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
Frame 2 Installation 2-5
Connecting Lifting Hooks to Proper Locations
Locate all four (4) lifting features on the drive (see Figure 2.5). All four (4)
locations must be used to maintain the drive center of gravity when lifting.
Figure 2.5 Lifting Locations on the Frame 2 Drive
Applying Strap Angles
TIP: To ensure that this angle is greater than 60°, make the length of chain
or cable between the center and the corners (B) longer than the distance
between the opposite corners (A).
B > A
Min. 60°
A
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
2-6 Frame 2 Installation
Rotating the Drive About the Board
Figure 2.6 shows the drive, with the lifting feet attached, on a skid. To avoid
damage to the drive input terminals when lifting the drive to a vertical
position, do the following:
Mounting Requirements
1. After the straps are in place (see Applying Strap Angles
carefully lift the drive to rotate it 90° to a vertical position.
2. Remove the lifting feet before installing the drive into the enclosure.
Figure 2.6 Frame 2 Drive on Skid
The PowerFlex700L Frame 2 drive is a single integrated assembly
consisting of a filter section and a power section. The filter section provides
the mounting feet and represents greater than 50% of the approximate 186
kg (410 lb.) total weight.
on page 2-5),
Input Terminals
Lifting Feet
Skid
1. The Frame 2 drive should be mounted into an enclosure that is designed
according to Electrical Equipment Pollution Degree 2 requirements.
2. Any enclosure mounting panel needs to be sized and fastened
appropriately to accommodate for the weight of the drive.
3. The Frame 2 drive is designed to use eight M8 x 1.25 fasteners in
mounting slots shown in Detail A and Detail B of Figure 2.1
4. The M8 x 1.25 fasteners shall be class 5.8 or greater.
5. The fasteners shall use a lock washer or similar mechanism to prevent
loosening after mounting.
6. All M8 x 1.25 fastener threads shall engage a steel panel with 6 - 7 full
threads or a permanent backing nut such as a weld nut or a
self-clinching PEM
7. M8 x 1.25 fasteners shall be tightened to 11.3 ± 2.8 N•m (100 ± 25
in•lbs) unless the lock washer mechanism requires a different torque. If
this is the case, the holding force shall be equivalent.
(1)
PEM is a registered trademark of PennEngineering.
®(1)
nut with 4 full threads.
.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Frame 2 Installation 2-7
Verifying the Drive’s Watts Loss Rating
Removing the Drive Cover
When mounting the drive inside of an enclosure, you should determine the
watts loss rating of the drive from Table A.E on page A-6
the typical full load power loss watts value at 4 kHz (rated carrier
frequency). Ensure that the enclosure is adequately ventilated with 0-50°C
(32-122°F) ambient air based on the drive’s watts loss rating.
(5 Captive Screws)
. This table lists
Removing the Active Converter Control Cassette
(For use with 700S Phase II Control only)
Synchronization Cable
(For use with 700 Vector Control only)
The Frame 2 regenerative-type drive is equipped with an Active Converter
control cassette. Figure 2.7
to access its terminal blocks for control wiring. Refer to the PowerFlex 700
Active Converter Power Module User Manual (publication
PFLEX-UM002) for control wiring details.
Figure 2.7 Removing the Frame 2 Active Converter Control Cassette
Synchronization Cable
Internal DPI Cable
shows the location and removal of this cassette
Pin 1
40-Pin
Ribbon Cable
Detail
P1
P2
Communications
Adapter Option
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
2-8 Frame 2 Installation
Removing the Inverter Control Cassette
For Frame 2 drives, the Inverter is equipped with either the standard
PowerFlex 700 Vector Control cassette or an optional PowerFlex 700S
Phase II Control cassette. In either case, the cassette is removed in the same
way.
PowerFlex 700 Vector Control Cassette (standard)
Figure 2.8 shows the location and removal of the drive’s standard
PowerFlex 700 Vector Control cassette to access its terminal blocks for
control wiring. Refer to the PowerFlex 700 Adjustable Frequency AC Drive
User Manual - Series B (publication 20B-UM002) for control wiring
details.
Figure 2.8 Removing the Standard PowerFlex 700 Vector Control Cassette
Pin 1
Detail
Communications
Adapter Option
PowerFlex 700S Phase II Control Cassette (optional)
Figure 2.9 shows the location and removal of the drive’s optional PowerFlex
700S Phase II Control cassette to access its terminal blocks for control
wiring. Please refer to the PowerFlex 700S High Performance AC Drive -
Phase II Control User Manual (publication 20D-UM006) for control wiring
details.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Frame 2 Installation 2-9
Figure 2.9 Removing the Optional PowerFlex 700S Phase II Control Cassette
Detail
TB1 Terminals
TB2 Terminals
Communications
Adapter Option
Determining Wire Routing for Control, Ground, Drive Input, and Motor Output
All wiring should be installed in conformance with the applicable local,
national, and international codes (e.g., NEC/CEC). Signal wiring, control
wiring, and power wiring must be routed in separate conduits to prevent
interference with drive operation. Use grommets, when hubs are not
provided, to guard against wire chafing.
ATTENTION: Do not route signal and control wiring with
power wiring in the same conduit. This can cause interference
!
with drive operation. Failure to observe this precaution could
result in damage to, or destruction of, the equipment.
Do not route more than three sets of motor leads through a single conduit.
This will minimize cross-talk that could reduce the effectiveness of noise
reduction methods. If more than three drive/motor connections per conduit
are required, shielded cable must be used. If possible, each conduit should
contain only one set of motor leads.
ATTENTION: Unused wires in conduit must be grounded at
both ends to avoid a possible shock hazard caused by induced
!
voltages. Also, if a drive sharing a conduit is being serviced or
installed, all drives using this conduit should be disabled to
eliminate the possible shock hazard from cross-coupled motor
leads. Failure to observe these precautions could result in bodily
injury.
Figure 2.10 shows locations for Frame 2 control wire routing, ground, drive
input, motor output, DPI communications ports/cable routing, and coolant
connections.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
2-10 Frame 2 Installation
Dimensions are in millimeters and (inches).
Figure 2.10 Frame 2 Drive Locations for Control Wire Routing, DPI Communications
Port, and Coolant Connections
12.6
28.0
(1.10)
Control Wire
Conduit Plug
62.7 (2.47) Dia.
223.2
(8.79)
222.0
(8.74)
152.0
(5.98)
280.5
(11.04)
112.0
(4.41)
72.0
(2.83)
(0.50)
Control Wire
Conduit Plug
22.2 (0.87) Dia.
DPI Communications
Port
Coolant Inlet
Coolant Outlet
Bottom View
of Drive
R/L1 S/L2 T/L3
199.9
257.1
(10.12)
(7.87)
Bottom Drive Cover
290.4
(11.43)
245.8
(9.68)
481.8
(18.97)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Frame 2 Installation 2-11
Grounding the Drive
Ungrounded or Resistive Grounded Installations
ATTENTION: The user is responsible for conforming with all
applicable local, national, and international codes. Failure to
!
observe this precaution could result in damage to, or destruction
of, the equipment.
The customer must supply a grounding conductor between the ground lug
of the drive and the ground lug in the cabinet. For PE ground terminal
location, refer to Figure 2.15
recommended torque shown in Table 2.B
PowerFlex 700L Frame 2 drives are equipped with a common mode
capacitor and MOV that are referenced to ground. To guard against drive
damage, this capacitor and MOV should be disconnected if the drive is
installed on a resistive ground or ungrounded distribution system.
Disconnecting the Common Mode Capacitor
To disconnect the 1 µF common mode capacitor from the circuit, refer to
Figure 2.11
and:
. Tighten the ground connection to the
.
1. Disconnect the Faston wire from the 1 µF common mode capacitor.
2. Insulate the wire end by applying a wire nut or electrical tape.
3. Tie wrap the disconnected wire to keep it away from any electrical
connections.
Disconnecting the MOV from Ground
To disconnect the MOV from ground, refer to Figure 2.11 and:
1. Unbolt the ground wire lug from the MOV’s ground connection point.
Screw the bolt back into the panel.
2. Cut the lug off the disconnected ground wire and apply a wire nut to its
end.
3. Tie wrap the disconnected ground wire to keep it away from any
electrical connections.
Refer to Wiring and Grounding Guidelines for Pulse Width Modulated
(PWM) AC Drives (publication DRIVES-IN001) for more information on
ungrounded distribution systems. Note: Removing the Common Mode
capacitor and input MOVs makes the drive more vulnerable to high voltage
line spikes.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
2-12 Frame 2 Installation
Figure 2.11 Removing Common Mode Capacitor and MOV
Common Mode
Capacitor Removal
Power Wiring
Side View of Drive
MOV Removal
This section describes incoming line components and how to install them,
and provides instructions on wiring input power, output contactors, motor
overload protection, and output wiring to the motor.
Installing Transformers and Reactors (Not Recommended)
Frame 2 drives may be used on distribution systems with 200,000 amps or
less symmetrical fault current capacity. The drive input components consist
of a 3% line reactor and a harmonic line filter. Additional input inductance
is not recommended.
Selecting/Verifying Control Transformer Voltage
A control transformer is used to match the input line voltage of the drive to
the 115V control voltage. If your line voltage is different than the voltage
class specified on the drive nameplate, it may be necessary to change
transformer taps as described below.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
1. Unfasten seven screws and remove the bottom drive cover
(Figure 2.10
).
Frame 2 Installation 2-13
Figure 2.12 Removing the Bottom Drive Cover
2. Remove the power section stirring fan. Unfasten two bracket screws,
disconnect the fan power leads (two fastons), and lift the fan from the
drive (Figure 2.13
).
Figure 2.13 Removing the Power Section Stirring Fan
3. Depending on the supplied AC line voltage used to power the drive,
refer to Table 2.A
Table 2.A Control Transformer Tap Usage
AC Line Voltage Transformer Tap To Use
380V AC
440V AC
460V AC
480V AC
and determine which transformer tap to use.
400V400V AC
480V
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
2-14 Frame 2 Installation
4. Pull the faston from the present tap and push it onto the appropriate tap.
Verify that the faston is fully seated on the tap.
TIP: Do not bend the faston. A straight blade screwdriver helps to
remove the faston by carefully prying on the bottom edge of the faston.
Figure 2.14 Control Transformer Voltage Taps
690V
600V
480V
400V
5. Reinstall the power section stirring fan. Connect power to the fan power
leads before fastening the two bracket screws.
6. Reinstall the bottom drive cover by fastening the six screws.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Frame 2 Installation 2-15
Installing Input Power Wiring to the Drive
Use the following steps to connect AC input power to the drive:
ATTENTION: Do not route signal and control wiring with
power wiring in the same conduit. This can cause interference
!
with drive operation. Failure to observe this precaution could
result in damage to, or destruction of, the equipment.
1. Connect the three-phase AC input power leads (three-wire 380-480V
AC) to the R/L1, S/L2, and T/L3 input power terminals on the Frame 2
drive. For terminal locations, refer to Figure 2.15
2. Tighten the AC input power terminal connections to the recommended
torque as shown in Table 2.B
Table 2.B Frame 2 Drive Power Terminal Specifications
.
.
Item Name Description
Input Power Bus Bar
➊
R/L1, S/L2, T/L3
Output Power Bus Bar
➋
U/T1, V/T2, W/T3
PE, Motor Ground Bus Bar
➌
DC Bus Test Point Socket
➍
(2 Terminals; DC+, DC-)
(1)
Apply counter torque to the nut on the other side of terminations when tightening or loosening the terminal bolt
to avoid damage to the terminal.
(2)
These connections are bus bar type terminations and require the use of lug connectors.
(3)
Use only to verify that DC bus capacitors are discharged before servicing the Power Module. No other external
use is permitted.
