Rockwell Automation PowerFlex 700S User manual

Installation Manual
700S High Performance AC
Drive
700H Adjustable Frequency
AC Drive
High Power

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
www.rockwellautomation.com/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.
Important: Identifies information that is critical for successful application and
understanding of the product.
PowerFlex is a registered trademark of Rockwell Automation, Inc.
DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.
PLC is a registered trademark of Rockwell Automation, Inc.
!
WARNING: Identifies information about practices or
circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property
damage, or economic loss.
!
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you:
•identify a hazard
•avoid the hazard
•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.

Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Summary of
Changes
Preface Overview
Drive Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
What Is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Chapter 1 General Installation Information
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Common Bus/Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
EMC Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Using Input/Output Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Chapter 2 PowerFlex 700H Control Wiring
Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Auto/Manual Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Chapter 3 PowerFlex 700S Control Wiring
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Hard Enable Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Auxiliary Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Main Control Board I/O and Encoder Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Connecting SynchLink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Chapter 4 Communication Options
Communication Module Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Chapter 5 Frame 9 Installation
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Removing the Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Nameplate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Ungrounded and Unbalanced Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Routing for I/O Wiring and Communication Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

ii
Chapter 6 Frame 10 Installation
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Removing Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Operating Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Ungrounded and Unbalanced Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Chapter 7 Frame 11 Installation
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Removing Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Operating Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Ungrounded and Unbalanced Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Appendix A Specifications
Drive, Fuse & Circuit Breaker Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Appendix B PowerFlex 700S Hi-Resolution (Stegmann) Encoder Feedback Option
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Wiring the Hi-Resolution Feedback Option Card to an Encoder . . . . . . . . . . . . . . . . . . . B-2
Appendix C PowerFlex 700S Resolver Feedback Option Card
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Wiring the Resolver Feedback Option Card to a Resolver . . . . . . . . . . . . . . . . . . . . . . . . C-3
Appendix D PowerFlex 700S Multi-Device Interface Option Card
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Wiring the MDI Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Index

Summary of Changes
The information below summarizes the changes to the PowerFlex High
Power Installation Instructions, publication PFLEX-IN006, since the last
release.
Manual Updates
Change Page
Frame 11 Installation added 7-1
Frame 11 Specifications added A-1
Frame 11 Drive, Fuse & Circuit Breaker Ratings
added
A-3
Stegmann Feedback Cables updated for
Stegmann Feedback Option Card
B-2
Stegmann Feedback Cables updated for
Multi-Device Interface Option Card
D-2

ii Summary of Changes
Notes:

Preface
Overview
Drive Description The PowerFlex 700 High Power AC drives consist of the 700H and 700S
products. Both are available in power ratings from 200 to 600 HP (132 kW
to 355 kW) normal duty, at input voltages from 380V to 500V.
The 700H features a parameter set modeled after the PowerFlex 700 AC
drive. Standard I/O includes either 24V or 115V digital I/O plus analog I/O
NetLinx™ communication options, including DeviceNet™, ControlNet™
and EtherNet/IP networks.
The PowerFlex 700S offers optimized integration for the most demanding
drive control and drive system applications. Available with embedded
high-performance Logix engine (DriveLogix) to produce a highly
functional, cost-effective drive and control solution.
Who Should Use this
Manual?
This manual is intended for qualified personnel. You must be able to mount
and wire Adjustable Frequency AC Drive devices.
What Is Not in this Manual This manual is designed to provide drive mounting and wiring information.
For start-up, programming and troubleshooting information, refer to the
appropriate manual listed below.
Reference Materials Allen-Bradley publications are available on the internet at
www.rockwellautomation.com/literature.
The following manuals are recommended for general drive information:
The following manuals are recommended for detailed PowerFlex 700H
information:
Title Publication
Industrial Automation Wiring and Grounding Guidelines 1770-4.1
Preventive Maintenance of Industrial Control and Drive System
Equipment
DRIVES-TD001A-EN-E
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
Title Publication
PowerFlex Reference Manual PFLEX-RM001
PowerFlex 700H Programming Manual 20C-PM001

