Allen-Bradley powerflex 700 Instruction manual

Quick Start
PowerFlex 700 Adjustable
Frequency AC Drive
When reading this document, look for this symbol “ ” to guide
you through the 6 BASIC STEPS needed to install, start-up and
program the PowerFlex 700.The information provided Does Not
replace the User Manual and is intended for qualified drive service
personnel only. For detailed PowerFlex 700 information including
application considerations and related precautions refer to the following:
Title Publication Available . . .
PowerFlex 700 User Manual 20B-UM001x on the CD supplied with the drive
or at www.ab.com/manuals/dr
PowerFlex Reference Manual PFLEX-RM001x
Step x
Step 1 Read the General Precautions
!
ATTENTION: This drive contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Static control precautions are required
when installing, testing, servicing or repairing this assembly.
Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures,
reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic
Damage” or any other applicable ESD protection handbook.
!
ATTENTION: An incorrectly applied or installed drive can result in
component damage or a reduction in product life. Wiring or application
errors, such as, undersizing the motor, incorrect or inadequate AC
supply, or excessive ambient temperatures may result in malfunction of
the system.
!
ATTENTION: Only qualified personnel familiar with adjustable
frequency AC drives and associated machinery should plan or
implement the installation, start-up and subsequent maintenance of the
system. Failure to comply may result in personal injury and/or
equipment damage.
!
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged before performing any
work on the drive. Measure the DC bus voltage at the +DC & –DC
terminals of the Power Terminal Block (refer to the User Manual for
location). The voltage must be zero.

2PowerFlex 700 Adjustable Frequency AC Drive Quick Start
!
ATTENTION: Risk of injury or equipment damage exists. DPI or
SCANport host products must not be directly connected together via
1202 cables. Unpredictable behavior can result if two or more devices
are connected in this manner.
!
ATTENTION: The “adjust freq” portion of the bus regulator function
is extremely useful for preventing nuisance overvoltage faults resulting
from aggressive decelerations, overhauling loads, and eccentric loads.
It forces the output frequency to be greater than commanded frequency
while the drive's bus voltage is increasing towards levels that would
otherwise cause a fault. However, it can also cause either of the
following two conditions to occur.
1. Fast positive changes in input voltage (more than a 10% increase
within 6 minutes) can cause uncommanded positive speed changes.
However an “OverSpeed Limit” fault will occur if the speed reaches
[Max Speed] + [Overspeed Limit]. If this condition is unacceptable,
action should be taken to 1) limit supply voltages within the
specification of the drive and, 2) limit fast positive input voltage
changes to less than 10%. Without taking such actions, if this
operation is unacceptable, the “adjust freq” portion of the bus
regulator function must be disabled (see parameters 161 and 162).
2. Actual deceleration times can be longer than commanded
deceleration times. However, a “Decel Inhibit” fault is generated if
the drive stops decelerating altogether. If this condition is
unacceptable, the “adjust freq” portion of the bus regulator must be
disabled (see parameters 161 and 162). In addition, installing a
properly sized dynamic brake resistor will provide equal or better
performance in most cases.
Important: These faults are not instantaneous. Test results have
shown that they can take between 2-12 seconds.
!
ATTENTION: A contactor or other device that routinely disconnects
and reapplies the AC line to the drive to start and stop the motor can
cause drive hardware damage. The drive is designed to use control
input signals that will start and stop the motor. If an input device is
used, operation must not exceed one cycle per minute or drive damage
will occur.
!
ATTENTION: The drive start/stop/enable control circuitry includes
solid state components. If hazards due to accidental contact with
moving machinery or unintentional flow of liquid, gas or solids exist,
an additional hardwired stop circuit may be required to remove the AC
line to the drive. An auxiliary braking method may be required.
!
ATTENTION: If using Output Contactors, refer to the “Output
Contactor Precaution” statement on page 1-12 of the PowerFlex 700
User Manual.

