Rockwell Automation 20D-700 User Manual

Installation Instructions

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

This document explains the 5 BASIC STEPS needed to install and perform a Basic Start-Up of the PowerFlex 700 AC drive. A Human Interface Module (HIM) is required to perform the Basic Start-Up routine covered in this manual.

The information provided is intended for qualified installers only.

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

Resource Description

PowerFlex 700 Standard Control User Manual, publication

20B-UM001

PowerFlex 700 Vector Control User Manual (v4.001 & up), publication 20B-UM002

PowerFlex 700 AC Drive Technical Data, publication

20B-TD001

PowerFlex Comm Adapter Manuals, publication

20COMM-UM…

PowerFlex 70 and PowerFlex 700 Reference Manual, publication PFLEX-RM001

PowerFlex 70 Enhanced Control and PowerFlex 700 Vector Control Reference Manual, publication PFLEX-RM004

Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001

Safety Guidelines for the Application, Installation and Maintenance of Solid State Control, publication SGI-1.1

Guarding Against Electrostatic Damage, publication

8000-4.5.2

Product Certifications website, http://ab.com

Provides detailed information on:

• Parameters and programming

• Faults, alarms, and troubleshooting

This publication provides detailed drive specifications, option specifications and input protection device ratings.

These publications provide information on configuring, using, and troubleshooting PowerFlex communication adapters.

These publications provide detailed application specific information for programming and configuring the PowerFlex 700 drive.

Provides basic information needed to properly wire and ground PWM AC drives.

Provides general guidelines for the application, installation, and maintenance of solid-state control.

Provides practices for guarding against Electrostatic damage (ESD)

Provides declarations of conformity, certificates, and other certification details.

You can view or download publications at

http://www.rockwellautomation.com/literature/

. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Allen-Bradley Drives Technical Support

Use the contacts below for PowerFlex 700 technical support including spare parts information.

Online at… By Email at… By Telephone at…

www.ab.com/support/abdrives support@drives.ra.rockwell.com 262-512-8176

Documentation in Other Languages

User Manuals are available in multiple languages at:

http://www.rockwellautomation.com/literature

Select publication language and type “20B-UM002” in the search field.

2 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step 1: Read the Precautions and General Information . . . . . . . . . . . . . . . . . . . . . 5

EMC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Step 2: Lifting and Mounting the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Minimum Mounting Clearances & Heat Dissipation. . . . . . . . . . . . . . . . . . . . . . .14

Removing the Frame 7 Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Step 3: Wire the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Special Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Cable Types Acceptable for 200…600 Volt Installations . . . . . . . . . . . . . . . . . . . .31

Single-Phase Input Power – Frame 7 Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Power Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Fan Circuit Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Additional Frame 10 Wiring Requirement for IP00 AC Input Drives. . . . . . . .38

DC Link Chokes – Frames 8…10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Auxiliary Control Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

General Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Motor Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Drive, Fuse & Circuit Breaker Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Output Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Using Input/Output Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Disconnecting MOVs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Step 4: I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

I/O Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Hardware Enable Circuitry (Vector Control Only) . . . . . . . . . . . . . . . . . . . . . . . .54

Encoder Interface Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Step 5: Start-Up Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Prepare For Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Supplemental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

DC Input (Common Bus) and Precharge Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Human Interface Module (HIM) Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Start-Up Routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Drive Status Indicators & DPI Port Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Common I/O Programming Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 3

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

20B D 325 A 3 A N N N E C 0

abcdefghijklmn

Drive

Code Type

20B PowerFlex 700

Voltage Rating

Code Voltage Ph. Prechg. Frames

C 400V AC 3 - 7…10

D 480V AC 3 - 7…10

H 540V DC - N 10

J 650V DC - N 10

P 540V DC - Y 7…9

R 650V DC - Y 7…9

ND Rating §

400/480V, 60 Hz Input

Code Amps Hp Frame

292 292 250 7

325 325 250 7

365 365 300 8

415 415 350 8

481 481 400 8

535 535 450 8

600 600 500 8

730 730 600 9

875 875 700 10

§ Refer to the rating tables for further

information.

Enclosure

Code Enclosure

A IP20, NEMA/UL Type 1

Open/Flange Mount

Front: IP00, NEMA/UL Type Open

Back/Heatsink: IP54, NEMA 12

Roll-In

Front: IP00, NEMA/UL Type Open

Back/Heatsink: IP54, NEMA 12

Frames 8 & 9 Only

Documentation

Code Type

A Manual

N No Manual

No Shipping Package

(Internal Use Only)

Comm Slot

Code Network Type

C ControlNet (Coax)

D DeviceNet

E EtherNet/IP

NNone

Feedback

Code Type

0None

1 Encoder, 12V/5V

Future Use

HIM

Code Operator Interface

0 Blank Cover

3 LCD Display, Full Numeric Keypad

Brake

Code w/Brake IGBT

‡

NNo

‡ Brake IGBT is not available on Frames 7…10.

Internal Braking Resistor

Code w/Resistor

NNo

Not available on Frames 7…10.

Emission

Code CE Filter

§ CM Choke

NNoNo

§ Frames 7…10, 400/480V AC drives (Voltage

Rating codes "C" and "D") meet CE certification requirements when installed per recommendations.

Future Use

Control & I/O

Code Control I/O Volts

Vector

24V DC

Vector

115V AC

Δ Vector Control Option utilizes DPI Only.

Catalog Number Explanation

4 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Step 1: Read the Precautions and General Information

Qualified Personnel

ATT EN TI ON : Allow only qualified personnel familiar with adjustable frequency

AC drives and associated machinery to plan or implement the installation, startup and subsequent maintenance of the system. Failure to comply can result in personal injury and/or equipment damage.

Personal Safety

ATT EN TI ON : 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 following points (refer to pages 8 for locations):

• +DC and -DC terminals of the Power Terminal Block

• +DC terminal of the Power Terminal Block and the chassis

• -DC terminal of the Power Terminal Block and the chassis

The voltage must be zero for all three measurements.

through 11

ATT EN TI ON : 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.

ATT EN TI ON : 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 can be required to remove the AC line to the drive. An auxiliary braking method can be required.

ATT EN TI ON : Loss of control in suspended load applications can cause personal injury and/or equipment damage. Loads must always be controlled by the drive or a mechanical brake. Parameters 600…611 are designed for lifting/torque proving applications. It is the responsibility of the engineer and/or end user to configure drive parameters, test any lifting functionality and meet safety requirements in accordance with all applicable codes and standards.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 5

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Product Safety

ATT EN TI ON : 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 can result in malfunction of the system.

ATT EN TI ON : 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 can result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference Guarding Against Electrostatic Damage, publication 8000-4.5.2 or any other applicable ESD protection handbook.

ATT EN TI ON : 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 drives bus voltage is increasing toward levels that will cause a fault. However, it can also cause either of the following two conditions to occur.

• 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 (F25) occurs if the speed reaches [Maximum Speed] + [Overspeed Limit], (parameters 82 and 83). If this condition is unacceptable, action must 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).

• Actual deceleration times can be longer than commanded deceleration times. However, a “Decel Inhibit” fault (F24) 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 provides 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 to occur.

6 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

EMC Compliance

Frame 7…10 drives are CE Certified for use with 400V AC and 480V AC center grounded neutral power supply systems only. The General Grounding

Requirements on page 40 must be followed for CE Compliance.

It is strongly recommended that the PowerFlex 700 User Manual, publication

20B-UM002

Modulated (PWM) AC Drives, publication DRIVES-IN001 assure CE EMC compliance.

Table 1 - Recommended Filters

and the Wiring and Grounding Guidelines for Pulse Width

be referenced to

EN61800-3 Cat. C1,

Power

Base Drive Catalog No.

20BC292 20BD248 20BD292

20BC325 20BC365 20BD325 20BD365

20BC415 20BD415

20BC535 20BD535

20BD600 355 800 FN3359-800-99

20BD730 400 800 FN3359-800-99

20BD875 500 1000 FN3359-1000-99

(1) Motor cable length limit with this filter. Supplementary EMC enclosure required to provide attenuation of radiated emissions.

Current

(kW)

A (at 50° C) Schaffner Part No.

160 320 FN3359-320-99 100

200 400 FN3359-400-99

250 600 FN3359-600-99

315 600 FN3359-600-99

EN6100-6-3, CISPR11, Group 1, Class B

(Meters)

(1)

EN61800-3 Cat. C2 EN6100-6-4, CISPR11, Group 1, Class A

(Meters)

(1)

150

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 7

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

+DC

USE 75° COPPER WIRE ONLY

TORQUE LARGE TERMINALS TO 10 N-m (87LB-IN)

-DC PE PE R-L1 T-L3

RISK OF SHOCK REPLACE AFTER

SERVICING

DANGER

U-M1 V-M2 W-M3S-L2

TB11

25 AMPERES RMS

MAXIMUM

CAUTION

HOT SURFACES

ALLEN-BRADLEY

MADE IN U.S.A.

DANGER

RISK OF SHOCK REPLACE AFTER

SERVICING

DANGER

➊

➋

➌

➍

➒

➐

➑

➏

➎

➓

➋

Component Locations

Frame 7

No. Component No. Component

Power Terminal Block

➊

PE Ground

➋

I/O & Auxiliary Control Voltage - TB11

➌

Fan Terminal Block (DC input only)

➍

Fan Transformer (AC input only) Encoder Feedback Board (Optional)

➎

Main Control Board

➏

8 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

Nameplate

➐

Precharge Board

➑

MOV

➒

HIM/Comm Module (Optional)

➓

Frame 8

TB11

25 AMPERES RMS MAXIMUM

RISK OF SHOCK REPLACE AFTER

SERVICING

DANGER

RISK OF SHOCK REPLACE AFTER

SERVICING

DANGER

TB9

8 AMPERES RMS MAXIMUM

DC+

R S T DC-DC+

GND

➊

➋

➌

➍

➓

➎

➐

➑

➏

➒

➋

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

No. Component No. Component

Power Terminals

➊

PE Ground (and MOV wire)

➋

I/O & Auxiliary Control Voltage - TB11

➌

Fan Terminal Block - TB9

➍

Fan Tra nsfor mer (AC input on ly) HIM/Comm Module (Optional)

➎

Main Control Board Encoder Feedback Board (Optional)

➏

Nameplate

➐

DC Bus/Brake Terminals

➑

MOV (under boards)

➒

DC Link Choke (AC input only)

➓

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 9

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

TB11

25 AMPERES RMS MAXIMUM

DANGER

RISK OF SHOCK REPLACE AFTER

SERVICING

DANGER

TB9

8 AMPERES RMS MAXIMUM

DC+

R S T DC-DC+

GND

4 T22 T1 6 T3

CAUTION

➊

➋

➌

➍

➓

➎

➑

➐

➏

➒

➋

Frames 9

No. Component No. Component

Power Terminals

➊

PE Ground (and MOV wire)

➋

I/O & Auxiliary Control Voltage - TB11

➌

Fan Terminal Block (cap. fan) - TB9 Phase Monitor Relay

➍

Fan Transformer (cap. fan) - AC input only Blower Terminal Block (three-phase)

➎

Main Control Board HIM/Comm Module (Optional)

➏

Nameplate Encoder Feedback Board (Optional)

➐

DC Bus/Brake Terminals

➑

MOV (under boards)

➒

DC Link Choke (AC input only)

➓

10 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

Frame 10

➋

➍

➎

➒

➐

➏

➑

➌

➓

➊

➐

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

DC+

DANGER

RISK OF SHOCK REPLACE AFTER SERVICING

TB9

8 AMPERES RMS MAXIMUM

120 IN1

120 IN2

DANGER

RISK OF SHOCK REPLACE AFTER SERVICING

TB11

25 AMPERES RMS MAXIMUM

DANGER

RISK OF SHOCK REPLACE AFTER SERVICING

VWU

GND

TB10

8 AMPERES RMS

MAXIMUM

120 IN1 120 IN2

DANGER

RISK OF SHOCK REPLACE AFTER SERVICING

120 IN1 120 IN2

TB10

8 AMPERES RMS MAXIMUM

GND

AC Input drive is shown. For DC Input drives, reference the left Inverter section.

No. Component No. Component

Motor Terminal Block Inverter Section

➊

PE Ground Converter Section

➋

I/O & Auxiliary Control Voltage - TB11 PE Bus Bar (IP20 Only)

➌

Fan Terminal Block - TB9

➍

(Capacitor Assembly Fan)

Fan Transformer (IP20 Only) AC Input Terminals (Behind Shield)

➎

Fan Terminal Block - TB10 (Heatsink Fan) PE Connection Point (IP00)

➏

Nameplate DC Bus/Brake Terminals

➐

Main Control Board HIM/Comm Module (Optional)

➑

MOV Jumper Encoder Feedback Board (Optional)

➒

Fan Terminal Block - TB12 (Heatsink Fan)

➓

DC Link Choke (AC input only, supplied loose for IP00)

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 11

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

IMPORTANT

Lifting Holes 4 Places

Step 2: Lifting and Mounting the Drive

ATT EN TI ON : To guard against possible personal injury and/or equipment

damage:

• Do Not allow any part of the drive or lifting mechanism to make contact with electrically charged conductors or components.

• At no time should a person or their limbs be directly underneath the items being lifted.

• Do not subject the load to high rates of acceleration or deceleration.

• Inspect all lifting hardware for proper attachment before lifting drive unit.

Braces attached to the front of Frame 8, 9 or 10 IP20, NEMA/UL Type 1 drives are required for structural integrity. If necessary, the braces can be removed for wiring, but must be replaced upon completion.

