Allen-Bradley powerflex 700 Installation Instructions Manual

Installation Instructions

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

0.37…132 kW (0.5…200 Hp)

This document explains the 5 BASIC STEPS needed to install and perform a

Basic Start-Up of the PowerFlex 700 (Series A or B) AC drive. A Human

Interface Module (HIM) is required to perform the Basic Start-Up routine covered in this manual.

The information provided is intended for qualified installers only.

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

Resource

PowerFlex 700 Standard Control User Manual, publication

20B-UM001

PowerFlex 700 Vector Control User Manual (v4.001 & up), publication 20B-UM002

PowerFlex 700 AC Drive Technical Data, publication

20B-TD001

PowerFlex Comm Adapter Manuals, publication

20COMM-UM…

PowerFlex 70 and PowerFlex 700 Reference Manual, publication PFLEX-RM001

PowerFlex 70 Enhanced Control and PowerFlex 700 Vector

Control Reference Manual, publication PFLEX-RM004

Wiring and Grounding Guidelines for Pulse Width

Modulated (PWM) AC Drives, publication DRIVES-IN001

Safety Guidelines for the Application, Installation and

Maintenance of Solid State Control, publication SGI-1.1

Guarding Against Electrostatic Damage, publication

8000-4.5.2

Product Certifications website, http://ab.com

Description

Provides detailed information on:

•

Parameters and programming

•

Faults, alarms, and troubleshooting

This publication provides detailed drive specifications, option specifications and input protection device ratings.

These publications provide information on configuring, using, and troubleshooting PowerFlex communication adapters.

These publications provide detailed application specific information for programming and configuring the

PowerFlex 700 drive.

Provides basic information needed to properly wire and ground PWM AC drives.

Provides general guidelines for the application, installation, and maintenance of solid-state control.

Provides practices for guarding against Electrostatic damage (ESD)

Provides declarations of conformity, certificates, and other certification details.

You can view or download publications at http://www.rockwellautomation.com/literature/ . To order paper copies of technical documentation, contact your local Allen-Bradley distributor or

Rockwell Automation sales representative.

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Allen-Bradley Drives Technical Support

Use the contacts below for PowerFlex 700 technical support including spare parts information.

Online at…

www.ab.com/support/abdrives

By Email at…

[email protected]

By Telephone at…

262-512-8176

Installation Instructions in

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English

Deutsch

Français

Italiano

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Select publication language and type “20B-IN019” in the search field.

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2

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

Table of Contents

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step 1: Read the Precautions and General Information . . . . . . . . . . . . . . . . . . . . . 5

EMC Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 2: Mount the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Accessing the Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Step 3: Wire the Drive – Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Special Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Cable Types Acceptable for 200…600 Volt Installations . . . . . . . . . . . . . . . . . . . .22

Single-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Selecting/Verifying Fan Voltage (Frames 5…6 Only) . . . . . . . . . . . . . . . . . . . . . . .26

Auxiliary Control Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Power Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Power and Ground Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Drive, Fuse & Circuit Breaker Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Output Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Using Input/Output Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Disconnecting MOVs and Common Mode Capacitors . . . . . . . . . . . . . . . . . . . . .43

Step 4: I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

I/O Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

I/O Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Hardware Enable Circuitry (Vector Control Only) . . . . . . . . . . . . . . . . . . . . . . . .57

Encoder Interface Option (Vector Control Only). . . . . . . . . . . . . . . . . . . . . . . . . .58

Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Step 5: Start-Up Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Prepare For Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Using PowerFlex Drives w/Regen Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

DC Input (Common Bus) and Precharge Notes . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Human Interface Module (HIM) Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Start-Up Routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Drive Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Common I/O Programming Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

3

4

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Catalog Number Explanation

20B D 2P1 A 3 A Y N A E C 0 NN AD

a b c d e f g h i j k l m n

Code

20B

a

Drive

Type

PowerFlex 700

b

P

R

J

N

T

W

F

H

D

E

Code Voltage

Voltage Rating

Ph.

Prechg.