PowerFlex 700 Adjustable Frequency AC Drive Quick Start 3
CE Conformity
Conformity with the Low Voltage (LV) Directive and Electromagnetic
Compatibility (EMC) Directive has been demonstrated using
harmonized European Norm (EN) standards published in the Official
Journal of the European Communities. PowerFlex Drives comply with
the EN standards listed below when installed according to the User and
Reference Manual.
CE Declarations of Conformity are available online at:
http://www.ab.com/certification/ce/docs.
Low Voltage Directive (73/23/EEC)
•EN50178 Electronic equipment for use in power installations.
EMC Directive (89/336/EEC)
•EN61800-3 Adjustable speed electrical power drive systems Part 3:
EMC product standard including specific test methods.
General Notes
•If the adhesive label is removed from the top of the drive, the drive
must be installed in an enclosure with side openings less than 12.5
mm (0.5 in.) and top openings less than 1.0 mm (0.04 in.) to
maintain compliance with the LV Directive.
•The motor cable should be kept as short as possible in order to avoid
electromagnetic emission as well as capacitive currents.
•Use of line filters in ungrounded systems is not recommended.
•PowerFlex drives may cause radio frequency interference if used in a
residential or domestic environment. The user is required to take
measures to prevent interference, in addition to the essential
requirements for CE compliance listed below, if necessary.
•Conformity of the drive with CE EMC requirements does not
guarantee an entire machine or installation complies with CE EMC
requirements. Many factors can influence total machine/installation
compliance.
•PowerFlex drives can generate conducted low frequency
disturbances (harmonic emissions) on the AC supply system. More
information regarding harmonic emissions can be found in the
PowerFlex Reference Manual.
EMC Instructions

4PowerFlex 700 Adjustable Frequency AC Drive Quick Start
Essential Requirements for CE Compliance
Conditions 1-6 listed below must be satisfied for PowerFlex drives to
meet the requirements of EN61800-3.
1. Standard PowerFlex 700 CE compatible Drive.
2. Review important precautions/attention statements throughout this
document before installing the drive.
3. Grounding as described on page 1-4 of the User Manual.
4. Output power, control (I/O) and signal wiring must be braided,
shielded cable with a coverage of 75% or better, metal conduit or
equivalent attenuation.
5. All shielded cables should terminate with the proper shielded
connector.
6. Conditions in Table A.
Table A PowerFlex 700 EN61800-3 EMC Compatibility
Operating Temperatures
PowerFlex 700 drives are designed to operate at 0°to 40°C ambient.
To operate in installations between 41°and 50°C, see Table B.
Frame
Second Environment
Restrict Motor Cable to 30 m (98 ft.)
First Environment
Restricted Distribution
Any Drive and Option
0✔Refer to
PowerFlex Reference Manual
1✔
2✔
3✔
Step 2 Mount the Drive – Minimum Requirements
101.6 mm
(4.0 in.)
101.6 mm
(4.0 in.)
50.8 mm
(2.0 in.)
101.6 mm
(4.0 in.)
101.6 mm
(4.0 in.)
PWR
STS
PORT
MOD
NETA
NETB
PWR
STS
PORT
MOD
NETA
NETB
Refer to Figures 1-3for
detailed dimension
information.
No Adhesive Label
(see below)
With Adhesive Label
(see below)
101.6 mm
(4.0 in.)
101.6 mm
(4.0 in.)
101.6 mm
(4.0 in.)
101.6 mm
(4.0 in.)
PWR
STS
PORT
MOD
NETA
NETB
PWR
STS
PORT
MOD
NETA
NETB