Lifting

Frame 7

IP00, NEMA/UL Type Open

Approximate Weight 147 kg (324 lbs.) + 26 kg (58 lbs.) for shipping materials

45°

2 A

IP20, NEMA/UL Type 1

Approximate Weight 170 kg (375 lbs.) + 26 kg (58 lbs.) for shipping materials

12 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

Frames 8, 9 and 10

Lifting Holes 2 Places

>60°

Important: a lifting angle must be used. Do Not

use the lifting holes on the side of the cabinet

IP00, NEMA/UL Type Open

Approximate Wei ght

IP00, NEMA/UL Type Open Roll-In

Approximate Wei ght

Frame 8 – 384 kg (847 lbs.) + 47 kg (103 lbs.) for shipping materials

Frame 9 – 401 kg (884 lbs.) + 47 kg (103 lbs.) for shipping materials

Frame 10 DC Input 305 kg (672 lbs.) + 47 kg (103 lbs.) for shipping materials

AC input 532 kg (1172 lbs.) + 91 kg (200 lbs.) for shipping materials

Lifting Holes 6 Places

Frame 8 – 250 kg (552 lbs.) + 47 kg (103 lbs.) for shipping materials

Frame 9 – 267 kg (589 lbs.) + 47 kg (103 lbs.) for shipping materials

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

IP20, NEMA/UL Type 1

Approximate Wei ght

Frame 8 – 509 kg (1122 lbs.) + 47 kg (103 lbs.) for shipping materials

Frame 9 – 526 kg (1159 lbs.) + 47 kg (103 lbs.) for shipping materials

Frame 10 DC Input 468 kg (1032 lbs.) + 47 kg (103 lbs.) for shipping materials

AC input 867 kg (1912 lbs.) + 91 kg (200 lbs.) for shipping materials

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 13

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Locating Tabs (backside of panel)

Hinge Tabs

Light Pipes

Environment

Operating Temperatures

PowerFlex 700 drives are designed to operate at 0…40 °C ambient. To operate the drive in installations between 41…50 °C, see Ta b l e 2 through 44

Table 2 - Acceptable Surrounding Air Temperature & Required Actions

Enclosure Rating Temperature Range Drive

IP20, NEMA/UL Type 1 0…40 °C (0…104 °F) Frames 7…10

IP00, NEMA/UL Type Open/Flange Mount

Front: IP00, NEMA/UL Type Open Back/Heat Sink: IP54, NEMA12

Roll In

Front: IP00, NEMA/UL Type Open Back/Heat Sink: IP54, NEMA12

for exceptions.

0…65 °C (0…149 °F) Control Board 0…40 °C (0…104 °F) Heat Sink Entry Air

and refer to pages 42

Frames 7…10

Frames 8…9

Minimum Mounting Clearances & Heat Dissipation

The drive must be mounted with sufficient space at the top, sides, and front of the cabinet to allow for proper heat dissipation.

Frame Recommendations

7 Minimum of 152 mm (6.0 in.) at the top and bottom of the enclosure and 102 mm (4.0 in.) on the sides.

Flange Mount - Minimum of 152 mm (6.0 in.) at the back of the enclosure (flange mount sur face to wall).

8…10 Minimum of 152 mm (6.0 in.) at the top of the enclosure. Additionally, allow a minimum of 102 mm (4.0 in.)

on each side OR 152 mm (6.0 in.) in the back. Flange Mount - Minimum of 102 mm (4.0 in.) on each side.

Removing the Frame 7 Cover

1. Loosen lower panel screws and pull the bottom edge out.

2. Tilt panel sufficiently to remove Hinge Tabs from the upper panel. Remove panel and set aside.

3. Loosen upper panel screws and pull bottom edge out slightly.

POWER

STS

PORT MOD NET A NET B

4. Slide panel down until Locating Tabs clear chassis. Remove panel and set aside.

5. Replace panels in reverse order. Carefully align tabs and light pipes.

14 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

Dimensions

Dimensions are in millimeters and (inches)

Frame 7 – IP20, NEMA/UL Type 1

514.4 (20.25)

477.3 (18.79)

440.2 (17.33)

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

406.5 (16.00)

1424.7 (56.01)

1447.8

PORT MOD NET A NET B

(57.00)

1498.6 (59.00)

406.7

(16.01)

354.3

(13.95)

312.4

261.6

(10.30)

(12.30)

38.7 (1.52)

Approx. Weight kg (lbs.)

Drive Drive & Packaging

170 (375) 1 96 (433)

210.8

(8.30)

89.5 (3.52)

178.4 (7.02)

Lifting Holes

4 Places

134.6 (5.30)

58.5

(2.30)

305.4 (12.02)

432.4 (17.02)

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 15

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Dimensions are in

millimeters and (inches)

Frame 7 – IP00, NEMA/UL Type Open

509.3 (20.05)

477.3 (18.79)

440.2 (17.33)

DANGER

409.3 (16.11)

1419.1

(55.87)

354.3

(13.95)

DANGER

RISK OF SHOCK REPLACE AFTER SERVICING

+DC

-DC PE PE R-L1 T-L3

USE 75° COPPER WIRE ONLY

CAUTION

HOT SURFACES

TB11

25 AMPERES RMS

MAXIMUM

ALLEN-BRADLEY

MADE IN U.S.A.

TORQUE LARGE TERMINALS TO 10 N-m (87LB-IN)

1447.8 (57.00)

1498.6

DANGER

RISK OF SHOCK REPLACE AFTER SERVICING

U-M1 V-M2 W-M3S-L2

(59.00)

Lifting Holes

4 Places

133.4 (5.25)

58.9

(2.32)

Approx. Weight kg (lbs.)

Drive Drive & Packaging

147 (324) 173 (382)

16 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

Frame 7 – Flange Mount Cutout

Dimensions are in millimeters and (inches)

IMPORTANT

5.8

(0.23)

1422.4 (56.00)

1095.8 (43.14)

1084.1

(42.68)

508.0

(20.00)

Cutout

489.0

(19.25)

477.3

(18.79)

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

127.0 (5.00)

54.1

(2.13)

Shading indicates approximate size

of drive inside enclosure.

127.0

(5.00)

75.4

(2.97)

5.8

(0.23)

Drive

26 Required

4.3 (0.171) Dia. for 10-32 x 9.7 (0.38) Self-Tap

4.0 (0.159) for 10-32 x 9.7 (0.38) Threaded

* Minimum dimension allowed – More space

will improve fan eectiveness and heat dissipation.

Back of Enclosure

132.3 (5.21) *

Use gasket kit catalog number SK-G1-GASKET1-F7 with user supplied IP54, NEMA/UL Type 12 enclosure.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 17

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Dimensions are in millimeters and (inches)

Frames 8 and 9 – IP20, NEMA/UL Type 1

254.6 (10.02) - 20Bx365, 415, 481

381.7 (15.03) - 20Bx535, 600, 730

898.8 (35.39) - 20Bx365, 415, 481

1025.9 (40.39) - 20Bx535, 600, 730

549.7

(21.64)

1466.6 (57.74)

757.9

(29.84)

Approx. Weight kg (lbs.)

Frame Drive Drive & Packaging

8 509 (1122) 55 6 (1225)

9 526 (1159) 60 3 (1262)

2349.1 (92.49)

18 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

TB11

25 AMPERES RMS MAXIMUM

RISK OF SHOCK REPLACE AFTER SERVICING

DANGER

RISK OF SHOCK REPLACE AFTER SERVICING

DANGER

TB9

8 AMPERES RMS MAXIMUM

DC+

VWU

R S T DC-DC+

GND

2283.7 (89.91)

463.8

(18.26)

603.0

(23.74)

1524.0

(60.00)

71.3 (2.81)

153.0 (6.02)

274.3

(10.80)

193.3 (7.61)

241.0 (9.49)

549.7

(21.64)

1466.6

(57.74)

85.5 (3.37)

757.8 (29.83)

145.3

(5.72)

See

Table

612.8 (24.13)

Dimensions are in millimeters and (inches)

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Frames 8 and 9 – IP00, NEMA/UL Type Open

Frame Cat. No. A B C

8 20Bx365, 415, 481 254.6 (10.02) 345.3 (13.59) 599.4 (2 3.60) 384 (847) 431 (950)

20Bx535, 600 381.7 (15.03) 345.5 (13. 60) 726.6 (28.61) 384 (847) 431 (950)

Approx. Weight kg (lbs.)

Drive Drive & Packaging

9 20Bx730 381.1 (15.00) 345.3 (13.60) 771.9 (30.39) 401 (884) 448 (987)

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 19

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

TB11

25 AMPERES RMS MAXIMUM

RISK OF SHOCK REPLACE AFTER

SERVICING

DANGER

RISK OF SHOCK REPLACE AFTER SERVICING

DANGER

TB9

8 AMPERES RMS

MAXIMUM

DC+

VWU

R S T DC-DC+

GND

➊

➋

➌

Frames 8 and 9 – Converting an IP00 Drive for Flange Mounting

No. Component

Remove these IP00 enclosure components.

➊

Drive assembly to be flange mounted.

➋

DC link choke - mounts separately in enclosure (see page 28 for dimensions) and is wired direc tly to drive.

➌

20 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

TB11

25 AMPERES RMS MAXIMUM

RISK OF SHOCK REPLACE AFTER

SERVICING

DANGER

RISK OF SHOCK REPLACE AFTER

SERVICING

DANGER

TB9

8 AMPERES RMS MAXIMUM

DC+

RSTDC-DC+

648.2 (25.52)

1612.4 (63.48)

719.8 (28.34)

45.2

(1.78)

31.8

(1.24)

Dimensions are in millimeters and (inches)

Frames 8 and 9 Roll-In – IP00, NEMA/UL Type Open

Frame C at. No. A

Approx. Weight kg (lbs.)

Drive Drive & Packaging

8 20Bx365, 415, 481 574.8 (22.63) 25 0 (552) 297 (655)

8 20Bx535, 600 574.8 (22.63) 25 0 (552) 297 (655)

9 20Bx730 594.3 (23.40) 267 (589) 314 (692)

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 21

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

IMPORTANT

Typical Fan Location

(2 Places - 1 Each Door)

Typ ica l Bra cke t

(May require additional anchoring for shipping)

Suggested Anchoring Point

(M10 Ha rdware Required)

Alternate Fan Locations

Typical Rail Detail

Cable Access Plate

(2 Places)

DC Link Choke

Mounted Separately - Typical Placement Shown

203.2…355.6 mm

(8.00…14.00 in.) Typical

Suggested Anti-Roll

Anchoring Point

Typical Air Inlet

(2 Places - 1 Each Door)

Frames 8 and 9 Roll-In Mounting Considerations

107.4 D =

(4.23)

465.8 (18.34)

58.9

(2.32)

GER

R E

G N A

K !

F O K IS R

E AC L P E R

V R SE

9 B T

S E R E P M A

U M I X A M

R E G

N A

OC H S F

O K IS R

TE F A E C

A L P E R

G IN C I V

R E S

T 1 1 B

M R S E R E P M A

5 2

M U M I X A M

108.0 x 158.8 (4.25 x 6.25)

196.9 (7.75)

19.1

(0.75)

This information illustrates how an open roll-in style drive could be mounted in a user supplied enclosure. Illustrations are intended only to identify structural mounting points and hardware shapes. You must design and fabricate steel components based on the actual mounting configuration, calculated loads and enclosure specifications. Minimum thickness of all parts = 4.6 mm (0.18 in.).

22 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

IMPORTANT

1471.9 (57.95)

279.4

(11.00)

279.4

(11.00)

279.4

(11.00)

152.4

(6.00)

152.4

(6.00)

203.2

(8.00)

5.6 (0.22) 20 Places

52.1 (2.05)

22.9 (0.90)

553.3 (21.79)

279.4

(11.00)

279.4

(11.00)

603.0

(23.74)

12.7 (0.50)

508.0 (20.00)

463.8

(18.26)

This cutout is only needed

if recessing the choke

Dimensions are in millimeters and (inches)

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Frames 8 & 9 Flange Mount Cutout

Use gasket kit catalog number SK-G1-GASKET1-F89 with user supplied IP54,

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 23

NEMA/UL Type 12 enclosure.

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

890.8

(35.07)

2374.0

(93.46)

1268.7

(49.95)

761.3

(29.97)

507.4

(19.98)

Dimensions are in millimeters and (inches)

Frame 10 – IP20, NEMA/UL Type 1

AC Input Shown, for DC Input Dimensions use the Inverter (Left) Bay

Approx. Weight kg (lbs.)

Type Drive Drive & Packaging

DC Input 468 (1032) 515 (1135)

AC Input 867 (1912) 958 (2112)

24 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

120 IN1

120 IN2

DC+

DANGER

TB9

8 AMPERES RMS MAXIMUM

120 IN1

120 IN2

VWU

TB11

25 AMPERES RMS MAXIMUM

GND

RISK OF SHOCK REPLACE AFTER SERVICING

DANGER

RISK OF SHOCK

REPLACE AFTER

SERVICING

DANGER

RISK OF SHOCK REPLACE AFTER SERVICING

DANGER

TB10

8 AMPERES RMS MAXIMUM

120 IN1

120 IN2

TB10

8 AMPERES RMS MAXIMUM

GND

RISK OF SHOCK REPLACE AFTER SERVICING

DANGER

543.6

(21.40)

591.8

(23.30)

2275.8

(89.60)

252.7 (9.95)

473.4

(18.64)

1267.8 (49.91)

757.8

(29.83)

503.7

(19.83)

353.8

(13.93)

445.8

(17.55)

Dimensions are in millimeters and (inches)

Frame 10 – IP00, NEMA/UL Type Open

AC Input Shown, for DC Input Dimensions use the Inverter (Left) Bay

Approx. Weight kg (lbs.)

Type Drive Drive & Packaging

DC Input 305 (672) 352 (775)

AC Input 532 (1172) 623 (1372)

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 25

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

IMPORTANT

Dimensions are in millimeters and (inches)

Frame 10 – Flange Mount Cutout

22.9

(0.90)

52.1 (2.05)

279.4 (11.00) hole spacing,

5 places,

both sides

66.5 (2.62)

508.0 (20.00)

355.6 (14.00)

152.4 (6.00)

553.3 (21.79)

1471.9 (57.95)

Inverter Converter

22.5 (0.89)

37.7 (1.49)

22.9 (0.90)

12.7 (0.50)

58.6 (2.31)

38.1

(1.50)

152.4 (6.00)

381.0 (15.00)

152.4

(6.00)

32.3 (1.27)

39.9 (1.57)

7.6 (0.30)

1588.5 (62.54)

254.0 (10.00) hole spacing

5 places,

both sides

See Detail

Holes are for M6 self tapping screws.

Backplate and extension are a single piece. Drive chassis can be removed from backplate to mount in user supplied IP54, NEMA/UL Type 12 enclosure.

26 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

Frame 10 – Flange Mount Cutout Detail

IMPORTANT

Dimensions are in millimeters and (inches)

95.9 (3.77)

178.8(7.04)

558.2 (21.98)

543.3 (21.39)

24.9 (0.98)

28.7 (1.13)

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

328.8 (12.94)

478.8 (18.85)

530.8 (20.90)

486.5 (19.15)

414.7 (16.33)

363.7 (14.32)

271.2 (10.68)

127.7 (5.03)

Ref. (0.00)

15.8 (0.62)

14.7 (0.58)

Ref. (0.00)

Fan studs are installed in alternating

directions. “ * ” indicates that the stud

points-in, all others point-out.

Fan Stud “Pointing-Out”

(Outside of Enclosure)

93.7 (3.69)

121.1 (4.77)

Enclosure Wall

Fan Stud “Pointing-In” (Inside of Enclosure)

253.7 (9.99)

413.8 (16.29)

507.5 (19.98)

522.2 (20.56)

Backplate and extension are a single piece. Drive chassis can be removed from backplate to mount in user supplied IP54, NEMA/UL Type 12 enclosure.

