-7, 2-11
Personal Computer (PC); 1-2
O Power Connection Drawing; 3-3
Power Disconnect Device; S-3
Operating Environment; 5-4, 5-5 Power Factor Correction; 2-12, 2-13
Ambient Operating Conditions; 5-4 Input Line Considerations and; 2-12
Cooling Air; 5-4 Output Power Considerations and; 2-13
Corrosive Environment; 5-5 Pre-Installation; S-3, 1-1, 2-1, 3-1 to 3-2, 5-8
Hazardous Environment; 5-5 Pre-Start Alarms; S-3
Heat Dissipation; 5-5 Pulse Width Modulation (PWM); 1-1
Solvent Withstand; 5-5
Storage Conditions; 5-4
Q
Operation Above 60 Hz; 2-5
Warning of; S-3 Quench Arc; 2-4
Operator’s Control Stations, Grounding Requirements and; EMI and; 2-4
2-6 Need For; 2-4
Optional NEMA Enclosure Door; 2-15
Arcnet® Network Considerations and; 2-15 R
Options; 2-4, 2-6, 2-13, 3-2, 5-1, 5-6, 5-8
OSHA 1910.219; 3-4, 3-5 Ratings for AF95 Adjustable Frequency Drives; 5-7
Output; S-3, 2-1, 2-6 to 2-13, 2-14, 3-1 to 3-4, 5-2, Ratings Table; 5-1
5-4 to 5-5, 5-8 Recommended Minimum Input Line Wire Size; 2-8
Output Contactor; 5-8 Recommended Minimum Output Power Wire Size; 2-8
Recommended Minimum Wire Size; 2-6, 2-13
Input Conductors; 2-6

6-5
Index
SECTION 6
Output Conductors; 2-13 T

Reporting Shipping Damage; 2-2
Terminal Block; 2-14, 2-15, 3-2 to 3-3, 3-6, 4-1,
Rotating Mechanical Equipment; 3-5
4-30 and 4-31, 5-3 to 5-4, 5-6
Loose Fitting Clothing and; 3-5
Arcnet® Considerations and; 2-15
Warning of; 3-5
Three Phase Motor; 2-5
Rough-In Enclosures; 3-2
Three Phase Motors; 1-1
Rough-In Wiring; 3-2
Torque; 1-1, 2-5, 5-2, 5-8
Motor Operation at Reduced Speed and; 2-5
S Transient Protection; 2-4, 5-4, 5-8
Safe Voltage; 3-6 Built-In and; 2-4, 5-8
Discharge of DC Bus Capacitors and; 3-6 Extended and; 2-4, 5-8
Safety Glasses; S-2, 3-5
Safety Statements; S-1 to S-2 U
Meaning of; S-2
UL; 2-5, 5-5
Schem; 5-2
Ungrounded Distribution Systems
Shipping Container, Inspection of; 2-2
Input Line Considerations and; 2-12, 2-13
Shock and Vibration; 5-5
Unpacking The Drive; 2-2
Shock Hazard Labels; S-2
Unusual Operating Requirements; 3-5
Short Circuit Capacity; 2-7
Calculation of; 2-7
Design of Power Distribution System and; 2-7 V
Example of Calculation; 2-7
Ventilation; 2-3
Relationship to Full Load Current Rating and; 2-7
Voltage Surge Protection (See Surge Protection)
Software Code No; 5-2
Solvent Withstand; 5-5
Source Impedance (See Input Line Impedance) W
Specifications; 1-1, 2-3 to 2-4, 2-5, 2-15, 5-1, 5-2, 5-3, 5-4,
Warning; S-1, S-2, S-3, 2-2, 2-5, 3-2, 3-4, 3-5
5-5, 5-6
Application and Installation; 2-5
General Specifications; 5-3, 5-4, 5-5, 5-6
Electric Shock; 3-2, 3-4
Nameplate Identification; 5-2
General Meaning; S-2
Speed; 1-1, 2-5, 3-5, 5-3 to 5-4
Heavy Equipment Handling; 2-2, 3-5
Speed pot; 5-3 to 5-4
Input Line Impedance; S-3, 2-4
Standards; 2-12, 5-3, 5-4, 5-5
Operation Above 60 Hz; 2-5
ANSI C62.41; 2-12, 5-3
Rotating Mechanical Equipment; 3-5
ASTM D999; 5-5
Where To Locate Drive; 2-1, 2-3, 3-1
ASTM-896; 5-5
Wire Size Capacity; 2-6, 2-9, 2-12
FCC Part 15B; 5-5
Input Terminals; 2-6, 2-9
IEC 801; 5-4, 5-5
Output Terminals; 2-9, 2-13
IEEE Standard 446; 5-3
Standby Power Generation; 2-12
Storage Conditions; 5-4
Storing The Drive; 2-2
Surge Protection; 2-12, 5-5
ANSI C62.41 and; 2-12
MOV’s and; 2-12
Phase-To-Ground; 2-12
Phase-To-Phase; 2-12