p-2 Overview
The following manuals are recommended for detailed PowerFlex 700S
information:
For Allen-Bradley Drives Technical Support:
Manual Conventions •In this manual we refer to the PowerFlex 700H or 700S High Power
Adjustable Frequency AC Drive as; drive, PowerFlex 700H, PowerFlex
700S or PowerFlex High Power drive.
•To help differentiate parameter names and LCD display text from other
text, the following conventions will be used:
–Parameter Names will appear in [brackets].
For example: [DC Bus Voltage].
–Display Text will appear in “quotes.” For example: “Enabled.”
•The following words are used throughout the manual to describe an
action:
General Precautions
Title Publication
PowerFlex Reference Manual PFLEX-RM002
PowerFlex 700S User Manual 20D-UM001
Title Online at . . .
Allen-Bradley Drives Technical Support www.ab.com/support/abdrives
Word Meaning
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
!
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.

Overview p-3
!
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
Installation Manual for location). The voltage must be zero.
!
ATTENTION: Risk of injury or equipment damage exists. DPI
host products must not be directly connected together via 1202
cables. Unpredictable behavior can result if two or more devices
are connected in this manner.

p-4 Overview
!
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 can cause
uncommanded positive speed changes.
A.PowerFlex 700H 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).
B.PowerFlex 700S An “Abs Overspd Det” fault will occur if
the speed reaches [Rev Speed Limit] - [Overspeed Limit] or
[Fwd Speed Limit] + [Abs Overspd Lim]. 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. Without taking such actions,
if this operation is unacceptable, disable the bus regulator by
setting parameter 414 [Brake/Bus Cnfg], bit 2 (Bus Reg En)
to zero (0).
2. Actual deceleration times can be longer than commanded
deceleration times.
A.PowerFlex 700H 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). The “Decel
Inhibit” fault can be disabled by setting parameter 238 [Fault
Config 1] bit 6 (Decel Inhibit) to zero (0).
B.PowerFlex 700S A “Vref Decel Fail” fault is generated if the
drive stops decelerating altogether. If this operation is
unacceptable, disable the bus regulator by setting parameter
414 [Brake/Bus Cnfg], bit 2 (Bus Reg En) to zero (0). This
fault cannot be disabled in the PowerFlex 700S.
Note: For both drives, installing a properly sized dynamic
brake resistor or external dynamic brake will provide equal or
better performance in most cases.
Important: These faults are not instantaneous. Test results
show they can take 2-12 seconds to occur.

Chapter 1
General Installation Information
AC Supply Source
Considerations
PowerFlex High Power drives are suitable for use on a circuit capable of
delivering up to a maximum of 200,000 rms symmetrical amperes, and a
maximum of 600 volts.
If a system ground fault monitor (RCD) is to be used, only Type B
(adjustable) devices should be used to avoid nuisance tripping.
Unbalanced or Ungrounded Distribution Systems
If phase to ground voltage will exceed 125% of normal line to line voltage
or the supply system is ungrounded, you must take specific steps during
installation.
Input Power Conditioning
All AC input drives include an internal line reactor.
Certain events on the power system supplying a drive can cause component
damage or shortened product life. These conditions 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.
!
ATTENTION: To guard against personal injury and/or
equipment damage caused by improper fusing or circuit breaker
selection, use only the recommended line fuses/circuit breakers
specified in Appendix A.
!
ATTENTION: If you intend to operate a Frame 9 drive on an
ungrounded distribution system, you must order a non-CE
PowerFlex High Power drive.
If you are installing... refer to:
a Frame 9 drive Ungrounded and Unbalanced Installations on page 5-5
a Frame 10 drive Ungrounded and Unbalanced Installations on page 6-9
a Frame 11 drive Ungrounded and Unbalanced Installations on page 7-9