425.6 (16.75)

343.0 (13.50)

199.5 (7.85)

56.0 (2.20)

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 27

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

370.8 (14.60)

396.2 (15.60)

179.8

(7.08)

217.9 (8.58)

228.6

(9.00) Max.

19.1 (0.75)

16.0 x 9.7 (0.63 x 0.38) 4 Places

203.2 (8.00)

279.4 (11.00)

4.7 (0.19)

215.9

(8.50) Max.

4.8

(0.19)

54.1

(2.13)

54.1

(2.13)

10.2 (0.40) Min.

162.1

(6.38)

Dimensions are in millimeters

and (inches)

Dimensions are in millimeters

and (inches)

DC Link Choke – Frame 8

DC Link Choke – Frame 9

14.2 (0.56)

188.0 (7.40)

218.4

(8.60)

28 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

101.6 (4.00)

287.0

(11.30)

214.4

(8.44)

35.3

(1.39)

342.9 (13.50)

304.8 (12.00)

50.8

(2.00)

L2 L3

50.8

(2.00)

25.4 (1.00)

See Detail

Dimensions are in millimeters and (inches)

DC Link Choke – Frame 10

266.7 (10.50) Max

220.9 (8.70)

Top

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Detail

219.7

(8.65)

31.8 (1.25)

9.5 (0.38) Dia.

280.7

(11.05)

251.0 (9.90)

244.6 (9.63)

57.2 (2.25)

121.8 (4.80)

25.4

(1.00) Dia.

2 Places

Front Side

12.7 (0.50)

34.9 (1.38)

222.0

(8.74)

247.7 (9.75)

12.7 (0.50)

13.5 (0.53)

31.8 (1.25)

11.8 (0.47)

7.9 (0.31) 4 PLACES

305.0

(12.00)

248.0

(9.76)

Step 3: Wire the Drive

280.7 (11.05)

Special Considerations

PowerFlex 700 drives are suitable for use on a circuit capable of delivering up to a maximum of 200,000 rms symmetrical amperes.

ATT EN TI ON : To guard against personal injury and/or equipment damage caused by improper fusing or circuit breaker selection, use only the recommended line fuses/circuit breakers specified on page 41

If a system ground fault monitor (RCD) is used, only Type B (adjustable) devices can be used to avoid nuisance tripping.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 29

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Unbalanced, Ungrounded, Resistive or B Phase Grounded Distribution Systems

If phase to ground voltage exceeds 125% of normal line to line voltage or the supply system is ungrounded, refer to the Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001

ATT EN TI ON : To guard against drive damage, PowerFlex 700 drives contain protective MOVs and common mode capacitors that are referenced to ground. These devices must be disconnected if the drive is not grounded system. See page 46

for details.

installed on a solidly

Input Power Conditioning

Certain events on the power system supplying a drive can cause component damage or shortened product life. These conditions include:

• The power system has power factor correction capacitors switched in and out of the system, either by the user or by the power company.

• The power source has intermittent voltage spikes in excess of 6000 volts. These spikes could be caused by other equipment on the line or by events such as lightning strikes.

• The power source has frequent interruptions.

If any or all of these conditions exist, it is recommended that the user install a minimum amount of impedance between the drive and the source. This impedance could come from the supply transformer itself, the cable between the transformer and drive or an additional transformer or reactor.

EMC Compliance

Frames 7…10: Drives are CE Certified for use with 400V AC and 480V AC center grounded neutral power supply systems only. Refer to page 7

for details.

Cable Trays and Conduit

If cable trays or large conduits are to be used, refer to the guidelines presented in the Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001

ATT EN TI ON : To avoid a possible shock hazard caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit must be disabled. This helps to minimize the possible shock hazard from “cross coupled” motor leads.

Motor Cable Lengths

Typically, motor lead lengths less than 91 meters (300 feet) are acceptable. However, if your application dictates longer lengths, refer to the Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001

20B-TD001

30 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

or the PowerFlex 700 Technical Data, publication

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Cable Types Acceptable for 200…600 Volt Installations

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.). Use Copper wire only. Wire gauge requirements and recommendations are based on 75 °C. Do not reduce wire gauge by using higher temperature wire.

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 not have large variations in insulation concentricity.

Shielded/Armored Cable

Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC Drive. Strong consideration for shielded cable must be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other devices that can be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations or a high degree of communications/ networking are also good candidates for shielded cable.

Shielded cable can also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable can help extend the distance between the motor and drive without the addition of motor protective devices such as terminator networks. Refer to Reflected Wave in the Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001

Consideration must be given to all of the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics and chemical resistance. In addition, a braided shield can be included and be specified by the cable manufacturer as having coverage of at least 75%. An additional foil shield can greatly improve noise containment.

A good example of recommended cable is Belden® 295xx (xx determines gauge). This cable has four (4) XLPE insulated conductors with a 100% coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a PVC jacket.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 31

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

IMPORTANT

Other types of shielded cable are available, but the selection of these types can limit the allowable cable length. Particularly, some of the newer cables bundle 4 conductors of THHN wire and wrap them tightly with a foil shield. This construction can greatly increase the cable charging current required and reduce the overall drive performance. Unless specified in the individual distance tables as tested with the drive, these cables are not recommended and their performance against the lead length limits supplied is not known. See Ta b l e 3

Table 3 - Recommended Shielded Wire

Location Rating/Type Description

Standard (Option 1)

Standard (Option 2)

Class I & II; Division I & II

600V, 90 °C (194 °F) XHHW2/RHW-2 Anixter B209500-B209507, Belden 29501-29507, or equivalent

Tray rated 600V, 90 °C (194 °F) RHH/RHW-2 Anixter OLF-7xxxxx or equivalent

Tray rated 600V, 90 °C (194 °F) RHH/RHW-2 Anixter 7V7xxxx-3G or equivalent

• Four tinned copper conductors with XLPE insulation.

• Copper braid/aluminum foil combination shield and tinned

copper drain wire.

• PVC jacket.

• 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.

• 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.

Single-Phase Input Power – Frame 7 Only

The PowerFlex 700 drive is typically used with a three-phase input supply. Frame 7 drives have been listed by UL to operate on single-phase input power with the requirement that the output current is derated by 50% (at maximum ambient temperature of 25 °C) of the three-phase ratings. Refer to Ta b l e 4

AC Input Phase Selection

ATT EN TI ON : To avoid a shock hazard, ensure that all power to the drive has been removed before performing the following.

Frames 8…10 are not designed for single-phase operation.

Moving the “Line Type” jumper on the Precharge Board (see below) allows single or three-phase operation.

When selecting single-phase operation, input power must be applied to the R (L1) and S (L2) terminals. This ensures that the fan is properly powered.

on page 33.

32 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Typical Location - Phase Select Jumper

333

1-PH 3-PH

LINE TYPE

JP1JP2 JP3

AC Input

Precharge

Board

3-PH 1-PH

LINE TYPE

SPARE 1

SPARE 2

Table 4 - 380…480 Volt Single-Phase AC Input Ratings

480V Single-Phase AC Input 380…400V Single-Phase AC Input

Drive Catalog Number

20BD292 7 125 237.4 0-460 146 20BC292 7 80 247.7 0-400 146 25

20BD325 7 125 264.3 0-460 162.5 20BC325 7 90 275.7 0-400 162.5 25

Frame

Hp Rating

Three-Phase Output

Input Amps

V AC Am ps V AC Amp s °C

Drive Catalog Number

kW RatingInput

Frame

Amps

Three-Ph ase Output

Power Terminal Blocks

Tem p.

ATT EN TI ON : National Codes and standards (NEC, VDE, BSI etc.) and local codes

outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices. Failure to do so can result in personal injury and/or equipment damage.

Refer to pages 8 through 11 for typical locations.

Wire Size Range

(2)

see Note

Name Frame Description

Power Ter mi na l Bl oc k

7Input power, DC+,

DC–, PE, motor connections

8…10 Input power, DC+,

DC–, PE, motor connections

AUX Terminal

(1)

Block

Fan Terminal Block

7…10 Auxiliary Control

Volt age

(1)

PS+, PS–

7User Supplied Fan

Volt age

8…10 4.0 mm

(1) External control power - select drives only, see Auxiliary Control Power Supply on page 39 for details.

(2) Maximum/minimum sizes that the terminal block accepts - these are not recommendations.

(3) If can be necessary to connect multiple wires in parallel to these terminals by using multiple lugs.

Maximum Minimum Maximum Recommended

150.0 mm2 (300 MCM) see Note

300.0 mm2 (600 MCM) see Note

4.0 mm (12 AWG)

(12 AWG)

(3)

2.5 mm (14 AWG)

0.049 mm (30 AWG)

0.5 mm (22 AWG)

Tor que

2.7 N•m (24 lb•in)

10.0 N•m (87 lb•in)

0.6 N•m (5.3 lb•in)

0.9 N•m (8.0 lb•in)

0.6 N•m (5.3 lb•in)

2.7 N•m (24 lb•in)

10.0 N•m (87 lb•in)

0.6 N•m (5.3 lb•in)

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 33

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

DC+

–

DC Bus/Brake

(top of drive)

Terminal Block

Frame

AC Input DC Input

8…9

DC–DC+ PE PE R-L1 S-L2 T-L3 U-T1 V-T2 W-T3

Bus Input Output

DC+

–

DC Bus/Brake

(top of drive)

DC+*

–

DC Bus/Brake

(top of drive)

(IP20 Versions Only)

* for DC link choke wiring

DC+

120

USE 75° COPPER WIRE ONLY

–*

–

DC Bus/Brake

(top of drive)

(IP20 Versions Only)

TORQUE LARGE TERMINALS TO 10 N-m (87 LB-IN)

DC+ DC-

DC+

U-T1 V-T2 W-T3

BUS OUTPUT

Terminal Description Notes

DC+/DCTop of drive

DC+/DCPower TB

DC Bus (+) DC Bus (–)

DC Input/Brake Chopper Connections

DC Link Choke - wire to:

Bottom of drives (Frames 8…9) Converter section (Frame 10)

PE PE Ground

PS+ PS–

AUX (+) AUX (–)

Auxiliary Control Voltage (see page 39

Motor Ground

U V W

R S T

34 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

U (T1) V (T2) W (T3)

R (L1) S (L2) T (L3)

To M oto r

AC Lin e Input Power

Three-Phase = R, S & T Single-Phase = R & S Only

) for details.

Fan Circuit Power Supply

IMPORTANT

Input Line Voltage

480/400V AC, 50/60 Hz

480 400

to TB9

JMP

115 0

H2H1

X1 XF X2

ATT EN TI ON : To avoid a shock hazard, ensure that all power to the drive has been removed before connecting the fan supply.

Some drives utilize a fan transformer to power the internal fan(s). This transformer is sized specifically for the internal fan(s) and must not be used to power other circuitry.

Frame 7

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Drive Type En closu re

IP00, NEMA/UL Type Open 250 VA 1 Power Terminal Block

Input

IP20, NEMA/UL Type 1 250 VA 1

IP00, NEMA/UL Type Open 250 VA 1 N/A (Connected internally)

Input

IP20, NEMA/UL Type 1 250 VA 1

Frame 8

Drive Type En closu re

IP00, NEMA/UL Type Open 500 VA 1 TB9

Input

IP20, NEMA/UL Type 1 500 VA 1

IP00, NEMA/UL Type Open 500 VA 1 TB9

Input

IP20, NEMA/UL Type 1 500 VA 1

Rating

(120VAC)

Rating (120VAC)

No. of Fans Connect at …

Requires user supplied 120V AC. See page 34 location.

No. of Fans Connect at …

Requires user supplied 120V AC. See page 9 location and page 37

for terminal designations.

A transformer matches the input line voltage to the internal fan voltage. If line voltage is different than the voltage class specified on the drive nameplate, the transformer taps may require changing.

for

for TB

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 35

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Input Line Voltage

480/400V AC, 50/60 Hz

480 400

to TB9

JMP

115 0

H2H1

X1 XF X2

L1 L2 L3

Frame 9

Drive Type E nclosu re

IP00, NEMA/UL Type Open 500 VA 2 TB9

Input

IP20, NEMA/UL Type 1 500 VA 2

IP00, NEMA/UL Type Open 500 VA 2 TB9

Input

IP20, NEMA/UL Type 1 500 VA 2

Rating (120VAC)

No. of Fans Connect at …

Requires user supplied 120V AC for cap. bank fan and phase monitor.

Blower Terminal Block

Three-phase power must be supplied to the Blower TB. See page 10 designations.

A transformer (see page 10 matches the input line voltage to the internal voltage used for the capacitor fan and phase detector module. If the line voltage is different than the voltage class specified on the drive nameplate, the transformer taps may require changing.

for TB locations and page 37 for terminal

for location)

Frame 9 Blower Operation

Frame 9 drives use a single-phase capacitor bank fan and a three-phase blower for cooling. Proper phasing must be supplied to terminals R, S, and T of the Power Terminal Block (AC drives) or the Blower Terminal Block (DC drives) to assure correct blower rotation. To verify this, a Phase Monitor relay (see page 10

for

location) is used.

When wiring is complete, apply drive power and check for proper fan operation. Depending on when the drive was manufactured, one of two different phase monitor relays is used:

• Drives Manufactured Before

January 20, 2011: If phasing is correct, a solid triangle is displayed on the phase monitor relay (shown at right).

• Drives Manufactured January 20, 2011 and after

: If phasing is correct, the “R/T” LED on

the phase monitor relay illuminates.

• If phasing is not correct, the “F1” and “F2” LEDs alternately illuminate.

Regardless of which phase monitor relay is used in the drive, if the blower does not operate:

1. Remove all input power and wait 5 minutes for the DC bus to discharge. Verify that the DC bus has discharged by measuring across the + and - DC bus terminals. The reading must be less than 50 volts.

2. Verify blower fuses and replace if necessary.

3. Switch any two input power leads at the top of the blower fuse block.

4. Apply power and verify proper operation.

36 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

Frame 10

Input Line Voltage

480/400V AC, 50/60 Hz

480 400

to TB9

JMP

115 0

H2H1

X1 XF X2

Frame 10, AC Input, IP20 Only

120V

AC Input

Line

Neutral

To Fan(s)

Ground

TB9, TB10 TB12

Frame 9 Onl y

Blower TB

Frames 8…10

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Drive Type E nclosu re

IP00, NEMA/UL Type Open 1000 VA 2 TB9 & 10

Input

IP20, NEMA/UL Type 1 1000 VA 2

IP00, NEMA/UL Type Open 1000 VA 3 TB9, 10 & 12

Rating

(120VAC)

Input

IP20, NEMA/UL Type 1 1000 VA 3 TB9, 10 & 12

Fan/Blower Terminal Blocks - Frames 8…10

120V

AC Input

Line

Neutral

Ground

120V

To Fan(s)

RTS

No. of Fans Connect at …

Requires user supplied 120V AC. See page 11 locations and page 37

for terminal designations.

