PowerFlex® 700L Liquid-Cooled
Adjustable Frequency AC Drive
USER MANUAL
Important User
Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application, Installation and
Maintenance of Solid State Controls (Publication SGI-1.1 available from your local
Rockwell Automation sales office or online at
literature) describes some important differences between solid state equipment and
hard-wired electromechanical devices. Because of this difference, and also because of
the wide variety of uses for solid state equipment, all persons responsible for applying
this equipment must satisfy themselves that each intended application of this
equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of
information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety
considerations.
http://www.rockwellautomation.com/
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.
Important: Identifies information that is critical for successful application and
understanding of the product.
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 consequences.
Shock Hazard labels may be located on or inside the equipment
(e.g., drive or motor) to alert people that dangerous voltage may be
present.
Burn Hazard labels may be located on or inside the equipment
(e.g., drive or motor) to alert people that surfaces may be at
dangerous temperatures.
Allen-Bradley, PowerFlex, DPI, and DriveLogix are either registered trademarks or trademarks of Rockwell Automation, Inc.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Summary of Changes
The information below summarizes the changes to this manual since its last
release (July 2007):
Description of New or Updated Information Page(s)
Revised conditions in the “Essential Requirements for CE Compliance” section. 1-8
Corrected overall height dimension in Figure 2.1 and Detail A dimension. 2-2
In the Equipment Lifting section, added subsection “Attaching the Lifting Feet to the Drive.” 2-4
Added Frame 2 information to remove PowerFlex 700S Phase II Control cassette. 2-8
Added Frame 2 “Selecting/Verifying Control Transformer Voltage” section. 2-12
In Figure 2.14, added Frame 2 TB1 details when TB4 is not present. 2-19
Added Frame 2 control synchronization information for 700S Phase II Control. 2-21
Added new information for Frame 3A and 3B to install the vented top cover. 3-16
Added “Selecting/Verifying Control Transformer Voltage” section for Frame 3A & 3B. 3-23
Updated Table 4.A and Table 4.G. 4-5 and 4-8
Added action to take for Table 6.B and 6.C. 6-4 and 6-5
Added PowerFlex 700S Phase II Control information to specifications. A-2 and A-3
Added Derating Guidelines. A-4
Added Tables A.H, A.I, A.J, and H.K for Frame 3A and 3B common bus inverter power module DC input fusing. A-7 and A-8
Added new schematic for Frame 2 drive without TB4 connections. B-4
PowerFlex® 700L Liquid-Cooled Drive User Manual
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PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
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
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Complete Drive Data Nameplate Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-7
Frame 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-7
Frames 3A and 3B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
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
Equipment Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
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
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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
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/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
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
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Grounding the Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Ungrounded or Resistive Grounded Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Disconnecting the 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/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
Recommended Cooling Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Liquid-to-Liquid Heat Exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Drive Coolant Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Recommended Coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Corrosion Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Biocide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Drive Cooling Loop Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Cooling Loop Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Drive Coolant Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Frame 2 Drive or Frame 3A or 3B Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Frame 3A or 3B Complete Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Chapter 5 Programming and Parameters
Affected 700 Vector Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Utility File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Communication File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
iv Table of Contents
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Converter Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
700 Vector Control Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
700S Phase II Control Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Clearing Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Alarm Descriptions (700S Phase II Control only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
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-4
Horsepower/Current Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Watts Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Fuse and Circuit Breaker Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Fusing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Appendix B Frame 2 Schematic
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 Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Preface
Overview
The purpose of this manual is to provide you with the basic information
needed to install, start-up, and troubleshoot the PowerFlex 700L
Liquid-Cooled AC Drive.
For information on ... See page ...
Who Should Use this Manual?
What Is Not in this Manual P-1
Reference Materials 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.
The PowerFlex 700L User 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, please refer to 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, please
refer to 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,
please refer to the PowerFlex 700S High Performance AC Drive - Phase II
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
P-2 Overview
Control User Manual (publication 20D-UM006) which provides I/O
wiring, start-up, programming, and other related information.