1-2 General Installation Information
If any or all of these conditions exist, it is recommended that the user install
a minimum amount of impedance between the drive and the source. This
impedance could come from the supply transformer itself, the cable
between the transformer and drive or an additional transformer or reactor.
The impedance can be calculated using the information supplied in either
the PowerFlex Reference Manual or the technical document on Wiring and
Grounding Guidelines, publication DRIVES-IN001.
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.
Table 1.A Typical Grounding
Safety Ground - PE
This is the safety ground for the drive that is required by code. This point
must be connected to adjacent building steel (girder, joist), a floor ground
rod or bus bar (see above). Grounding points must comply with national and
local industrial safety regulations and/or electrical codes.
Shield Termination - 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). A shield terminating cable gland
may also be used.
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.
U (T1)
V (T2)
W (T3)
R (L1)
S (L2)
T (L3)
PE
SHLD

General Installation Information 1-3
RFI Filter Grounding
Using an optional RFI filter may result in relatively high ground leakage
currents. Therefore, the filter must only be used in installations with
grounded AC supply systems and be permanently installed and solidly
grounded (bonded) to the building power distribution ground. Ensure that
the incoming supply neutral is solidly connected (bonded) to the same
building power distribution ground. Grounding must not rely on flexible
cables and should not include any form of plug or socket that would permit
inadvertent disconnection. Some local codes may require redundant ground
connections. The integrity of all connections should be periodically
checked. Refer to the instructions supplied with the filter.
Fuses and Circuit Breakers High Power drives should be installed with input fuses. National and local
industrial safety regulations and/or electrical codes may determine
additional requirements for these installations. Refer to Appendix A for
recommended fuses/circuit breakers.
Power Wiring
Cable Types Acceptable for 200-600 Volt Installations
A variety of cable types are acceptable for drive installations. For many
installations, unshielded cable is adequate, provided it can be separated
from sensitive circuits. As an approximate guide, allow a spacing of 0.3
meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases, long
parallel runs must be avoided. Do not use cable with an insulation thickness
less than or equal to 15 mils (0.4mm/0.015 in.). Use Copper wire only. Wire
gauge requirements and recommendations are based on 75 degrees C. Do
not reduce wire gauge when using higher temperature wire.
!
ATTENTION: PowerFlex High Power drives do not provide
branch short circuit protection. Specifications for recommended
fuses to provide protection against short circuits are provided in
Appendix A.
!
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.
If you are installing... refer to:
a Frame 9 drive Power Wiring on page 5-6
a Frame 10 drive Power Wiring on page 6-10
a Frame 11 drive Power Wiring on page 7-10

1-4 General Installation Information
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 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 that 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 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 be specified by the cable manufacturer as
having coverage of at least 75%. An additional foil shield can greatly
improve noise containment.
A good example of recommended cable is Belden® 295xx (xx determines
gauge). This cable has four (4) XLPE insulated conductors with a 100%
coverage foil and an 85% coverage copper braided shield (with drain wire)
surrounded by a PVC jacket.
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. Unless specified in the individual
distance tables as tested with the drive, these cables are not recommended
and their performance against the lead length limits supplied is not known.
Armored Cable
Cable with continuous aluminum armor is often recommended in drive
system applications or specific industries. It offers most of the advantages

General Installation Information 1-5
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 (see Chapter 2. “Wire Types,” of publication
Drives-IN001, Wiring and Grounding Guidelines for Pulse Width
Modulated (PWM) AC Drives) when the cable is mounted, it is
recommended the armored cable have an overall PVC jacket.
Interlocked armor is acceptable for shorter cable runs, but continuous
welded armor is preferred.
Best performance is achieved with 3 spaced ground conductors, but
acceptable performance below 200 HP is provided via a single ground
conductor.
See Table 1.B.
Table 1.B Recommended Shielded / Armored Cable
EMC Compliance
Refer to EMC Instructions for details.
CabIe Trays and Conduit
If cable trays or large conduits are to be used, refer to guidelines presented
in the PowerFlex Reference Manual.
Location Rating/Type Description
Standard
(Option 1)
600V, 90°C (194°F)
XHHW2/RHW-2
Anixter B209500-B209507,
Belden 29501-29507, or
equivalent
•Four tinned copper conductors with XLPE 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.
!
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.

