Allen-Bradley Powerflex 700 Instruction manual

Quick Start

PowerFlex 700 Adjustable

Frequency AC Drive

When reading this document, look for this symbol “ ” to guide

you through the 6 BASIC STEPS needed to install, start-up and

program the PowerFlex 700.The information provided Does Not

replace the User Manual and is intended for qualiﬁed drive service

personnel only. For detailed PowerFlex 700 information including

application considerations and related precautions refer to the following:

Title Publication Available . . .

PowerFlex 700 User Manual 20B-UM001x on the CD supplied with the drive

or at www.ab.com/manuals/dr

PowerFlex Reference Manual PFLEX-RM001x

Step x

Step 1 Read the General Precautions

ATTENTION: This drive contains ESD (Electrostatic Discharge)

sensitive parts and assemblies. Static control precautions are required

when installing, testing, servicing or repairing this assembly.

Component damage may result if ESD control procedures are not

followed. If you are not familiar with static control procedures,

reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic

Damage” or any other applicable ESD protection handbook.

ATTENTION: An incorrectly applied or installed drive can result in

component damage or a reduction in product life. Wiring or application

errors, such as, undersizing the motor, incorrect or inadequate AC

supply, or excessive ambient temperatures may result in malfunction of

the system.

ATTENTION: Only qualiﬁed personnel familiar with adjustable

frequency AC drives and associated machinery should plan or

implement the installation, start-up and subsequent maintenance of the

system. Failure to comply may result in personal injury and/or

equipment damage.

ATTENTION: To avoid an electric shock hazard, verify that the

voltage on the bus capacitors has discharged before performing any

work on the drive. Measure the DC bus voltage at the +DC & –DC

terminals of the Power Terminal Block (refer to the User Manual for

location). The voltage must be zero.

2PowerFlex 700 Adjustable Frequency AC Drive Quick Start

ATTENTION: Risk of injury or equipment damage exists. DPI or

SCANport host products must not be directly connected together via

1202 cables. Unpredictable behavior can result if two or more devices

are connected in this manner.

ATTENTION: The “adjust freq” portion of the bus regulator function

is extremely useful for preventing nuisance overvoltage faults resulting

from aggressive decelerations, overhauling loads, and eccentric loads.

It forces the output frequency to be greater than commanded frequency

while the drive's bus voltage is increasing towards levels that would

otherwise cause a fault. However, it can also cause either of the

following two conditions to occur.

1. Fast positive changes in input voltage (more than a 10% increase

within 6 minutes) can cause uncommanded positive speed changes.

However an “OverSpeed Limit” fault will occur if the speed reaches

[Max Speed] + [Overspeed Limit]. If this condition is unacceptable,

action should be taken to 1) limit supply voltages within the

speciﬁcation of the drive and, 2) limit fast positive input voltage

changes to less than 10%. Without taking such actions, if this

operation is unacceptable, the “adjust freq” portion of the bus

regulator function must be disabled (see parameters 161 and 162).

2. Actual deceleration times can be longer than commanded

deceleration times. However, a “Decel Inhibit” fault is generated if

the drive stops decelerating altogether. If this condition is

unacceptable, the “adjust freq” portion of the bus regulator must be

disabled (see parameters 161 and 162). In addition, installing a

properly sized dynamic brake resistor will provide equal or better

performance in most cases.

Important: These faults are not instantaneous. Test results have

shown that they can take between 2-12 seconds.

ATTENTION: A contactor or other device that routinely disconnects

and reapplies the AC line to the drive to start and stop the motor can

cause drive hardware damage. The drive is designed to use control

input signals that will start and stop the motor. If an input device is

used, operation must not exceed one cycle per minute or drive damage

will occur.

ATTENTION: The drive start/stop/enable control circuitry includes

solid state components. If hazards due to accidental contact with

moving machinery or unintentional ﬂow of liquid, gas or solids exist,

an additional hardwired stop circuit may be required to remove the AC

line to the drive. An auxiliary braking method may be required.