HIM (Human Interface Module) Information
For an overview of the HIM operation, please refer to 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, please refer to the adapter User Manual (publication
20COMM-UM) for information on configuring and using I/O and explicit
messaging over the network.
PowerFlex 700L Service Information
For Frame 2 drive service information, please refer to the PowerFlex 700L
Liquid-Cooled Adjustable Frequency AC Drive Frame 2 Hardware Service
Manual (publication 20L-TG002).
Reference Materials
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 70/700 Reference Manual PFLEX-RM001
Safety Guidelines for the Application, Installation, and Maintenance of Solid State Control SGI-1.1
A Global Reference Guide for Reading Schematic Diagrams 0100-2.10
Guarding Against Electrostatic Damage 8000-4.5.2
For Frame 3A and 3B drive service information, please refer to the
PowerFlex 700L Liquid-Cooled Adjustable Frequency AC Drive Frames 3A
and 3B Hardware Service Manual (publication 20L-TG001).
You can view or download publications at www.rockwellautomation.com/
literature. 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 www.rockwellautomation.com/locations
For information such as firmware updates or answers to drive-related
questions, go to the Drives Service & Support website at www.ab.com/
support/abdrives and click on the “Downloads” or Knowledgebase” link.
The following publications provide general drive information:
.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Overview P-3
The following publications provide specific feedback card information for
PowerFlex 700L drives with Optional 700S Phase II Control:
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
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 1786-5.7
ControlNet Cable System Planning and Installation Manual 1786-6.2.1
ControlNet Fiber Media Planning and Installation Guide CNET-IN001
SynchLink™ Design Guide 1756-TD008
Manual Conventions
• 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 are used throughout the manual to describe an
action:
Word Me aning
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 Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
P-4 Overview
General Precautions
ATTENTION: This drive contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Static control precautions are
!
required when installing, testing, servicing or repairing this
assembly. Component damage may result if ESD control
procedures are not followed. If you are not familiar with static
control procedures, refer to Allen-Bradley publication 8000-4.5.2,
“Guarding Against Electrostatic Damage” or any other applicable
ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can
result in component damage or a reduction in product life. Wiring
!
or application errors, such as undersizing the motor, incorrect or
inadequate AC supply, or excessive ambient temperatures may
result in malfunction of the system.
ATTENTION: Only qualified personnel familiar with adjustable
frequency AC drives and associated machinery should plan or
!
implement the installation, start-up, and subsequent maintenance
of the system. Failure to comply may result in personal injury and/
or equipment damage.
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged 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
3.27 for Frame 3B. The voltage must be zero.
for Frame 2, Figure 3.25 for Frame 3A, or Figure
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 Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Overview P-5
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 defghi jklmn
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 ♠
5 Programmer Only 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
DPI
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
R RIO - DPI ‡ 20-COMM-R
S RS-485 DF-1 - DPI ‡ 20-COMM-S
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.
User-Install
ed Kit Cat.
No. ✧
—
—
—
—
—
—
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-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 defghi 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 Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Overview P-7
Complete Drive Data Nameplate Locations
Frame 2
Figure P.2 shows multiple data nameplate locations for the drive. 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
Cat No.
20LC360N3ENNAN10WA
NEMA Type
Complete Regenerative Drive
Nominal Voltage
Normal Duty Power
Input: 3 Phase, 47-63 Hz
AC Voltage Range
Amps
Output: 3 Phase, 0-400Hz
AC Voltage Range
Base Hz (default)
Continuous Amps
Rated Coolant
Nom. Coolant Pressure
MFD. in 2007 on JUL 05
Made in the U.S.A. (FAC1C)
Series: A
Original Firmware V. x.xxx
Frame: 2
Serial Number: MEAE2WJ0
SIDE VIEW
Cat No.