B

C

240V AC

400V AC

3

3

-

-

480V AC

600V AC

690V AC

540V DC

3

3

3

-

-

-

-

N

650V DC

325V DC

540V DC

650V DC

810V DC

932V DC

-

-

-

-

-

-

Y

Y

N

Y

Y

Y

Frames

0…6

0…6

0…6

0…6

5…6

5…6

5…6

5…6

5…6

5…6

5…6

5…6

Code

2P2

022

c

ND Output Rating

Example

Amps

2.2

22

kW (Hp)

0.37 (0.5)

5.5 (7.5)

d

Code

A

F

♠

Enclosure

Enclosure

IP20, NEMA/UL Type 1

Open/Flange Mount

Front: IP00, NEMA/UL Type Open

Back/Heatsink: IP54, NEMA Type 12

G

♠

Stand-Alone/Wall Mount

IP54, NEMA/UL Type 12

♠

Only available for Frame 5 & Frame 6 drives,

400…690V.

e

Code

0

3

HIM

Operator Interface

Blank Cover

LCD Display, Full Numeric Keypad

J

♦

Remote (Panel Mount), IP66, NEMA/UL

Type 12 Full Numeric LCD HIM

K

♦

Remote (Panel Mount), IP66, NEMA/UL

Type 12 Prog. Only LCD HIM

♦

Available with Frames 5…6 Stand-Alone IP54 drives (Enclosure Code "G").

Code

C

D

E

N

j

Comm Slot

Network Type

ControlNet (Coax)

DeviceNet

EtherNet/IP

None

Code

A

N

Q

f

Documentation

Type

Manual

No Manual

No Shipping Package

(Internal Use Only)

k

Code

A

Control & I/O

Control

Standard

I/O Volts

24V DC/AC

B

C

D

Standard

Vector

Δ

Vector

Δ

115V AC

24V DC

115V AC

N Standard None

Δ

Vector Control Option utilizes DPI Only.

g

Brake

Code

Y

w/Brake IGBT ‡

Yes

N No

‡ Brake IGBT is standard on Frames 0-3, optional on Frames 4-6.

Code

0

1

l

Feedback

Type

None

Encoder, 12V/5V

m

Future Use

h

Internal Braking Resistor

Code w/Resistor

Y

N

Yes

No

Not available for Frame 3 drives or larger.

i

Code

A

B

#

N

Emission

CE Filter

Yes

Yes

No

§ CM Choke

Yes

No

No

§ Note: 600V class drives below 77 Amps

(Frames 0-4) are declared to meet the Low

Voltage Directive. It is the responsibility of the user to determine compliance to the EMC directive.

#

Only available for 208…240V Frame 0-3 drives.

n

Special Firmware (Frames 0…6 Only)

Code

AD

♦

Type

60 Hz Maximum

AE

♦

AX

♦

BA

♦

Cascading Fan/Pump Control

82 Hz Maximum

Pump Off (for pump jack)

♦

Must be used with Vector Control option C or

D (Position k). Positions m-n are only required when custom firmware is supplied.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Step 1: Read the Precautions and General Information

Qualified Personnel

ATTENTION:

Only qualified personnel familiar with adjustable frequency AC drives and associated machinery must plan or implement the installation, startup and subsequent maintenance of the system. Failure to comply can result in personal injury and/or equipment damage.

Personal Safety

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 following points (refer to pages 28 through

30 for locations):

•

+DC and -DC terminals of the Power Terminal Block

•

+DC terminal of the Power Terminal Block and the chassis

•

-DC terminal of the Power Terminal Block and the chassis

The voltage must be zero for all three measurements.

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 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 can be required to remove the AC line to the drive. An auxiliary braking method can be required.

ATTENTION:

Loss of control in suspended load applications can cause personal injury and/or equipment damage. Loads must always be controlled by the drive or a mechanical brake. Parameters 600…611 are designed for lifting/torque proving applications. It is the responsibility of the engineer and/or end user to configure drive parameters, test any lifting functionality and meet safety requirements in accordance with all applicable codes and standards.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

5

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Product Safety

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 can result in malfunction of the system.

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 can result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference Guarding Against Electrostatic Damage, publication

8000-4.5.2 or any other applicable ESD protection handbook.

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 bus voltage is increasing toward a level that causes a fault. However, it can also cause either of the following two conditions to occur.

•

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 (F25) occurs if the speed reaches [Maximum Speed] +

[Overspeed Limit], (parameters 82 and 83). If this condition is unacceptable, action must 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).

•

Actual deceleration times can be longer than commanded deceleration times.

However, a “Decel Inhibit” fault (F24) 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 provides 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 to occur.