6-6
Cutler-Hammer Solid State Motor Control
Aftermarket Services
• Technical/telephone support.
• Resident service engineers in major trading centers.
• Factory repair services.
• Warranty administration.
• Equipment modification and upgrading services.
• Training seminars.
For service or more information call

1-800-322-4986
A response network that gives new meaning to customer service

• Personalized
• Comprehensive
• Professional
Cutler-Hammer
110 Douglas Road E
Oldsmar, FL 34677
0IM-530028-1001/2
NOV 98
Printed in U.S.A.

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Installation Manual

For Model AF95 Adjustable Frequency Drives

Installation Check List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

AF95 Installation Manual

AF95 Installation Manual

After you review this section you will:

• Understand the meaning of the Safety Alert Symbol, Danger,

• Know the basic safety statements applicable to this entire

AF95 Installation Manual

Notice - Make sure you read and understand

! Danger ! Danger High Voltage

• Observe all shock hazard labels that may be

AF95 Installation Manual

• When installing the equipment, connect the

• Keep your hands and tools away from the

• When replacing a printed circuit board, do

• Printed circuit boards must be repaired by

AF95 Installation Manual

AF95 Installation Manual

This manual provides a check list, drawings, specifications and

To assure successful installation, thoroughly read and understand

AF95 Adjustable Frequency Drives are designed to provide

AF95 Installation Manual

Every AF95 comes packed with these manuals:

The following manual is available from Cutler-Hammer:

AF95 Installation Manual

• Handling of Drive After Delivery.

• Where to Locate Drive.

• Input Line Considerations.

• Output Power Considerations.

• Analog and Digital Signal Considerations.

• Arcnet® Network Considerations.

AF95 Installation Manual

Handling of Drive After Delivery

2. Carefully unpack the drive, taking care to

AF95 Installation Manual

Where to Locate Drive

Consider the following: 3. Refer to the illustrations in Section 4,

2. Select the type of enclosure that meets your

Note: AF95 units are rated for a maximum of ! Danger

See pages 5-4 and 5-5 for other

AF95 Installation Manual

You must ensure that the input line power has

Install an AF95 1% input line reactor if your line

AF95 Installation Manual

AF95 Installation Manual

Input Line Considerations

AF95 Installation Manual

Input Line Considerations

AF95 Installation Manual

75 101 1 1 2/0 4/0

100 130 2/0 2/0 3/0 250

125 164 3/0 3/0 4/0 400

150 189 4/0 4/0 250 500

200 252 350 350 500 2x250

250 300 350 350 2x4/0 2x350

300 380 500 2x3/0 2x300 2x600

Recommended Minimum Input Line and Output Power Wire Size

AF95 Installation Manual

AF95 Installation Manual

AF95 Installation Manual

Input Line Considerations

Harmonic Distortion For example, if the source impedance

Contact your Cutler-Hammer Distributor or Field