ATTENTION: If using Output Contactors, refer to the “Output

Contactor Precaution” statement on page 1-12 of the PowerFlex 700

User Manual.

PowerFlex 700 Adjustable Frequency AC Drive Quick Start 3

CE Conformity

Conformity with the Low Voltage (LV) Directive and Electromagnetic

Compatibility (EMC) Directive has been demonstrated using

harmonized European Norm (EN) standards published in the Ofﬁcial

Journal of the European Communities. PowerFlex Drives comply with

the EN standards listed below when installed according to the User and

Reference Manual.

CE Declarations of Conformity are available online at:

http://www.ab.com/certiﬁcation/ce/docs.

Low Voltage Directive (73/23/EEC)

•EN50178 Electronic equipment for use in power installations.

EMC Directive (89/336/EEC)

•EN61800-3 Adjustable speed electrical power drive systems Part 3:

EMC product standard including speciﬁc test methods.

General Notes

•If the adhesive label is removed from the top of the drive, the drive

must be installed in an enclosure with side openings less than 12.5

mm (0.5 in.) and top openings less than 1.0 mm (0.04 in.) to

maintain compliance with the LV Directive.

•The motor cable should be kept as short as possible in order to avoid

electromagnetic emission as well as capacitive currents.

•Use of line ﬁlters in ungrounded systems is not recommended.

•PowerFlex drives may cause radio frequency interference if used in a

residential or domestic environment. The user is required to take

measures to prevent interference, in addition to the essential

requirements for CE compliance listed below, if necessary.

•Conformity of the drive with CE EMC requirements does not

guarantee an entire machine or installation complies with CE EMC

requirements. Many factors can inﬂuence total machine/installation

compliance.

•PowerFlex drives can generate conducted low frequency

disturbances (harmonic emissions) on the AC supply system. More

information regarding harmonic emissions can be found in the

PowerFlex Reference Manual.

EMC Instructions

4PowerFlex 700 Adjustable Frequency AC Drive Quick Start

Essential Requirements for CE Compliance

Conditions 1-6 listed below must be satisﬁed for PowerFlex drives to

meet the requirements of EN61800-3.

1. Standard PowerFlex 700 CE compatible Drive.

2. Review important precautions/attention statements throughout this

document before installing the drive.

3. Grounding as described on page 1-4 of the User Manual.

4. Output power, control (I/O) and signal wiring must be braided,

shielded cable with a coverage of 75% or better, metal conduit or

equivalent attenuation.

5. All shielded cables should terminate with the proper shielded

connector.

6. Conditions in Table A.

Table A PowerFlex 700 EN61800-3 EMC Compatibility

Operating Temperatures

PowerFlex 700 drives are designed to operate at 0°to 40°C ambient.

To operate in installations between 41°and 50°C, see Table B.

Frame

Second Environment

Restrict Motor Cable to 30 m (98 ft.)

First Environment

Restricted Distribution

Any Drive and Option

0✔Refer to

PowerFlex Reference Manual

1✔

2✔

3✔

Step 2 Mount the Drive – Minimum Requirements

101.6 mm

(4.0 in.)

101.6 mm

(4.0 in.)

50.8 mm

(2.0 in.)

101.6 mm

(4.0 in.)

101.6 mm

(4.0 in.)

PWR

STS

PORT

MOD

NETA

NETB

PWR

STS

PORT

MOD

NETA

NETB

Refer to Figures 1-3for

detailed dimension

information.

No Adhesive Label

(see below)

With Adhesive Label

(see below)

101.6 mm

(4.0 in.)

101.6 mm

(4.0 in.)

101.6 mm

(4.0 in.)

101.6 mm

(4.0 in.)

PWR

STS

PORT

MOD

NETA

NETB

PWR

STS

PORT

MOD

NETA

NETB

PowerFlex 700 Adjustable Frequency AC Drive Quick Start 5

Table B Acceptable Surrounding Air Temperature & Required Actions

Important: Removing the adhesive label from the drive changes the

NEMA enclosure rating from Type 1 to Open type.

Figure 1 PowerFlex 700 Frames 0-3 (0 Frame Shown)

Dimensions are in millimeters and (inches).

