Rockwell Automation 20L -700L User Manual
User Manual
PowerFlex 700L Liquid-Cooled
Adjustable Frequency AC Drive
Frames 2, 3A, and 3B
Important User Information
IMPORTANT
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
available from
) describes some
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Summary of Changes
The information below summarizes the changes made to this manual since
its last release (August 2008).
Description of Changes Page
Revised and re-organized information in Chapter 4. 4-1
Revised information for Electronic Motor Overload Protection in the “Control” section of
the specification.
Revised information in the section “Fuse and Circuit Breaker Ratings.” A-6
…4-11
A-3
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Notes:
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Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Preface Overview
Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
What Is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
PowerFlex 700L Active Converter Power Module Information . . . . . . . . . . . . . . . . . . P-1
PowerFlex 700 Vector Control Information (standard) . . . . . . . . . . . . . . . . . . . . . . . . P-1
PowerFlex 700S Phase II Control Information (optional) . . . . . . . . . . . . . . . . . . . . . . P-1
HIM (Human Interface Module) Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
PowerFlex 7-Class Network Communication Adapter Information. . . . . . . . . . . . . . . P-2
PowerFlex 700L Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Complete Drive Data Nameplate Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-7
Frame 2 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-7
Frames 3A and 3B Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-8
Chapter 1 General Installation Information
Enclosure Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Unbalanced, Ungrounded or Resistive Grounded Distribution Systems . . . . . . . . . . . 1-2
Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Wiring Requirements for the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Input Line Branch Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Cable Types Acceptable for 400-690 Volt Installations . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Cable Trays and Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Low Voltage Directive (2006/95/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
EMC Directive (2004/108/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Essential Requirements for CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
C-Tick Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Using Input/Output Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Input Contactor Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Output Contactor Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Table of Contents
Chapter 2 Frame 2 Installation
Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Total Area Required for Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Recommended Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Verifying Drive Input Ratings Match Supplied Power . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
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Equipment Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Verifying the Drive’s Watts Loss Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Removing the Drive Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Removing the Active Converter Control Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Removing the Inverter Control Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Determining Wire Routing for Control, Ground, Drive Input, and Motor Output . . . . . . 2-9
Grounding the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Ungrounded or Resistive Grounded Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Synchronization Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
DPI Connections for Frame 2 Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Coolant Loop Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Attaching the Lifting Feet to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Attaching the Lifting Hardware to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Connecting Lifting Hooks to Proper Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Applying Strap Angles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Rotating the Drive About the Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
PowerFlex 700 Vector Control Cassette (standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
PowerFlex 700S Phase II Control Cassette (optional). . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Disconnecting the Common Mode Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Disconnecting the MOV from Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Installing Transformers and Reactors (Not Recommended) . . . . . . . . . . . . . . . . . . . . 2-12
Selecting and Verifying Control Transformer Voltage . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Installing Input Power Wiring to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Installing Mechanical Motor Overload Protection (Optional) . . . . . . . . . . . . . . . . . . 2-16
Installing Output Wiring from the Drive Output Terminals to the Motor . . . . . . . . . . 2-17
Coupled Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Control Synchronization Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Inverter-to-Converter DPI Communication Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Drive Connection Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
External Door-Mounted HIM Connection (optional) . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Chapter 3 Frame 3A and 3B Installation
Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Total Area Required for Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Recommended Air Flow Clearances for Complete Drive . . . . . . . . . . . . . . . . . . . . . . . 3-2
Recommended Mounting Clearances for Power Modules . . . . . . . . . . . . . . . . . . . . . . 3-7
Verifying Power Module Input Ratings Match Supplied Power . . . . . . . . . . . . . . . . . . 3-8
Equipment Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Lifting the Complete Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Lifting the Input Filter Bay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Lifting the Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Supporting the Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Removing the Power Module Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Removing the Active Converter Power Module Control Cassette . . . . . . . . . . . . . . . . . 3-13
Frame 3A Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Frame 3B Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
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Removing the Inverter Power Module Control Cassette. . . . . . . . . . . . . . . . . . . . . . . . . 3-14
PowerFlex 700 Vector Control Cassette (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
PowerFlex 700S Phase II Control Cassette (optional) . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Verifying the Drive’s Watts Loss Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Installing the Vented Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Determining Wire Routing for Control, Ground, Drive Input, and Motor Output . . . . . 3-16
Frame 3A Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Frame 3B Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Grounding the Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Ungrounded or Resistive Grounded Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Disconnecting the Input Filter Common Mode Capacitor . . . . . . . . . . . . . . . . . . . . . 3-22
Disconnecting the MOV from Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Installing Input Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Installing Transformers and Reactors (Not Recommended). . . . . . . . . . . . . . . . . . . . 3-23
Selecting and Verifying Control Transformer Voltage . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Installing an External/Separate Input Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Installing Power Wiring from Input Filter Bay to the Power Module Bay . . . . . . . . . 3-25
Installing Output Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Installing Mechanical Motor Overload Protection (Optional) . . . . . . . . . . . . . . . . . . 3-29
Installing Output Wiring from the Drive Output Terminals to the Motor . . . . . . . . . . 3-29
Installing Control Wiring from the Input Filter Bay to the Power Module Bay . . . . . . . 3-30