Requires user supplied 120V AC. See page 11 locations and page 37

for terminal designations.

A transformer (see page 11

) matches the input line voltage to the internal fan voltage. If line voltage is different than the voltage class specified on the drive nameplate, the transformer taps may require changing.

for TB

Fan Transformer Specifications/Fusing

Recommended Fuses

Frame Rating

Primary (Quantity 2) Secondary (Quantity 1)

8 & 9 500 VA 2.8A, 600V AC, KLDR/ATQR Type 6.25A, 250V AC, Time Delay

10 1000 VA 6A, 600V AC, KLDR/ATQR Type 9A, 250V AC, Time Delay

Three-Phase Blower Fusing

Frame Recommended Fuses (Quantity 3)

9 5A, 600V AC, Time Delay

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 37

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Output to Inverter

Capacitor Bank

Input from

Converter

CNV+

CNV–

INV+

(1) (2)

(4) (3)

INV–

DC–

DC+

to Mounting Foot

Additional Frame 10 Wiring Requirement for IP00 AC Input Drives

The Inverter and Converter sections of Frame 10 AC Input IP00, NEMA/UL Type Open drives are shipped separately. Once installed, the following connections are required.

1. DC Link Choke Wiring DC link chokes are supplied loose for customer mounting and wiring in IP00 drives. Refer to DC Link Chokes – Frames 8…10

2. Thermistor Wiring Thermistor wiring is coiled loose in the Converter section for shipping. Locate the wire (labeled “To INV”) and route through the enclosure wall. Connect it to the mating connector above the HIM cradle.

ATTENTION: To avoid possible drive damage, ensure that the thermistor wiring described above has been properly performed.

3. Ground the drive chassis Refer to page 11

for IP00 PE grounding locations.

below.

DC Link Chokes – Frames 8…10

DC Link Chokes are supplied with Frame 8…10 AC input drives.

Frame Type DC Link Choke is supplied …

8…9 IP00, NEMA/UL Type Open Mounted and wired

IP20, NEMA/UL Type 1 Mounted and wired

IP00, NEMA/UL Type Open Roll-In Loose without cables (see wiring info below)

10 IP00, NEMA/UL Type Open Loose without cables (see wiring info below)

IP20, NEMA/UL Type 1 Mounted and wired

DC Link Choke Wiring

Refer to the diagram and page 34 for connection information. Drive rating information can be found on pages 42

…42.

38 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Auxiliary Control Power Supply

If desired, an auxiliary control power supply can be used with certain drives to keep the drive control logic up when the main AC power is removed.

An auxiliary control power supply can only be used with:

• 400/480

and 600/690 Volt drives with Vector Control (15th position of

the catalog number string equals “C,” or “D”).

Using an auxiliary control power supply requires the use of some type of AC line monitoring, as well as control of the Precharge Enable signal. Consult the factory for additional guidance.

ATT EN TI ON : An Auxiliary Control Power Supply Must Not be used with any PowerFlex 700 Standard Control drive or 200/240 Volt Vector Control drive. Using the power supply with these drives causes equipment/component damage.

Connection is performed at the I/O terminal block (see pages 8

Power supply must provide

UL Installation 300V DC, ±10%

Non UL Installation 270…600V DC, ±10%

Auxiliary Control Voltage Terminal Block Specification

Wire Size Range

Maximum Minimum Maximum Recommended

4.0 mm2 (12 AWG) 0.049 mm2 (30 AWG) 0.6 N•m (5.3 lb•in) 0.6 N•m (5.3 lb•in)

(1)

Tor que

…11).

PS+ PS –

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

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 39

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

IMPORTANT

General Grounding Requirements

The drive Safety Ground - PE must be connected to system ground. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections must be periodically checked.

For installations within a cabinet, use only a single safety ground point or ground bus bar connected directly to building steel. All circuits including the AC input ground conductor must be grounded independently and directly to this point/ bar.

Do Not discard or replace grounding hardware.

Typical Grounding

SHLD

U (T1) V (T2)

W (T3)

R (L1) S (L2) T (L3)

Safety Ground - PE

This is the safety ground for the drive that is required by code. This point must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar (see above). Grounding points must comply with national and local industrial safety regulations and/or electrical codes.

Shield Termination

The Shield terminal (PE) provides a grounding point for the motor cable shield. Connect the motor cable shield to this terminal on the drive (drive end) and the motor frame (motor end). A shield terminating cable gland can also be used.

When shielded cable is used for control and signal wiring, ground the shield at the source end only, not at the drive end.

RFI Filter Grounding

Using an optional RFI filter can result in relatively high ground leakage currents. Therefore, the filter must be used only in installations with grounded AC supply systems and be permanently installed and solidly grounded (bonded) to the building power distribution ground. Ensure that the incoming supply neutral is solidly connected (bonded) to the same building power distribution ground. Grounding must not rely on flexible cables and must not include any form of plug or socket that permits inadvertent disconnection. Some local codes can require redundant ground connections. Periodically check the integrity of all connections. Refer to the instructions supplied with the filter.

40 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Motor Overload Protection

Class 10 motor overload protection according to NEC article 430 and motor over-temperature protection according to NEC article 430.126 (A)(2). UL 508C File E59272.

Drive, Fuse & Circuit Breaker Ratings

The PowerFlex 700 can be installed with input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes can determine additional requirements for these installations.

ATT EN TI ON : The PowerFlex 700 does not provide branch short circuit protection. Specifications for the recommended fuse or circuit breaker to provide protection against short circuits are provided on pages 42

The tables on the following pages provide recommended AC line input fuse and circuit breaker information. See Fusing and Circuit Breakers below for UL and IEC requirements. Sizes listed are the recommended sizes based on 40 °C (104 °F) and the U.S. NEC. Other country, state, or local codes can require different ratings. Tables with DC link fuse recommendations for DC input drives are also provided.

through 44.

Fusi ng

The recommended fuse types are listed below. If available current ratings do not match those listed in the tables provided, choose the next higher fuse rating.

• IEC – BS88 (British Standard) Parts 1 & 2, EN60269-1, Parts 1 & 2

(1)

type gG or equivalent must be used.

• UL Class T, RK1, J, or L must be used.

Circuit Breakers

The “non-fuse” listings in the following tables include inverse time circuit breakers and instantaneous trip circuit breakers (motor circuit protectors). If one of these is chosen as the desired protection method, the following requirements apply:

• IEC – Both types of circuit breakers are acceptable for IEC installations.

• UL - Only inverse time circuit breakers are acceptable for UL installations.

(1) Typical designations include, but may not be limited to the following; Parts 1 & 2: AC, AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG,

GH.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 41

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

(7)

Dual Element Time Delay Fuse

(1)

Max.

Non-Time Delay Fuse

(2)

Min.

Circuit

(3)

(1)

Max.

Breaker

(2)

Max.

(5)

Drive Catalog

(6)

Number

400 Volt AC Input Protection Devices

kW Rating PWM Freq. Temp.

ND HD kHz °C Amps kVA Cont. 1 Min. 3 Sec. Min.

Frame

(8)

Input Ratings Output Amps

20BC292 7 160 4 40 293 203 292 322 438 375 650 375 850 850 400

150 4 40 264 183 263 395 526 3 50 550 350 550 750 400

20BC325 7 180 4 40 326 226 325 358 488 425 700 425 950 950 600

180 4 40 326 226 325 488 650 4 25 700 425 950 950 600

20BC365 8 200 2 40 366 253 365 402 548 475 800 475 1000 1000 600

180 2 40 326 226 325 488 650 4 25 700 425 950 950 600

20BC415 8 240 2 40 416 288 415 457 623 525 900 525 1200 1200 600

200 2 40 366 253 365 548 730 4 75 800 475 1000 1000 600

20BC481 8 280 2 40 483 334 481 530 722 600 1000 600 1400 1400 700

240 2 40 416 288 415 623 830 5 25 900 525 1200 1200 600

20BC535 8 300 2 40 537 372 535 589 803 700 1200 700 1600 1600 700

280 2 40 483 334 481 722 962 6 00 1000 600 1400 1400 700

20BC600 8 350 2 40 602 417 600 660 900 750 1300 750 1800 1800 800

300 2 40 537 371 535 803 1070 700 1200 700 1600 1600 700

20BC730 9 400 2 40 702 486 730 803 1095 900 1500 900 2100 210 0 900

350 2 40 602 417 600 900 1200 750 1300 750 1800 1800 800

20BC875 10 500 2 40 877 608 875 963 1313 1100 1900 1100 2600 2600 1200

400 2 40 877 486 700 1050 1400 900 1500 900 2100 2100 900

See page 43

for Notes.

Motor Circuit

(4)

Protector

(5)

Max.

Drive Catalog Number

20BD292

20BD325

20BD365

20BD415

20BD481

20BD535

20BD600

20BD730

20BD875

See page 43

Hp Rating PWM Freq. Temp. Input Ratings Output Amps

ND HD kHz °C Amps kVA Cont. 1 Min. 3 Sec. Min.

Frame

(6)

7 250 4 40

200 4 40

(6)

7 250 4 40

250 4 40

(6)

8 300 2 40

250 2 40

(6)

8 350 2 40

300 2 40

(6)

8 400 2 40

350 2 40

(6)

8 450 2 40

400 2 40

(6)

8 500 2 40

450 2 40

(6)

9 600 2 40

500 2 40

(6)

10 700 2 40

600 2 40

for Notes.

480 Volt AC Input Protection Devices

(8)

281 233 292 322 438 375 650 37 5 850 850 400

(8)

253 210 263 395 526 350 550 35 0 550 750 400

(8)

313 260 325 358 488 425 700 42 5 950 950 600

(8)

313 260 325 488 650 425 700 42 5 950 950 600

(8)

351 292 365 402 548 475 800 47 5 1000 1000 600

(8)

313 260 325 488 650 425 700 42 5 950 950 600

(8)

399 331 415 457 623 525 900 52 5 1200 1200 600

(8)

351 291 365 548 730 475 800 47 5 1000 1000 600

(8)

462 384 481 530 722 600 1000 600 1400 1400 700

(8)

399 331 415 623 830 525 900 52 5 1200 1200 600

(8)

514 427 535 589 803 700 1200 700 1600 1600 700

(8)

462 384 481 722 962 600 1000 600 1400 1400 700

(8)

577 479 600 660 900 750 1300 750 1800 1800 800

(8)

514 427 535 803 1070 700 1 200 70 0 1600 1600 700

(8)

673 559 730 803 1095 900 1 500 90 0 2100 2100 900

(8)

577 479 600 900 1200 750 1 300 75 0 1800 1800 800

(8)

841 699 875 963 1313 1100 1900 1100 2600 2600 1200

(8)

673 559 700 1050 1400 900 1500 900 2100 2100 900

(7)

Dual Element Time Delay Fuse

(1)

Max.

Non-Time Delay Fuse

(2)

Min.

(1)

Max.

(2)

Circuit Breaker

Max.

(5)

(3)

Motor Circuit

(4)

Protector

(5)

Max.

42 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Notes:

(1)

Minimum protection device size is the lowest rated device that supplies maximum protection without nuisance tripping.

(2)

Maximum protection device size is the highest rated device that supplies drive protection. For US NEC, minimum size is 125% of motor FLA. Ratings shown are maximum.

(3)

Circuit Breaker - inverse time breaker. For US NEC, minimum size is 125% of motor FLA. Ratings shown are maximum.

(4)

Motor Circuit Protector - instantaneous trip circuit breaker. For US NEC minimum size is 125% of motor FLA. Ratings shown are maximum.

(5)

Maximum allowable rating by US NEC. Exact size must be chosen for each installation.

(6)

Drives have dual current ratings; one for normal duty applications, and one for heavy duty applications. The drive can be operated at either rating.

(7)

Frame 7…10 drives are CE Certified for use with 400V AC and 480V AC center grounded neutral power supply systems only. It is the responsibility of the user to determine compliance to the EMC directive.

(8)

Temperature rat ing is for IP 20, NEMA/UL Ty pe 1. For IP00 , NEMA Type Open the temperatu re rating is 65 °C for the co ntrol board and 40 °C for the heat sink entry air.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 43

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

540 Volt DC Input with Precharge

Drive Catalog Number

kW Rating

ND HD kHz °C Amps kW Cont. 1 Min. 3 Sec.

Frame

PWM Freq. Temp.

20BP292 7 160 4 40 342 185 292 322 438 500 170M6608

150 4 40 309 166 263 395 526 630 170M6610

20BP325 7 180 4 40 381 206 325 358 488 630 170M6610

180 4 40 381 206 325 488 650 800 170M6612

20BP365 8 200 2 40 428 231 365 402 548 630 170M6610

180 2 40 381 206 325 488 650 800 170M6612

20BP415 8 240 2 40 487 262 415 457 623 800 170M6612

200 2 40 428 231 365 548 730 900 170M6613

20BP481 8 280 2 40 564 304 481 530 722 900 170M6613

240 2 40 487 262 415 623 830 1000 170M6614

20BP535 8 300 2 40 627 338 535 589 803 1000 170M6614

280 2 40 564 304 481 722 962 1100 170M6615

20BP600 8 350 2 40 703 379 600 660 900 1100

300 2 40 627 338 535 803 1070 1200

20BP730 9 400 2 40 855 461 730 803 1095 1200

350 2 40 703 379 600 900 1200 1400

20BH875 No Precharge

10 5 00 2 40 1025 553 875 963 1313 2 x 800 170M6612

400 2 40 820 443 700 1050 14 00 2 x 800 170M6612

DC Input Ratings Output Amps

Fuse

(2)

(3)

Non-Time Delay Fuse

170M6615

170M6616

170M6617

(1)(5)

(4)

650 Volt DC Input with Precharge

Drive Catalog Number

Hp Rating

ND HD kHz °C Amps kW Cont. 1 Min. 3 Sec.

Frame

PWM Freq. Temp.