(2)
Input power 40 N•m
(2)
Motor connections 40 N•m
(2)
Terminating point for wiring
shields and grounds
(3)
4 mm socket for DC bus voltage
measurement only
Recommended
Tightening
Torque (+
(354 lb•in)
(354 lb•in)
40 N•m
(354 lb•in)
——
10%)
Termi nal
Bolt Size
M8
M8
M8
(1)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
2-16 Frame 2 Installation
➌
W/T3
➋
V/T2
U/T1
Figure 2.15 Frame 2 Drive Power Terminal Locations
➍
DC+
Testpoint
DC-
Testpoint
AA
Section A-A
T/L3S/L2R/L1
➊
Installing Mechanical Motor Overload Protection (Optional)
To provide the motor with overload protection, local, national, and
international codes (e.g., NEC/CEC) may require one of the following:
• a motor thermostat be installed internal to the motor.
• a mechanical thermal motor overload relay, sized to protect the motor, be
installed between the motor and the drive’s output terminals.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
In multiple motor applications (V/Hz regulation only), each motor must
have its own user-supplied overload and branch circuit protection.
Frame 2 Installation 2-17
Installing Output Wiring from the Drive Output Terminals to the Motor
Important: See the PowerFlex 700L Technical Data, publication
20L-TD001, for motor lead length restrictions.
Use the following steps to connect the AC output power wiring from the
drive to the motor:
1. Route the three-phase AC output power motor leads to the drive power
module.
Do not route more than three sets of motor leads through a single
conduit. This will minimize cross-talk that could reduce the
effectiveness of noise reduction methods. If more than three drive/motor
connections per conduit are required, shielded cable must be used. If
possible, each conduit should contain only one set of motor leads.
ATTENTION: Do not route signal and control wiring with
power wiring in the same conduit. This can cause interference
!
with drive operation. Failure to observe these precautions could
result in damage to, or destruction of, the equipment
ATTENTION: Unused wires in conduit must be grounded at
both ends to avoid a possible shock hazard caused by induced
!
voltages. Also, if a drive sharing a conduit is being serviced or
installed, all drives using this conduit should be disabled to
eliminate the possible shock hazard from cross-coupled motor
leads. Failure to observe these precautions could result in bodily
injury.
2. Connect the three-phase AC power motor leads to the U/T1, V/T2, and
W/T3 output power terminals. For terminal locations, see Figure 2.15
Tighten the AC output power terminal connections to the proper torque
as shown in Table 2.B
.
.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
2-18 Frame 2 Installation
Control Wiring
Item Name Description
Active Converter Cassette
➊
Terminal Blocks—P1 & P2
SHLD Terminal Terminating point for control wiring shields on the
➋
Terminal Block—TB1
➌
➍
(1)
1b 5: +12/+24V Cooling Loop
1b 6: Cooling Loop Return
1b 7: +24V (digin) Drive-supplied +24V DC
1b 8: Gate Enable Enables the firing of the IGBTs.
PS- Terminal
PS+ Terminal
Maximum/minimum sizes that the terminals will accept - these are not recommendations.
This section provides details on control wiring to the drive.
ATTENTION: Risk of equipment damage exists. Do not use
drive terminal blocks TB5-1 and TB5-3 to connect any type of
!
power wiring for auxiliary equipment. These terminals are for
low amperage control wiring only.
ATTENTION: Do not route signal and control wiring with
power wiring in the same conduit. This can cause interference
!
with drive operation. Failure to observe this precaution could
result in damage to, or destruction of, the equipment.
Connect wiring to terminals in accordance with Table 2.C
the Frame 2 drive schematic on page B-2
Table 2.C Frame 2 Drive Control Wiring Terminal Specifications
Active Converter AC power and control wiring 3.3 mm
drive
Drive control wiring:
Output dry contact (12V DC/24V DC, 2 Amps
max.) indicating the drive is powered and has
completed precharge.
Factory-installed jumper from terminal 1b 7 to
terminal 1b 8 allows firing of the IGBTs.
300V DC Auxiliary Control voltage 4.0 mm
.
Wire Size Range
Maximum Minimum
2
(#12 AWG)
2
2.1 mm
(#14 AWG)
2
4.0 mm
(#10 AWG)
2
(#12 AWG)
(1)
0.3 mm
(#22 AWG)
0.3 mm
(#22 AWG)
0.2 mm
(#24 AWG)
0.5 mm
(#22 AWG)
Recommended
Tightening
Torque (+10%)
2
0.8 N•m
(7 lb•in)
2
1.4 N•m
(12 lb•in)
2
0.9 N•m
(8 lb•in)
2
0.6 N•m
(5.3 lb•in)
, Figure 2.16, and
Wire Strip
Length
8 mm
(0.31 in.)
10 mm
(0.39 in.)
8 mm
(0.31 in.)
10 mm
(0.39 in.)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Frame 2 Installation 2-19
Figure 2.16 Frame 2 Drive Control Wiring Terminal Locations
➊
TB1
1
P1
15
7
P2
1
TB4 (NOTE: On drives without TB4,
there are additional terminals on TB1.)
SHLD
SHLD
➌
➋
➍
1a15
1b15
TB1
1a14
1b14
➌
1a9
1a8
1a13
1a12
1a11
1a10
1b13
1b12
1b11
1b10
Customer Connection Side
TB1 When TB4 is Not Present
1a7
1b9
1b8
1b7
1a 8
1a 9
1a 10
1a 11
1a 12
1b 7
1b 8
1b 9
1b 10
1b 11
1b 12
➍
PE1PE2
PS+
1a6
1a5
1a4
1a3
1b6
1b5
1b4
1b3
PS-
1a2
1a1
PS+
PS-
1b2
1b1
PE1PE2
Customer Connection Side
TB1 When TB4 is Present
1a 4
1b 5
1b 6
1b 4
1a 1
1a 2
1a 3
PS-
PS+
1b 1
1b 2
1b 3
1a 5
1a 6
1a 7
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
2-20 Frame 2 Installation
Synchronization Connections
Coupled Power Modules
Frame 2 combined Converter/Inverter Power Modules are only configured
as coupled power modules. Coupling the Converter and Inverter is achieved
by using two factory-installed cables: a control synchronization cable and
an inverter-to-converter DPI communication cable. The two cables are
described in the next two subsections.
Control Synchronization Cable
To enable synchronization between the Inverter control printed circuit board
and the Converter control printed circuit board, a factory-installed control
synchronization cable connects each board. No user connection is required.
However, the connection method is different for PowerFlex 700L
Liquid-Cooled AC drives with 700 Vector Control and 700S Phase II
Control. The 700 Vector Control synchronization cable connection is shown
in Figure 2.17
is shown in Figure 2.18
Figure 2.17 Frame 2 700 Vector Control Synchronization Cable Connection
. The 700S Phase II Control synchronization cable connection
.
TB2 Header on
700 Vector
Control Cassette
P1 Terminal Block
on Active Converter
Control Cassette
15
TB2-2
TB2-1
Control Synchronization
Cable (Factory-Installed)
1
P1-7
P1-8
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Figure 2.18 Frame 2 700S Phase II Control Synchronization Cable Connection
J9 Header on
Active Converter
Control Cassette
Frame 2 Installation 2-21
P6 Header on
700S Phase II
Control Cassette
Control Synchronization
Cable (Factory-Installed)
Inverter-to-Converter DPI Communication Cable
To enable the Inverter and Converter section of the Frame 2 drive to
communicate with each other, a factory-installed DPI communications
cable is used. No user connection is required.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
2-22 Frame 2 Installation
DPI Connections for Frame 2 Drives
External
DPI Cable
Drive Connection Points
The PowerFlex 700L Frame 2 drive provides a number of cable connection
points as shown in Figure 2.19
the application, the HIM can be connected to the DPI port on the bottom of
the drive. Only one additional external HIM device may be connected. The
use of two external HIM devices is not supported. If multiple external HIM
devices are required, then install a user-supplied splitter cable or splitter box.
Figure 2.19 Frame 2 Drive DPI Connection Points
➌
External
HIM Option
➋
. If an additional external HIM is required for
Drive
HIM Option
Communications
➎
Active
Converter
PCB
Adapter Option
➊
➍
Bottom View
of Drive
T/L3S/L2R/L1
Item Connector Description
DPI Port 1 HIM connection when installed in the drive.
➊
DPI Port 2 Cable connection for handheld and remote options.
➋
DPI Port 3 or 2 Splitter cable connection to DPI Port 2 provides additional port.
➌
DPI Port 5 Cable connection for communications adapter.
➍
DPI Port 6 Internal DPI connection to Active Converter pcb.
➎
External Door-Mounted HIM Connection (optional)
For a Frame 2 drive installed in a user-supplied enclosure, an optional
external door-mounted HIM may be connected as an alternative to the
external HIM option. The cable supplied with the door-mount HIM option
kit connects to the DPI port on the bottom of the drive (see Figure 2.19
additional installation information, refer to the instructions provided with
the door-mount HIM option kit.
). For
Coolant Loop Connections
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Please refer to Chapter 4, Cooling Loop Installation for details.
Chapter 3
Frame 3A and 3B Installation
For information on… See page…
Drive Components
Equipment Lifting 3-8
Supporting the Power Module 3-12
Removing the Power Module Covers 3-12
Removing the Active Converter Power Module Control Cassette 3-13
Removing the Inverter Power Module Control Cassette 3-14
Verifying the Drive’s Watts Loss Rating 3-16
Determining Wire Routing for Control, Ground, Drive Input, and Motor Output 3-16
Grounding the Power Module 3-22
Ungrounded or Resistive Grounded Installations 3-22
Installing Input Power Wiring 3-23
Installing Output Power Wiring 3-29
Installing Control Wiring from the Input Filter Bay to the Power Module Bay 3-30
Synchronization Connections for Frame 3A 3-34
Synchronization Connections for Frame 3B 3-35
DPI Connections for Frame 3A and 3B Drives 3-37
Coolant Loop Connections 3-39
3-1
Drive Components
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.
Frame 3A and 3B complete drives are comprised of an Input Filter Bay and
a Power Module Bay. For Frame 3A drives, the Power Module Bay contains
a combined Converter/Inverter Power Module. For Frame 3B drives, the
Power Module Bay contains separate Converter and Inverter Power
Modules.
Total Area Required for Drive Installation
Overall drive dimensions are illustrated in Figure 3.1 as an aid in calculating
the total area required for installing Frame 3A and 3B drives.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-2 Frame 3A and 3B Installation
Figure 3.1 Frame 3 Complete Drive Installation Dimensions
38
(1.50)
C
INPUT
FILTER BAY
GH
Ø
35 (Ø1.38)
POWER
MODULE BAY
61 (2.39)
B
D Max.
Dimensions are in millimeters and (inches).
65 (2.56)
J
E
A
Frame
Size
A B C D E F G H J Complete Drive
3A 1200
3B 1600
(47.2)
(63.0)
2000
(78.7)
2200
(86.6)
600
(23.6)
800
(31.5)
Dimensions Approximate Weight kg (lbs.)
2078
1500
233
542
542
(81.9)
(59.1)
(9.2)
(21.3)
(21.3)
2278
1500
233
542
(89.8)
(59.1)
(9.2)
(21.3)
942
(37.1)
F Max.
535
(21.1)
735
(28.9)
Recommended Air Flow Clearances for Complete Drive
Be sure there is adequate clearance for air circulation around the drive
enclosures. A 15 cm (6-in.) minimum clearance is required wherever vents
are located in the cabinet.
OUTLET
INLET
950 (2090)
1361 (3000)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Frame 3A and 3B Installation 3-3
Figure 3.2 Frame 3A Input Filter Bay Power Wiring and Installation Dimensions
Dimensions are in millimeters and (inches).
31.8 (1.25)
125.2
(4.93)
177.8
(7.00)
607.3
(23.91)
177.8
(7.00)
117.2
(4.62)
58.5 (2.30)
2001.9
(78.82)
Ø
Ø
(
3 Places
113.5
(4.47)
12.7
0.50)
CONNECTION DETAIL
101.6
(4.00)
CABLE
605.0
(23.82)
19.0 (0.75)
507.7
(19.99)
2087.2
(82.17)
Max
See CABLE
CONNECTION
DETAIL
125.2
(4.93)
R/L1
177.8
(7.00)
S/L2
177.8
(7.00)
T/L3
1487.0
(58.54)
507.7
(19.99)
46.5 (1.83)
114.4 (4.50)
Approximate Weight kg (lbs.)