Frame 3A Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Frame 3B Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Synchronization Connections for Frame 3A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Coupled Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Control Synchronization Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Inverter-to-Converter DPI Communication Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Synchronization Connections for Frame 3B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Coupled or Stand-Alone Inverter Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Control Synchronization Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Inverter-to-Converter DPI Communication Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
DPI Connections for Frame 3A and 3B Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Drive Connection Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
External Door-Mounted HIM Connection (optional) . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Coolant Loop Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Chapter 4 Cooling Loop Installation
Explanation of Cooling Loop Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Liquid-to-Liquid Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Liquid-to-Air Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Cooling Loop Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Cooling Loop Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Drive Coolant Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Frame 2 Drive or Frame 3A or 3B Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Frame 3A or 3B Complete Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Drive Coolant Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Recommended Coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Corrosion Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Biocide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Drive Cooling Loop Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
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Chapter 5 Programming and Parameters
Affected 700 Vector Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Utility File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Communication File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Affected 700S Phase II Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Utility File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Chapter 6 Troubleshooting
Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Frame 2 Drive LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Accessing Status Indicators of Powered Frame 3A and 3B Complete Drives . . . . . . . 6-2
HIM Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Manually Clearing Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Converter Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
700 Vector Control Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
700S Phase II Control Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Clearing Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Alarm Descriptions (only 700S Phase II Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Replacement of Door Filter of the Input Filter Cabinet (Frames 3A and 3B). . . . . . . . . . 6-7
Appendix A Supplemental Drive Information
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Derating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Ambient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Carrier Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Horsepower/Current Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Watts Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Fuse and Circuit Breaker Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Fusing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Appendix B Frame 2 Schematics
Regenerative Drive Wiring Diagram with TB4 Connections – 400/480V, 3 Phase . . . . . B-2
Regenerative Drive Wiring Diagram without TB4 Connections – 400/480V, 3 Phase . . . B-4
Appendix C Frame 3A and 3B Schematics
Frame 3A Regenerative Drive Wiring Diagram – 400/480V, 3 Phase . . . . . . . . . . . . . . . C-2
Frame 3A Regenerative Drive Wiring Diagram – 600/690V, 3 Phase . . . . . . . . . . . . . . . C-4
Frame 3A Converter/Inverter Power Module Wiring Diagram – 400/690V, 3 Phase . . . . C-6
Frame 3A Dual Inverter Power Module Wiring Diagram – 400/690V, 3 Phase . . . . . . . . C-8
Frame 3B Regenerative Drive Wiring Diagram – 400/480V, 3 Phase. . . . . . . . . . . . . . . C-10
Frame 3B Regenerative Drive Wiring Diagram – 600/690V, 3 Phase. . . . . . . . . . . . . . . C-12
Frame 3B Active Converter Power Module Schematic – 400/690V, 3 Phase . . . . . . . . . C-14
Frame 3B Inverter Power Module Schematic – 400/690V, 3 Phase . . . . . . . . . . . . . . . . C-16
Index
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
Preface
Overview
This manual provides the basic information needed to install, start-up, and
troubleshoot the PowerFlex 700L Liquid-Cooled AC Drive.
Topic Page
Who Should Use this Manual?
What Is Not in this Manual P-1
Additional Resources P-2
Manual Conventions P-3
General Precautions P-4
Catalog Number Explanation P-5
Complete Drive Data Nameplate Locations P-7
P-1
Who Should Use this
Manual?
What Is Not in this Manual
This manual is intended for qualified personnel. You must be able to install,
wire, and operate Adjustable Frequency AC Drive devices. In addition, you
must have an understanding of the parameter settings and functions.
This manual is designed to provide only basic installation and start-up
information. The following information is not included:
PowerFlex 700L Active Converter Power Module Information
Regenerative PowerFlex 700L drives are equipped with a PowerFlex 700L
Active Converter Power Module. For details on active converter I/O wiring,
start-up, programming, and other related information, see the PowerFlex
700L Active Converter Power Module User Manual, publication
PFLEX-UM002.
PowerFlex 700 Vector Control Information (standard)
For PowerFlex 700L drives equipped with Standard Vector Control, see the
PowerFlex 700 Adjustable Frequency AC Drive User Manual - Series B,
publication 20B-UM002, which provides I/O wiring, start-up,
programming, and vector control encoder information.
PowerFlex 700S Phase II Control Information (optional)
For PowerFlex 700L drives equipped with Optional 700S Phase II Control,
see the PowerFlex 700S High Performance AC Drive - Phase II Control
User Manual, publication 20D-UM006, which provides I/O wiring, start-up,
programming, and other related information.
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
P-2 Overview
HIM (Human Interface Module) Information
For an overview of the HIM operation, see the PowerFlex 700 Adjustable
Frequency AC Drive User Manual - Series B, publication 20B-UM002, or
the PowerFlex 700S High Performance AC Drive - Phase II Control User
Manual, publication 20D-UM006.
PowerFlex 7-Class Network Communication Adapter Information
For PowerFlex 700L drives equipped with a network communication
adapter, see the adapter User Manual, publication 20COMM-UMxxx, for
information on configuring and using I/O and explicit messaging over the
network.
PowerFlex 700L Service Information
For Frame 2 drive service information, see the PowerFlex 700L
Liquid-Cooled Adjustable Frequency AC Drive Frame 2 Hardware Service
Manual, publication 20L-TG002.
Additional Resources
For Frame 3A and 3B drive service information, see the PowerFlex 700L
Liquid-Cooled Adjustable Frequency AC Drive Frames 3A and 3B
Hardware Service Manual, publication 20L-TG001.
Documentation can be obtained online at http://
literature.rockwellautomation.com. To order paper copies of technical
documentation, contact your local Rockwell Automation distributor or sales
representative.
To find your local Rockwell Automation distributor or sales representative,
visit http://www.rockwellautomation.com/locations
For information such as firmware updates or answers to drive-related
questions, go to the Drives Service & Support website at http://
www.ab.com/support/abdrives and click on the Downloads or
Knowledgebase link.
The following publications provide general drive information.
Title Publication
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001
Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001
PowerFlex 70EC/700VC Reference Manual PFLEX-RM004
Safety Guidelines for the Application, Installation, and Maintenance of Solid State Control SGI-1.1
A Global Reference Guide for Reading Schematic Diagrams 100-2.10
Guarding Against Electrostatic Damage 8000-4.5.2
.
The following publications provide specific feedback card information for
PowerFlex 700L drives with Optional 700S Phase II Control.