20BR292 7 250 4 40 328 212 29 2 322 438 500 170M6608

200 4 40 296 191 263 395 526 630 170M6610

20BR325 7 250 4 40 365 236 32 5 358 488 550 170M6609

250 4 40 365 236 325 488 650 800 170M6612

20BR365 8 300 2 40 410 265 36 5 402 548 630 170M6610

250 2 40 365 236 325 488 650 800 170M6612

20BR415 8 350 2 40 466 302 41 5 457 623 700 170M6611

300 2 40 410 265 365 548 730 800 170M6612

20BR481 8 400 2 40 540 350 48 1 530 722 800 170M6619

350 2 40 466 302 415 623 830 900 170M6613

20BR535 8 450 2 40 601 389 53 5 589 803 900 170M6613

400 2 40 540 350 481 722 962 1000 170M6614

20BR600 8 500 2 40 674 436 600 660 900 1000

450 2 40 601 389 535 803 1070 1200

20BR730 9 600 2 40 820 533 730 803 1095 1200

500 2 40 674 436 600 900 1200 1400

20BJ875 No Precharge

(1)

The power source to common bus inverters must be derived from AC voltages 600V or less, as defined in NFPA70; Art 430-18 (NEC).

10 700 2 40 983 636 875 963 1313 1400 2-170M6611

600 2 40 786 509 700 1050 1400 1600 2-170M6612

Battery supplies or MG sets are not included. The following devices were validated to break current of the derived power DC Bus. Disconnects: Allen-Bradley Bulletin 1494, 30-400A; 19 4, 30-400A; or ABB OESA, 600 & 800A; OESL, all sizes. Fuses: Bussmann Type JKS, all sizes; Type 170M, Case Sizes 1, 2 and 3, or Ferraz Shawmut Type HSJ, all sizes. For any other devices, please contact the factory.

(2)

Two 630A Bussmann 170M6608 can also be used.

(3)

Two 700A Bussmann 170M6611 can also be used.

(4)

Bussmann or equivalent.

(5)

See Fuse Certification and Test Data in PowerFlex AC Drives in Common Bus Configurations Application Guidelines, public ation

DRIVES-AT002

, for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

DC Input Ratings Output Amps

Fuse

(2)

(3)

Non-Time Delay Fuse

170M6614

170M6616

170M6617

(1)(5 )

(4)

(3)

(4)

44 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Output Devices

Common mode cores are internal to the drive. For information on output contactors see below. Other devices such as cable terminators and output reactors are discussed in the Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001

Using Input/Output Contactors

Input Contactor Precautions

ATT EN TI ON : 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 start and stop the motor. If an input device is used, operation must not exceed one cycle per minute or drive damage occurs.

Output Contactor Precaution

ATT EN TI ON : To guard against drive damage when using output contactors, the following information must be read and understood. One or more output contactors can be installed between the drive and motor(s) for the purpose of disconnecting or isolating certain motors/loads. If a contactor is opened while the drive is operating, power is removed from the respective motor, but the drive continues to produce voltage at the output terminals. In addition, reconnecting a motor to an active drive (by closing the contactor) could produce excessive current that can cause the drive to fault. If any of these conditions are determined to be undesirable or unsafe, an auxiliary contact on the output contactor must be wired to a drive digital input that is programmed as “Enable.” This causes the drive to execute a coast-to-stop (cease output) whenever an output contactor is opened.

Bypass Contactor Precaution

ATT EN TI ON : An incorrectly applied or installed bypass system can result in component damage or reduction in product life. The most common causes are:

• Wiring AC line to drive output or control terminals.

• Improper bypass or output circuits not approved by Allen-Bradley.

• Output circuits which do not connect directly to the motor.

Contact Allen-Bradley for assistance with application or wiring.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 45

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

MOV and AC EMI Capacitor Phase to Ground

Jumper-Wire

Disconnecting MOVs

The PowerFlex 700 drive contains protective MOVs referenced to ground (see below). To guard against unstable operation and/or damage, the drive must be properly configured as shown in Table 5 on page 47.

R/L1 S/L2

T/L3

See Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001 grounded and ungrounded systems.

Before proceeding, ensure that all power to the drive has been removed.

for more information on impedance

ATT EN TI ON : Allow only qualified personnel familiar with adjustable frequency AC drives and associated machinery to perform maintenance/repair of the system. Failure to comply can result in personal injury and/or equipment damage.

ATT EN TI ON : 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 following points (refer to pages 8

through 11

for locations):

• +DC and -DC terminals of the Power Terminal Block

• +DC terminal of the Power Block and the chassis

• -DC terminal of the Power Terminal Block and the chassis

The voltage must be zero for all three measurements.

ATT EN TI ON : The following information is merely a guide for proper installation. Rockwell Automation cannot assume responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.

46 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Cat No. 20B D xxx x x xxxxxxx

Made in the USA (TAC 1J) Rockwell Automation, Mequon WI 53092-4400

UL TYPE 1/IP20

Mfd. in 2007 on Aug 1

Frame: 3 Serial Number: xxxxxxx

Series: B

I/O: 24VAC/DC (Standard) Original Firmware V. x.xxx

Listed Ind. Cont Eq. 966X

Normal Duty Power Heavy Duty Power

AC Voltage Range Amps

Input: 3 Phase, 47-63Hz

Output: 3 Phase, 0-400 Hz

AC Voltage Range Base Hz (default) Continuous Amps 1 Min Overload Amps 3 Sec Overload Amps

xxx kW xxx kW

342-440

xxx

0-400 50 Hz

xxx xxx xxx

xxx kW xxx kW

432-528

xxx

400V 480V

0-460 60 Hz

xxx xxx xxx

N223

Voltage Code

Frame

Current Rating

UL Type

Series

Table 5 - Recommended Power Jumper Configurations

Power S ource Ty pe

(1)

Solid Ground

• AC fed, solidly grounded

• DC fed from passive rectifier which has an AC

source and solid ground

MOV/Input Filter

(2)

Caps

Conne cted • Reduced electrical noise,

Benefits of Correct Configuration on Power S ource Ty pe

• Most stable operation,

• EMC compliance,

• Reduced voltage stress on components

and motor bearings.

Non-Solid Ground

• AC fed ungrounded

Disconnected • Helps avoid severe equipment damage

when ground fault occurs.

• Impedance grounded

• High resistive ground

• B phase ground

• Regenerative unit such as common DC bus

supply & brake

• DC fed from an active converter

(1) It is highly recommended to accurately determine the power source type and then configure appropriately.

(2) When MOVs are disconnected, the power sy stem must have its own transient protection to ensure known and controlled voltages.

To connect or disconnect these devices, refer to pages 48 and 49.

On an ungrounded distribution system where the line-to-ground voltages on any phase could exceed 125% of the nominal line-to-line voltage, install an isolation transformer. See Wiring and Grounding Guidelines for PWM AC Drives, publication DRIVES-IN001 for more information on impedance grounded and ungrounded systems.

Drive Identification

Refer to the drive nameplate and locate th e “ Vo lt ag e C od e,” “C urr ent Ra ting ,” and “Frame.” Use this information to find the proper procedure in the following tables.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 47

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

MOV

Ground

Stud

MOV

(under boards)

PE Bus

Bar

Jumper Settings and Locations

Factory Default Jumper Settings

Frame

Voltag e

Code

Current

7 All All A green/yellow wire connected to a

(1) (2)

Rating

ground stud on the drive chassis.

TB11

25 AMPERES RMS

MAXIMUM

ALLEN-BRADLEY

MADE IN U.S.A.

DANGER

RISK OF SHOCK REPLACE AFTER

+DC

-DC PE PE R-L1 T-L3

USE 75° COPPER WIRE ONLY

TORQUE LARGE TERMINALS TO 10 N-m (87LB-IN)

SERVICING

U-M1 V-M2 W-M3S-L2

Power Source TypeMOV

Solid Ground

Connect the green/yellow MOV jumper wire to the ground stud on the drive chassis.

Non-Solid Ground

The green/yellow MOV jumper wire must be insulated from ground. If necessary, remove the wire from the stud on the drive chassis. Insulate/ secure the wire to guard against unintentional contact with the chassis or components.

8…9 All All A green/yell ow wire connected

bus bar.

RSTDC-DC+

GND

to the PE

Solid Ground

Connect the green/yellow MOV jumper wire to “PE.”

Non-Solid Ground

Remove the green/yellow MOV jumper wire from the PE bus bar. Insulate/secure the wire to guard against unintentional contact with the chassis or components.

48 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

Factory Default Jumper Settings

MOV

Jumper Wire

Converter Section

IMPORTANT

Frame

Volt age

Code

Current

(1) (2)

Rating

10 All All A green/yellow wire connected to

chassis

DANGER

RISK OF SHOCK REPLACE AFTER

SERVICING

120 IN1 120 IN2

TB10

8 AMPERES RMS

MAXIMUM

GND

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Power Source TypeMOV

Solid Ground

Connect the green/yellow MOV jumper wire to the chassis.

Non-Solid Ground

Remove the green/yellow MOV jumper wire from the chassis. Insulate/secure the wire to guard against unintentional contact with the chassis or components.

Step 4: I/O Wiring

(1) AC input drives only. MOV’s do not exist on DC input drives.

(2) Frame 7…10 drives do not have common mode capacitors.

Important points to remember about I/O wiring:

• Use Copper wire only. Wire gauge requirements and recommendations are based on 75 degrees C. Do not reduce wire gauge when by using higher temperature wire.

• Wire with an insulation rating of 600V or greater is recommended.

• Separate control and signal wires from power wires by at least 0.3 meters (1

foot).

I/O terminals labeled “(–)” or “Common” are not referenced to earth ground and are designed to greatly reduce common mode interference. Grounding these terminals can cause signal noise.

ATT EN TI ON : Configuring an analog input for 0…20 mA operation and driving it from a voltage source could cause component damage. Verify proper configuration prior to applying input signals.

ATT EN TI ON : Hazard of personal injury or equipment damage exists when using bipolar input sources. Noise and drift in sensitive input circuits can cause unpredictable changes in motor speed and direction. Use speed command parameters to help reduce input source sensitivity.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 49

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Wire Recommendations

Min.

Type Wire Type(s) Description

Signal

(1) (2)(3)

Digital I/O

(1)(2)(3)

Standard Analog I/O

Belden 8760/9460 (or equivalent)

Belden 8770 (or equivalent)

Encoder/Pulse I/O < 30 m (100 ft.)

Encoder/Pulse I/O 30 to 152 m (100 to 500 ft.)

Encoder/Pulse I/O 152 to 259 m (500 to 850 ft.)

Combin ed: Belden 9730

(4)

Signal: Belden 9730/9728

Power: Belden 8790

Combin ed: Belden 9892

(6)

Signal: Belden 9730/9728

Power: Belden 8790

Combin ed: Belden 9773/9774

(4)

(5)

(4)

(5)

(7)

Shielded Multi-conductor shielded

cable such as Belden

0.750 mm2(18AWG), twisted pair, 100% shield with drain.

0.750 mm

(18AWG), 3 conductor,

shielded for remote pot only.

0.196 mm2(24AWG), individually shielded

0.750 mm2(18AWG)

0.330 mm2 (22 AWG) or 0.500 mm (20AWG)

0.196 mm2(24AWG), individually shielded

0.750 mm2(18AWG)

0.750 mm2(18AWG), individually shielded

0.750 mm

(18AWG), 3 conductor,

shielded.

8770 (or equivalent)

Unshielded Per US NEC or applicable

–

national or local code

(1) Control and signal wires must be separate d from power wires by at least 0.3 meters (1 foot).

(2) If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessar y,

but is always recommended.

(3) I/O terminals labe led “(–)” or “Common” are not referenced to earth ground and are designed to greatly reduce common mode

interference. Grounding these terminals can cause signal noise.

(4) 9730 is 3 individually shielded pairs (2 channel + power). If 3 channel is required, use 9728.

(5) 8790 is 1 shielded pair.

(6) 9892 is 3 individually shielded pairs (3 channel) + 1 shielded pair for power.

(7) 9773 is 3 individually shielded pairs (2 channel + power). If 3 channel is required, use 9774.

Insulation Rating

300V, 75…90 °C (167…194 °F)

300V, 60 °C (140 °F)

I/O Terminal Block Specifications

Wire Size Range

Name Description

I/O Terminal Block Signal & control

connections

Encoder Terminal Block

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

Encoder power & signal connections

50 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

Maximum Minimum Maximum Recommended

4.0 mm (12 AWG)

0.75 mm (18 AWG)

(1)

0.049 mm (30 AWG)

0.196 mm (24 AWG)

Tor que

0.6 N•m (5.3 lb•in)

I/O Terminal Designations

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

No. Signal

1Analog In 1 (–)

2Analog In 1 (+)

3Analog In 2 (–)

4Analog In 2 (+)

(1)

(3)

Description

Fact ory

Default

(4)

Isolated

, bipolar, differential, ±10V/4-20mA, 11 bit & sign, 88k ohm input impedance. For 4-20mA, a jumper must be installed at terminals 17 & 18 (or 19 & 20).

320… 327

Param.

5 Pot Common – For (+) and (–) 10V pot references.

6Analog Out 1 (–)

7Analog Out 1 (+)

8Analog Out 2 (–)

(3)

Bipolar (current output is not bipolar), ±10V/4-20mA, 11 bit & sign, voltage mode - limit current to 5 mA. Current mode - max. load resistance is 400 ohms.

340… 347

9Analog Out 2 (+)

10 HW PTC Input 1 – 1.8k ohm PTC, Internal 3.32k ohm pull-up resistor 238, 259

11 Digital O ut 1 – N.C.

12 Digital O ut 1 Common

13 Digital O ut 1 – N.O.

14 Digital O ut 2 – N.C.

15 Digital O ut 2/3 Com.

16 Digital O ut 3 – N.O.

17 Current In Jumper

Analog In 1

19 Current In Jumper

Analog In 2

(1)

(2)

Fault Max. Resistive Load:

(2)

NOT Fault

(2)

NOT Run

(2)

Run

–

240V AC/30V DC – 1200VA, 150W Max. Current: 5A, Min. Load: 10mA

Max. Inductive Load: 240V AC/30V DC – 840VA, 105W Max. Current: 3.5A, Min. Load: 10mA

Placing a jumper across terminals 17 & 18 (or 19 & 20) configures that analog input for current.

380… 391

21 –10V Pot Reference – 2k ohm minimum load.

22 +10V Pot Reference –

23 HW PTC Input 2 – See above

24 +24V DC

(5)

– Drive supplied logic input power.

(5)

25 Dig ital In Common –

26 24V Common

27 Digita l In 1 Stop - CF 115V AC, 50/60 Hz

28 Digital In 2 Start

29 Digital In 3 Auto/Man.

30 Dig ital In 4 Speed Sel 1

31 Dig ital In 5 Speed Sel 2

32 Digita l In 6/Hardware

Enable, see pg. 54

33 Digital O ut 4 – N.C. Fault Dedicated fault output - Not user configurable. Relay energizes (picks

34 Digital O ut 4 Common

35 Digital O ut 4 – N.O. NOT Fault

PS+ Aux. Control Power (+) Refer to page 39

PS- Aux. Control Power (–) R efer to page39

(5)

– Common for inte rnal power sup ply.