Input Filter Assembly
695 (1530)
267.7
(10.54)
321.6
(12.66)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
507.7
(19.99)
3-4 Frame 3A and 3B Installation
Figure 3.3 Frame 3B Input Filter Bay Power Wiring and Installation Dimensions
35.5 (1.40)
535
(21.1)
76.4 (3.01)
82.6 (3.25)
T/L3
S/L2
R/L1
82.6 (3.25)
2200
(86.6)
44.5 (1.75)
Ø
14.3
(
Ø
0.56)
Ty p.
2256
(88.8)
Max
800
(31.5)
Dimensions are in millimeters and (inches).
735
(28.9)
34.8 (1.37)
26.8 (1.05)
1500
(59.1)
Ø
Ø
(
28.6
1.13)
(23.6)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
600
615.0 (24.23)
157.7 (6.21)
Approximate Weight kg (lbs.)
Input Filter Assembly
861.8 (1900)
233
(9.2)
Max
Frame 3A and 3B Installation 3-5
Figure 3.4 Frame 3A Converter/Inverter Power Module Installation Dimensions
23 (0.90)
Ø
14 (Ø0.56)
See
DETAIL A
See
DETAIL B
44 (1.75)
DETAIL A
368 (14.50)
25 (1.00)
21 (0.81)
51 (2.00)
119 (4.67)
119 (4.67)
119 (4.67)
1227 (48.30)
119 (4.67)
119 (4.67)
38 (1.50)
Ø
14 (Ø0.56)
37 (1.46)
100 (3.95)
86 (3.39)
72 (2.83)
100 (3.95)
86 (3.39)
72 (2.83)
44 (1.75)
DETAIL B
21 (0.81)
19 (0.73)
38 (1.50)
255 (10.05)
Dimensions are in millimeters and (inches).
175 (6.89) 39 (1.56)
51 (1.99)
GRD
U/T1
V/T2
W/T3
R/L1
S/L2
T/L3
12 (0.45)
1200 (47.25)
265 (10.44)
402 (15.82)
BACK VIEW
396 (15.59)
24 (0.94)
LEFT SIDE VIEW FRONT VIEW
Approximate Weight kg (lbs.)
Power Module Power Module and Packaging
112 (247) 144 (317)
AIRFLOW
567 (22.32)
51 (1.99)
15 (0.60)
39 (1.56)
175 (6.89)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-6 Frame 3A and 3B Installation
Figure 3.5 Frame 3A Dual Inverter Power Module Installation Dimensions
23 (0.90)
Ø
14 (Ø0.56)
97 (3.82)
DC
Neg.
See
DETAIL A
See
DETAIL B
44 (1.75)
368 (14.50)
DETAIL A
21 (0.81)
25 (1.00)
51 (2.00)
55 (2.16)
DC Pos.
119 (4.67)
119 (4.67)
119 (4.67)
119 (4.67)
119 (4.67)
38 (1.50)
Ø
14 (Ø0.56)
57 (2.24)
57 (2.24)
37 (1.46)
100 (3.95)
86 (3.39)
72 (2.83)
100 (3.95)
86 (3.39)
72 (2.83)
44 (1.75)
21 (0.81)
19 (0.73)
38 (1.50)
DETAIL B DETAIL C
255 (10.05)
See DETAIL C
To p
Bot
76 (2.98)
16 (0.63)
44 (1.75)
Dimensions are in millimeters and (inches).
175 (6.89)
51 (1.99)
GRD
U/T1
V/T2
W/T3
U/T1
V/T2
W/T3
44 (1.75)
16 (0.63)
Ø
14 (Ø0.56)
39 (1.56)
362 (14.25)
700 (27.58)
12 (0.45)
1200
(47.25)
396 (15.59)
265 (10.44)
402 (15.82)
BACK VIEW
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
1326 (52.20)
24 (0.94)
LEFT SIDE VIEW FRONT VIEW
Approximate Weight kg (lbs.)
Power Module Power Module and Packaging
113.9 (251) 145.6 (321)
AIRFLOW
567 (22.32) 51 (1.99)
15 (0.60)
39 (1.56)
175 (6.89)
Frame 3A and 3B Installation 3-7
Figure 3.6 Frame 3B Power Module Installation Dimensions
Ø
97 (3.82)
DC Neg.
See
DETAIL A
See
DETAIL B
44 (1.75)
23 (0.90)
14 (Ø0.56)
DETAIL A
368 (14.50)
21 (0.81)
25 (1.00)
51 (2.00)
55 (2.16)
275 (10.83)
231 (9.09)
231 (9.09)
461 (18.16)
DC Pos.
44 (1.75)
37 (1.44)
Ø
14 (Ø0.56)
57 (2.24)
57 (2.24)
37 (1.46)
104 (4.08)
1326 (52.20)
89 (3.51)
75 (2.95)
21 (0.81)
29 (1.12)
57 (2.25)
DETAIL B DETAIL C
255 (10.05)
76 (3.00)
16 (0.62)
44 (1.75)
Dimensions are in millimeters and (inches).
51 (1.99)
See DETAIL C
GRD
R/L1
or
U/T1
S/L2
or
V/T2
T/L3
or
W/T3
44 (1.75)
16 (0.62)
Ø
14 (Ø0.56)
175 (6.89)
39 (1.56)
12 (0.45)
1200 (47.25)
265 (10.44)
402 (15.81)
BACK VIEW LEFT SIDE VIEW FRONT VIEW
Approximate Weight kg (lbs.)
Power Module Power Module and Packaging
132 (290) 166 (365)
24 (0.94)
AIRFLOW
567 (22.32)
51 (1.99)
Recommended Mounting Clearances for Power Modules
Specified vertical clearance requirements (Figure 3.7) are intended to be
from power module to cabinet surface. Other objects can occupy this space;
however, reduced air flow may cause protection circuits to fault the module.
In addition, inlet air temperature must not exceed the product specification.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
15 (0.60)
39 (1.56)
175 (6.89)
3-8 Frame 3A and 3B Installation
Figure 3.7 Frame 3A and 3B Power Module Minimum Mounting Clearances
Cabinet Surface
101.6 mm
(4.0 in.)
50.8 mm
(2.0 in.)
101.6 mm
(4.0 in.)
Equipment Lifting
152.4 mm
(6.0 in.)
Cabinet Surface
Verifying Power Module 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 drive’s Power Module
circuitry. See Appendix
input power to the drive corresponds to the drive nameplate voltage and
frequency.
This section explains how to lift the equipment.
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.
A for input power rating specifications. Be sure
152.4 mm
(6.0 in.)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
• Do not subject the load to high rates of acceleration or
deceleration.
• Inspect all lifting hardware for proper attachment before
lifting any drive unit.
Lifting the Complete Drive
For the complete drive equipment, always hoist the cabinet using the lifting
angles provided with the equipment (see Figure 3.8
). Prior to placing the
Frame 3A and 3B Installation 3-9
complete drive equipment at its installation site, remove both the pallet and
the pallet mounting brackets. For safety when removing the pallet mounting
brackets, place blocks under the hoisted cabinet (Figure 3.9
provide a measure of safety while the six (6) M12 screws are unfastened
under the cabinet to remove the pallet mounting brackets. After the
complete drive equipment is placed at its installation position, remove the
lifting angles to permit the installation of the vented top cover over the input
filter bay. Assembly instructions are provided with the vented top cover. If
the complete drive equipment must be moved for any reason, remove the
vented top cover and then reinstall the lifting angles to hoist the cabinet.
Figure 3.8 Frame 3 Complete Drive Lifting Instructions
Drive lifting points: three front (shown), and three back (not shown).
Dimensions are in
millimeters and (inches).
). The blocks
203
(8.00)
Maximum
Pallet mounting brackets: three front (shown), and three back (not shown).
Blocks for safe removal of pallet mounting brackets.
Full depth of cabinet. (4) - Places
ATTENTION: To guard against possible personal injury and/or
equipment damage, block the cabinet while removing the pallet
!
mounting brackets.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-10 Frame 3A and 3B Installation
Removing the Pallet and Pallet Mounting Brackets
ATTENTION: To guard against personal injury and equipment
damage, do not work under the drive unless the drive is securely
!
mounted on appropriate blocks.
Figure 3.9 Frame 3 Complete Drive Pallet/Mounting Bracket Removal Instructions
A
C
D
Task Description
Using a 15 mm wrench, remove the hardware which secures the drive to the pallet.
A
Lift the drive off the pallet.
B
Place the drive on proper blocks on a hard, level surface.
C
The blocks should be approximately 10 cm (4 inches) high.
Using a 17 mm wrench, remove the hardware which secures the pallet mounting brackets to
D
the drive and remove the brackets.
Lifting the Input Filter Bay
B
C
A
D
D
A
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Figure 3.10 Frame 3 Input Filter Bay Lifting Instructions
Vertical Lift Only
Frame 3A and 3B Installation 3-11
Lifting the Power Module
Figure 3.11 Frame 3 Power Module Lifting Instructions
DC Bus Bar
Ground
Bus Bar
Input and
Output
Bus Bar
Frame 3B Inverter
Power Module shown
ATTENTION: Risk of equipment damage exists. Do not use
input, output, ground, and DC bus bars for lifting or handling.
!
Mechanically support conductors to minimize mechanical load
on the input and output bus bars.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-12 Frame 3A and 3B Installation
Supporting the Power Module
The Frame 3 power module has features for attaching support brackets with
screws. The support brackets are required to prevent mechanical damage to
the AC input, DC, and AC output bus bars. The feature locations, feature
size, and screw type are shown in Figure 3.12
Figure 3.12 Frame 3 Power Module Support Locations
(Frame 3B Power Module shown)
Ø 0.213 Thru Hole
Suitable for M6 x 1.0
Taptite Screw
4 Places
.
Dimensions are in millimeters (inches).
1107 (43.59)
Clinch Nut
Suitable for M6 x 1.0
Machine Screw
515 (20.26)
LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW
Removing the Power Module Covers
66 (2.59)
19 (0.75)
236 (9.28)
47 (1.84)
66 (2.59)
15 (0.58)
Inverter or Converter Module
(Frame 3B Inverter Power Module shown)
(4 Captive Screws)
Clinch Nut
Suitable for M6 x 1.0
Machine Screw
2 Places
515 (20.26)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Frame 3A and 3B Installation 3-13
Removing the Active Converter Power Module Control Cassette
Synchronization Cable
(For use with 700S Phase II Control only)
Internal DPI Cable
Synchronization Cable
(For use with 700 Vector Control only)
Frame 3A Drives
For Frame 3A regenerative-type drives, the combined Active Converter/
Inverter Power Module is equipped with an Active Converter control
cassette. Figure 3.13
access its terminal blocks for control wiring. Please refer to the Powe rFlex
700 Active Converter Power Module User Manual (publication
PFLEX-UM002) for control wiring details.
Figure 3.13 Removing the Frame 3A Active Converter Control Cassette
shows the location and removal of this cassette to
Pin 1
40-Pin
Ribbon Cable
Detail
P2
P1
Communications
Adapter Option
Frame 3B Drives
For Frame 3B regenerative-type drives, the separate Active Converter
Power Module is equipped with a control cassette. Figure 3.14
location and removal of this cassette to access its terminal blocks for control
wiring. Please refer to the PowerFlex 700 Active Converter Power Module
User Manual (publication PFLEX-UM002) for control wiring details.
shows the
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-14 Frame 3A and 3B Installation
Synchronization Cable
(For use with coupled Inverter Power
Modules with 700S Phase II Control only)
Internal DPI Cable
Figure 3.14 Removing the Frame 3B Active Converter Control Cassette
Synchronization Cable
(For use with coupled Inverter Power
Modules with 700 Vector Control only)
Removing the Inverter Power Module Control Cassette
40-Pin
Ribbon Cable
For Frame 3A drives (with a combined Active Converter/Inverter Power
Module) or Frame 3B drives (with a separate Inverter Power Module), the
Inverter is equipped with either the standard PowerFlex 700 Vector Control
cassette or an optional PowerFlex 700S Phase II Control cassette. In either
case, the cassette is removed in the same way.