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
Overview P-3
Title Publication
Hi-Resolution (Stegmann) Feedback Option Card Installation Instructions for PowerFlex 700S Drives 20D-IN001
Resolver Feedback Option Card Installation Instructions for PowerFlex 700S Drives 20D-IN002
Multi-Device Interface Option Card Installation Instructions for PowerFlex 700S Drives 20D-IN004
Second Encoder Option Card for PowerFlex 700S Drives with Phase II Control 20D-IN009
DriveGuard Safe Torque Off Option for PowerFlex 700S Phase II and PowerFlex 700L Drives 20D-UM007
The following publication provides information that is necessary when
applying the 700S Phase II Control DriveLogix™ 5730 Controller.
Title Publication
DriveLogix 5730 Controller User Manual 20D-UM003
The following publications provide information that is useful when
planning and installing communication networks.
Title Publication
ControlNet Coax Tap Installation Instructions 1786-IN007
ControlNet Coax Media Planning and Installation Manual 1786-6.2.1
ControlNet Fiber Media Planning and Installation Guide CNET-IN001
DeviceNet Product Overview DNET-SO002
DeviceNet Media Design and Installation Guide DNET-UM072
DeviceNet Starter Kit User Manual DNET-UM003
EtherNet/IP Media Planning and Installation Manual
EtherNet/IP Network Infrastructure Guidelines
EtherNet/IP Performance Application Solution ENET-AP001
SynchLink™ Design Guide 1756-TD008
(1)
(1)
ODVA Pub. 148
ODVA Pub. 35
Manual Conventions
(1)
Use this link to the ODVA EtherNet/IP library for these publications: http://odva.org/Home/
ODVATECHNOLOGIES/EtherNetIP/EtherNetIPLibrary/tabid/76/Default.aspx
• In this manual, we also refer to the PowerFlex 700L Liquid-Cooled AC
Drive as drive, PowerFlex 700L, or PowerFlex Drive.
• To help differentiate parameter names and LCD display text from other
text, the following conventions are used:
– Parameter Names appear in [brackets] – example: [DC Bus Voltage].
– Display Text appears in “quotes” – example: “Enabled.”
• The following words may be used in the manual to describe an action.
Word Mean ing
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Must Unavoidable, you must do this
Shall Required and necessary
Should Recommended
Should Not Not recommended
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
P-4 Overview
!
!
!
!
!
General Precautions
ATTENTION: This drive contains electrostatic discharge (ESD)
sensitive parts and assemblies. Static control precautions are
required when installing, testing, servicing, or repairing this
assembly. Component damage may result if ESD control
procedures are not followed. If you are not familiar with static
control procedures, see Guarding Against Electrostatic Damage,
publication 8000-4.5.2, or any other applicable ESD protection
handbook.
ATTENTION: An incorrectly applied or installed drive can
result in component damage or a reduction in product life. Wiring
or application errors, such as undersizing the motor, incorrect or
inadequate AC supply, or excessive ambient temperatures may
result in malfunction of the system.
ATTENTION: Only qualified personnel familiar with adjustable
frequency AC drives and associated machinery should plan or
implement the installation, start-up, and subsequent maintenance
of the system. Failure to comply may result in personal injury and/
or equipment damage.
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged completely before
servicing. After removing power to the drive, wait 5 minutes for
the bus capacitors to discharge. Measure the DC bus voltage at the
DC+ and DC- TESTPOINT sockets on the drive or power module.
See Figure 2.15
Figure 3.27
for Frame 2, Figure 3.25 for Frame 3A, or
for Frame 3B. The voltage must be zero.
ATTENTION: Risk of injury or equipment damage exists. DPI
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.
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
Catalog Number Explanation
Position
1-3 4 5-7 8 9 101112 13 1415161718
20L E 800 A 0 E N N A N 1 0 W A
a bc defgh i jklmn
Overview P-5
a
Drive
Code Type
20L PowerFlex 700L
b
Voltage Rating
Code Voltage Ph.
C400V AC3
D480V AC3
E600V AC3
F690V AC3
c1
ND Rating
400V, 60 Hz Input
Code Amps Hp (KW) Frame
360 360 268 (200) 2
650 650 500 (370) 3A
1K2 1250 960 (715) 3B
c2
ND Rating
480V, 60 Hz Input
Code Amps Hp (KW) Frame
360 360 300 (224) 2
650 650 600 (445) 3A
1K2 1250 1150 (860) 3B
c3
ND Rating
600V, 60 Hz Input
Code Amps Hp (KW) Frame
425 425 465 (345) 3A
800 800 870 (650) 3B
1K1 1175 1275 (950) 3B ♣
♣ Must operate at 2 kHZ PWM only, and only as a
stand-alone inverter module (“K” in position 13).
c4
ND Rating
690V, 60 Hz Input
Code Amps Hp (KW) Frame
380 380 475 (355) 3A
705 705 881 (657) 3B
1K0 1050 1310 (980) 3B ♣
♣ Must operate at 2 kHZ PWM only, and only as a
stand-alone inverter module (“K” in position 13).
d
Enclosure
Code Type
A NEMA/UL Type 1, IP20 ✝ No
N Open-Chassis Style/IP00 ❖ No
✝ Frame 3 complete drive.
❖ Frame 2 drive and Frame 3 input filter and power
modules.
Conformal
Coating
e
HIM
Code Operator Interface
0 No HIM/Blank Cover
3 Full Numeric LCD ♠
C Door-Mounted Full Numeric LCD ✝
♠ Frame 2 and Frame 3 power modules.
✝ Frame 3 complete drive only.
f
Documentation
Code Documents Ship Carton
E English Doc Set Yes
N No Documentation Yes
Q No Documentation No
g
Brake
Code w/Brake IGBT
NNo
h
Brake Resistor
Code w/Resistor
NNo
i
Equipment Type
Code Description Frame
Complete Regenerative
A
Drive - Std. Interrupt Rating
C Input Filter 3A and 3B
Combined Active Converter/
E
Inverter Power Module
G
J
K
L Dual Inverter Power Module 3A only
P
X Spare Power Module ◆ 3A and 3B
◆ No control cassettes.