Drive Catalog

Number

Required Action . . .

IP 20, NEMA

Type 1

IP 20, NEMA

Type Open

IP 00, NEMA

Type Open

No Action

Required

Remove Top

Label

Remove Top Label

& Vent Plate (1)

(1) To remove vent plate (see Figure 3 on page 8for location), lift top edge of

plate from the chassis. Rotate the plate out from the back plate.

All Except 20BC072 40°C50°CNA

20BC072 40°C45°C50°C

Dimensions

15.0 (0.59)

5.8 (0.23) dia.

see below

8.0

(0.31)

5.5 (0.22) - Frames 0-1

7.0 (0.28) - Frames 2-3

3 Places

HOTsurfaces can cause severe burns

CAUTION

Frame

(Table C)

ABCDE

Weight (1) kg (lbs.)

Drive

Drive &

Packaging

0 110.0 (4.33) 336.0 (13.23) 200.0 (7.87) 80.0 (3.15) 320.0 (12.60) 5.22 (11.5) 8.16 (18)

1 135.0 (5.31) 336.0 (13.23) 200.0 (7.87) 105.0 (4.13) 320.0 (12.60) 7.03 (15.5) 9.98 (22)

2 222.0 (8.74) 342.5 (13.48) 200.0 (7.87) 192.0 (7.56) 320.0 (12.60) 12.52 (27.6) 15.20 (33.5)

3 222.0 (8.74) 517.5 (20.37) 200.0 (7.87) 192.0 (7.56) 500.0 (19.69) 18.55 (40.9) 22.68 (50)

(1) Weights include HIM and Standard I/O.

6PowerFlex 700 Adjustable Frequency AC Drive Quick Start

Figure 2 PowerFlex 700 Frame 5

Dimensions are in millimeters and (inches).

Table C PowerFlex 700 Frames

HOTsurfacescan cause severe burns

CAUTION

12.5

(0.49)

6.5 (0.26)

259.1 (10.20) Detail

15.0 (0.59)

6.5 (0.26)

37.6 (1.48) C

Lifting Holes - 4 Places

12.7 (1.37) Dia.

Frame

(Table C)

A(Max.) BC(Max.) DE

Approx. Weight (1) kg (lbs.)

Drive

Drive &

Packaging

5 308.9 (12.16) 644.5 (25.37) (2) 275.4 (10.84) 225.0 (8.86) 625.0 (24.61) 37.19 (82.0) 42.18 (93.0)

(1) Weights include HIM and Standard I/O.

(2) When using the supplied junction box (100 HP drives Only), add an additional 45.1 mm (1.78 in.).

Frame

208/240V AC Input 400V AC Input 480V AC Input

ND HP HD HP ND kW HD kW ND HP HD HP

00.5 0.33 0.37 0.25 0.5 0.33

1 0.75 0.75 0.55 1 0.75

2 1.5 1.5 0.75 2 1.5

322.21.532

––42.253

––5.547.55

15 3 7.5 5.5 10 7.5

7.5 5 11 7.5 15 10

210 7.5 15 11 20 15

– – 18.5 15 25 20

315 10 22 18.5 30 25

20 15 30 22 40 30

– – 37305040

5––5545––

––––7560

– – – – 100 75

PowerFlex 700 Adjustable Frequency AC Drive Quick Start 7

Figure 3 Bottom View Dimensions

Dimensions are in millimeters and (inches).

132.9

(5.23)

187.5

(7.38)

30.2

(1.19)

41.9 (1.65)

56.1 (2.21)

96.0 (3.78)

75.9 (2.99)

96.0 (3.78)

55.0 (2.17)

75.0 (2.95)

35.0 (1.38) 22.2 (0.87) Dia. – 4 Places

185.0

(7.28)

133.3

(5.25)

187.6

(7.39)

25.5

(1.00)

70.0 (2.76)

43.0 (1.69)

96.0 (3.78)

75.9 (2.99)

108.5 (4.27)

67.5 (2.66)

47.5 (1.87)

87.5 (3.44)

22.2 (0.87) Dia.