Pin 1
P2
P1
Detail
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
PowerFlex 700 Vector Control Cassette (standard)
Figure 3.15 shows the location and removal of the Inverter Power Module’s
standard PowerFlex 700 Vector Control cassette to access its terminal
blocks for control wiring. Please refer to the PowerFlex 700 Adjustable
Frequency AC Drive User Manual - Series B (publication 20B-UM002) for
control wiring details.
Frame 3A and 3B Installation 3-15
Figure 3.15 Removing the Standard PowerFlex 700 Vector Control Cassette
Frame 3B Inverter Power Module shown
Pin 1
Communications
Adapter Option
Detail
PowerFlex 700S Phase II Control Cassette (optional)
Figure 3.16 shows the location and removal of the Inverter Power Module’s
optional PowerFlex 700S Phase II Control cassette to access its terminal
blocks for control wiring. Please refer to the PowerFlex 700S High
Performance AC Drive - Phase II Control User Manual (publication
20D-UM006) for control wiring details.
Figure 3.16 Removing the Optional PowerFlex 700S Phase II Control Cassette
Frame 3B Inverter Power Module shown
Detail
TB1 Terminals
TB2 Terminals
Communications
Adapter Option
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-16 Frame 3A and 3B Installation
Verifying the Drive’s Watts Loss Rating
Installing the Vented Top Cover
Determining Wire Routing for Control, Ground, Drive Input, and Motor Output
When mounting the drive inside of an enclosure, you should determine the
watts loss rating of the drive from Table A.E on page A-6
the typical full load power loss watts value at 4 kHz (rated carrier
frequency). Ensure that the enclosure is adequately ventilated with 0-40°C
(32-105°F) ambient air based on the drive’s watts loss rating.
Important:The vented top cover for the PowerFlex 700L Frame 3A and 3B
complete drives should be installed before routing input wiring.
Refer to the vented top cover installation instructions,
publication 20L-IN002, for more information.
All wiring should be installed in conformance with the applicable local,
national, and international codes (e.g., NEC/CEC). Signal wiring, control
wiring, and power wiring must be routed in separate conduits to prevent
interference with drive operation. Use grommets, when hubs are not
provided, to guard against wire chafing.
ATTENTION: Do not route signal and control wiring with
power wiring in the same conduit. This can cause interference
!
with drive operation. Failure to observe this precaution could
result in damage to, or destruction of, the equipment.
. This table lists
Do not route more than three sets of motor leads through a single conduit.
This will minimize cross-talk that could reduce the effectiveness of noise
reduction methods. If more than three drive/motor connections per conduit
are required, shielded cable must be used. If possible, each conduit should
contain only one set of motor leads.
ATTENTION: Unused wires in conduit must be grounded at
both ends to avoid a possible shock hazard caused by induced
!
voltages. Also, if a drive sharing a conduit is being serviced or
installed, all drives using this conduit should be disabled to
eliminate the possible shock hazard from cross-coupled motor
leads. Failure to observe these precautions could result in bodily
injury.
Frame 3A Drives
Figure 3.17 shows the location of Frame 3A Input Filter Bay wire routing.
Figure 3.20
routing, DPI communications ports/cable routing, and coolant connections.
Figure 3.18
drive input, motor output, and coolant connections.
shows locations for Frame 3A Power Module control wire
shows locations of Frame 3A complete drive control, ground,
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Frame 3A and 3B Installation 3-17
Frame 3B Drives
Figure 3.19 shows the location of Frame 3B Input Filter Bay wire routing.
Figure 3.20
routing, DPI communications ports/cable routing, and coolant connections.
Figure 3.21
drive input, motor output, and coolant connections.
Figure 3.17 Location of Frame 3A Input Filter Bay Wire Routing
shows locations for Frame 3B Power Module control wire
shows locations of Frame 3B complete drive control, ground,
Dimensions are in millimeters and (inches).
87 (3.43)
379 (14.92)
152 (6.00)
Cable Opening
Under Cover
432 (17.00)
Cable Opening
Under Cover
Field-Installed
Vented Top Cover
146 (5.74)
473 (18.64)
413 (16.25)
L1 L2 L3
L1 L2 L3
436 (17.18)
70 (2.75)
2 Places
PE
PE
423 (16.67)
FU7, FU8, FU9, TB2
INSTALLED VIEWS CUTAWAY VIEWS
2092 (82.35)
Maximum
Installed Height
362 (14.26)
418 (16.46)
1027 (40.43)
1150 (45.27)
FU7, FU8, FU9
TB2
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-18 Frame 3A and 3B Installation
Dimensions are in millimeters and (inches).
Figure 3.18 Locations for Frame 3A Complete Drive Power Module Bay Control,
Ground, Motor Output, and Coolant Connections
536 (21.09)
P1 & P2
559 (22.00)
TB5
175 (6.89) GRD
142 (5.58) U/V/W
192 (7.58)
119 (4.67)
210 (8.25)
GRD
119 (4.67)
P1
P2
249 (9.82)
P1
Backplane of Power
See Figure 3.4 and Figure 3.20
for Inlet, Outlet, PE, and Motor
Lead Depth Dimensions
Top Anti-sway
Bracket
Power Module
Status Indicators
Converter/Inverter
Power Module
Cutaway of Bottom Cover
Showing P1 and P2
Cutaway of Bottom Cover
Showing TB5
24 (0.94)
Module Chassis.
1365 (53.75)
862 (33.92)
Bottom Anti-sway
Bracket
262 (10.30)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Inlet
1166 (45.92)
P2
Outlet
62 (2.43)
168 (6.62)
1226 (48.27)
P1
Right Wall
in Right Wall for Cooling
Cutaway
Ø22 (Ø0.88) through
Knockout Size 1/2 inch
Loop Equipment Wiring
Inlet
90 (3.56)
132 (5.18)
90 (3.56)
Outlet
97 (3.81)
174 (6.87)
391 (15.38)
87 (3.43)
Figure 3.19 Location of Frame 3B Input Filter Bay Wire Routing
432 (17.00)
Cable Opening
Under Cover
Dimensions are in millimeters and (inches).
224 (8.80)
95 (3.74)
Frame 3A and 3B Installation 3-19
114 (4.50)
114 (4.50)
464 (18.26)
152 (6.00)
Cable Opening
Under Cover
540 (21.27)
2286 (90.0)
Maximum
Installed Height
448 (17.65)
PE
Vented Top Cover
647 (25.46)
Installed
L1 L2 L3
L1 L2 L3
730 (28.75)
FU7, FU8, FU9, TB2
847 (33.36)
946 (37.25)
PE
477 (18.77)
504 (19.84)
INSTALLED VIEWS CUTAWAY VIEWS
PowerFlex® 700L Liquid-Cooled Drive User Manual
FU7, FU8, FU9
TB2
Publication 20L-UM001D-EN-P
3-20 Frame 3A and 3B Installation
Figure 3.20 Frame 3A and 3B Power Module Locations for Control Wire Routing, DPI
Communications Ports/Cable Routing, and Coolant Connections
Dimensions are in millimeters and (inches).
Fluid Inlet
23.9 (0.94)
108.1 (4.26)
78.2 (3.08)
48.2 (1.90)
Control Wire
Routing Grommets
18.5 (0.73) Dia.
4 Places
236.4 (9.31)
225.7 (8.89)
203.6 (8.02)
171.9 (6.77)
138.1 (5.44)
28.0 (1.10)
Fluid
Outlet
39.5 (1.56)
DPI Communications Port (for module interconnection
and external HIM) 2 Places
Note: For Active Converter Power Modules, connect
the cable to only one port. Operation of two cables from
the Active Converter Power Module is not supported.
Communications Cable
Routing Grommet
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Coolant
Inlet
91.1
(3.58)
Bottom View of Power Module
106.5
(4.19)
67.5
(2.66)
Coolant
Outlet
107.6 (4.24)
66.3 (2.61)
559.5 (22.03)
549.0 (21.61)
Figure 3.21 Locations for Frame 3B Complete Drive Control, Ground, Drive Input,
Motor Output, and Coolant Connections
Dimensions are in millimeters and (inches).
Frame 3A and 3B Installation 3-21
536 (21.09)
P1 & P2
559 (22.00)
TB5
Converter
Power Module
Cutaway of Top Cover
Showing P1 and P2
P1
600 (23.62)
224 (8.82)
24 (0.94)
Backplane of Power
Module Chassis.
See Figure 3.6 and Figure 3.20
for Inlet, Outlet, PE, and Motor
Lead Depth Dimensions
Top Anti-sway
Bracket
Power Module
Status Indicators
450 (17.72)117 (4.59)
Inverter
Power Module
275 (10.83)
1441 (56.72)
P1
1378 (54.27)
P2
P2
Cutaway of
Bottom Cover
Showing TB5
706 (27.80)
Bracket
231 (9.09)
231 (9.09)
925 (36.44)
Outlet
Right
Wall
Cutaway
InletBottom Anti-sway
51 (2.00)
157 (6.19)
Ø22 (Ø0.88) through
Knockout Size 1/2 inch
in Right Wall for Cooling
Loop Equipment Wiring
Inlet
90 (3.56)
132 (5.18)
90 (3.56)
Outlet
391 (15.38)
97 (3.81)
174 (6.87)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-22 Frame 3A and 3B Installation
Grounding the Power Module
Ungrounded or Resistive Grounded Installations
ATTENTION: The user is responsible for conforming with all
applicable local, national, and international codes. Failure to
!
observe this precaution could result in damage to, or destruction
of, the equipment.
Complete drives consist of an Input Filter Bay and a Power Module Bay
(see Figure 3.1
Inc. are furnished with a grounding conductor between the ground lug of the
Inverter Power Module and the ground lug in the Input Filter Bay.
However, when power modules are purchased separately and mounted in a
customer's cabinet, the customer must supply a grounding conductor
between:
• Frame 3A — the ground lug of the combined Converter/Inverter Power
Module (or the ground lug of the Dual Inverter Power Module) and the
ground lug in the Input Filter Bay (see Figure 3.23
• Frame 3B — the ground lugs of each separate Power Module and the
ground lug in the Input Filter Bay (see Figure 3.24
PowerFlex 700L Frame 3A and 3B drives are equipped with a common
mode capacitor and MOV that are referenced to ground. To guard against
drive damage, this capacitor and MOV should be disconnected if the drive is
installed on a resistive ground or ungrounded distribution system.
). Complete drives purchased from Rockwell Automation,
).
).
ATTENTION: The PowerFlex 700L Liquid-Cooled AC Drive
has not been designed to be used on IT (insulated tera) or
!
corner-grounded power networks above 600V (phase-to-phase
voltage). Operation on such a network may cause a hazardous
failure of the insulation system of the drive.
Disconnecting the Common Mode Capacitor
To disconnect the 1 µF common mode capacitor from the circuit, refer to
Figure 3.22
1. Disconnect the Faston wire from the 1 µF common mode capacitor.
2. Insulate the wire end by applying a wire nut or electrical tape.
3. Tie wrap the disconnected wire to keep it away from any electrical
connections.
Disconnecting the MOV from Ground
To disconnect the MOV from ground, refer to Figure 3.22 and:
and:
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
1. Unbolt the ground wire lug from the MOV’s ground connection point.
Screw the bolt back into the panel.
Frame 3A and 3B Installation 3-23
2. Cut the lug off the disconnected ground wire and apply a wire nut to its
end.
3. Tie wrap the disconnected ground wire to keep it away from any
electrical connections.
Refer to Wiring and Grounding Guidelines for Pulse Width Modulated
(PWM) AC Drives, publication DRIVES-IN001, for more information on
ungrounded distribution systems. Note: Removing the Common Mode
capacitor and input MOVs makes the drive more vulnerable to high voltage
line spikes.
Figure 3.22 Removing Common Mode Capacitor and MOV
MOV Lug
(See Capacitor Lug
and Resistor Lug)
Installing Input Power Wiring
MOV
FU1 FU2
TB2
FU4
This section describes incoming line components and how to install them.