Active Converter
Power Module
Inverter Power Module -
Coupled Version
Inverter Power Module -
Common DC Bus Version
Active Converter Power
Module - Stand Alone Version
2, 3A, and 3B
3A only
3B only
3B only
3B only
3B only
j
Comm Slot
Code Communication Option
NNone N
C ControlNet (Coax) - DPI ‡ 20-COMM-C
D DeviceNet - DPI ‡ 20-COMM-D
E EtherNet/IP - DPI ‡ 20-COMM-E
DriveLogix Comm Option,
1
2
3
4
5
6
✧ For 700S Phase II Control with DriveLogix5730,
‡ 700 Vector Control uses DPI comm. slot options
✽ DriveLogix comm. slot options require 700S
ControlNet (Coax) ✽
DriveLogix Comm Option,
ControlNet Redundant (Coax) ✽
DriveLogix Comm Option,
ControlNet (Fiber) ✽
DriveLogix Comm Option,
ControlNet Redundant (Fiber) ✽
DriveLogix Comm Option,
DeviceNet (Open
Connection) ✽
DriveLogix Comm Option,
DeviceNet (Twisted Pair) ✽
comm. slot option selections are mutually
exclusive. For two communication adapters, (DPI
and DriveLogix), select the DriveLogix comm.
slot option and order the DPI user installed kit
catalog number separately.
only.
Phase II Control with DriveLogix5730.
DPI
User-Installed
Kit Cat. No. ✧
—
—
—
—
—
—
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
P-6 Overview
Position
1-3 4 5-7 8 9 101112 13 1415161718
20L E 800 A 0 E N N A N 1 0 W A
a bc defgh i jklmn
k
Control Option
Logic
Code Control Cassette
700VC
1
24V I/O
700VC
2
115V I/O
A 700S Ph. II Expanded No No
B 700S Ph. II Expanded No Yes
C 700S Ph. II Expanded Yes No ▲
D 700S Ph. II Expanded Yes Yes ▲
W None ❖ N/A N/A N/A
❖ Frame 3 input filter, Active Converter Power
Modules, and spare power modules.
▲ Requires DriveLogix5730.
Expansion
Base N/A N/A
Base N/A N/A
Synch
Link
l
Feedback
Control
Code
Option
0 All None
1 700VC Encoder 5V/12V
A 700S Ph. II Resolver ❤
B 700S Ph. II Hi-Res. Stegmann Encoder ❤
C 700S Ph. II Multi-Device Interface ❤ ✠
E 700S Ph. II 2nd Encoder ❤
S 700S Ph. II Safe-Off (w/2nd Encoder) ❤
❤ Requires expanded cassette.
✠ Multi-Device Interface allows the connection of
the Stegmann and Temposonics linear sensors.
The Temposonics sensor cannot
close motor control or speed loops.
Type
be used to
m
Additional 700S Configuration
Code Logix Option
WNone —
E Phase II Control No
K
L
Phase II Control
with DriveLogix5730
Phase II Control
with DriveLogix5730
Embedded
Comm.
No
EtherNet/IP
n
Coolant Type
Code Coolant Frame
N None 3 Input Filter only
AWater All
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
Overview P-7
SIDE VIEW
Complete Regenerative Drive
Output: 3 Phase, 0-400Hz
Made in the U.S.A. (FAC1C)
Nom. Coolant Pressure
20LC360N3ENNAN10WA
Input: 3 Phase, 47-63 Hz
MFD. in 2007 on JUL 05
Normal Duty Power
AC Voltage Range
Amps
Base Hz (default)
Continuous Amps
Rated Coolant
AC Voltage Range
Nominal Voltage
NEMA Type
Cat No.
Serial Number: MEAE2WJ0
Frame: 2
Original Firmware V. x.xxx
Series: A
Complete Regenerative Drive
Output: 3 Phase, 0-400Hz
Made in the U.S.A. (FAC1C)
Nom. Coolant Pressure
20LC360N3ENNAN10WA
Input: 3 Phase, 47-63 Hz
MFD. in 2007 on JUL 05
Normal Duty Power
AC Voltage Range
Amps
Base Hz (default)
Continuous Amps
Rated Coolant
AC Voltage Range
Nominal Voltage
NEMA Type
Cat No.
Serial Number: MEAE2WJ0
Frame: 2
Original Firmware V. x.xxx
Series: A
FRONT VIEW (Cover Removed)
Complete Drive Data Nameplate Locations
Frame 2 Drives
Figure P.1 shows multiple data nameplate locations for Frame 2 drives. The
data and agency markings are different for equipment type. For example,
the complete drive is UL listed component; and the Power Modules are UL
recognized.
Figure P.1 Frame 2 Drive Data Nameplate Locations
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
P-8 Overview
Inverter Power Module - Coupled With Converter
Nom. Coolant Pressure
Output: 3 Phase, 0-400Hz
20LE800N0NNNJND0LA
Inverter Power Module
Series: A
Original Firmware V. 2.005
20LE800N0NNNGNW0WA
Serial Number: MEAE2WJ0
Treated Water
Frame: 3B
Input: AC, 47-63 Hz
DC Voltage Range
DC Voltage Range
Base Hz (default)
P/N 181255-A01
Nom. Coolant Pressure
MFD. in 2005 on MAR 05
Rated Coolant
Continuous Amps
Output: DC
Amps
185 psig
N.A.
800
730-900
518-633
800
Normal Duty Power
Converter Power Module
UL Open Type/IP00
Nominal Voltage
Cat No.