20LC360N3ENNAN10WA
NEMA Type
Complete Regenerative Drive
Nominal Voltage
Normal Duty Power
Input: 3 Phase, 47-63 Hz
AC Voltage Range
Amps
Output: 3 Phase, 0-400Hz
AC Voltage Range
Base Hz (default)
Continuous Amps
Rated Coolant
Nom. Coolant Pressure
MFD. in 2007 on JUL 05
Made in the U.S.A. (FAC1C)
Series: A
Original Firmware V. x.xxx
Frame: 2
Serial Number: MEAE2WJ0
FRONT VIEW (Cover Removed)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
P-8 Overview
Frames 3A and 3B
Figure P.2 shows multiple data nameplate locations for the complete drive.
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
Input Filter Assembly
(Label on inside front of door)
Cat No.
20LE800N0NNNCNW0WN
UL Open Type/IP00
Input Filter Assembly
Nominal Voltage
Normal Duty Power
Input: 3 Phase, 47-63 Hz
AC Voltage Range
Amps
Output: 3 Phase, 47-63 Hz
AC Voltage Range
Base Hz (default)
Continuous Amps
Rated Coolant
Nom. Coolant Pressure
MFD. in 2005 on MAR 05
Made in the U.S.A. (FAC1C)
P/N 181255-A01
Input
Filter Bay
Converter Power Module
Cat No.
20LE800N0NNNGNW0WA
UL Open Type/IP00
Converter Power Module
Nominal Voltage
Normal Duty Power
Input: AC, 47-63 Hz
DC Voltage Range
Amps
Output: DC
DC Voltage Range
Base Hz (default)
Continuous Amps
Rated Coolant
Nom. Coolant Pressure
MFD. in 2005 on MAR 05
Made in the U.S.A. (FAC1C)
P/N 181255-A01
600V
870HP
518-633
800
518-633
N.A.
800
N.A.
N.A.
Power
Module Bay
600V
870HP
518-633
800
730-900
N.A.
800
Treated Water
185 psig
Series: A
Original Firmware V. 2.005
C
TUV
Rheinland
Production inspected
Product Safety
EN 50178
TUV
TUV Rheinland
of North America
Bauart gepruft
TUV
Rheinland
Frame: 3B
Serial Number: MEAE2WJ0
Type approved
Power Module Front,
Bottom Covers Removed
Series: A
Original Firmware V. 2.005
C
TUV
Rheinland
Production inspected
Product Safety
EN 50178
TUV
TUV Rheinland
of North America
Bauart gepruft
TUV
Rheinland
Frame: 3B
Serial Number: MEAE2WJ0
Type approved
R
US
Functional
Safety
Power Module
Bay Door
Cutaway
R
US
Functional
Safety
Complete Regenerative Drive
(Label on inside front of door)
Cat No.
20LE800ACENNA6DELA
NEMA Type 1/IP20
Complete Regenerative Drive
Nominal Voltage
Normal Duty Power
Input: 3 Phase, 47-63 Hz
AC Voltage Range
Amps
Output: 3 Phase, 0-400Hz
AC Voltage Range
Base Hz (default)
Continuous Amps
Rated Coolant
Nom. Coolant Pressure
MFD. in 2005 on MAR 05
Made in the U.S.A. (FAC1C)
P/N 181255-A01
600V
870HP
518-633
800
0-600
60 Hz
800
Treated Water
100 psig
Series: A
Original Firmware V. 2.005
Frame: 3B
Serial Number: MEAE2WJ0
Inverter Power Module
Cat No.