Installing Transformers and Reactors (Not Recommended)
FU5
1 µF Common Mode Capacitor
Capacitor Lug Screw
M6 x 16 mm Lg
10 mm / P#2
5.1 N
Capacitor Receptacle Faston
•
m (45 lb•in)
Frame 3A and 3B drives may be used on distribution systems with 200,000
amps or less symmetrical fault current capacity. The Drive Input
components consist of a 3% line reactor and a harmonic line filter.
Additional input inductance is not recommended.
Selecting/Verifying Control Transformer Voltage
A control transformer in the input filter bay of the drive is used to match the
input line voltage of the drive to the 115V control voltage. If your line
voltage is different than the voltage class specified on the drive nameplate, it
may be necessary to change transformer taps as described below.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-24 Frame 3A and 3B Installation
Depending on the supplied AC line voltage used to power the drive, connect
FU1 and FU2 to TB1 in accordance with Table 3.A
Figure 3.30
Table 3.A Input Voltage Setting for Control Transformer
Supplied Input Voltage From To
For all input voltages FU1 TB1-1
380/415V AC FU2 TB1-2
440/480V AC FU2 TB1-3
575/600V AC FU2 TB1-4
690V AC FU2 TB1-5
Figure 3.23 Frame 3A Regenerative Drive Input Power and PE Wiring
for the fuse and terminal block locations.
INPUT FILTER BAY
. Refer to Figure 3.29 or
L3
DETAIL
➊
➋
PE
INPUT FILTER BAY
L1
L2
L3
➊
L1
L2
Figure 3.24 Frame 3B Regenerative Drive Input Power and PE Wiring
➋
PE
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
PE
L1
DETAIL
L2
L3
PE
L1
L2
L3
Table 3.B Frame 3 Power Terminal Specifications
Item Name Description
Input Power Wire Lugs
➊
R/L1, S/L2, T/L3
Input power
connections on drive
Frame 3A and 3B Installation 3-25
Frame
Size
3A 400 MCM 3/0 42 N•m (375 lb•in)
3B 1000 MCM 500 MCM 62 N•m (550 lb•in)
Wire Size Range
Maximum Minimum
(1)
Recommended Tightening
Torque (+
10%)
PE Wire Lug Terminating point for
➋
(1)
Maximum/minimum sizes that the terminals will accept - these are not recommendations.
Installing an External/Separate Input Disconnect
An input disconnect can be installed in the line before the drive input
terminals in accordance with local, national, and international codes (e.g.,
NEC/CEC). The disconnect should be sized according to the in-rush current
as well as any additional loads the disconnect might supply. The trip rating
for the inrush current (10-12 times full load current) should be coordinated
with that of the input isolation transformer, if used. Refer to Installing
Transformers and Reactors (Not Recommended) on page 3-23 for
additional information.
Installing Power Wiring from Input Filter Bay to the Power Module Bay
Use the following steps to connect AC input power to the drive:
ground wires
ATTENTION: Do not route signal and control wiring with
power wiring in the same conduit. This can cause interference
!
with drive operation. Failure to observe this precaution could
result in damage to, or destruction of, the equipment.
3A or 3B600 MCM #2 AWG 34 N•m (300 lb•in)
1. Connect the three-phase AC input power leads (three-wire 380-480V
AC or three-wire 600-690V AC depending on drive nameplate voltage
rating) to the R/L1, S/L2, and T/L3 input power terminals on the:
– Frame 3A Combined Converter/Inverter Power Module: For
terminal locations, refer to Figure 3.2
– Frame 3A Dual Inverter Power Module: For terminal locations, refer
to Figure 3.2
– Frame 3B Separate Converter Power Module: For terminal locations,
refer to Figure 3.3
2. Tighten the AC input power terminal connections to the recommended
torque as shown in Table 3.C
, Figure 3.18, and Figure 3.26.
, Figure 3.21, and Figure 3.27.
.
, Figure 3.18, and Figure 3.25.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-26 Frame 3A and 3B Installation
Table 3.C Power Module Terminal Specifications
Item Name Description
Input Power Bus Bar
➊
R/L1, S/L2, T/L3
Output Power Bus Bar
➋
U/T1, V/T2, W/T3
PE, Motor Ground Bus Bar
➌
DC Bus Test Point Socket
➍
(2 Terminals; DC+, DC-)
DC Power Bus Bar
➎
(2 Terminals; DC+, DC-)
(1)
Apply counter torque to the nut on the other side of terminations when tightening or loosening the terminal bolt to avoid damage to the terminal.
(2)
These connections are bus bar type terminations and require the use of lug connectors.
(3)
Use only to verify that DC bus capacitors are discharged before servicing the Power Module. No other external use is permitted.
(4)
Size DC power conductors for current carrying capacity as follows: 400/480V, 1000 Amps; 600/690V, 800 Amps.
(2)
Input power 62 N•m (550 lb•in) M12
(2)
Motor connections 62 N•m (550 lb•in) M12
(2)
Terminating point for wiring shields 11 N•m (100 lb•in) M8
(3)
4 mm socket for DC bus voltage
measurement only
(2) (4)
DC power from Converter Power Module to
Inverter Power Module (Frame 3B only)
Figure 3.25 Frame 3A Converter/Inverter Power Module Terminal Locations
Recommended Tightening
Torque (+
——
62 N•m (550 lb•in) M12
10%)
Termi nal
Bolt Size
➌
(1)
➋
➊
U/T1
V/T2
W/T3
R/L1
S/L2
T/L3
➍
DC+ TESTPOINT
DC- TESTPOINT
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
To p
Inverter
➋
Frame 3A and 3B Installation 3-27
Figure 3.26 Frame 3A Dual Inverter Power Module Terminal Locations
DC+ DC-
➎
➌
U/T1
➍
V/T2
W/T3
Bottom
Inverter
➋
U/T1
V/T2
W/T3
DC+ TESTPOINT
DC- TESTPOINT
E
SITIV
O
P
DC
E
IV
AT
G
E
N
C
D
COIL
E
G
R
A
H
C
E
R
2 P
C
D
V
K
C
FEEDBA
E
H
EC
R
P
4
LE
B
A
N
E
P
TEM
VER
O
R
TO
C
U
D
6 IN
:
GE
N
A
R
E
IR
W
G
-10 AW
24
2
)
M
(0.24 - 4 M
:
H
NGT
LE
IP
R
ST
)
M
(8 M
IN
1
.3
0
:
UE
ORQ
T
- LB
IN
8
)
(0.9 N - M
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-28 Frame 3A and 3B Installation
Figure 3.27 Frame 3B Active Converter Power Module Terminal Locations
➊
➌
R/L1
S/L2
T/L3
DC +
➎
DC -
➍
DC+ TESTPOINT
DC- TESTPOINT
E
V
I
T
I
S
O
P
C
D
E
V
I
T
A
G
E
N
C
D
L
I
O
C
E
G
R
A
H
C
E
R
P
2
C
D
V
K
C
A
B
D
E
E
F
E
H
C
E
R
P
4
E
L
B
A
N
E
P
M
E
T
ER
V
O
R
O
T
C
U
D
N
I
6
:
E
G
AN
R
E
R
I
W
G
W
A
0
1
4
2
2
)
M
M
4
-
4
.2
0
(
:
H
T
G
N
E
L
P
I
R
T
S
)
M
M
8
(
N
I
1
.3
0
:
E
U
Q
R
O
T
B
L
N
I
8
)
M
N
9
.
0
(
Figure 3.28 Frame 3B Inverter Power Module Terminal Locations
DC +
➎
DC -
➌
➋
U/T1
V/T2
W/T3
IVE
T
I
S
O
P
C
D
E
V
I
T
A
EG
N
C
D
L
I
O
C
E
G
R
A
H
C
E
R
P
2
C
D
V
K
AC
B
D
E
E
F
E
H
C
E
R
P
4
E
L
B
A
N
E
P
M
E
T
ER
V
O
R
O
T
C
U
D
IN
6
:
E
G
N
A
R
E
R
I
W
G
W
A
0
1
4
2
2
)
M
M
4
-
4
.2
0
(
:
H
T
G
N
E
L
P
I
R
T
S
)
M
M
8
(
IN
1
3
.
0
:
E
U
Q
R
O
T
B
L
N
I
8
)
M
-
N
.9
0
(
➍
DC+ TESTPOINT
DC- TESTPOINT
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Frame 3A and 3B Installation 3-29
Installing Output Power Wiring
This section provides instructions on wiring output contactors, motor
overload protection, and output wiring to the motor.
Installing Mechanical Motor Overload Protection (Optional)
To provide the motor with overload protection, local, national, and
international codes (e.g., NEC/CEC) may require one of the following:
• A motor thermostat be installed internal to the motor.
• A mechanical thermal motor overload relay, sized to protect the motor,
be installed between the motor and the drive’s output terminals.
In multiple motor applications (V/Hz regulation only), each motor must
have its own user-supplied overload and branch circuit protection.
Installing Output Wiring from the Drive Output Terminals to the Motor
Important: See the PowerFlex 700L Technical Data, publication
20L-TD001, for motor lead length restrictions.
Use the following steps to connect the AC output power wiring from the
drive to the motor:
1. Route the three-phase AC output power motor leads to the drive power
module.
Do not route more than three sets of motor leads through a single
conduit. This will minimize cross-talk that could reduce the
effectiveness of noise reduction methods. If more than three drive/motor
connections per conduit are required, shielded cable must be used. If
possible, each conduit should contain only one set of motor leads.
ATTENTION: Do not route signal and control wiring with
power wiring in the same conduit. This can cause interference
!
with drive operation. Failure to observe these precautions could
result in damage to, or destruction of, the equipment
ATTENTION: Unused wires in conduit must be grounded at
both ends to avoid a possible shock hazard caused by induced
!
voltages. Also, if a drive sharing a conduit is being serviced or
installed, all drives using this conduit should be disabled to
eliminate the possible shock hazard from cross-coupled motor
leads. Failure to observe these precautions could result in bodily
injury.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-30 Frame 3A and 3B Installation
2. Connect the three-phase AC power motor leads to the U/T1, V/T2, and
W/T3 output power terminals.
– Frame 3A Combined Converter/Inverter Power Module: For
terminal locations, see Figure 3.18
– Frame 3A Dual Inverter Power Module: For terminal locations, see
Figure 3.18
– Frame 3B Separate Converter Power Module: For terminal locations,
see Figure 3.21
Tighten the AC output power terminal connections to the proper torque
as shown in Table 3.C
and Figure 3.26.
and Figure 3.27.
.
and Figure 3.25.
Installing Control Wiring from the Input Filter Bay to the Power Module Bay
This section provides details on control wiring between the Input Filter Bay
and the Power Module Bay. When a Frame 3A or 3B Complete Drive has
been ordered, wiring from the Input Filter Bay to the Power Module Bay
was completed at the factory. In this case, this section can be used as
verification or reference for installation or maintenance.
ATTENTION: Risk of equipment damage exists. Do not use
power module terminal blocks TB5-1 and TB5-3 to connect any
!
type of power wiring for auxiliary equipment. These terminals are
for low amperage control wiring only.
ATTENTION: Do not route signal and control wiring with
power wiring in the same conduit. This can cause interference
!
with drive operation. Failure to observe this precaution could
result in damage to, or destruction of, the equipment.
Frame 3A Drives
Connect wiring to terminals in accordance with Table 3.D, Table 3.A,
Table 3.E
page C-4
Frame 3B Drives
, Figure 3.29, and the Frame 3A drive schematic on page C-2 or
.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Connect wiring to terminals in accordance with Table 3.D, Table 3.A,
Table 3.E
page C-12
, Figure 3.30, and the Frame 3B drive schematic on page C-10 or
.
Table 3.D Power Module Control Wiring Terminal Specifications
Item Name Description
400/480V Line Voltage Fuses
➊
FU7, FU8, and FU9
600/690V Line Voltage Fuses
FU7, FU8, and FU9
Input filter AC power 21.1 mm2
Wire Size Range
Maximum Minimum
(#4 AWG)
21.1 mm2
(#4 AWG)
(1)
2.1 mm2
(#14 AWG)
2.1 mm2
(#14 AWG)
Frame 3A and 3B Installation 3-31
Recommended
Tightening
Torque (+10%)
4 N•m
(35 lb•in)
4 N•m
(35 lb•in)
Wire Strip
Length
(2) (2)
6 mm
(0.25 in.)