3 Places

28.6 (1.13) Dia.

185.1

(7.29)

39.3 (1.55)

57.2 (2.25)

72.7 (2.86)

106.0 (4.17)

139.4 (5.49)

177.4 (6.98)

167.5 (6.59)

156.9 (6.18)

150.9

(5.94)

184.8

(7.28)

157.5

(6.20)

112.1

(4.41)

22.4 (0.88) Dia.

2 Places

28.7 (1.13) Dia.

3 Places

Frame 0 Frame 1

Frame 2

8PowerFlex 700 Adjustable Frequency AC Drive Quick Start

Figure 3 PowerFlex 700 Bottom View Dimensions (continued)

66.0 (2.60)

94.7 (3.73)

105.3 (4.15)

130.0 (5.12)

186.0 (7.32)

22.7 (0.89)

29.0 (1.14)

127.7

(5.03)

160.1

(6.30)

165.1

(6.50)

184.5

(7.26)

28.7 (1.13) Dia.

2 Places

46.7 (1.84) Dia.

2 Places

34.9 (1.37) Dia.

2 Places

Vent Plate

Frame 3 – All Drives

except 50 HP, 480V (37 kW, 400V)

Frame 3 – 50 HP, 480V (37 kW, 400V)

Normal Duty Drive

66.0 (2.60)

94.7 (3.73)

105.3 (4.15)

97.0 (3.82)

137.2 (5.40)

187.0 (7.36)

22.7 (0.89)

29.0 (1.14)

127.7

(5.03)

151.1

(5.95)

160.1

(6.30)

165.1

(6.50)

184.5

(7.26)

22.2 (0.87) Dia.

28.7 (1.13) Dia.

2 Places

37.3 (1.47) Dia.

2 Places

96.0

(3.78)

159.5

(6.28)

184.0

(7.24)

220.0

(8.66)

229.5

(9.04)

241.9

(9.52)

45.0 (1.77)

85.0 (3.35)

93.2 (3.67)

104.0 (4.09)

150.0 (5.91)

215.0 (8.46)

255.0 (10.04)

28.0 (1.10)

22.2 (0.87) Dia.

2 Places

62.7 (2.47) Dia.

2 Places

34.9 (1.37) Dia.

2 Places

96.0

(3.78)

153.5

(6.04)

184.3

(7.26)

188.5

(7.42)

223.5

(8.80)

241.9

(9.52)

44.0 (1.73)

66.4 (2.61)

31.9 (1.26)

42.6 (1.68)

128.0 (5.04)

232.3 (9.15)

28.0 (1.10)

22.2 (0.87) Dia.

2 Places

62.7 (2.47) Dia.

2 Places

Removable Junction Box

34.9 (1.37) Dia.

Frame 5 – 75 HP, 480V (55kW, 400V) Normal Duty Drive

Frame 5 – 100 HP, 480V Normal Duty Drive

Dimensions are in millimeters

and (inches)

PowerFlex 700 Adjustable Frequency AC Drive Quick Start 9

A variety of cable types are acceptable for drive installations. For many

installations, unshielded cable is adequate, provided it can be separated

from sensitive circuits. As an approximate guide, allow a spacing of 0.3

meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases,

long parallel runs must be avoided. Do not use cable with an insulation

thickness less than or equal to 15 mils (0.4mm/0.015 in.). See Table D.

Unshielded

THHN, THWN or similar wire is acceptable for drive installation in dry

environments provided adequate free air space and/or conduit ﬁll rates

limits are provided. Do not use THHN or similarly coated wire in wet

areas. Any wire chosen must have a minimum insulation thickness of 15

Mils and should not have large variations in insulation concentricity.

Shielded/Armored Cable

Shielded cable is recommended if sensitive circuits or devices are

connected or mounted to the machinery driven by the motor. See Table

D. For further information on acceptable and unacceptable cable types,

refer to “Power Wiring” in the PowerFlex 700 User Manual.