PowerFlex 700 Adjustable Frequency AC Drive Quick Start 5
Table B Acceptable Surrounding Air Temperature & Required Actions
Important: Removing the adhesive label from the drive changes the
NEMA enclosure rating from Type 1 to Open type.
Figure 1 PowerFlex 700 Frames 0-3 (0 Frame Shown)
Dimensions are in millimeters and (inches).
Drive Catalog
Number
Required Action . . .
IP 20, NEMA
Type 1
IP 20, NEMA
Type Open
IP 00, NEMA
Type Open
No Action
Required
Remove Top
Label
Remove Top Label
& Vent Plate (1)
(1) To remove vent plate (see Figure 3 on page 8for location), lift top edge of
plate from the chassis. Rotate the plate out from the back plate.
All Except 20BC072 40°C50°CNA
20BC072 40°C45°C50°C
Dimensions
C
A
D
15.0 (0.59)
5.8 (0.23) dia.
see below
E
8.0
(0.31)
5.5 (0.22) - Frames 0-1
7.0 (0.28) - Frames 2-3
3 Places
B
HOTsurfaces can cause severe burns
CAUTION
Frame (Table C)
ABCDE
Weight (1) kg (lbs.)
Drive
Drive &
Packaging
0 110.0 (4.33) 336.0 (13.23) 200.0 (7.87) 80.0 (3.15) 320.0 (12.60) 5.22 (11.5) 8.16 (18)
1 135.0 (5.31) 336.0 (13.23) 200.0 (7.87) 105.0 (4.13) 320.0 (12.60) 7.03 (15.5) 9.98 (22)
2 222.0 (8.74) 342.5 (13.48) 200.0 (7.87) 192.0 (7.56) 320.0 (12.60) 12.52 (27.6) 15.20 (33.5)
3 222.0 (8.74) 517.5 (20.37) 200.0 (7.87) 192.0 (7.56) 500.0 (19.69) 18.55 (40.9) 22.68 (50)
(1) Weights include HIM and Standard I/O.

6PowerFlex 700 Adjustable Frequency AC Drive Quick Start
Figure 2 PowerFlex 700 Frame 5
Dimensions are in millimeters and (inches).
Table C PowerFlex 700 Frames
HOTsurfacescan cause severe burns
CAUTION
E
12.5
(0.49)
6.5 (0.26)
B
D
A
259.1 (10.20) Detail
15.0 (0.59)
6.5 (0.26)
37.6 (1.48) C
Lifting Holes - 4 Places
12.7 (1.37) Dia.
Frame (Table C)
A(Max.) BC(Max.) DE
Approx. Weight (1) kg (lbs.)
Drive
Drive &
Packaging
5 308.9 (12.16) 644.5 (25.37) (2) 275.4 (10.84) 225.0 (8.86) 625.0 (24.61) 37.19 (82.0) 42.18 (93.0)
(1) Weights include HIM and Standard I/O.
(2) When using the supplied junction box (100 HP drives Only), add an additional 45.1 mm (1.78 in.).
Frame
208/240V AC Input 400V AC Input 480V AC Input
ND HP HD HP ND kW HD kW ND HP HD HP
00.5 0.33 0.37 0.25 0.5 0.33
1 0.75 0.75 0.55 1 0.75
2 1.5 1.5 0.75 2 1.5
322.21.532
––42.253
––5.547.55
15 3 7.5 5.5 10 7.5
7.5 5 11 7.5 15 10
210 7.5 15 11 20 15
– – 18.5 15 25 20
315 10 22 18.5 30 25
20 15 30 22 40 30
– – 37305040
5––5545––
––––7560
– – – – 100 75

PowerFlex 700 Adjustable Frequency AC Drive Quick Start 7
Figure 3 Bottom View Dimensions
Dimensions are in millimeters and (inches).
132.9
(5.23)
187.5
(7.38)
30.2
(1.19)
41.9 (1.65)
56.1 (2.21)
96.0 (3.78)
75.9 (2.99)
96.0 (3.78)
55.0 (2.17)
75.0 (2.95)
35.0 (1.38) 22.2 (0.87) Dia. – 4 Places
185.0
(7.28)
133.3
(5.25)
187.6
(7.39)
25.5
(1.00)
70.0 (2.76)
43.0 (1.69)
96.0 (3.78)
75.9 (2.99)
108.5 (4.27)
67.5 (2.66)
47.5 (1.87)
87.5 (3.44)
22.2 (0.87) Dia.
3 Places
28.6 (1.13) Dia.
185.1
(7.29)
39.3 (1.55)
57.2 (2.25)
72.7 (2.86)
106.0 (4.17)
139.4 (5.49)
177.4 (6.98)
167.5 (6.59)
156.9 (6.18)
150.9
(5.94)
184.8
(7.28)
157.5
(6.20)
112.1
(4.41)
22.4 (0.88) Dia.
2 Places
28.7 (1.13) Dia.
3 Places
Frame 0 Frame 1
Frame 2