600V
870HP
Input: DC
US
C
EN 50178
Production inspected
Type approved
Bauart gepruft
TUV
Rheinland
TUV
of North America
TUV Rheinland
Functional
Product Safety
Rheinland
TUV
Safety
MFD. in 2005 on MAR 05
P/N 181255-A01
DC Voltage Range
Base Hz (default)
AC Voltage Range
Amps
Continuous Amps
Rated Coolant
R
Cat No.
UL Open Type/IP00
Normal Duty Power
Nominal Voltage
US
C
TUV
TUV
Product Safety
Rheinland
Serial Number: MEAE2WJ0
of North America
TUV
Rheinland
TUV Rheinland
Frame: 3B
Treated Water
60 Hz
185 psig
800
0-600
800
730-900
EN 50178
Type approved
Bauart gepruft
Functional
Safety
Production inspected
Original Firmware V. 2.005
Series: A
870HP
600V
R
Complete Regenerative Drive
Output: 3 Phase, 0-400Hz
Made in the U.S.A. (FAC1C)
Nom. Coolant Pressure
20LE800ACENNA6DELA
Input: 3 Phase, 47-63 Hz
N.A.
Nom. Coolant Pressure
Serial Number: MEAE2WJ0
Frame: 3B
MFD. in 2005 on MAR 05
P/N 181255-A01
Type approved
TUV
Rheinland
Safety
MFD. in 2005 on MAR 05
P/N 181255-A01
Original Firmware V. 2.005
Series: A
20LE800N0NNNCNW0WN
Base Hz (default)
Rated Coolant
Continuous Amps
AC Voltage Range
Output: 3 Phase, 47-63 Hz
Input Filter Assembly
AC Voltage Range
Normal Duty Power
Nominal Voltage
Input: 3 Phase, 47-63 Hz
UL Open Type/IP00
Amps
Cat No.
870HP
518-633
N.A.
N.A.
800
518-633
800
600V
Production inspected
EN 50178
Bauart gepruft
Product Safety
TUV Rheinland
of North America
TUV
Functional
Rheinland
C
TUV
R
US
Normal Duty Power
AC Voltage Range
Amps
Base Hz (default)
Continuous Amps
Rated Coolant
AC Voltage Range
Nominal Voltage
NEMA Type 1/IP20
Cat No.
100 psig
Serial Number: MEAE2WJ0
TUV
Rheinland
Frame: 3B
Functional
Type approved
Safety
TUV
of North America
TUV Rheinland
Rheinland
Product Safety
Original Firmware V. 2.005
Series: A
N223
870HP
Treated Water
800
60 Hz
0-600
800
518-633
TUV
600V
EN 50178
Production inspected
Bauart gepruft
Ind. Cont.
Eq. 966X
US
C
Listed
R
Made in the U.S.A. (FAC1C)
Made in the U.S.A. (FAC1C)
Made in the U.S.A. (FAC1C)
Input
Filter Bay
Powe r
Module Bay
Inverter Power Module
Converter Power Module
Power Module Front,
Bottom Covers Removed
Input Filter Assembly
(Label on inside front of door)
Complete Regenerative Drive
(Label on inside front of door)
Power Module
Bay Door
Cutaway
NOTE: Power Module data nameplate labels
are duplicated on the exterior left side
wall of the Power Modules. These labels
may be viewed without removing the front,
bottom covers of the Power Modules.
Firmware
20-HIM-
20-COMM-
20B_-DB1-
20-I/O-
# : Date:
HIM
I/O
COMM Module
Internal Dynamic Brake
Date:
# :
Firmware
FIELD INSTALLED OPTIONS
Frames 3A and 3B Drives
Figure P.2 shows multiple data nameplate locations for complete Frame 3A/
3B drives. The data and agency markings are different for equipment type.
For example, except for 690V AC input, the complete drive is UL listed
component; and the Input Filter and Power Modules are UL recognized.
Base Power Module catalog numbers do not reflect the position 14 and
position 16 options actually installed inside the Inverter Power Module.
When ordering a replacement Inverter Power Module for use in a complete
drive, inform Rockwell Customer Service of both the Inverter Power
Module catalog string, and the position 14 and position 16 factory-installed
options shown on the Factory Installed Options label.
Figure P.2 Complete Frame 3A and 3B Drive Data Nameplate Locations
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
Chapter 1
General Installation Information
This chapter provides general information on mounting and wiring
PowerFlex 700L Liquid-Cooled AC Drives.
Topic Page
Enclosure Ratings
AC Supply Source Considerations 1-1
Power Wir ing 1-4
CE Conformity 1-7
C-Tick Conformity 1-9
Using Input/Output Contactors 1-9
1-1
Enclosure Ratings
AC Supply Source Considerations
PowerFlex 700L Liquid-Cooled AC drives have the following enclosure
ratings:
• Open-Chassis Style (IP00) - Frame 2: Intended to be installed in an
enclosure. Frame 3: Input filter and power modules, when purchased
individually, are intended to be mounted in an enclosure.
• Type 1 (IP20) - Frame 3: Drive is mounted in a separate NEMA/UL Type
1 enclosure to obtain this rating.
PowerFlex 700L Liquid-Cooled AC drives must be placed in an enclosure.
See the catalog string on page P-5
drive options.
PowerFlex 700L Liquid-Cooled AC drives are suitable for use on a circuit
capable of delivering up to a maximum of 200,000 rms symmetrical
amperes. For the PowerFlex 700L Frame 3A or 3B complete drive, a circuit
breaker with shunt trip with the appropriate kAIC rating must always be
used upstream of the power module. See Table 1 .A
PowerFlex 700L Liquid Cooled AC drives should not be used on undersized
or high-impedance supply systems. The supply system kVA should be equal
to or greater than the drive-rated kW, and the system impedance should be
less than 10%. Operation outside these limits could cause instability
resulting in drive shutdown.
for fully assembled NEMA/UL Type 1
for details.
System Impedance = (PowerFlex 700L kVA ÷ Transformer kVA) x Transformer % Impedance
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
1-2 General Installation Information
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!