Opto isolated Low State: less than 30V AC

- Control & I/O Cat. No. option D

361… 366

High State: greater than 100V AC 24V DC

- Control & I/O Cat. No. option C Opto isolated Low State: less than 5V DC

Speed Sel 3

High State: greater than 20V DC

11.2 mA DC

up) when power is applied to the drive and deenergizes (drops out) when a fault exists. See Terminals 11-16 for specs.

PE PE Ground PE Ground

(1) Important: 0…20mA operation requires a jumper at terminals 17 & 18 (or 19 & 20). Drive damage can occur if jumper is not

installed.

(2) Contacts in unpowered state. Any relay programmed as Fault or Alarm energizes (picks up) when power is applied to the drive and

deenergizes (drops out) when a fault or alarm exists. Relays selected for other functions energize only when that condition exists and deenergize when condition is removed.

(3) These inputs/outputs are dependant on a number of parameters (see “Related Parameters”).

(4) Differential Isolation - External source must be maintained at less than 160V with respect to PE. Input provides high common mode

immunity.

(5) 150mA maximum Load. Not present on 115V versions.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 51

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

3 4 5

21 22

3 4

Common

3 4

Common

3 4

19 20

Common

I/O Wiring Examples

Input/Output Connection Example Required Parameter Changes

Potentiometer Unipolar Speed Reference

(1)

10k Ohm Pot. Recommended (2k Ohm Minimum)

• Adjust Scaling: Parameters 91/92 and 325/326

• View Results: Parameter 002

Joystick Bipolar Speed Reference

(1)

±10V Input

• Set Direction Mode: Parameter 190 = “1, Bipolar”

• Adjust Scaling: Parameters 91/92 and 325/326

• View Results: Parameter 002

Analog Input Bipolar Speed Reference

±10V Input

• Set Direction Mode: Parameter 190 = “1, Bipolar”

• Adjust Scaling: Parameters 91/92 and 325/326

• View Results: Parameter 002

Analog Voltage Input Unipolar Speed Reference

0 to +10V Input

Analog Current Input Unipolar Speed Reference

0-20 mA Input

• Configure Input with parameter 320

• Adjust Scaling:

Parameters 91/92 and 325/326

• View results: Parameter 002

• Configure Input for Current: Parameter 320 and add jumper at appropriate terminals

• Adjust Scaling: Parameters 91/92 and 325/326

• View results: Parameter 002

Analog Input, PTC

PTC OT set > 5V PTC OT cleared < 4V PTC Short < 0.2V

HW PTC Input

(2)

PTC OT set > 5V PTC OT cleared < 4V PTC Short < 0.2V

1.8k PTC

1.8k

PTC

Ferrite

Bead

3.32k Ohm

Ferrite

Bead

1 2

• Set Fault Config 1: Parameter 238, bit 7 = “Enabled”

• Set Alarm Config 1: Parameter 259, bit 11 = “Enabled”

• View Status Drive Alarm 1:

Parameter 211, bit 11 = “True”

• Set Fault Config 1: Parameter 238, bit 13 = “Enabled”

• Set Alarm Config 1: Parameter 259, bit 18 = “Enabled”

• View Status: Drive Alarm 1: Parameter 211, bit 18 = “True”

(1) Refer to the Attention statement on page 49 for important bipolar wiring information.

(2) A PTC (Positive Temperature Coefficient) device (motor thermistor) embedded in the motor windings, can be monitored by the drive

for motor thermal protection.

52 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

+–

24 25 26

Stop-Run

Start

24 25 26 27 28

Stop

Start

27 28

Stop

115V/ +24V

Neutral/

Common

27 28

Control from Prog. Controller

Neutral/

Common

10k Ohm, 2 Watt

Input/Output Connection Example Required Parameter Changes

Analog Output

±10V, 0-20 mA Bipolar +10V Unipolar (shown)

• Configure with Parameter 340

• Select Source Value:

Parameter 380, [Digital Out1 Sel]

• Adjust Scaling: Parameters 343/344

2-Wire Control NonReversing

(1)

24V DC internal supply

• Disable Digital Input:#1: Parameter 361 = “0, Unused”

• Set Digital Input #2: Parameter 362 = “7, Run”

• Set Direction Mode: Parameter 190 = “0, Unipolar”

2-Wire Control Reversing

(1)

External supply (I/O Board dependent)

3-Wire Control

Neutral/

Common

Run Fwd.

27 28

Run Rev.

115V +24V

• Set Digital Input:#1: Parameter 361 = “8, Run For ward”

• Set Digital Input #2: Parameter 362 = “9, Run Reverse”

• No Changes Required

Internal supply

3-Wire Control

• No Changes Required

External supply (I/O Board dependent). Requires 3-wire functions only ([Digital In1 Sel]). Using 2-wire selections causes a type 2 alarm.

Digital Input

• No Changes Required

PLC Output Card (Board dependent).

Digital Output

Relays (two at terminals 14-

16) shown in powered state with drive faulted. See page

Power Source

11 12 13 14 15 16

• Select Source to Activate:

Faul t NOT Fault

NOT Run Run

Parameters 380/384

Enable Input • Configure with parameter 366

For dedicated hardware Enable: Remove Jumper J10 (see page

(1) Important: Programming inputs for 2 wire control deactivates all HIM Start buttons unless parameter 192, [S ave HIM

Ref], bit 1 [Manual Mode] = “1.” This allows the HIM to control Star t and Jog.

)

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 53

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Hardware Enable Circuitry (Vector Control Only)

By default, the user can program a digital input as an Enable input. The status of this input is interpreted by drive software be disabled without

software interpretation, a “dedicated” hardware enable configuration can be utilized. This is done by removing a jumper and wiring the enable input to “Digital In 6.”

1. Remove HIM support plate to gain access to the Main Control Board (see pages 8

through 11).

2. Locate & remove Jumper J10 on the Main Control Board (see below).

. If the application requires the drive to

3. Wire Enable to “Digital In 6” (see page 51

4. Verify that [Digital In6 Sel], parameter 366 is set to “1, Enable.”

Hardware Enable Jumper (J10) Location

Encoder Interface Option

Encoder Terminal Designations

No. Description

(1)

8 +12V

7 +12V

6 Encoder Z (NOT) Pulse, marker or registration input.

5 Encoder Z

4 Encoder B (NOT) Quadrature B input.

3 Encoder B

2 Encoder A (NOT) Single channel or quadrature A input.

1 Encoder A

(1) Jumper selectable +5/12V is available on 20B-ENC-1 Encoder Boards.

(2) Z channel can be used as a pulse input while A & B are used for encoder.

54 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

DC Power

(1)

DC Return (Common)

Internal power source 250 mA.

(2)

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Common

External

Power Supply

SHLD

(1)

to SHLD

(1)

A NOT

B NOT

Z NOT

Encoder Specifications

Type: Incremental, dual channel

Supply: 12V, 250 mA. 12V, 10 mA minimum inputs isolated with differential transmitter, 250 kHz

maximum.

Quadrature: 90°, ±27 degrees at 25 degrees C.

Duty Cycle: 50%, +10%

Requirements: Encoders must be line driver type, quadrature (dual channel) or pulse (single channel), 8-15V DC

output (3.5-6V DC when jumpers are in 5V position), single- ended or differential and capable of supplying a minimum of 10 mA per channel. Maximum input frequency is 250 kHz. The Encoder Interface Board accepts 12V DC square-wave with a minimum high state voltage of 7.0V DC. With the jumpers in the 5V position, the encoder accepts a 5V DC square-wave with a minimum high state voltage of 3.1V DC. In either jumper position, the maximum low state voltage is 0.4V DC.

+5/12V Encoder Jumper Location

Output Cong.

+12V

+5V

123

Output Cong.

+12V

+5V

123

+5VREF

+12V

123

12 11

123

+12V

+5VREF

+12V

+5V

Intput Cong.

12 11

5/12V

(20B-ENC-2)

5/12V

(20B-ENC-1, Series B)

Sample Encoder Wiring

I/O Connection Example I/O Connection Example

Encoder Power – Internal Drive Power

Internal (drive) 12V DC, 250mA

(1)

Encoder Signal – Single-Ended, Dual Channel

(1) SHLD connection is on drive chassis.

(2) Example applies to 20B-ENC-1 only.

(2)

+12V DC (250 mA)

Common

to Power Supply

Common

Z NOT

B NOT

A NOT

to SHLD

(1)

Encoder Power – External Power Source

Encoder Signal – Differential, Dual Channel

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 55

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Reference Control

Auto Speed Sources

The drive speed command can be obtained from a number of different sources. The source is determined by drive programming and the condition of the Speed Select digital inputs, Auto/Manual digital inputs or reference select bits of a command word.

The default source for a command reference (all speed select inputs are open— the default setting) is the selection programmed in [Speed Ref A Sel]. If any of the speed select inputs are closed, the drive uses other parameters as the speed command source.

Manual Speed Sources

The manual source for speed command to the drive can be selected several ways:

• The HIM can provide the manual source when: – manual control is requested from the HIM (see ALT Functions

page 64

)

or …

– the I/O terminal block requests manual control through a digital input

programmed for “Auto/Manual.” [TB Man Ref Sel] is then set to one of the DPI ports with a HIM connected to it.

(1)

• The I/O terminal block analog input can provide the manual source when a digital input is programmed for “Auto/Manual” when active. [TB Man Ref Sel] is set to “Analog Input.”

Changing Speed Sources

The selection of the active Speed Reference can be made through digital inputs, DPI command, jog button or Auto/Manual HIM operation.

Torque Reference Source

The torque reference is normally supplied by an analog input or network reference. Switching between available sources while the drive is running is not available. Digital inputs programmed as “Speed Sel 1,2,3” and the HIM Auto/ Manual function (see above) do not affect the active torque reference when the drive is in Vector Control Mode.

(1) Requires drive firmware v7.001 or greater and a S er ies B HIM with firmware v5.004 or greater.

56 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Speed Reference Selection Chart

= Default

Auto Speed Ref Options

Speed Ref A Sel, Parameter 090

Speed Ref B Sel, Parameter 093

Preset Speed 2, Parameter 102

Preset Speed 3, Parameter 103

Preset Speed 4, Parameter 104

Preset Speed 5, Parameter 105

Preset Speed 6, Parameter 106

Preset Speed 7, Parameter 107

DPI Port Ref 1-6, See Parameter 209 DPI Command

Manual Speed Ref Options

HIM Requesting Auto/Manual

TB Man Ref Sel, Parameter 096

Jog Speed, Parameter 100

Speed Adders [Speed Mode]:

PI Output 2 "Process Pi"

Slip Compensation

None

Tr im

(1)

[Digital Inx Select]: Speed Sel

321

000 001 010 011 100 101 110 111

Digital Input

Jog Command

1 "Slip Comp"

0 "Open Loop"

PI Exclusive Mode

[PI Configuration]: Bit 0, Excl Mode = 0

Auto

Man

Drive Ref Rslt

Mod Functions

(Skip, Clamp,

Direction, etc.)

Min/Max Speed

Commanded

Frequency

Acc/Dec Ramp

and

S Curve

Output Frequency

Pure Reference

to follower drive for Frequency Referenc

Post Ramp

to follower drive for Frequency Referenc

Auto/Manual Examples

PLC = Auto, HIM = Manual

A process is run by a PLC when in Auto mode and requires manual control from the HIM during set-up. The Auto speed reference is issued by the PLC through a communications module installed in the drive. Because the internal communication is designated as Port 5, [Speed Ref A Sel] is set to “DPI Port 5” with the drive running from the Auto source.

• Attain Manual Control – Press ALT then Auto/Man on the HIM. When the HIM attains

manual control, the drive speed command comes from the HIM speed control keys.

• Release to Auto Control – Press ALT then Auto/Man on the HIM again. When the HIM releases

manual control, the drive speed command returns to the PLC.

PLC = Auto, Terminal Block = Manual

A process is run by a PLC when in Auto mode and requires manual control from an analog potentiometer wired to the drive terminal block. The auto speed reference is issued by the PLC through a communications module installed in the drive. Because the internal communication is designated as Port 5, [Speed Ref A Sel] is set to “DPI Port 5” with the drive running from the Auto source. Since the Manual speed reference is issued by an analog input (“Analog In 1 or 2”), [TB Man Ref Sel] is set to the same input. To switch between Auto and Manual, [Digital In3 Sel] is set to “Auto/Manual.”

• Attain Manual Control – Close the digital input.

With the input closed, the speed command comes from the pot.

• Release to Auto Control – Open the digital input.

With the input open, the speed command returns to the PLC.

(1) To access Preset Speed 1, set parameter 090 or 093 to “Preset Speed 1.”

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 57

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

IMPORTANT

PLC = Auto, Terminal Block = Manual, with speed reference from the HIM

Requires drive firmware v7.001 or greater and a Series B HIM with firmware v5.004 or greater.

A process is run by a PLC when in Auto mode and requires manual control from the terminal block with the speed reference provided by the HIM.

The auto speed reference is produced by the PLC and transmitted to the drive through a communications module installed in the drive. Because the internal communication is designated as Port 5, [Speed Ref A Sel] is set to “DPI Port 5" with the drive running from the Auto source.

When Manual mode is requested through the terminal block digital input, the drive evaluates if Manual mode can be granted.

If [TB Man Ref Sel], parameter 96 is set to a DPI Port and [Man Ref Preload], parameter 193 is enabled, the drive transfers the last value of the automatic speed reference to the HIM. The HIM is now the speed reference source. The terminal block has exclusive control based on [Save HIM Ref ], parameter 192, bit 1 (Manual Mode).

If [TB Man Ref Sel] is set to a DPI Port and [Man Ref Preload] is disabled, the HIM is now the speed reference source. The terminal block has exclusive control based on [Save HIM Ref ], bit 1 (Manual Mode).

If [TB Man Ref Sel] is set to one of the DPI Ports, a HIM must be connected on the DPI Port selected.

The HIM does not enter Manual mode, it is only the reference source for the terminal block.

• Attain Manual Control – Close the digital input.

With the input closed, the speed command comes from the HIM.

• Release to Auto Control – Open the digital input.

With the input open, the speed command returns to the PLC.

Auto/Manual Notes

1. Manual control is exclusive. If a HIM or terminal block takes manual control, no other device can take manual control until the controlling device releases manual control.

2. If a HIM has manual control and power is removed from the drive, the drive returns to Auto mode when power is reapplied.

3. Parameter 192 - [Save HIM Ref ], bit 1 can enable Manual mode to allow starts and jogs from the HIM in 2-wire mode.

58 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

IMPORTANT

Step 5: Start-Up Check List

• This check list supports the Basic Start-Up menu option. See page 64 for information on other start-up routines.