6

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

EMC Instructions

CE Conformity

Conformity with the Low Voltage (LV) Directive and Electromagnetic

Compatibility (EMC) Directive has been demonstrated by using harmonized

European Norm (EN) standards published in the Official Journal of the

European Communities. PowerFlex Drives

(1)

comply with the EN standards listed below when installed according to the information supplied in this publication and the Wiring & Grounding Guidelines Manual.

CE Declarations of Conformity are available online at: http://www.rockwellautomation.com/rockwellautomation/certification.

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

•

Some drives are equipped with an adhesive label on the top of the drive. 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 must be kept as short as possible to avoid electromagnetic emission as well as capacitive currents.

•

Use of line filters in ungrounded systems is not recommended.

•

PowerFlex drives can cause radio frequency interference if used in a residential or domestic environment. The installer 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.

•

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.

(1) 600V class drives below 77A (Frames 0…4) are declared to meet the essential requirements of the Low Voltage Directive. It is the responsibility of the user to determine compliance to the EMC directive.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

7

8

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

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 publication and the User Manual before installing the drive.

3.

Grounding as described in this publication and 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 must terminate with the proper shielded connector.

6.

The following conditions:

–

First Environment Restricted Distribution - For any drive and option a filter is required for motor cable lengths greater than 150 m (492 ft.).

–

Second Environment (Industrial) - Motor cable is limited to 30 m (98 ft.) for installations without additional external line filters.

External filters for First Environment installations and increasing motor cable lengths in Second Environment installations are available. Roxburgh models

KMFA (RF3 for UL installations) and MIF or Schaffner FN3258 and FN258 models are recommended. Refer to Table 1 and http://www.dem-uk.com

and http://www.mtecorp.com

(USA) or http://www.schaffner.com, respectively .

Table 1 - PowerFlex 700 Recommended Filters

Manufacturer Frame

Deltron 0

1

2

Manufacturer Part

No.

MIF316

KMF318A

KMF325A

KMF350A

2 without DC Common Mode Capacitor KMF350A

3 KMF370A

Class A

(Meters)

—

—

—

200

176

150

Schaffner

1

2

3 without DC Common Mode Capacitor KMF370A

0 FN358-16-45

FN358-30-47

FN358-42-47

150

—

—

50

2 without DC Common Mode Capacitor FN358-42-47

3 FN358-75-52

3 without DC Common Mode Capacitor FN358-75-52

150

100

150

150

150

150

100

100

Class B

(Meters)

150

100

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

Step 2: Mount the Drive

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Accessing the Terminals

Opening the Cover

S.M.A.R.T.

Esc

Exit

Sel

Lang Auto / Man Remove

Alt

1

.

Exp

7

4

2

0

8

5

9

6

3

+/-

Param #

Jog

CAUTION

HOT surfaces can cause severe burns

PORT

MOD

NET A

NET B

POWER

STS

Frames 0…4

Locate the slot in the upper left corner. Slide the locking tab up and swing the cover open. Special hinges allow cover to move away from drive and lay on top of adjacent drive (if present). See below for frame 4 access panel removal.

Frame 5

Slide the locking tab up, loosen the right-hand cover screw and remove. See below for access panel removal.

Frame 6

Loosen 2 screws at bottom of drive cover. Carefully slide bottom cover down & out. Loosen the 2 screws at top of cover and remove.

Cable Entry Plate Removal

If additional wiring access is needed, the Cable Entry Plate on 0…3 Frame drives can be removed. Simply loosen the screws securing the plate to the chassis. The slotted mounting holes assure easy removal.

IMPORTANT

Removing the Cable Entry Plate limits the maximum ambient temperature to

40 °C (104 °F).

Power Wiring Access Panel Removal

3

4

Frame

0, 1, 2 & 6

5

Removal Procedure

(Replace when wiring is complete)

Part of front cover, see above.

Open front cover and gently tap/slide cover down and out.

Loosen the 4 screws and remove.

Remove front cover (see above), gently tap/slide panel up and out.