Table D Recommended Shielded Cable

Step 3 Power Wiring – Wire Recommendations

Type Wire Type(s) Description

Power Standard

(Option 1)

600V, 90°C (194°F)

XHHW2/RHW-2

Anixter B209500-B209507,

Belden 29501-29507, or

equivalent

•Four tinned copper conductors with XLP

insulation.

•Copper braid/aluminum foil combination

shield and tinned copper drain wire.

•PVC jacket.

Standard

(Option 2)

Tray rated 600V, 90°C (194°F)

RHH/RHW-2

Anixter OLF-7xxxxx or

equivalent

•Three tinned copper conductors with

XLPE insulation.

•5 mil single helical copper tape (25%

overlap min.) with three bare copper

grounds in contact with shield.

•PVC jacket.

Class I & II;

Division I & II

Tray rated 600V, 90°C (194°F)

RHH/RHW-2

Anixter 7V-7xxxx-3G or

equivalent

•Three bare copper conductors with XLPE

insulation and impervious corrugated

continuously welded aluminum armor.

•Black sunlight resistant PVC jacket

overall.

•Three copper grounds on #10 AWG and

smaller.

10 PowerFlex 700 Adjustable Frequency AC Drive Quick Start

Table E Power Terminal Block Speciﬁcations

Name Frame Description

Wire Size Range (1) Torque

Maximum Minimum Maximum Recommended

Power Terminal

Block

0 & 1 Input power and

motor connections

4.0 mm2

(10 AWG)

0.5 mm2

(22 AWG)

1.7 N-m

(15 lb.-in.)

0.8 N-m

(7 lb.-in.)

2 Input power and

motor connections

10.0 mm2

(6 AWG)

0.8 mm2

(18 AWG)

1.7 N-m

(15 lb.-in.)

1.4 N-m

(12 lb.-in.)

3 Input power and

motor connections

25.0 mm2

(3 AWG)

2.5 mm2

(14 AWG)

3.6 N-m

(32 lb.-in.)

1.8 N-m

(16 lb.-in.)

BR1, 2 terminals 10.0 mm2

(6 AWG)

0.8 mm2

(18 AWG)

1.7 N-m

(15 lb.-in.)

1.4 N-m

(12 lb.-in.)

(75 HP)

Input power, BR1,

2, DC+, DC– and

motor connections

35.0 mm2

(1/0 AWG)

2.5 mm2

(14 AWG)

3.6 N-m

(32 lb.-in.)

3.6 N-m

(32 lb.-in.)

PE 35.0 mm2

(1/0 AWG)

16.0 mm2

(6 AWG)

5 N-m

(44 lb.-in.)

5 N-m

(44 lb.-in.)

(100

HP)

Input power, DC+,

DC– and motor

connections

70.0 mm2

(3/0 AWG)

16.0 mm2

(4 AWG)

15 N-m

(133 lb.-in.)

15 N-m

(133 lb.-in.)

BR1, 2, terminals 35.0 mm2

(1/0 AWG)

2.5 mm2

(14 AWG)

3.6 N-m

(32 lb.-in.)

3.6 N-m

(32 lb.-in.)

PE 35.0 mm2

(1/0 AWG)

16.0 mm2

(6 AWG)

5 N-m

(44 lb.-in.)

5 N-m

(44 lb.-in.)

AUX Terminal

Block

0-3 Auxiliary Control

Voltage(2)

1.3 mm2

(16 AWG)

0.2 mm2

(24 AWG)

——

5 4.0 mm2

(10 AWG)

0.5 mm2

(22 AWG)

0.6 N-m

(5.3 lb.-in.)

0.6 N-m

(5.3 lb.-in.)

(1) Maximum/minimum sizes that the terminal block will accept - these are not recommendations.

(2) External control power:

UL Installation - 300V DC, ±10%, Non UL Installation - 270-600V DC, ±10%.

0-3 Frame - 40 W, 165 mA, 5 Frame - 80 W, 90 mA.

Power & Ground Wiring

(L1)

(L2)

(L3)

(T1)

(T2)

(T3)

–

Required

Input Fusing

Required Branch

Circuit Disconnect

BR1 BR2

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