• A Human Interface Module (HIM) is required to run the Basic Start-Up routine.

• The Basic Start-Up routine can modify parameter values for Analog and Digital I/O. Refer to Common I/O Programming Changes on page 70

ATT EN TI ON : Power must be applied to the drive to perform the following start-up procedure. Some of the voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, allow only qualified service personnel to perform the following procedure. Thoroughly read and understand the procedure before beginning.

Prepare For Drive Start-Up

1. Confirm that all inputs are connected to the correct terminals and are secure.

2. Verify that AC line power at the disconnect device is within the rated value of the drive.

3. Verify that control power voltage is correct.

4. The remainder of this procedure requires that a HIM be installed.

Connect a Human Interface Module (HIM) to Drive Peripheral Interface (DPI) Port 1 or 2. If an operator interface is not available, use remote devices to start up the drive.

When power is first applied, the HIM can require approximately 5 seconds until commands are recognized (including the Stop key). An explanation of the LED indicators can be found on page 68

5. Apply AC power and control voltages to the drive.

If any of the six digital inputs are configured to “Stop – CF” (CF = Clear Fault) or “Enable,” verify that signals are present or reconfigure [Digital Inx Sel], parameters 361…366. If an I/O option is not installed (i.e. no I/O terminal block), verify that [Digital Inx Sel] is not configured to “Stop – CF” or “Enable.” If this is not done, the drive will not start. Refer to Abbreviated Fault Listing potential digital input conflicts.

If the STS LED is not flashing green at this point, refer to Drive Status

Indicators & DPI Port Locations on page 68.

on page 71 for a list of

6. When prompted, select a display language. The PowerFlex 700 Start-Up Screen is displayed.

7. Press the Enter key to display the Start-Up Menu.

8. Use the Arrow keys to highlight “2. Basic”.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 59

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

9. Press the Enter key. Follow the menu by using the Enter key which steps you through the Start-Up routine.

The Basic Start-Up routine asks simple questions and prompts you to input required information. See also Common I/O Programming

Changes on page 70.

Information About Start-Up Motor Tests

Control schemes vary based on which Start/Jog Source is selected in Step 3. Motor Tests.

Start/Jog Source Control Source Description

Digital Inputs Digital In 1 = Stop / Digital In 2 = Start / Digital In 3 = Jog

Local H uman Inter face Module (HIM)–Port 1

Remote HIM Human Interface Module (HIM) connected to DPI Port 2 controls Stop / Start / Jog

During motor tests and tuning procedures, the drive can modify certain parameter values for proper Start Up operation. These values are then reset to their original values when Start Up is complete. The affected parameters are: 053, 080, 276, 278 and 361…366. If power is removed from the drive during the tests without aborting the auto-tune procedure, these parameters cannot reset to their original value. If this situation occurs, reset the drive to factory defaults (see

page 70

) and repeat the Start Up procedure.

Human Interface Module (HIM) connected to DPI Port 1 controls Stop / Star t / Jog Digital In 1…6 are temporarily disabled during motor tests.

Digital In 1…6 are temporarily disabled during motor tests.

60 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

First Powerup Menu Structure

English?

Français? Español? Italiano? Deutsch? Port uguês ? Nederlands? Not Selected

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Main Menu: Diagnostics Parameter Device Select Memory Storage

Start-Up

Preferences

PowerFlex 700 Start-Up Startup consists of several steps to configure a drive for basic applications.

PowerFlex 700 Start-Up Make a selection

1. SMART

2. Basic

3. Detailed

4. More info

PowerFlex 700 Start-Up Complete these steps in order:

1. Motor Control

2. Motr Data/Ramp

3. Motor Tests

4. Speed Limits

5. Speed/Trq Cntl

6. Start/Stop/I/O

7. Done/Exit

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 61

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

JMP3 (W3) JMP2 (W2) JMP1 (W1)

TB1

1 2 3

Supplemental Information

DC Input (Common Bus) and Precharge Notes

The following notes must be read and understood.

Important Application Notes

1. If drives without internal precharge are used (Frame 10 700 Hp only), then:

a. precharge capability must be provided in the system to guard against

possible damage, and …

b. disconnect switches Must

and a common DC bus without the use of an external precharge device.

2. If drives with internal precharge (Frames 7…9) are used with a disconnect switch to the common bus, then:

a. an auxiliary contact on the disconnect must be connected to a digital

input of the drive. The corresponding input (parameter 361…366) must be set to option 30, “Precharge Enable.” This provides the proper precharge interlock, guarding against possible damage to the drive when connected to a common DC bus, and …

b. an auxiliary contact on the disconnect must also be connected to TB1

on the Precharge Board. Set JMP1 to the voltage being used and JMP2 to “Interlock.”

Not be used between the input of the drive

3. Set jumpers on the Precharge Board as shown below:

Jumper Setting Description

JMP1 1-2 24V DC input

(1)

2-3

JMP2 1-2 Interlock

2-3

JMP3 1-2 Do Not Use

2-3

(1) Default setting.

(1)

120V AC Input

Bypass

62 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

F-> Power Loss Auto

0.0

Main Menu: Diagnostics Parameter Device Select

Esc

Human Interface Module (HIM)

Sel

ALT

F-> Power Loss Auto

0.0

Main Menu: Diagnostics Parameter Device Select

Human Interface Module (HIM) Overview

LCD Display Elements

Display Description

Direction⎥ Drive Status⎥ Alarm⎥ Auto/Man⎥ Information

Commanded or Output Frequency

Programming / Monitoring / Troubleshooting

Human Interface Module (HIM) Key Functions

Key Description

Exit a menu, cancel a change to a parameter value, or acknowledge a fault/alarm.

Select a digit, select a bit, or enter edit mode in a parameter screen.

Scroll through options, increase a value, or toggle a bit.

Scroll through options, decrease a value, or toggle a bit.

Enter a menu, enter edit mode in a parameter screen, or save a change to a parameter value.

Access the function associated with a programming or numeric key. Refer to the drive user manual for more information.

Start the drive.

Stop the drive or clear a fault.

Jog the drive.

Jog

Change direction. These keys are active only when the HIM is granted Manual Control or

Param. 090 [Speed Ref A Sel] / 093 [Speed Ref B Sel] is set to:

Increase speed.

Option 18 “DPI Port 1” for a HIM installed in the drive cover or

Decrease speed.

Option 19 “DPI Port 2” for a HIM connected by cable for handheld or remote installation option

Human Interface Module (HIM) Main Menu

Main Menu Screen Menu Selections

Main Menu:

Diagnostics Parameter Device Select Memory Storage Start-Up Preferences

S.M.A.R.T.

Esc

Alt

Lang

View

Sel

7 8 9

4 5 6

1 2 3

0 +/-

Exp

Auto / Man

Param #

Remove

Jog

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 63

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Esc

Sel

+/–

ALT Functions

To use an ALT function, start at the Main Menu and press the ALT key, release it, then press the programming key associated with one of the following functions:

ALT Key then Function Function Description

S.M.A.R.T. Displays the S.M.A.R.T. screen. This function allows the drive parameter values to be

quickly programed by directly accessing the most frequently used drive functions. Refer to the User Manual for more information.

ALT

View Allows the selection of how parameters are viewed or detailed information about a

Device Select a connected adapter for editing.

Log out to protect parameter settings. Change a password.

parameter or component.

Lang Displays the language selection screen. The LCD Human Interface Module (HIM) on

Auto /Man Switches between Auto and Manual Modes. If the Human Interface Module (HIM)

Remove Allows Human Interface Module (HIM) removal without causing a fault if the

Param # Allows entry of a parameter number for viewing/editing.

an architecture class drive allows you to change the display language any time.

requests Manual Mode, the Speed Reference source is transferred to the Human Interface Module (HIM).

Human Interface Module (HIM) is not the last controlling device and does not have Manual control of the drive.

Start-Up Routines

The PowerFlex 700 start up routines allow the user to commission the drive more quickly and accurately. If you have an LCD HIM, two methods are provided.

• S.M.A.R.T. Start

This routine is accessible by using the “ALT” function key on the LCD HIM. This keystroke brings up a list of parameters needed to program the eight most commonly adjusted drive functions. These include Start, Stop, Minimum Speed, Maximum Speed, Acceleration Time, Deceleration Time, Reference source (speed command) and Electronic Overload setting for the motor. No knowledge of parameter organization or access is required. S.M.A.R.T. Start can commission the drive in just a few minutes. See page 66

64 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

IMPORTANT

•Assisted Start Up

Three levels of Assisted Start Up (Basic, Detailed and Application) aid the user in commissioning the drive asking simple Yes/No or “Enter Data” questions. The user is guided through the Start Up to reduce the amount of time necessary to get the drive “up and running.” The following are included in startup:

– Input Voltage Ratings – Motor Data – Motor Tests & Auto-tuning – Speed/Torque Control & Direction Limits – Speed Reference – Start & Stop Modes – Ramp Setup – Digital and Analog I/O – Application Set-up (TorqProve, Oil Well Pumps, Positioning/Speed

Profiling ) See page 67

for details.

Power must be applied to the drive when viewing or changing parameters. Previous programming can affect the drive status and operation when power is applied. If the I/O Cassette has been changed, a Reset Defaults operation must be performed.

Torque Proving applications can use the Assisted Start Up to tune the motor. However, it is recommended that the motor be disconnected from the hoist/ crane equipment during the routine. If this is not possible, refer to the manual tuning procedure in the User Manual.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 65

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Configures

Motor Control

Method

Motor Control

Select

Enter Motor NP

Data, Stop Mode,

Accel/Decel Ramp Times

Motor Data and

Ramp Times

Optimize Torque

and

Verify Direction

Motor Tests

(1)

Set Min/Max

Speed and

Direction Control

Speed Limits

Configure

Source, Value

and Scale for

Speed References

Speed/Torque

Control

Start/Stop/I/O

Configure

Control Method

(2 Wire/3 Wire),

I/O, Digital I/O

& Analog Outputs

Configure for a

Specific Application

such as; Auto Restart,

Flying Start, etc.

Basic

Start-Up

Continue

Start Over

Intro

Configures

Motor Control

Method

Motor Control

Select

Enter Motor NP

Data, Stop Mode,

Accel/Decel

Ramp Times

Motor Data and

Ramp Times

Optimize Torque

and

Verify Direction

Motor Tests

Set Min/Max

Speed and

Direction Control

Speed Limits

Configure Source, Value and Scale for

Speed References

Speed/Torque

Control

Done / Exit

Pos/Spd Profile

Done / Exit

Torq P rovi ng

Torq Proving

Detailed

Done / Exit

Application

Selection:

1. SMART

2. Basic

3. Detailed

4. Application

Enter Motor NP

Data, Stop Mode,

Accel/Decel

Ramp Times

Enter Pump

Data

Motor Data and

Ramp Times

Well Pump

Type

Optimize Torque

and

Verify Direction

Motor TestsPump Data Start/Stop/I/O

Configure

Control Method

(2 Wire/3 Wire),

I/O, Digital I/O

& Analog Outputs

Configure Source, Value and Scale for

Speed References

Speed/Torque

Control

Torque Alarm Process Display

Done / Exit

Selection:

1. Torq Prove

2. Pos/Spd Profile

3. Oil Well Pumps

Done / Exit

(1)

During Motor Tests and tuning procedures, the drive can modify certain parameter values for proper Start Up operation. These values are then reset to their original values when Start Up is complete. The affected parameters are: 053, 080, 276, 278 and 361…366. If power is removed from the drive during the tests without aborting the auto-tune procedure, these parameters cannot be reset to their original value. If this situation occurs, reset the drive to factory defaults and repeat the Start Up procedure.

Esc

ALT

F-> Stopped Auto

0.0

Main Menu: Diagnostics Parameter

SMART List: Digital In2 Sel Stop Mode A Minimum Speed

Start Up Menu

Running S.M.A.R.T. Start

During a Start Up, the majority of applications require changes to only a few parameters. The LCD HIM on a PowerFlex 700 drive offers S.M.A.R.T. start, which displays the most commonly changed parameters. With these parameters, you can set the following functions:

S - Start Mode and Stop Mode M - Minimum and Maximum Speed A - Accel Time 1 and Decel Time 1 R - Reference Source T - Thermal Motor Overload

To ru n a S .M .A . R .T. st ar t r ou ti ne :

Step Key(s) Example LCD Displays

1. Press ALT and then Esc (S.M.A.R.T). The S.M.A.R.T. start screen appears.

2. View and change parameter values as desired. For HIM information, see Appendix B in the User Manual.

3. Press Esc to exit the S.M.A.R.T. start.

66 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

IMPORTANT

F-> Stopped Auto

0.0

Main Menu: Memory Storage

Start Up

Preferences

Running an Assisted Start Up

This start-up routine requires an LCD HIM.

The Assisted start-up routine prompts you to input required information. Access Assisted Start Up by selecting “Start Up” from the Main Menu.

To perform an Assisted Start-Up

Step Key(s) Example LCD Displays

In the Main Menu, press the Up Arrow or Down Arrow to scroll to “Star t Up”.

Press Enter.

Done/Exit must be selected upon completion of the Start Up routine in order for any Start Up/Autotune data to be saved.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 67

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

PORT

NET A NET B

MOD

➊

➋ ➌

o r3

➍

➐

➏

➊

➋

➌ ➎

Important:

Verify metal ground tab is bent 90° and is under the adapter before tightening screw. After tightening the screw, verify that continuity exists between the head of the screw and drive ground.

Drive Status Indicators & DPI Port Locations

TB11

25 AMPERES RMS

MAXIMUM

No. Name Color State Description

➊

PWR

Green Steady Illuminates when power is applied to the drive.

(Power)

➋

STS (Status)

Green Flashing Drive ready, but not running and no faults are present.

Steady Drive running, no faults are present.

Yellow Flashing, Drive Stopped A start inhibit condition exists, the drive cannot be started.

Check parameter 214 [Start Inhibits].

Flashing, Drive Running An intermittent type 1 alarm condition is occurring.

Check parameter 211 [Drive Alarm 1].

Steady, Drive Running A continuous type 1 alarm condition exists.

Check parameter 211 [Drive Alarm 1].

Red Flashing Fault has occurred. Check [Fault x Code] or Fault Queue.

Steady A non-resettable fault has occurred.

PORT Refer to the Communication

➌

MOD Status of communications module (when installed).

Adapter User Manual.

Status of DPI port internal communications (if present).

NET A Status of network (if connected).

NET B Status of secondary network (if connected).

➍ DPI Port 1 HIM connection. ➎ DPI Port 5 Cable connection for communications adapter. ➏ DPI Port 3 or 2 Splitter cable connected to DPI Port 2 provides additional port. ➐ DPI Port 2 Cable connection for handheld and remote options. Located

on side of chassis for Frame 7 IP20, NEMA/UL Type 1.

