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.