20LE800N0NNNJND0LA
UL Open Type/IP00
Inverter Power Module - Coupled With Converter
Nominal Voltage
Normal Duty Power
Input: DC
DC Voltage Range
Amps
Output: 3 Phase, 0-400Hz
AC Voltage Range
Base Hz (default)
Continuous Amps
Rated Coolant
Nom. Coolant Pressure
MFD. in 2005 on MAR 05
Made in the U.S.A. (FAC1C)
P/N 181255-A01
600V
870HP
730-900
800
0-600
60 Hz
800
Treated Water
185 psig
Series: A
Original Firmware V. 2.005
Frame: 3B
Serial Number: MEAE2WJ0
Inverter Power Module
FIELD INSTALLED OPTIONS
Firmware
Firmware
20-HIM-
20-I/O20-COMM20B_-DB1-
# :
# :
Date:
Date:
HIM
I/O
COMM Module
Internal Dynamic Brake
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.
Rheinland
Product Safety
TUV
TUV Rheinland
of North America
TUV
Rheinland
C
Rheinland
Product Safety
TUV
TUV Rheinland
of North America
TUV
Rheinland
N223
TUV
TUV
C
Listed
Ind. Cont.
Eq. 966X
Production inspected
EN 50178
Bauart gepruft
Functional
Type approved
Production inspected
EN 50178
Bauart gepruft
Functional
Type approved
R
US
Safety
R
US
Safety
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Chapter 1
General Installation Information
This chapter provides general information on mounting and wiring the
PowerFlex 700L Liquid-Cooled AC Drive.
For information on ... See page ...
Enclosure Ratings
AC Supply Source Considerations 1-1
Power Wiring 1-4
CE Conformity 1-7
C-Tick Conformity 1-8
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
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
PowerFlex® 700L Liquid-Cooled Drive User Manual
.
Publication 20L-UM001D-EN-P
1-2 General Installation Information
Unbalanced, Ungrounded or Resistive Grounded Distribution Systems
If phase-to-ground voltage will exceed 125% of normal or the supply
system is ungrounded, refer to Wiring and Grounding Guidelines for Pulse
Width Modulated (PWM) AC Drives (publication DRIVES-IN001) for more
information.
!
When installing a...
Frame 2 drive Page 2-11
Frame 3A or 3B drive Page 3-22
ATTENTION: PowerFlex 700L Liquid Cooled Frame 2, Frame
3A, and Frame 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.
Refer to Ungrounded or Resistive
Grounded Installations on...
Input Power Conditioning
Certain events on the power system supplying a drive can cause component
damage or shortened product life. They are:
• 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
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.
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 point/bar.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
General Installation Information 1-3
Figure 1.1 Typical Grounding
R
S
(L2)
T
(L3)
(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, joist), a floor ground
rod or bus bar (Figure 1.1
and local industrial safety regulations and/or electrical codes.
PE
). Grounding points must comply with national
U
(T1)V(T2)W(T3)
DC
DC
+
BR1 BR2
–
Shield Termination - SHLD
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
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.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
1-4 General Installation Information
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 Table 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
.
and Table A.G.
Power Wiring
Frame
Size
3A 400-480V AC 800 A 65 kAIC
3B 400-480V AC 1500 A 100 kAIC
Since most start-up difficulties are the result of incorrect wiring, take every
precaution to assure 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, Inc. 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.
ATTENTION: 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 may result in personal
injury and/or equipment damage.
Circuit Breaker
Provided
Shunt Trip
Rating
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
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
General Installation Information 1-5
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 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 (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 communications/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. Refer to 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. In addition, a braided
shield should be included and specified by the cable manufacturer as having
coverage of at least 75%. An additional foil shield can be greatly improve
noise containment.
A good example of recommended cable is Belden® 29528 - 29532 (AWG-1
through AWG-410). This cable has 3 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
and reduce the overall drive performance. These cables are not
recommended.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
1-6 General Installation Information
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, it is recommended the
armor cable have an overall PVC jacket. See Chapter 2, “Wire Types” in
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC
Drives (publication DRIVES-IN001) for details.
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 below 200 HP is provided via a single ground
conductor.
Table 1.B Recommended Shielded/Armored Wire
Location Rating/Type Description
Standard
(Option 1)
Standard
(Option 2)
Class I & II;
Division I & II
Cable Trays and Conduit
If cable trays or large conduits are to be used, refer to guidelines presented
in Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC
Drives (publication DRIVES-IN001).