8PowerFlex 700 Adjustable Frequency AC Drive Quick Start
Figure 3 PowerFlex 700 Bottom View Dimensions (continued)
66.0 (2.60)
94.7 (3.73)
105.3 (4.15)
130.0 (5.12)
186.0 (7.32)
22.7 (0.89)
29.0 (1.14)
127.7
(5.03)
160.1
(6.30)
165.1
(6.50)
184.5
(7.26)
28.7 (1.13) Dia.
2 Places
46.7 (1.84) Dia.
2 Places
34.9 (1.37) Dia.
2 Places
Vent Plate
Frame 3 – All Drives
except 50 HP, 480V (37 kW, 400V)
Frame 3 – 50 HP, 480V (37 kW, 400V)
Normal Duty Drive
66.0 (2.60)
94.7 (3.73)
105.3 (4.15)
97.0 (3.82)
137.2 (5.40)
187.0 (7.36)
22.7 (0.89)
29.0 (1.14)
127.7
(5.03)
151.1
(5.95)
160.1
(6.30)
165.1
(6.50)
184.5
(7.26)
22.2 (0.87) Dia.
28.7 (1.13) Dia.
2 Places
37.3 (1.47) Dia.
2 Places
96.0
(3.78)
159.5
(6.28)
184.0
(7.24)
220.0
(8.66)
229.5
(9.04)
241.9
(9.52)
45.0 (1.77)
85.0 (3.35)
93.2 (3.67)
104.0 (4.09)
150.0 (5.91)
215.0 (8.46)
255.0 (10.04)
28.0 (1.10)
22.2 (0.87) Dia.
2 Places
62.7 (2.47) Dia.
2 Places
34.9 (1.37) Dia.
2 Places
96.0
(3.78)
153.5
(6.04)
184.3
(7.26)
188.5
(7.42)
223.5
(8.80)
241.9
(9.52)
44.0 (1.73)
66.4 (2.61)
31.9 (1.26)
42.6 (1.68)
128.0 (5.04)
232.3 (9.15)
28.0 (1.10)
22.2 (0.87) Dia.
2 Places
62.7 (2.47) Dia.
2 Places
Removable Junction Box
34.9 (1.37) Dia.
Frame 5 – 75 HP, 480V (55kW, 400V) Normal Duty Drive
Frame 5 – 100 HP, 480V Normal Duty Drive
Dimensions are in millimeters
and (inches)

PowerFlex 700 Adjustable Frequency AC Drive Quick Start 9
A variety of cable types are acceptable for drive installations. For many
installations, unshielded cable is adequate, provided it can be separated
from sensitive circuits. As an approximate guide, allow a spacing of 0.3
meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases,
long parallel runs must be avoided. Do not use cable with an insulation
thickness less than or equal to 15 mils (0.4mm/0.015 in.). See Table D.
Unshielded
THHN, THWN or similar wire is acceptable for drive installation in dry
environments provided adequate free air space and/or conduit fill rates
limits are provided. Do not use THHN or similarly coated wire in wet
areas. Any wire chosen must have a minimum insulation thickness of 15
Mils and should not have large variations in insulation concentricity.
Shielded/Armored Cable
Shielded cable is recommended if sensitive circuits or devices are
connected or mounted to the machinery driven by the motor. See Table
D. For further information on acceptable and unacceptable cable types,
refer to “Power Wiring” in the PowerFlex 700 User Manual.
Table D Recommended Shielded Cable
Step 3 Power Wiring – Wire Recommendations
Type Wire Type(s) Description
Power Standard
(Option 1)
600V, 90°C (194°F)
XHHW2/RHW-2
Anixter B209500-B209507,
Belden 29501-29507, or
equivalent
•Four tinned copper conductors with XLP
insulation.
•Copper braid/aluminum foil combination
shield and tinned copper drain wire.
•PVC jacket.
Standard
(Option 2)
Tray rated 600V, 90°C (194°F)
RHH/RHW-2
Anixter OLF-7xxxxx or
equivalent
•Three tinned copper conductors with
XLPE insulation.
•5 mil single helical copper tape (25%
overlap min.) with three bare copper
grounds in contact with shield.
•PVC jacket.
Class I & II;
Division I & II
Tray rated 600V, 90°C (194°F)
RHH/RHW-2
Anixter 7V-7xxxx-3G or
equivalent
•Three bare copper conductors with XLPE
insulation and impervious corrugated
continuously welded aluminum armor.
•Black sunlight resistant PVC jacket
overall.
•Three copper grounds on #10 AWG and
smaller.