1-6 General Installation Information
Common Bus/Precharge
EMC Instructions 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.
!
ATTENTION: To avoid possible equipment damage, please
note that PowerFlex High Power common bus drives do not have
precharge. In addition, precharge capability must be provided in
the system and disconnect switches must not be used between
the input of the drive and a common DC bus without the use of
an external precharge device.

General Installation Information 1-7
General Notes
•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.
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 High Power CE compatible Drive. For Frames 10
and up, the drive must also be installed in a suitable Rittal TS 8 (or
equivalent) enclosure.
2. Review important precautions/attention statements throughout this
manual before installing the drive.
3. Grounding as described on page 1-3.
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 1.C.
Table 1.C PowerFlex High Power EN61800-3 EMC Compatibility
Frame
Second Environment
Restrict Motor Cable to 30 m (98 ft.)
First Environment
Restricted Distribution
Any Drive and Option
9✔See PowerFlex Reference
Manual
10 ✔
11 ✔

1-8 General Installation Information
Using Input/Output
Contactors
Input Contactor Precautions
Output Contactor Precaution
!
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: 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.

Chapter 2
PowerFlex 700H Control Wiring
Important points to remember about I/O wiring:
•Always use copper wire.
•Wire with an insulation rating of 600V or greater is recommended.
•Control and signal wires should be separated from power wires by at
least 0.3 meters (1 foot).
Important: I/O terminals labeled “(–)” or “Common” are not referenced to
earth ground and are designed to greatly reduce common mode
interference. Grounding these terminals can cause signal noise.
Signal and Control Wire Types
Table 2.A Recommended Signal Wire
Table 2.B Recommended Control Wire for Digital I/O
!
ATTENTION: Inputs must be configured with software and
jumpers (see page 2-5). In addition, configuring an analog input
for 0-20mA operation and driving it from a voltage source could
cause component damage. Verify proper configuration prior to
applying input signals.
!
ATTENTION: Hazard of personal injury or equipment damage
exists when using bipolar input sources. Noise and drift in
sensitive input circuits can cause unpredictable changes in motor
speed and direction. Use speed command parameters to help
reduce input source sensitivity.
Signal Type Wire Type(s) Description
Minimum
Insulation Rating
Analog I/O Belden 8760/9460 (or equiv.) 0.750 mm2(18AWG), twisted
pair, 100% shield with drain(1).
(1) If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire
may not be necessary, but is always recommended.
300V,
75-90 degrees C
(167-194 degrees F)
Belden 8770 (or equiv.) 0.750 mm2(18AWG), 3 cond.,
shielded for remote pot only.
EMC Compliance Refer to EMC Instructions on page 1-6 for details.
Type Wire Type(s) Description
Minimum
Insulation Rating
Unshielded Per US NEC or applicable national or
local code
–300V,
60 degrees C
(140 degrees F)
Shielded Multi-conductor shielded cable such
as Belden 8770 (or equiv.)
0.750 mm2(18AWG), 3
conductor, shielded.

2-2 PowerFlex 700H Control Wiring
Figure 2.1 PowerFlex 700H I/O Terminal Blocks & Jumpers
I/O Terminal Blocks
Table 2.C I/O Terminal Block Specifications
No. Name Description
Wire Size Range (1)
(1) Maximum/minimum that the terminal block will accept - these are not recommendations.
Torque
Maximum Minimum Maximum Recommended
➊Analog I/O Analog I/O Signals 2.5 mm2
(14 AWG)
0.5 mm2
(22 AWG)
0.2 N-m
1.8 lb.-in.
0.2 N-m
1.8 lb.-in.
➋Digital Inputs Digital Input Signals 2.5 mm2
(14 AWG)
0.5 mm2
(22 AWG)
0.2 N-m
1.8 lb.-in.
0.2 N-m
1.8 lb.-in.
➌Digital Outputs Digital Out Relays 2.5 mm2
(14 AWG)
0.5 mm2
(22 AWG)
0.5 N-m
4.5 lb.-in.
0.5 N-m
4.5 lb.-in.
➊
➋
J1 & J2
J3 & J4
J5
➌
I/O Terminal Blocks and Jumpers