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 Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
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 will help minimize the possible shock hazard from
“cross coupled” motor leads.
General Installation Information 1-7
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 700 - Series B User Manual or
PowerFlex 700S Phase II Control User Manual, and PowerFlex 70/700
Reference 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 cable should be kept as short as possible in order to
minimize electromagnetic emission and capacitive currents.
• 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 ensure, by consultation with the distribution network
operator and Rockwell Automation, if necessary, that applicable
requirements have been met.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
1-8 General Installation Information
Essential Requirements for CE Compliance
Conditions 1-6 listed below must be satisfied for PowerFlex 700L
Liquid-Cooled AC drives to meet the requirements of EN61800-3:
1. 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
employ cable with a braided shield with coverage of 75% or greater, or
cables must be housed 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/attention statements throughout this
manual before installing the drive.
.
C-Tick Conformity
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
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
General Installation Information 1-9
Using Input/Output Contactors
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 hardwired 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 Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
1-10 General Installation Information
Notes:
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Chapter 2
Frame 2 Installation
For information on… See 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 Wiring 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
Most start-up difficulties are the result of incorrect wiring. Every precaution
must be taken to assure that the wiring is done as instructed. All items must
be read and understood before actual installation begins.
ATTENTION: The following information is merely a guide for
proper installation. Rockwell Automation, Inc. 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.
Total Area Required for Drive Installation
Overall drive dimensions are illustrated in Figure 2.1 as an aid in calculating
the total area required for installing Frame 2 drives.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
2-2 Frame 2 Installation
Figure 2.1 Frame 2 Drive Installation Dimensions
730.2
(28.75)
(6.06)
591.2
(23.28)
153.8
389.6
(15.34)
(13.82)
Dimensions are in millimeters and (inches).
351.0
See
DETAIL
A
See
DETAIL
B
566.1
(22.29)
Coolant Outlet
37 Deg Flare -12
with 2 Clearance
Holes for M8 Stud
955.7
(37.63)
Coolant Inlet
37 Deg Flare -12
Ground Terminal
66.6
(2.62)
Motor
Output
Terminals
3x Clearance
Hole for
M8 Stud
3x Clearance
Hole for
M8 Stud
W/T3
V/T2
U/T1
423.8
(16.68)
R/L1 S/L2 T/L3
AC Input Terminals
46.9
(1.85)
Stirring
Fan
Housing
4x Ø
15.0 (0.59)
BACK VIEW SIDE VIEW FRONT VIEW
4x Ø
8.5 (0.33)
16.0 (0.63)
4x
DETAIL A DETAIL B
Approximate Weight kg (lbs.)
186 (410)
8.6 (0.34)
4x
14.9 (0.59)
4x
Recommended Mounting Clearances
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.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Figure 2.2 Frame 2 Drive Minimum Mounting Clearances
Frame 2 Installation 2-3
101.6 mm
(4.0 in.)
101.6 mm
(4.0 in.)
101.6 mm
(4.0 in.)
Verifying Drive Input Ratings Match Supplied Power
It is important to verify that plant power will meet the input power
requirements of the PowerFlex 700L Liquid-Cooled Frame 2 drive’s
circuitry. See Appendix
input power to the drive corresponds to the drive nameplate voltage and
frequency.
A for input power rating specifications. Be sure
101.6 mm
(4.0 in.)
101.6 mm
(4.0 in.)
Equipment Lifting
This section explains how to lift the drive.
ATTENTION: 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 any drive unit.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
2-4 Frame 2 Installation
Attaching the Lifting Feet to the Drive
1. Remove the four (4) 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 ensure that there
are lifting hooks secured in all four (4) locations (Figure 2.5
Figure 2.4 Attaching Lifting Hardware to the Frame 2 Drive
) on the drive.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
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