10 PowerFlex 700 Adjustable Frequency AC Drive Quick Start
Table E Power Terminal Block Specifications
Name Frame Description
Wire Size Range (1) Torque
Maximum Minimum Maximum Recommended
Power Terminal
Block
0 & 1 Input power and
motor connections
4.0 mm2
(10 AWG)
0.5 mm2
(22 AWG)
1.7 N-m
(15 lb.-in.)
0.8 N-m
(7 lb.-in.)
2 Input power and
motor connections
10.0 mm2
(6 AWG)
0.8 mm2
(18 AWG)
1.7 N-m
(15 lb.-in.)
1.4 N-m
(12 lb.-in.)
3 Input power and
motor connections
25.0 mm2
(3 AWG)
2.5 mm2
(14 AWG)
3.6 N-m
(32 lb.-in.)
1.8 N-m
(16 lb.-in.)
BR1, 2 terminals 10.0 mm2
(6 AWG)
0.8 mm2
(18 AWG)
1.7 N-m
(15 lb.-in.)
1.4 N-m
(12 lb.-in.)
5
(75 HP)
Input power, BR1,
2, DC+, DC– and
motor connections
35.0 mm2
(1/0 AWG)
2.5 mm2
(14 AWG)
3.6 N-m
(32 lb.-in.)
3.6 N-m
(32 lb.-in.)
PE 35.0 mm2
(1/0 AWG)
16.0 mm2
(6 AWG)
5 N-m
(44 lb.-in.)
5 N-m
(44 lb.-in.)
5
(100
HP)
Input power, DC+,
DC– and motor
connections
70.0 mm2
(3/0 AWG)
16.0 mm2
(4 AWG)
15 N-m
(133 lb.-in.)
15 N-m
(133 lb.-in.)
BR1, 2, terminals 35.0 mm2
(1/0 AWG)
2.5 mm2
(14 AWG)
3.6 N-m
(32 lb.-in.)
3.6 N-m
(32 lb.-in.)
PE 35.0 mm2
(1/0 AWG)
16.0 mm2
(6 AWG)
5 N-m
(44 lb.-in.)
5 N-m
(44 lb.-in.)
AUX Terminal
Block
0-3 Auxiliary Control
Voltage(2)
1.3 mm2
(16 AWG)
0.2 mm2
(24 AWG)
——
5 4.0 mm2
(10 AWG)
0.5 mm2
(22 AWG)
0.6 N-m
(5.3 lb.-in.)
0.6 N-m
(5.3 lb.-in.)
(1) Maximum/minimum sizes that the terminal block will accept - these are not recommendations.
(2) External control power:
UL Installation - 300V DC, ±10%, Non UL Installation - 270-600V DC, ±10%.
0-3 Frame - 40 W, 165 mA, 5 Frame - 80 W, 90 mA.
Power & Ground Wiring
PE
R
(L1)
S
(L2)
T
(L3)
U
(T1)
V
(T2)
W
(T3)
DC
+
DC
–
Required
Input Fusing
Required Branch
Circuit Disconnect
BR1 BR2