Environment

Operating Temperatures

PowerFlex 700 drives are designed to operate at 0 to 40 °C ambient. To operate the drive in installations between 41 and 50 °C (106…122 °F), see Table 2 and refer to pages 34 through 41 for exceptions.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

9

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Table 2 - Acceptable Surrounding Air Temperature & Required Actions

Enclosure Rating

IP20, NEMA/UL Type 1

(with Top Label)

(1)

IP20, NEMA/UL Type Open

(Top Label Removed)

(1)

Temperature Range

0…40 °C (0…104 °F)

0…50 °C (0…122 °F)

0…50 °C (0…122 °F)

Drive

Frames 0…4, All Ratings

Frames 5…6, Most Ratings

(2)

Frames 0…6, Most Ratings

(2)

20BC072 Only

20BC072 Only

(3)

IP00, NEMA/UL Type Open

(Top Label & Vent Plate Removed)

Flange Mount

Front: IP00, NEMA/UL Type Open

Back/Heat Sink: IP54, NEMA/UL Type 12

0…45 °C (0…113 °F)

0…50 °C (0…122 °F)

0…55 °C (0…131 °F) Front (Inside Encl.)

0…40 °C (0…104 °F) Back (External)

Frames 5…6

Stand-alone/Wall Mount

IP54, NEMA/UL Type 12

0…40 °C (0…104 °F) Frames 5…6

(1) Removing the adhesive top label from the drive changes the NEMA/UL enclosure rating from Type 1 to Open. Frames 5 and 6 do not have a top label.

(2) Refer to pages 34 through 41 for exceptions.

(3) To remove vent plate (see page 11

for location), lift top edge of plate from the chassis. Rotate the plate out from the back plate.

Minimum Mounting Clearances

101.6 mm

(4.0 in.)

101.6 mm

(4.0 in.)

PWR

STS

PWR

STS

No Adhesive Label

(see Table 2 )

101.6 mm

(4.0 in.)

PWR

STS

With Adhesive Label

(see Table 2 )

PORT

MOD

NET A

NET B

PORT

MOD

NET A

NET B

PORT

MOD

NET A

NET B

Airflow through the drive must not be impeded.

Refer to pages 11 through 20 for detailed dimension information.

101.6 mm

(4.0 in.)

101.6 mm

(4.0 in.)

101.6 mm

(4.0 in.)

50.8 mm

(2.0 in.)

101.6 mm

(4.0 in.)

PWR

STS

PORT

MOD

NET A

NET B

101.6 mm

(4.0 in.)

Specified vertical clearance requirements (indicated above) are intended to be from the drive to the closest object that can restrict airflow through the drive heat sink and chassis. The drive must be mounted in a vertical orientation as shown and must make full contact with the mounting surface. Do not use standoffs or spacers. In addition, inlet air temperature must not exceed the product specification.

10

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

15.0 (0.59)

5.8 (0.23) dia.

D

A

B

E

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Dimensions

Frames 0…3 – IP20, NEMA/UL Type 1

Frame 0 Shown

C

Weight

(1)

kg (lbs.)

Drive

Drive &

Packaging A B C D E

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) 495.0 (19.49) 18.55 (40.9) 22.68 (50)

(1) Weights include HIM and Standard I/O.

96.0 (3.78)

75.0 (2.95)

55.0 (2.17)

35.0 (1.38)

30.2

(1.19)

187.5

(7.38)

132.9

(5.23)

8.0

(0.31)

CAUTION

HOT surfaces can cause severe burns

5.5 (0.22) x 3 - Frames 0…1

7.0 (0.28) x 3 - Frames 2…3

Frame 0

22.2 (0.87) Dia.

4 Places

185.0

(7.28)

.

108.5 (4.27)

87.5 (3.44)

67.5 (2.66)

47.5 (1.87)

28.6 (1.13) Dia.

187.6

(7.39)

25.5

(1.00)

133.3

(5.25)

Frame 1

22.2 (0.87) Dia.

3 Places

162.3

(6.39)

185.1

(7.29)

41.9 (1.65)

56.1 (2.21)

75.9 (2.99)

96.0 (3.78)

43.0 (1.69)

70.0 (2.76)

75.9 (2.99)

96.0 (3.78)

22.2 (0.87) Dia.

28.7 (1.13) Dia.

2 Places

Frame 3

All

except

50 Hp, 480V (37 kW, 400V)

105.3 (4.15)

94.7 (3.73)

37.3 (1.47) Dia.

2 Places

165.1

(6.50)

151.1

(5.95)

127.7

(5.03)

160.1

(6.30)

184.5

(7.26)

22.7 (0.89)

29.0 (1.14)

66.0 (2.60)

97.0 (3.82)

137.2 (5.40)

187.0 (7.36)

Dimensions are in millimeters and (inches)

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

Frame 2

167.5 (6.59)

156.9 (6.18) 28.7 (1.13) D

3 Places

22.4 (0.88) Dia.