Wire
Termina l
not
applicable
Terminal Blocks—TB2 Input filter control signals 3.3 mm2
➋
Active Converter Cassette
➌
Terminal Blocks—P1 & P2
SHLD Terminal Terminating point for control
➍
Terminal Blocks—TB5 and
➎
TB6
Fan—M6 Power Module Bay cooling fan 4.0 mm2
➏
(1)
Maximum/minimum sizes that the terminals will accept - these are not recommendations.
(2)
For 400/480V applications, terminate wires with #10 spade tongue terminal. Maximum terminal width is 11 mm (0.43 in.). Wire strip length per terminal
manufacture’s recommendation.
Active Converter AC power and
control wiring
wiring shields on Power Module
Power Module control wiring 4.0 mm2
(#12 AWG)
3.3 mm2
(#12 AWG)
2.1 mm2
(#14 AWG)
(#10 AWG)
(#10 AWG)
0.3 mm2
(#22 AWG)
0.3 mm2
(#22 AWG)
0.3 mm2
(#22 AWG)
0.2 mm2
(#24 AWG)
0.3 mm2
(#22 AWG)
1.5 N•m
(13 lb•in)
0.8 N•m
(7 lb•in)
1.4 N•m
(12 lb•in)
1.4 N•m
(12 lb•in)
0.8 N•m
(7 lb•in)
13 mm
(0.51 in.)
8 mm
(0.31 in.)
10 mm
(0.39 in.)
8 mm
(0.31 in.)
8 mm
(0.31 in.)
Wire the Input Filter Bay to the Power Module Bay in accordance with
Table 3.E
Table 3.E Input Filter-to-Power Module Bay Wiring
From To Comments
FU7 PMC P2-1 PMC = Power Module, Converter
FU8 PMC P2-4
FU9 PMC P2-7
TB2-1 PMC P1-9
TB2-1 PMC TB5-1
TB2-3 M6-N M6 = Power Module Bay Door Fan
TB2-4 PMC TB5-3
TB2-5 PMC P1-10
TB2-6 PMC TB5-2
TB2-6 M6-L1
TB2-7 M6-PE
TB2-9 PMC TB5-4
TB2-10 PMC TB5-7
TB2-11 PMC TB5-5
PMC TB5-4 PMC TB5-6 Factory-installed jumper
and drive schematics in Appendix C.
not
applicable
not
applicable
not
applicable
not
applicable
not
applicable
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-32 Frame 3A and 3B Installation
Figure 3.29 Frame 3A Complete Drive Control Wiring Terminal Locations
FU1 FU2
12345
H1 H2 H3 H4 H5
TB1
41235
FU8FU7 FU9 FU3
12345
12345
123456GG91011
6
9
10
GND
GND
6
9
10
GND
GND
TB2
1
P1
15
7
P2
1
➊
11
11
➋
➌
SHLDSHLD
➍
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
DC POSITIVE
TB5
DC NEGATIVE
1 120 VAC
2 PRECHARGE COIL
3 120 VAC NEUTRAL
24 VDC
5 PR HARGE FEEDBACK
GATE ENABLE
7 INDUCTOR OVERTEMP
WIRE RANGE:
24-10 AWG
(0.2-4 MM)
STRIP LENGTH:
0.31 IN (8 MM)
TORQUE:
8 IN-LB
(0.9 N-M)
M5 - Power Module Bay Fan
(Door-Mounted)
DC+ TESTPOINT
TB5
DC- TESTPOINT
1 120 VAC
2 PRECHARGE COIL
3 120 VAC NEUTRAL
4 24 VDC
5 PRECHARGE F/B
6 GATE ENABLE
7 IND OVERTEMP
WIRE RANGE
24-10 AWG
(0.2-4 MM2)
STRIP LENGTH
0.31 IN (8 MM)
TORQUE
8 IN-LB
(0.9 N-M)
PE L1 N
➎
➏
Frame 3A and 3B Installation 3-33
Figure 3.30 Frame 3B Complete Drive Control Wiring Terminal Locations
FU1 FU2
12345
H1 H2 H3 H4 H5
TB1
41235
FU8FU7 FU9 FU3
12345
12345
123456GG91011
6
9
10
GND
GND
6
9
10
GND
GND
TB2
➊
11
11
➋
➌
1
P1
15
7
P2
1
SHLDSHLD
➍
DC+ TESTPOINT
TB5
DC POSITIVE
DC NEGATIVE
TB5
1 120 VAC
2 PRECHARGE COIL
24 VDC
4 PR HARGE FEEDBACK
ATE ENABLE
6 INDUCTOR OVERTEMP
WIRE RANGE:
24-10 AWG
(0.2-4 MM)
STRIP LENGTH:
0.31 IN (8 MM)
TORQUE:
8 IN-LB
(0.9 N-M)
DC- TESTPOINT
1 120 VAC
2 PRECHARGE COIL
3 120 VAC NEUTRAL
4 24 VDC
5 PRECHARGE F/B
6 GATE ENABLE
7 IND OVERTEMP
WIRE RANGE
24-10 AWG
(0.2-4 MM2)
STRIP LENGTH
0.31 IN (8 MM)
TORQUE
8 IN-LB
(0.9 N-M)
➎
➏
M6 - Power Module Bay Fan
(Door-Mounted)
PE L1 N
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-34 Frame 3A and 3B Installation
Synchronization Connections for Frame 3A
Coupled Power Modules
Frame 3A combined Converter/Inverter Power Modules are only configured
as coupled power modules. Coupling the Converter and Inverter is achieved
by using two factory-installed cables: a control synchronization cable and
an inverter-to-converter DPI communication cable. The two cables are
described in the next two subsections.
Control Synchronization Cable
To enable synchronization between the Inverter control printed circuit board
and the Converter control printed circuit board, a factory-installed control
synchronization cable connects each board. No user connection is required.
However, the connection method is different for PowerFlex 700L
Liquid-Cooled AC drives with 700 Vector Control and 700S Phase II
Control. The 700 Vector Control synchronization cable connection is shown
in Figure 3.31
is shown in Figure 3.32
Figure 3.31 Frame 3A 700 Vector Control Synchronization Cable Connection
. The 700S Phase II Control synchronization cable connection
.
TB2 Header on
700 Vector
Control Cassette
P1 Terminal Block
on Active Converter
Control Cassette
15
TB2-2
TB2-1
Control Synchronization
Cable (Factory-Installed)
SHLDSHLD
1
P1-7
P1-8
1 120 VAC
2 PRECHARGE COIL
24 VDC
4 CHARGE FEEDBACK
GATE ENABLE
6 INDUCTOR OVERTEMP
WIRE RANGE:
24-10 AWG
(0.2-4 MM)
STRIP LENGTH:
0.31 IN (8 MM)
TORQUE:
8 IN-LB
(0.9 N-M)
DC POSITIVE
DC NEGATIVE
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Frame 3A and 3B Installation 3-35
Figure 3.32 Frame 3A 700S Phase II Control Synchronization Cable Connection
P6 Header on
700S Phase II
Control Cassette
Control Synchronization
Cable (Factory-Installed)
J9 Header on
Active Converter
Control Cassette
DC POSITIVE
DC NEGATIVE
1 120 VAC
2 PRECHARGE COIL
24 VDC
4 CHARGE FEEDBACK
GATE ENABLE
6 INDUCTOR OVERTEMP
WIRE RANGE:
24-10 AWG
(0.2-4 MM)
STRIP LENGTH:
0.31 IN (8 MM)
TORQUE:
8 IN-LB
(0.9 N-M)
Synchronization Connections for Frame 3B
Inverter-to-Converter DPI Communication Cable
To enable the Inverter and Converter section of the Frame 3A Power
Module to communicate with each other, a factory-installed DPI
communications cable is used. No user connection is required.
Coupled or Stand-Alone Inverter Power Modules
Frame 3B Inverter Power Modules may be configured in two ways. One
way is an Inverter Power Module coupled with a Converter Power Module.
The coupling is achieved by using two cables: a control synchronization
cable and an inverter-to-converter DPI connection cable. The other way is a
stand-alone Inverter Power Module. In this case, synchronization and DPI
connection cables are not needed to connect the Inverter Power Module to
the Converter Power Module. The two cables for coupling are described in
the next two subsections.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-36 Frame 3A and 3B Installation
Control Synchronization Cable
To enable synchronization between the Inverter control printed circuit board
and the Converter control printed circuit board, you must connect a
synchronization cable to each board. The connection method is different for
PowerFlex 700L Liquid-Cooled AC drives with 700 Vector Control and
700S Phase II Control. The 700 Vector Control synchronization cable
connection is shown in Figure 3.33
synchronization cable connection is shown in Figure 3.34
version of the cable is provided in a plastic bag with each Inverter Power
Module. Only one Inverter Power Module may be coupled to a Converter
Power Module.
Figure 3.33 Frame 3B 700 Vector Control Synchronization Cable Connection
. The 700S Phase II Control
. The appropriate
Active Converter
Control Cassette
P1 Terminal Block for
Control Synchronization
Cable Connection
15
700 Vector
Control Cassette
TB2-2
1
P1-7
DC POSITIVE
P1-8
DC NEGATIVE
1 120 VAC
2 PRECHARGE COIL
24 VDC
4 CHARGE FEEDBACK
GATE ENABLE
6 INDUCTOR OVERTEMP
WIRE RANGE:
24-10 AWG
(0.2-4 MM)
STRIP LENGTH:
0.31 IN (8 MM)
TORQUE:
8 IN-LB
(0.9 N-M)
Active Converter Power Module Inverter Power Module
TB2 Header for
Control Synchronization
Cable Connection
Control Synchronization Cable
(Factory-Provided)
TB2-1
1 120 VAC
2 PRECHARGE COIL
24 VDC
4 CHARGE FEEDBACK
GATE ENABLE
6 INDUCTOR OVERTEMP
WIRE RANGE:
24-10 AWG
(0.2-4 MM)
STRIP LENGTH:
0.31 IN (8 MM)
TORQUE:
8 IN-LB
(0.9 N-M)
DC POSITIVE
DC NEGATIVE
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Frame 3A and 3B Installation 3-37
Figure 3.34 Frame 3B 700S Phase II Control Synchronization Cable Connection
P6 Header for
Control Synchronization
Cable Connection
Active Converter
Control Cassette
J9 Header for
Control Synchronization
Cable Connection
700S Phase II
Control Cassette
DC POSITIVE
DC NEGATIVE
1 120 VAC
2 PRECHARGE COIL
24 VDC
4 CHARGE FEEDBACK
GATE ENABLE
6 INDUCTOR OVERTEMP
WIRE RANGE:
24-10 AWG
(0.2-4 MM)
STRIP LENGTH:
0.31 IN (8 MM)
TORQUE:
8 IN-LB
(0.9 N-M)
Control Synchronization Cable
(Factory-Provided)
Active Converter Power Module Inverter Power Module
1 120 VAC
2 PRECHARGE COIL
24 VDC
4 CHARGE FEEDBACK
GATE ENABLE
6 INDUCTOR OVERTEMP
WIRE RANGE:
24-10 AWG
(0.2-4 MM)
STRIP LENGTH:
0.31 IN (8 MM)
TORQUE:
8 IN-LB
(0.9 N-M)
DC POSITIVE
DC NEGATIVE
Inverter-to-Converter DPI Communication Cable
DPI Connections for Frame 3A and 3B Drives
To enable the Frame 3B Inverter and Converter Power Modules to
communicate with each other, you must connect one DPI port on the bottom
of the Converter to a DPI port on the bottom of the Inverter using a DPI
communication cable (see Figure 3.36
).