The kVA of all PowerFlex 700L drives on the distribution system and the
system impedance of upstream transformers should be taken into account.
ATTENTION: To guard against personal injury and/or equipment
damage caused by improper circuit breaker selection, use only the
recommended circuit breakers specified in Table 1.A
Unbalanced, Ungrounded or Resistive Grounded Distribution Systems
If phase-to-ground voltage will exceed 125% of normal or the supply
system is ungrounded, see Wiring and Grounding Guidelines for Pulse
Width Modulated (PWM) AC Drives, publication DRIVES-IN001, for
more information.
ATTENTION: PowerFlex 700L Liquid Cooled Frame 2, 3A,
and 3B drives contain protective MOVs and a common mode
capacitor that are referenced to ground. (The protective MOVs
and common mode capacitor in Frame 3A and 3B drives are
mounted in the Input Filter Bay.) These devices must be
disconnected if the drive is installed on a resistive grounded
distribution system or an ungrounded distribution system.
.
Drive Frame Size
2 Page 2-11
3A or 3B Page 3-22
Input Power Conditioning
Certain events on the power system supplying a drive can cause component
damage or shortened product life. These events include the following:
• 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.
General Grounding Requirements
See Ungrounded or Resistive
Grounded Installations on...
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 should be periodically checked.
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
General Installation Information 1-3
For installations within a cabinet, a single safety ground point or ground bus
bar connected directly to building steel should be used. All circuits
including the AC input ground conductor should be grounded
independently and directly to this ground point or ground bus bar.
Figure 1.1 Typical Grounding
R
S
(L2)
(L3)
T
(L1)
Required
Input Fusing
Required Branch
Circuit Disconnect
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 or joist), a floor ground
rod, or bus bar (Figure 1.1
and local industrial safety regulations and/or electrical codes.
Shield Termination - SHLD
PE
). Grounding points must comply with national
U
(T1)V(T2)W(T3)
DC
DC
+
BR1 BR2
–
The Shield terminal provides a grounding point for the motor cable shield.
It must be connected to an earth ground by a separate continuous lead. The
motor cable shield should be connected to this terminal on the drive (drive
end) and the motor frame (motor end). Use a shield terminating or EMI
clamp to connect shield to this terminal.
When shielded cable is used for control and signal wiring, the shield
should be grounded at the source end only, not at the drive end.
Wiring Requirements for the Drive
Certain drive requirements should be checked before continuing with the
drive installation. Wire sizes, branch circuit protection, encoder feedback
(for FVC regulation), and wiring to disable the drive are all areas that need
to be evaluated.
Operation of the drive can be disabled in two locations. The Gate Enable
terminal block on the front of the power structure can be used to disable the
firing of inverter IGBTs. When the Gate Enable signal is opened, inverter
IGBTs are disabled independent of any software control. This action also
generates fault 207 in the Inverter Power Module to enunciate this
condition. As a result of this fault, the Active Converter Power Module is
also turned off, but this is done via software operation. The firing of IGBTs
in the Active Converter Power Module can be disabled independently of any
software control by opening the connection between terminals 13 and 14 on
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
1-4 General Installation Information
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the Active Converter Power Module control cassette PCB assembly
terminal block P1. This action also generates a fault in the Inverter Power
Module to enunciate this condition.
Input Line Branch Circuit Protection
ATTENTION: Most codes require that upstream branch circuit
protection be provided to protect input power wiring.
The PowerFlex 700L Frame 2 drive does not provide input power
short circuit protection. Specifications for the recommended fuse
or circuit breaker to provide Frame 2 drive input power protection
against short circuits are provided in Tabl e A. F
Frame 3A and 3B complete drives include an input power circuit
breaker. The value of the circuit breaker provided with the drive is
listed in Table 1.A
Table 1.A AC Input Circuit Breaker Values for Frame 3A and 3B Complete Drives
.
and Tabl e A. G .
Power Wiring
Frame
Size
3A 400…480V AC 800 A 65 kAIC
3B 400…480V AC 1500 A 100 kAIC
Because most start-up difficulties are the result of incorrect wiring, take
every precaution to verify that the wiring is correct. Read and understand all
items in this section before beginning installation.
Cable Types Acceptable for 400-690 Volt Installations
Input Voltage
575…690V AC 800 A 35 kAIC
575…690V AC 1500 A 35 kAIC
ATTENTION: The following information is merely a guide for
proper installation. Rockwell Automation cannot assume
responsibility for the compliance or noncompliance to any code,
national, local, or otherwise for the proper installation of this
drive or associated equipment. A risk of personal injury and/or
equipment damage exists if codes are ignored during installation.
Circuit Breaker
Provided
Shunt Trip
Rating
ATTENTION: National Codes and standards (NEC, VDE, BSI,
and so forth) 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 may
result in personal injury and/or equipment damage.
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
General Installation Information 1-5
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 (167 °F). Do not
reduce wire gauge when using higher temperature wire.
Unshielded Cable
THHN, THWN, or similar wire is acceptable for drive installation in dry
environments provided adequate free air space and/or conduit fill rate limits
are used. Do not use THHN or similarly coated wire in wet areas. Any
wire chosen must have a minimum insulation thickness of 15 mils (0.4mm/
0.015 in.) and should not have large variations in insulation concentricity.
Shielded 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 should be given in installations with sensitive equipment such as
weigh scales, capacitive proximity switches, and other devices that may 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 communication/networking are also good candidates for
shielded cable.
Shielded cable may also help reduce shaft voltage and induced bearing
currents for some applications. In addition, the increased impedance of
shielded cable may help extend the distance the motor can be located from
the drive without the addition of motor protective devices such as terminator
networks. See Chapter 5, “Reflected Wave” in Wiring and Grounding
Guidelines for Pulse Width Modulated (PWM) AC Drives, publication
DRIVES-IN001.