68 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

AC Precharge Board LED Indications

The LEDs are above the “Line Type” jumper shown on page 33.

Name Color State Description

Power Green Steady Indicates when precharge board power supply is operational

Alarm Yellow Flashing

[1] [2] [3] [4] [5] [6] [7]

Fault Red Flashing

[2] [4]

(1) An alarm condition automatically resets when the condition no longer exists

(2) A fault indicates a malfunction that must be corrected and can only be reset after cycling power.

Number in “[ ]” indicates flashes and associated alarm Low line voltage (<90%).

Very low line voltage (<50%). Low phase (one phase <80% of line voltage). Frequency out of range or asymmetry (line sync failed). Low DC bus voltage (triggers ride-through operation). Input frequency momentarily out of range (40…65 Hz). DC bus short circuit detection active.

Number in “[ ]” indicates flashes and associated fault DC bus short (Udc <2% after 20 ms).

Line sync failed or low line (Uac <50% Unom).

(1)

(2)

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 69

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

IMPORTANT

Common I/O Programming Changes

Your application needs may require changing parameters from their factory default settings.

Speed Reference A

Change Speed Reference A from Analog In 2 to Analog In 1 to connect an external potentiometer.

1. Set Parameter 090 [Speed Ref A Sel] to option 1 “Analog In 1”

This sets the speed reference input to I/O terminals 1 & 2. For 4…20 mA operation, a jumper must be placed between terminals 17 & 18.

2. Set Parameter 096 [TB Man Ref Sel] to option 9 “MOP Level”

This eliminates a potential Conflict alarm condition. Analog In 2 is not a valid Speed Reference source if selected for any of the following:

– 117 [Trim In Select] – 126 [PI Reference Sel] – 128 [PI Feedback Sel] – 147 [Current Lmt Sel] – 179 [Sleep-Wake Ref ]

3. Set Parameter 091 [Speed Ref A Hi] to the upper value of the desired

speed reference range in Hz

4. Set Parameter 092 [Speed Ref A Lo] to the lower value of the desired

speed reference range in Hz

Control Scheme

Change from 3 Wire Start/Stop to 2 Wire Run/Not Run at Digital In 1 & Digital In 2.

This disables the Start button on the HIM.

1. Set Parameter 361 [Digital In1 Sel] to option 7 “Run” or 9 “Run Reverse”

2. Set Parameter 362 [Digital In2 Sel] to another option such as 8 “Run

Forward” or 10 “Jog”

See I/O Wiring Examples beginning on page 52

Restoring Factory Defaults

From the Human Interface Module (HIM) Main Menu select: Memory Storage / Reset To Defaults

70 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Troubleshooting

For a complete listing of Faults and Alarms, refer to the PowerFlex 700 User Manual.

Table 6 - Abbreviated Fault Listing

(1)

Faul t

Auxiliary Input

Decel Inhibit 24

FluxAmps Ref Rang

HW OverCurrent

IR Volts Range

Motor Overload

OverSpeed Limit

OverVoltage 5

SW OverCurrent

(1) See the User Manual for a description of fault types.

Description Action

No.

Type

2 ➀ Auxiliary input interlock is open. Check remote wiring.

➂ The drive is not following a commanded

deceleration because it is attempting to limit bus voltage.

78 The value for flux amps determined by

the Autotune procedure exceeds the programmed [Motor NP FLA], parameter 042.

➀ The drive output current has exceeded

the hardware current limit.

77 “Calculate” is the autotune default and

the value determined by the autotune procedure for IR Drop Volts is not in the range of acceptable values.

➀

Internal electronic overload trip. Enable/Disable with [Fault Config 1].

➂

25 ➀ Functions such as Slip Compensation or

Bus Regulation have attempted to add an output frequency adjustment greater than that programmed in [Overspeed Limit], parameter 083.

➀ DC bus voltage exceeded maximum

value.

➀ Drive output current has exceeded the

1ms current rating. This rating is greater than the 3 second current rating and less than the hardware overcurrent fault level. It is typically 200…250% of the drive continuous rating.

1. Verify input voltage is within drive specified limits.

2. Verify system ground impedance follows proper grounding techniques.

3. Disable bus regulation and/or add dynamic brake resistor and/or ex tend deceleration time. Refer to page 6

4. Disable with parameter 238.

1. Reprogram [Motor NP FLA] with the correct motor nameplate value.

2. Repeat Autot une.

Check programming. Check for excess load, improper DC boost setting, DC brake volts set too high or other causes of excess current.

Re-enter motor nameplate data.

An excessive motor load exists. Reduce load so drive output current does not exceed the current set by [Motor NP FLA].

Remove excessive load or overhauling conditions or increase [Overspeed Limit].

Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install dynamic brake option.

Check for excess load, improper DC boost setting. DC brake volts set too high.

for further info.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 71

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Acc2/Dec2 Accel 2 Decel 2 Jog 1/2 Jog Fwd Jog Rev Fwd/Re v

Acc2/Dec2

Accel 2

Decel 2

Jog 1/2

Jog Fwd

Jog Rev

Fwd/Rev

Start Stop -CF Run Run Fwd Run Rev Jog 1/2 Jog Fwd Jog Rev Fwd/Rev

Start

Stop-CF

Run

Run Fwd

Run Rev

Jog 1/2

Jog Fwd

Jog Rev

Fwd/Rev

Table 7 - Abbreviated Alarm Listing

(1)

Alarm

Dig In Confl ictA

Description

No.

Type

17 ➁ Digital input functions are in conflict. Combinations marked with a “ ” will cause an alarm.

Dig In Confl ictB

Dig In Confl ictC

➁ A digital Start input has been configured without a Stop input or other functions are in conflict.

Combinations that conflict are marked with a “ ” and will cause an alarm.

19 ➁ More than one physical input has been configured to the same input function. Multiple

configurations are not allowed for the following input functions. Forward/Reverse Run Reverse Bus Regulation Mode B Speed Select 1 Jog Forward Acc2 / Dec2 Speed Select 2 Jog Reverse Accel 2 Speed Select 3 Run Decel 2 Run Forward Stop Mode B

TB Man Ref Cflct

➁ Occurs when:

• “Auto/Manual” is selected (default) for [Digital In3 Sel], parameter 363 and

• [TB Man Ref Sel], parameter 96 has been reprogrammed.

No other use for the selected analog input can be programmed. Example: If [TB Man Ref Sel] is reprogrammed to “Analog In 2,” all of the factory default uses for

“Analog In 2” must be reprogrammed (such as parameters 90, 117, 128 and 179). Refer to the Auto/Manual Examples section of the PowerFlex 700 User Manual.

To c orr ec t:

• Verify/reprogram the parameters that reference an analog input or

• Reprogram [Digital In3] to another function or “Unused.”

(1) See the User Manual for a description of alarm types.

72 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Common Symptoms and Corrective Actions

Drive does not Start from Start or Run Inputs wired to the terminal block.

Cause(s) Indication Corrective Action

Drive is Faulted Flashing red status light • Clear fault.

Incorrect input wiring. Refer to the wiring examples starting on page 52

• 2 wire co ntrol requires Run, Ru n Forward, Run Reverse or Jog input.

• 3 wire control requires Start and Stop inputs.

• Jumper from terminal 25 to 26 is required.

Incorrect digital input programming.

• Mutually exclusive choices have been made (i.e., Jog and Jog For ward).

• 2 wire and 3 wire programming can be conflicting.

• Exclusive functions (i.e, direction control) can have multiple inputs configured.

• Stop is factory default and is not wired.

None Wire inputs correc tly and/or install jumper.

None Program [Digital Inx Sel], parameters

Flashing yellow status light and “DigIn CflctB” indication on LCD HIM.

[Drive Status 2] shows type 2 alarm(s).

• Press Stop

• Cycl e pow er

• Set [Fault Clear] to 1

• “Clear Faults” on the HIM Diagnostic

menu.

361…366 for correct inputs. Start or Run programming can be missing.

Program [Digital Inx Sel] to resolve conflicts. Remove multiple selections for the same

function. Install stop button to apply a signal at stop

terminal.

Drive does not Start from Human Interface Module (HIM).

Cause(s) Indication Corrective Action

Drive is programmed for 2 wire control. HIM Start button is disabled for 2 wire control u nless param. 192, bit 1 = “1.”

None I f 2 wire control is required, no action

needed. If 3 wire control is required, program [Digital

Inx Sel] for correct inputs.

Drive does not respond to changes in speed command.

Cause(s) Indication Corrective Action

No value is coming from the source of the command.

Incorrect reference source has been programmed.

Incorrect Reference source is being selected via remote device or digital inputs.

LCD HIM Status Line indicates “At Speed” and output is 0 Hz.

None 3. Check parameter 213, [Speed Ref Source]

None 5. Check parameter 209, [Drive Status 1],

1. If the source is an analog input, check wiring and use a meter to check for presence of signal.

2. Check [Commanded Speed], parameter 002 for correct source.

for the source of the speed reference.

4. Reprogram parameter 090, [Speed Ref A Sel] for correct source.

bits 12 & 13 for unexpected source selections.

6. Check parameter 216 [Dig In Status] to see if inputs are selecting an alternate source.

7. Reprogram digital inputs to correct “Speed Sel x” option.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 73

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Motor and/or drive will not accelerate to commanded speed.

Cause(s) Indication Corrective Action

Acceleration time is excessive. None Reprogram [Accel Time x].

Excess load or short acceleration times force the drive into current limit, slowing or stopping acceleration.

Speed command source or value is not as expected.

Programming is preventing the drive output from exceeding limiting values.

None Check [Drive Status 2], bit 10 to see if the

drive is in Current Limit. Remove excess load or reprogram [Accel Time

x].

None Check for the proper Speed Command by

using Steps 1 through 7 above.

None Check [Maximum Speed] and [Maximum

Freq] (parameters 082 and 055) to assure that speed is not limited by programming.

Motor operation is unstable.

Cause(s) Indication Corrective Action

Motor data was incorrectly entered or Autotune was not per formed.

None 1. Correctly enter motor nameplate data.

2. Perform “Static” or “Rotate” Autotune procedure.

Drive will not reverse motor direction.

Cause(s) Indication Corrective Action

Digital input is not selected for reversing control.

Digital input is incorrectly wired. None Check input wiring.

Direction mode parameter is incorrectly programmed.

Motor wiring is improperly phased for reverse.

A bipolar analog speed command input is incorrectly wired or signal is absent.

None Check [Digital Inx Sel]. Choose correct input

and program for reversing mode.

None Reprogram [Direction Mode] for analog

“Bipolar” or digital “Unipolar” control.

None Switch two motor leads.

None 1. Use meter to check that an analog input

voltage is present.

2. Check wiring.

Positive vol tage commands fo rward direction. Negative voltage commands reverse directi on.

Stopping the drive results in a Decel Inhibit fault.

Cause(s) Indication Corrective Action

The bus regulation feature is enabled and is halting deceleration due to excessive bus voltage. Excess bus voltage is normally due to excessive regenerated energy or unstable AC line input voltages.

Internal timer has halted drive operation.

Decel Inhibit fault screen. LCD Status Line indicates

“Faulted”.

1. See Attention statement on page 6

2. Reprogram parameters 161/162 to eliminate any “Adjust Freq” selec tion.

3. Disable bus regulation (parameters 161 &

162) and add a dynamic brake.

4. Correct AC input line instability or add an isolation transformer.

5. Reset drive.

74 Rockwell Automation Publication 20B-IN014H-EN-P - June 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 7…10

Esc

Manually Clearing Faults

Step Key(s)

1. Press Esc to acknowledge the fault. The fault information is removed so that you can use the Human Interface Module (HIM).

2. Address the condition that caused the fault.

3. The cause must be corrected before the fault can be cleared.

4. After corrective action has been taken, clear the fault by one of these methods:

– Press Stop – Cycle drive power – Set parameter 240 [Fault Clear] to “1.” – “Clear Faults” on the Human Interface Module (HIM) Diagnostic menu.

Rockwell Automation Publication 20B-IN014H-EN-P - June 2013 75

Rockwell Automation Support

*PN-208994*

PN-208994

Rockwell Automation provides technical information on the Web to assist you in using its products. At http://www.rockwellautomation.com/support code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. You can also visit our Knowledgebase at http://www.rockwellautomation.com/knowledgebase information, support chat and forums, software updates, and to sign up for product notification updates.

, you can find technical manuals, technical and application notes, sample

for FAQs, technical

For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer Te c h C o n n e c t representative, or visit http://www.rockwellautomation.com/support/

support programs. For more information, contact your local distributor or Rockwell Automation

Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running.

United States or Canada 1.440.646.3434

Outside United States or Canada Use the Wo rld wid e Loc ato r

Automation representative.

at http://www.rockwellautomation.com/support/americas/phone_en.html, or contac t your local Rockwell

New Product Satisfaction Return

Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.

United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to you r

distributor to complete the return process.

Outside United States Please contact your local Rockwell Automation representative for the return procedure.

Documentation Feedback

Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete this form, publication RA-DU002

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

Publication 20B-IN014H-EN-P - June 2013 PN-208994

, available at http://www.rockwellautomation.com/literature/.

Rockwell Automation 20D-700 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Additional Resources

Allen-Bradley Drives Technical Support

Documentation in Other Languages

Table of Contents

Catalog Number Explanation

Step 1: Read the Precautions and General Information

Qualified Personnel

Personal Safety

Product Safety

EMC Compliance

Component Locations

Step 2: Lifting and Mounting the Drive

Lifting

Environment

Minimum Mounting Clearances & Heat Dissipation

Removing the Frame 7 Cover

Dimensions

Step 3: Wire the Drive

Special Considerations

Cable Types Acceptable for 200…600 Volt Installations

Single-Phase Input Power – Frame 7 Only

Power Terminal Blocks

Fan Circuit Power Supply

Additional Frame 10 Wiring Requirement for IP00 AC Input Drives

DC Link Chokes – Frames 8…10

Auxiliary Control Power Supply

General Grounding Requirements

Motor Overload Protection

Drive, Fuse & Circuit Breaker Ratings

Output Devices

Using Input/Output Contactors

Disconnecting MOVs

Step 4: I/O Wiring

I/O Wiring Examples

Hardware Enable Circuitry (Vector Control Only)

Encoder Interface Option

Reference Control

Step 5: Start-Up Check List

Prepare For Drive Start-Up

Supplemental Information

DC Input (Common Bus) and Precharge Notes

Human Interface Module (HIM) Overview

Start-Up Routines

Drive Status Indicators & DPI Port Locations

Common I/O Programming Changes

Troubleshooting

Common Symptoms and Corrective Actions

Manually Clearing Faults