Drive Connection Points
The PowerFlex 700L provides a number of cable connection points as
shown in Figure 3.35
required for the application, the HIM can be connected to the DPI port on
the bottom of the Power Module. Only one additional external HIM device
may be connected. The use of two external HIM devices is not supported. If
multiple external HIM devices are required, then install a user-supplied
splitter cable or splitter box.
and Figure 3.36. If an additional external HIM is
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-38 Frame 3A and 3B Installation
Figure 3.35 Frame 3A DPI Connection Points
➎
Active
Converter
PCB
Combined
Active Converter/Inverter
Power Module
No Connection
Permitted
➋
Power Module
HIM Option
➊
Communications
Adapter Option
➍
Internal
DPI Cable
Figure 3.36 Frame 3B DPI Connection Points
Top Main
Control PCB
Option
Bottom Main
Control PCB
Option
Bottom Inverter
Dual Inverter Power Module
Power Module
HIM Option
Power Module
HIM Option
Top Inverter
DPI Port
➋
➋
DPI Port
➊
Communications
Adapter Option
➍
➊
Communications
Adapter Option
➍
Internal
DPI Cable
To p
Inverter
Bottom
Inverter
External
HIM Option
External
DPI Cable
Bottom of Power Module
➌
➋
Active
Converter
PCB
Active Converter Power Module Inverter Power Module
➎
No Connection
Permitted
Blank HIM
No Connections
Permitted
No Communications
Adapter Permitted
Internal
DPI Cable
Inverter-to-Converter
DPI Cable
Item Connector Description
DPI Port 1 HIM connection when installed in Power Module.
➊
DPI Port 2 Cable connection for handheld and remote options.
➋
DPI Port 3 or 2 Splitter cable connected to DPI Port 2 provides an additional port.
➌
DPI Port 5 Cable connection for communications adapter.
➍
DPI Port 6 Internal DPI connection to Active Converter PCB.
➎
Power Module
HIM Option
➊
Communications
Adapter Option
➍
Internal
DPI Cable
➋
Inverter-to-Converter
DPI Cable
External
HIM Option
External
DPI Cable
Bottom of Modules
➌
➋
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Frame 3A and 3B Installation 3-39
.
External Door-Mounted HIM Connection (optional)
For complete drives, the door-mounted HIM is standard equipment.
Figure 3.37
Power Module Bay.
For power modules installed in user-supplied enclosures, an optional
external door-mounted HIM may be connected as an alternative to the
external HIM option. The cable supplied with the door-mount HIM option
kit connects to the DPI port on the bottom of the Power Module (see
Figure 3.35
installation information, refer to the instructions provided with the
door-mount HIM option kit.
Figure 3.37 Complete Drive External Door-Mounted HIM Location
shows the location for the door mount bezel in the door of the
for Frame 3A or Figure 3.36 for Frame 3B). For additional
Dimensions are in millimeters and (inches)
A
116 (4.57)
Frame Size
3A 1206 (47.49)
3B 1301 (51.21)
Dimensions
A
Coolant Loop Connections
Please refer to Chapter 4, Cooling Loop Installation for details.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
3-40 Frame 3A and 3B Installation
Notes:
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Chapter 4
r
Cooling Loop Installation
Proper liquid cooling is critical to drive operation and reliability. This
chapter provides information about the types of drive cooling loops, drive
coolant requirements, and cooling loop connections for the PowerFlex 700L
Liquid-Cooled drive power structure.
For information on … See page…
Explanation of Cooling Loop Types
Recommended Cooling Loops 4-5
Drive Coolant Requirements 4-7
Cooling Loop Application Guidelines 4-9
Drive Coolant Connections 4-10
4-1
Explanation of Cooling Loop Types
PowerFlex 700L
Drive
Drive
Inlet
Outlet
Flow
Indicator
Liquid-to-Liquid Heat Exchanger
The liquid to liquid heat exchanger utilizes a heat transfer plate to transfer
heat from one liquid to another. This method requires a stable water supply
from the user.
Figure 4.1 Drive and Liquid-to-Liquid Heat Exchanger Plumbing Arrangement
Liquid-to-Liquid
Heat Exchanger
From
Drive
Hose Kit
= hose or pipe connection
Figure 4.2 shows a cooling loop diagram for a typical liquid-to-liquid heat
exchanger.
Outlet
To
Drive
Inlet
Return
To
Supply
In
From
Supply
Customer
Supplied Piping
To Facility Wate
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
4-2 Cooling Loop Installation
Figure 4.2 Liquid-to-Liquid Heat Exchanger Plumbing Diagram
Ambient Sensor
TE
Supply
Process
Water
Strainer
Control
Val ve
Drive Coolant Temp.
TE FS
IN
OUT
The main components of the liquid-to-liquid heat exchanger cooling loop
include:
Part Description
Strainer Filters particles from the supply water.
Control Valve Controls the supply loop water flow.
Heat Exchanger Plate Transfers heat from the drive loop to the supply loop.
Ambient Sensor Senses the ambient temperature used for the dew point control.
Drive Coolant Temperature Sensor Senses the drive coolant temperature used for the dew point control.
Drive Coolant Flow Switch Measures the drive coolant flow rate.
Level Switch Senses the level of coolant in the reservoir.
Reservoir Stores drive coolant.
Pump and Motor Circulates drive coolant.
OUT
Heat Exchanger
IN
Pump
Flow Switch
Level Switch
LS
Reservoir
IN
OUT
Drive
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Cooling Loop Installation 4-3
Liquid-to-Air Heat Exchanger
The liquid to air heat exchanger utilizes radiator technology to transfer heat
from a liquid to surrounding air. This is a simple closed loop system — it
does not require a water supply from the user. However, this system
requires surrounding air 5 to 10°C below the maximum operating
temperature of the drive.
Figure 4.3 Drive and Liquid-to-Air Heat Exchanger Plumbing Arrangement
Fan
On/Off
Control
PowerFlex 700L
Drive
Drive
Inlet
Outlet
Flow
Indicator
Figure 4.4 shows a cooling loop diagram for a typical liquid-to-air heat
exchanger.
Figure 4.4 Liquid-to-Air Heat Exchanger Plumbing Diagram
Ambient
Sensor
TE
Drive Coolant Temp.
TE
OUT
Radiator
IN
Hose Kit
= hose or pipe connection
Flow Switch
FS
Level Switch
LS
Reservoir
Liquid-to-Air
Heat Exchanger
From
Drive
Outlet
To
Drive
Inlet
Radiator
IN
OUT
Pump
The main components of the liquid-to-air heat exchanger cooling loop
include:
Part Description
Fan Blows air across the radiator.
Radiator Transfers heat from liquid to air.
Ambient Sensor Senses the ambient temperature used for the dew point control.
Drive Coolant Temperature Sensor Senses the drive coolant temperature used for the dew point control.
Drive Coolant Flow Switch Measures the drive coolant flow rate.
Level Switch Senses the level of coolant in the reservoir.
Reservoir Allows for expansion of coolant.
Pump and Motor Circulates drive coolant.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Drive
4-4 Cooling Loop Installation
Chiller
The chiller utilizes refrigerant to transfer heat from a liquid to air. This is a
simple closed loop system — it does not require a water supply from the
user. A chiller can achieve almost any coolant temperature required.
Coolant temperature should be at or above ambient temperature to avoid
condensation on drive components.
Figure 4.5 Drive and Chiller Plumbing Arrangement
PowerFlex 700L
Drive
Drive
Inlet
Outlet
Flow
Indicator
Figure 4.6 shows a cooling loop diagram for a typical chiller.
Figure 4.6 Chiller Plumbing Diagram
Compressor
Hose Kit
= hose or pipe connection
Condenser/Subcooler
Fan
From
Drive
Outlet
To
Drive
Inlet
Chiller
Radiator
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Pump
Expansion Valve
Level
LS
Switch
TE FS
Drive Coolant
Temperature
Thermostatic
Reservoir
Flow
Switch
Sight Glass
TE
Filter-Drier
SOL
Out
Drive
In
Ambient
Sensor
Cooling Loop Installation 4-5
The main components of the chiller cooling loop include:
Part Description
Compressor Forces the refrigerant into a smaller space.
Fan Blows air across the condenser/subcooler.
Condenser/Subcooler Cools the refrigerant.
Filter-Drier Filters the refrigerant.
Sight Glass Allows viewing of the level of drive coolant in the reservoir.
Thermostatic Expansion Valve Allows for expansion of the refrigerant.
Level Switch Senses the level of coolant in the reservoir.
Reservoir Allows for expansion of coolant.
Pump and Motor Circulates drive coolant.
Drive Coolant Temperature Sensor Senses the drive coolant temperature used for the dew point control.
Drive Coolant Flow Switch Measures the drive coolant flow rate.
Ambient Sensor Senses the ambient temperature used for the dew point control.
Recommended Cooling Loops
Liquid-to-Liquid Heat Exchanger
Recommended Liquid-to-Liquid Heat Exchangers from Rockwell
Automation are listed in Table 4.A
Table 4.A Liquid-to-Liquid Heat Exchanger Requirements
Drive
Frame Size
2 15.1 LPM @ 0.83 bar
3A 22.7 LPM @ 0.83 bar
3B
(1)
Supply loop requirements are for the input to the heat exchanger. These are not requirements for the drive. The
output of the heat exchanger is designed to meet the flow and pressure requirements of the drive. For the flow
and pressure requirements of the drive, see Table 4.G on page 4-8
(2)
The minimum pressure applies to the pressure drop across the heat exchanger and does not take into account
additional pressure drop in the system such as piping or hosing.
(3)
Recommended cooling loops shown are based on a single drive per cooling loop. Consult the factory for use of
multiple drives on one cooling loop.
Table 4.B lists the estimated amount of coolant needed for the drive loop
based on the drive frame size. For recommended drive loop coolants, refer
to Table 4.F
Supply Loop Requirements
Minimum Flow @
Pressure
(4 GPM @ 12 PSI)
(6 GPM @ 12 PSI)
56.8 LPM @ 0.83 bar
(15 GPM @ 12 PSI)
.
(2)
.
(1)
Maximum
Pressure
8.62 bar
(125 PSI)
8.62 bar
(125 PSI)
8.62 bar
(125 PSi)
Temperature
Range
0-40°C (32-104°F) 20L-LL13K-P75A
0-35°C (32-95°F) 20L-LL13K-P75A
0-35°C (32-95°F) 20L-LL24K-1P0A
.
Liquid-to-Liquid Heat
Exchanger Cat. No.
(3)
Table 4.B Estimated Coolant Amount for the Drive Loop
Drive Size Estimated Amount of Coolant
Frame 2 15.1 liters (4 gal.)
Frame 3A 19 liters (5 gal.)
Frame 3B 19 liters (5 gal.)
(1)
The estimated amount of coolant is based on the heat exchanger
using 1.2 m (4 ft.) hoses. Longer hoses require more coolant. The
maximum hose length of 9.1 m (30 ft.) would require up to an
additional 2.8 liters (3/4 gal.).
(1)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
4-6 Cooling Loop Installation
Depending on the location of the heat exchanger or chiller relative to the
drive, the following drive cooling loop hose kits are available:
Table 4.C Drive Cooling Loop Hose Kits
Hose
Length
3 m
(10 ft.)
9.1 m
(30 ft.)
3 m
(10 ft.)
9.1 m
(30 ft.)
3 m
(10 ft.)
9.1 m
(30 ft.)
(1)
(2)
Hoses
Drive Side
in Kit
Coupling Size
2 0.75 inch 0.75 inch Frame 2 and
2 0.75 inch 0.75 inch Frame 2 and
2 1 inch 1 inch with 90° elbow Frame 3A and
2 1 inch 1 inch with 90° elbow Frame 3A and
2 1 inch 1 inch Frame 3B and
2 1 inch 1 inch Frame 3B and
All drive side hose kit fittings are 37 degree flare.
Each hose kit contains two (2) hoses and the appropriate connectors.
(1)
Heat Exchanger Side
Coupling Size
Used With
13 kW heat exchanger
13 kW heat exchanger
13 kW heat exchanger
13 kW heat exchanger
24 kW heat exchanger
24 kW heat exchanger
Hose Kit
Catalog Number
20L-GH10-B1
20L-GH30-B1
20L-GH10-A2
20L-GH30-A2
20L-GH10-A1
20L-GH30-A1
(2)
Chiller
Recommended chillers from Dimplex Thermal Solutions are listed in
Frame Size Capacity Flow Rate Pressure Reservoir Size
2 and 3A 16,983 watts 94.6 LPM (25 GPM) 3.44 bar (50 PSI) 117.3 L (31 gal) 1-1/4 in. NPT KV5000
3B 28,110 watts 151.4 LPM (40 GPM) 3.44 bar (50 PSI) 181.7 L (48 gal) 1-1/4 in. NPT KV7500
(1)
Each chiller is designed for single drive cooling for indoor installation only. For applications requiring multiple drives using one chiller,
contact Dimplex Thermal Solutions.