Consideration should be given to all of the general specifications dictated by
the environment of the installation, including temperature, flexibility,
moisture characteristics, and chemical resistance. Additionally, a braided
shield should be included and 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
through AWG-410). This cable has three XLPE insulated conductors plus
ground with a spiral copper shield surrounded by a PVC jacket.
Other types of shielded cable are available, but the selection of these types
may limit the allowable cable length. Particularly, some of the newer cables
twist 4 conductors of THHN wire and wrap them tightly with a foil shield.
This construction can greatly increase the cable charging current required,
29528 - 29532 (AWG-1
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
1-6 General Installation Information
and reduce the overall drive performance. These cables are not
recommended.
Armored Cable
Cable with continuous aluminum armor is often recommended in drive
system applications or specific industries. It offers most of the advantages
of standard shielded cable and also combines considerable mechanical
strength and resistance to moisture. It can be installed in concealed and
exposed manners and removes the requirement for conduit (EMT) in the
installation. It can also be directly buried or embedded in concrete.
Because noise containment can be affected by incidental grounding of the
armor to building steel when the cable is mounted, we recommend that the
armor cable have an overall PVC jacket. For details, see Chapter 2, “Wire
Types” in Wiring and Grounding Guidelines for Pulse Width Modulated
(PWM) AC Drives, publication DRIVES-IN001.
Interlocked armor is acceptable for shorter cable runs, but continuous
welded armor is preferred.
Best performance is achieved with three spaced ground conductors, but
acceptable performance for drives below 200 HP is provided by way of a
single ground conductor.
Table 1.B Recommended Shielded or Armored Wire
Location Rating/Type Description
Standard
(Option 1)
Standard
(Option 2)
Class I & II;
Division I & II
1000V, 90 °C (194 °F)
XHHW2/RHW-2 Anixter
B29528-B29532, Belden
29528-29532, or
equivalent
Tray rated 1000V, 90 °C
(194 °F) RHH/RHW-2
Anixter
OLFLEX-76xxx03 or
equivalent
Tray rated 1000V, 90 °C
(194 °F) RHH/RHW-2
Anixter 7VFD-xxxx 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.
• corrugated copper tape 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.
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
General Installation Information 1-7
!
Cable Trays and Conduit
If cable trays or large conduits are to be used, see the guidelines in Wiring
and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives,
publication DRIVES-IN001.
ATTENTION: 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 should be
disabled. This helps to minimize the possible shock hazard from
“cross coupled” motor leads.
CE Conformity
Compliance with the Low Voltage (LV) Directive and Electromagnetic
Compatibility Directive (EMC) has been demonstrated using harmonized
European Norm (EN) standards published in the Official Journal of the
European Communities. PowerFlex 700L Liquid-Cooled AC drives comply
with the EN standards listed below when installed according to this
PowerFlex 700L Liquid-Cooled AC Drive User Manual, PowerFlex 700
Active Converter User Manual, PowerFlex 70/700 Reference Manual and,
depending on the equipped drive control option, either the PowerFlex 700 Series B User Manual or PowerFlex 700S Phase II Control User Manual.
CE Declarations of Conformity are available online at www.ab.com/
certification/ce/docs.
Low Voltage Directive (2006/95/EC)
EN50178 Electronic equipment for use in power installations.
EMC Directive (2004/108/EC)
EN61800-3 Adjustable speed electrical power drive systems - Part 3: EMC
requirements and specific test methods.
General Notes
• Without additional external filtering, PowerFlex 700L Liquid-Cooled
AC drives satisfy the 2nd Environment high-frequency emission limits of
EN61800-3. Without external mitigation, PowerFlex 700L
Liquid-Cooled drives are not intended to be used on a low-voltage public
network which supplies residential or office premises; radio frequency
interference is expected if used in such an environment.
• The drive motor cabling should be kept as short as possible to minimize
electromagnetic emission and capacitive currents.
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
1-8 General Installation Information
• Use of line filters in ungrounded systems is not recommended.
• Conformity of the drive with CE EMC requirements does not guarantee
an entire machine or installation complies with CE EMC requirements.
Many factors can influence total machine/installation compliance.
• Non-regenerative PowerFlex 700L Liquid-Cooled AC drives generate
conducted low frequency disturbances (harmonic emissions) on the AC
supply system which may require mitigation in some applications. More
information regarding harmonic emissions can be found in the
PowerFlex 70/700 Reference Manual, publication PFLEX-RM001.
• When operated on a public supply system, it is the responsibility of the
installer or user to make sure, by consultation with the distribution
network operator and Rockwell Automation, if necessary, that applicable
requirements have been met.
Essential Requirements for CE Compliance
Conditions 1 through 6 listed below must be accomplished for a
PowerFlex 700L drive installation to meet the requirements of EN61800-3.
1. Use a standard PowerFlex 700L Liquid-Cooled CE-compliant drive.
For the Frame 2 drive, kit Catalog Number SK-L1-CHK2-F2, which
includes common mode chokes and shielded cable clamps, must be
installed according to its included instructions, publication 20L-IN011.
For Frame 3A and 3B, the drive must be installed in a suitable enclosure
which attenuates radio frequency emissions (Rittal TS 8 or equivalent).
2. System grounding as described on page 1-2
3. Output power wiring to the motor, control (I/O) and signal wiring must
use cable with a braided shield with coverage of 75% or greater, or
cables must be contained in metal conduit, or equivalent shielding must
be provided.
4. All control (I/O) and signal wiring to the drive must use cable with a
braided shield providing 75% or greater coverage, or the cables be
housed in a metal conduit, or equivalent shielding must be provided.
When shielded cable is used, only the drive end of the cable shield
should be terminated with a low-impedance connection to earth.
5. The shields of all shielded cables must be terminated with the proper
shielded connectors to chassis/earth.
6. Motor cables must not exceed 20 meters (65.6 feet) in length.
.