Table 4.D
Table 4.D Recommended Chillers (from Dimplex Thermal Solutions)
Table 4.E Dimplex Thermal Solutions Chiller Specifications
Chiller
Model
KV5000
KV7500
(1)
Desired Line Voltage must be specified upon ordering.
.
Piping (Inlet
and Outlet)
Rated
Electrical Line Input
230V, 3 phase, 60 Hz 29 Amp 1067 mm L x 711 mm W x 1676 mm H
460V, 3 phase, 60 Hz 17 Amp
230V, 3 phase, 60 Hz 40 Amp 1270 mm L x 914 mm W x 1676 mm H
460V, 3 phase, 60 Hz 22 Amp
(1)
Load
Dimensions Weight
(42 in. L x 28 in. W x 66 in. H)
(50 in. L x 36 in. W x 66 in. H)
Chiller
Model
249.5 kg
(550 lbs.)
340 kg
(750 lbs.)
(1)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
For chiller pricing/ordering, contact Dimplex Thermal Solutions:
USA and Canada: 1-800-968-5665
Elsewhere: 1-269-349-6800
Cooling Loop Installation 4-7
Drive Coolant Requirements
Source Coolant
Interstate Chemical
http://www.interstatechemical.com/
contact.htm
Koolant Koolers/Dimplex Thermal
Solutions
http://www.koolantkoolers.com/
index.php/nic=contact
Dow Chemical
http://www.dow.com
(1)
Available in 5 gallon pails.
(2)
Not premixed with distilled water, and may not be available in 5 gallon quantities.
Recommended Coolants
Table 4.F lists approved sources and recommended coolants with
appropriate corrosion inhibitors
Table 4.F Recommended Drive Loop Coolants
• NFP-50
• NFE-50
• K-Kool-E
• Propylene glycol
• Dowtherm
• Dowfrost
Dowtherm and Dowfrost are registered trademarks of the Dow Chemical Company
Non-premixed coolants require a coolant-to-water mix ratio of 50% by
volume.
For an estimated amount of coolant needed for Allen-Bradley 20L-LL*
Liquid-to-Liquid Heat Exchangers, refer to Table 4. B
Important: Since coolant performance slowly degrades over time, the drive
loop coolant should be replaced every two years and/or
whenever the loop is drained for servicing.
for the drive loop:
(1)
; a 50/50 premix of propylene glycol and distilled water
(1)
; a 50/50 premix of ethylene glycol and distilled water
(1)
; ethylene glycol (available premixed with distilled water)
(1)
also available
®
(2)
SR-1
® (2)
; ethylene glycol
; propylene glycol
.
Corrosion Inhibitor
If an approved coolant is not used, the drive coolant must consist of clean
water with a corrosion inhibitor. An approved corrosion inhibitor is
Chemtool, Inc. (www.chemtool.com) part number Watertool 4435-C. The
recommended concentration of the inhibitor is 8-10% by volume. Deionized
water is prohibited. Use distilled water or water with less than 50 ppm
concentrations of:
• Sulfate and chloride
• Hard water ions such as Mg++ and Ca++
ATTENTION: Ethylene and propylene glycols must be
inhibited and silicate free. Use of common silicate-containing,
!
automotive-type ethylene glycol solutions is prohibited as they
may damage the heat exchanger and/or drive and cooling
module equipment.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
4-8 Cooling Loop Installation
The drive coolant must be compatible with the following materials:
• Copper
• Brass
• Aluminum
• Arimid fiber gasket with nitrile binder (Garlock, Inc. Blue-Gard 3000
Blue-Gard 3000 is a registered trademark of Garlock, Inc.
• Synthetic rubber hose (Parker Hannifan Corp 801 General Purpose Hose)
• Viton seal (Complete Drive only)
Biocide
A biocide may be needed to control biological growth. Use of a biocide is
permitted. For specific recommendations, consult a reputable water
treatment company.
Drive Cooling Loop Specifications
®
)
Table 4.G Coolant Requirements for One Frame 2, 3A or 3B Drive
Drive
Frame Size
2 0-50°C (32-122°F) 30.3 LPM (8 GPM) 1.58 bar (23 PSI)
3A 0-40°C (32-104°F) 30.3 LPM (8 GPM) 0.35 bar (5 PSI)
3B 0-40°C (32-104°F) 56.8 LPM (15 GPM)
(1)
Frame 3B includes separate converter and inverter power modules. A single inverter or converter power module requires a minimum flow rate
of 30.3 LPM (8 GPM) at 0.35 bar (5 PSI).
(2)
Pressure drop does not include any system connections such as hoses or piping. Cooling systems must be sized to provide minimum flow
considering entire system pressure drop.
(3)
WEG50 equals good quality or distilled water with approved inhibited* ethylene glycol, 50% glycol by volume.
(4)
WPG50 equals good quality or distilled water with approved inhibited* propylene glycol, 50% glycol by volume.
Coolant
Temperature Range
Minimum Coolant
Flow Rate
* Inhibited ethylene glycol or propylene gylcol must contain a corrosion inhibitor. See Corrosion Inhibitor on
page 4-7 for an approved source.
Pressure Drop
Outlet at Minimum Coolant Flow Rate
(1)
0.48 bar (7 PSI)
(2)
From Drive Inlet to Drive
(1)
Coolant Type
WEG50
WPG50
(3)
or
(4)
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Cooling Loop Installation 4-9
Cooling Loop Application Guidelines
ATTENTION: Risk of equipment damage exists. Do not use
!
The following section is intended to provide guidelines for applying cooling
loops other than those recommended.
1. The allowable drive coolant temperature range is:
2. The cooling loop should include a flow switch on the connection to the
ferrous and plated-ferrous materials for pipe-treated water to the
power modules and drive. Use of ferrous materials will degrade
the performance of the power module chillplate.
• Frame 2 Drives: 0-50°C (32-122°F)
• Frame 3A and 3B Drives: 0-40°C (32-105°F)
When using coolant at a temperature below the dew point of the
surrounding air, condensation could accumulate on the drive heatsink
and/or circuit boards and damage the drive. In this situation, install a
coolant flow regulating device and tube/hose insulation. A flow
regulating device modulates the coolant flow rate to a level that permits
the drive heatsink temperature to rise above the dew point. Insulation
for customer side tube or hose may be closed-cell foam insulation with
minimum 12.7 mm (0.50 in.) wall thickness.
drive inlet to turn off the drive if coolant flow drops below the minimum
flow required by the drive (see Table 4.G
).
3. Circulate coolant through the drive only when the drive is also powered.
Failure to do this may result in condensation accumulating on the drive
heatsink and/or circuit boards, which could damage the drive.
4. An interlock from the cooling loop should be used to stop the drive
when the cooling loop is faulted.
5. For applications requiring a closed loop coolant system, ensure the
system is vented to remove air that would otherwise degrade the
performance of the drive heatsink.
6. Install a flow measuring device at the inlet of each Converter and each
Inverter Power Module. Note that flow measuring devices are included
in the PF700L Frame 3A and 3B Complete Drive cabinets (13th
position in catalog number = A). The coolant flow rate (GPM) must
meet the requirements in Table 4.G
7. The following types of pipe are recommended for cooling loop
connections:
• Copper tubing, type L
• Brass pipe
• Stainless steel, 300 series
Important:Do not use galvanized pipe.
.
8. The cooling loop should have a method for draining and replacing the
coolant.
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
4-10 Cooling Loop Installation
Drive Coolant Connections
Frame 2 Drive or Frame 3A or 3B Power Module
For locations of the coolant inlet and outlet connections on PowerFlex 700L
Liquid-Cooled Frame 2 drives, refer to Figure 2.10
3A and 3B Power Modules, see Figure 3.20
The rated working pressure of the Frame 2 drive is 6.89 bar (100 psig).
Coolant supply and return lines should be sized for 76 LPM (20 GPM) /
6.89 bar (100 PSI) service with a maximum operating temperature of 50°C
(122°F). The required operating flow rate and pressure drop is specified in
Table 4.G
The rated working pressure of the Frame 3A or 3B Power Module is 12.76
bar (185 PSI). Coolant supply and return lines should be sized for 38 LPM
(10 GPM) / 12.76 bar (185 PSI) service with a maximum operating
temperature of 40°C (105°F). The required operating flow rate and pressure
drop is specified in Table 4. G
Coolant connections for Frame 2 drives and Frame 3A and 3B Power
Modules are made using 37 degree flare fittings which have a:
.
.
• 3/4-inch nominal size
• “-12” SAE dash size
• 1 1/16-12 UN/UNF-2B external thread size
.
. For locations on Frame
The mating connection is shown in Figure 4.7
the following steps:
1. Assemble the mating version of the fitting (with swivel nut) to each
fluid fitting, and tighten to a wrench resistance of approximately 3.4
N•m (30 lb•in).
2. Using a backup wrench on the Power Module fitting, tighten the swivel
nut fitting by either of the following two methods:
– Hex flats from wrench resistance method (recommended): one and
one-quarter (1-¼) hex flat from wrench resistance.
– Torque method: 69-77 N•m (51-57 lb•ft).
Figure 4.7 Power Module Mating Coolant Connection
Wrench Flats
37° Flare Fitting
Backup Wrench
(use to prevent twisting
during swivel nut tightening)
. The mating process includes
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
Swivel Nut
Cooling Loop Installation 4-11
Frame 3A or 3B Complete Drive
For locations of the coolant inlet and outlet connections on PowerFlex 700L
Liquid-Cooled Frame 3A Complete Drives, refer to Figure 3.18
side views). For locations on Frame 3B Complete Drives, see Figure 3.21
(front and side views).
The rated working pressure of the Frame 3A and 3B Complete Drive is 6.89
bar (100 PSI). Coolant supply and return lines should be sized for 76 LPM
(20 GPM) / 6.89 bar (100 PSI) service with a maximum operating
temperature of 40°C (105°F). The required operating flow rate is specified
in Table 4.G
Before connecting the coolant hoses to the Complete Drive hose fittings
located at the lower-right back corner of the drive enclosure, refer to
Figure 4.8
1. Remove the factory-installed hose fitting plugs and the enclosure wall
dome plugs.
2. Install the factory-supplied snap bushings to the enclosure wall.
.
and:
(front and
Figure 4.8 Frame 3A and 3B Complete Drive Coolant Connection Components
Enclosure Wall
Snap Bushings
Hose Fitting Plugs
Enclosure Wall
Dome Plugs
Frame 3A and Frame 3B Complete Drive coolant connections are made
using 37 degree flare fittings which have a:
• 1-inch nominal size
• “-16” SAE dash size
• 1 5/16-12 UN/UNF-2B external thread size
The mating connection is shown in Figure 4.9
the following steps:
. The mating process includes
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
4-12 Cooling Loop Installation
1. Assemble the mating version of the fitting (with swivel nut) to each
fluid fitting, and tighten to a wrench resistance of approximately 3.4
N•m (30 lb•in).
2. Using a backup wrench on the Complete Drive fitting, tighten the
swivel nut fitting by either of the following two methods:
– Hex flats from wrench resistance method (recommended): one (1)
hex flat from wrench resistance.
– Torque method: 103-109 N•m (76-81 lb•ft).
Figure 4.9 Frame 3A and 3B Complete Drive Mating Coolant Connection
DRIVE SIDE
CONNECTION
1 5/8" Wrench Flats
Backup Wrench
(use to prevent twisting
during swivel nut tightening)
37° Flare Fitting
Swivel Nut
Do not use Backup Wrench
on fitting locknut
USER SIDE
CONNECTION
PowerFlex® 700L Liquid-Cooled Drive User Manual
Publication 20L-UM001D-EN-P
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