7. Motor cabling must be separated from control and signal wiring
wherever possible.
8. Review important precautions and attention statements throughout this
manual before installing the drive.
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
General Installation Information 1-9
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C-Tick Conformity
Using Input/Output Contactors
Compliance of PowerFlex 700L Liquid-Cooled AC drives with the
Australian Radiocommunications Act of 1992 has been demonstrated
through compliance with EN61800-3. Both the General Notes and the
Essential Requirements for CE Compliance provided above apply to C-Tick
compliance for PowerFlex 700L Liquid-Cooled AC drives.
C-Tick Declarations of Compliance are available online at www.ab.com/
certification/c-tick/index.html.
Input Contactor Precautions
ATTENTION: A contactor or other device that routinely
disconnects and reapplies the AC line to the drive to start and stop
the motor can cause drive hardware damage. The drive is
designed to use control input signals that will start and stop the
motor. If an input device is used, operation must not exceed one
cycle per minute or drive damage will occur.
ATTENTION: The drive start/stop/enable control circuitry
includes solid-state components. If hazards due to accidental
contact with moving machinery, or unintentional flow of liquid,
gas, or solids exist, an additional hard-wired stop circuit may be
required to remove the AC line to the drive. An auxiliary braking
method may be required.
Output Contactor Precaution
ATTENTION: To guard against drive damage when using
output contactors, the following information must be read and
understood. One or more output contactors may 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 will be removed from the respective
motor, but the drive will continue 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 may
cause the drive to fault. If any of these conditions are determined
to be undesirable or unsafe, an auxiliary contact on the output
contactor should be wired to a drive digital input that is
programmed as “Enable.” This will cause the drive to execute a
coast-to-stop (cease output) whenever an output contactor is
opened.
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
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1-10 General Installation Information
Notes:
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
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Chapter 2
Frame 2 Installation
Topic Page
Mounting Considerations
Equipment Lifting 2-3
Mounting Requirements 2-6
Verifying the Drive’s Watts Loss Rating 2-7
Removing the Drive Cover 2-7
Removing the Active Converter Control Cassette 2-7
Removing the Inverter Control Cassette 2-8
Determining Wire Routing for Control, Ground, Drive Input, and Motor Output 2-9
Grounding the Drive 2-11
Ungrounded or Resistive Grounded Installations 2-11
Power Wir ing 2-12
Control Wiring 2-18
Synchronization Connections 2-20
DPI Connections for Frame 2 Drives 2-22
Coolant Loop Connections 2-22
2-1
Mounting Considerations
Because most start-up difficulties are the result of incorrect wiring, take
every precaution to verify that the wiring is completed as instructed. Read
and understand all items before starting actual installation.
ATTENTION: The following information is merely a guide for
proper installation. Rockwell Automation does not assume
responsibility or liability for the compliance or 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.
Total Area Required for Drive Installation
Overall drive dimensions are shown in Figure 2.1 as an aid in calculating
the total area required for installing Frame 2 drives.
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
2-2 Frame 2 Installation
46.9
(1.85)
66.6
(2.62)
423.8
(16.68)
955.7
(37.63)
Coolant Inlet
37 Deg Flare -12
Coolant Outlet
37 Deg Flare -12
566.1
(22.29)
389.6
(15.34)
351.0
(13.82)
153.8
(6.06)
591.2
(23.28)
730.2
(28.75)
See
DETAIL
A
See
DETAIL
B
DETAIL A DETAIL B
Ground Terminal
with 2 Clearance
Holes for M8 Stud
3x Clearance
Hole for
M8 Stud
W/T3
V/T2
U/T1
Motor
Output
Terminals
Stirring
Fan
Housing
4x Ø
8.5 (0.33)
4x Ø
15.0 (0.59)
16.0 (0.63)
4x
14.9 (0.59)
4x
8.6 (0.34)
4x
BACK VIEW SIDE VIEW FRONT VIEW
R/L1 S/L2 T/L3
AC Input Terminals
3x Clearance
Hole for
M8 Stud
Dimensions are in millimeters and (inches).
Figure 2.1 Frame 2 Drive Installation Dimensions
Approximate Weight
186 kg (410 lb)
Recommended Mounting Clearances
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
Specified vertical clearance requirements (Figure 2.2) are intended to be
from drive to drive. Other objects can occupy this space; however, reduced
air flow may cause protection circuits to fault the drive. In addition, inlet air
temperature must not exceed the product specification.
Figure 2.2 Frame 2 Drive Minimum Mounting Clearances
101.6 mm
(4.0 in.)
101.6 mm
(4.0 in.)
101.6 mm
(4.0 in.)
101.6 mm
(4.0 in.)
101.6 mm
(4.0 in.)
!
Frame 2 Installation 2-3
Equipment Lifting
Verifying Drive Input Ratings Match Supplied Power
It is important to verify that plant power meets the input power requirements
of the PowerFlex 700L Frame 2 drive circuitry. See Appendix
power rating specifications. Be sure input power to the drive corresponds to
the drive nameplate voltage and frequency.
This section explains how to lift the drive.
ATTENTION: To guard against possible personal injury and/or
equipment damage, observe the following:
• 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 any drive unit.
A for input
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
2-4 Frame 2 Installation
Attaching the Lifting Feet to the Drive
1. Remove the four shipping bolts that hold the drive to the skid.
2. Attach the two lifting feet provided with the drive to the bottom drive
mounting holes as shown in Figure 2.3
Figure 2.3 Attaching Lifting Feet to the Drive
.
Attaching the Lifting Hardware to the Drive
Apply lifting hooks (see Figure 2.4). Take precautions to verify that there
are lifting hooks secured in all four locations (Figure 2.5
Figure 2.4 Attaching Lifting Hardware to the Frame 2 Drive
) on the drive.
PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual
Publication 20L-UM001E-EN-P
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