2 Places

157.5

(6.20)

150.9

(5.94)

112.1

(4.41)

184.8

(7.28)

39.3 (1.55)

57.2 (2.25)

72.7 (2.86)

106.0 (4.17)

139.4 (5.49)

177.4 (6.98)

Frame 3

50 Hp, 480V (37 kW, 400V) Normal Duty Drive

34.9 (1.37) Dia.

2 Places

46.7 (1.84) Dia.

2 Places

28.7 (1.13) Dia.

2 Places

105.3 (4.15)

94.7 (3.73)

165.1

(6.50)

127.7

(5.03)

160.1

(6.30)

184.5

(7.26)

Vent Plate

22.7 (0.89)

29.0 (1.14)

66.0 (2.60)

130.0 (5.12)

186.0 (7.32)

11

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Frame 4 – IP20, NEMA/UL Type 1

15.0 (0.59)

7.0 (0.28) dia.

220.0 (8.66)

192.0 (7.56)

201.7 (7.94)

758.8

(29.87)

738.2

(29.06)

Dimensions are in millimeters and (inches)

12

7.0 (0.28) x 3

8.0

(0.31)

Lifting Holes x 4

e Approx. Weight

(1)

kg (lbs.)

Drive Drive & Packaging

4 24.49 (54.0) 29.03 (64.0)

(1) Weights include HIM and Standard I/O.

28.7 (1.13) Dia.

2 Places

47.0 (1.85) Dia.

2 Places

54.1 (2.13) Dia.

2 Places

76.0 (2.99)

65.3 (2.57)

22.2 (0.87) Dia.

189.7

(7.47)

177.9

(7.00)

157.9

(6.21)

141.9

(5.59)

105.1

(4.14)

26.8 (1.06)

36.8 (1.45)

50.7 (2.00)

63.8 (2.51)

112.0 (4.41)

180.0 (7.09)

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

Frame 5 – IP20, NEMA/UL Type 1

37.6 (1.48)

308.9 (12.16)

259.1 (10.20)

225.0 (8.86)

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

6.5 (0.26)

15.0 (0.59)

275.4 (10.84)

689.6

(27.15)

644.5

(25.37)

625.0

(24.61)

617.0

(24.29)

CAUTION

HOT surfaces can cause severe burns

Junction Box

12.5

(0.49)

6.5

(0.26)

Lifting Holes x 4

12.7 (0.50) Dia.

Dimensions are in millimeters and (inches)

241.9

(9.52)

229.5

(9.04)

220.0

(8.66)

184.0

(7.24)

159.5

(6.28)

96.0

(3.78)

28.0 (1.10)

45.0 (1.77)

85.0 (3.35)

150.0 (5.91)

215.0 (8.46)

255.0 (10.04)

30 kW, 208V (40 Hp, 240V)

55 kW, 400V (75 Hp, 480V)

45/55/75 kW, 690V (75 Hp, 600V)

104.0 (4.09)

93.2 (3.67)

Approx. Weight

(1)

kg (lbs.)

Drive Drive & Packaging

5 37.19 (82.0) 49.50 (109.0)

(1) Weights include HIM and Standard I/O. Add 2.70 kg (6.0 lbs.) for the 20BC140 drive.

34.9 (1.37) Dia.

2 Places

22.2 (0.87) Dia.

2 Places

62.7 (2.47) Dia.

2 Places

241.9

(9.52)

223.5

(8.80)

188.5

(7.42)

184.3

(7.26)

153.5

(6.04)

96.0

(3.78)

28.0 (1.10)

44.0 (1.73)

66.4 (2.61)

128.0 (5.04)

232.3 (9.15)

42.6 (1.68)

31.9 (1.26)

37 kW, 208V (50 Hp, 240V)

75 kW, 400V (100 Hp, 480V)

90kW, 690V (100 Hp, 600V)

34.9 (1.37) Dia.

22.2 (0.87) Dia.

2 Places

62.7 (2.47) Dia.

2 Places

Removable Junction Box

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

13

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Frame 5 – IP54, NEMA Type 12 Standalone (400…690V drives only)

25.4 (1.00)

105.5 (4.15)

609.6 (24.00)

558.8 (22.00)

1543.0 ±1.5

(62.75 ±0.06)

1574.8

(62.00)

1061.5

(41.79)

DANGER

REMOTE SOURCE(S) OF POWER.

DISCONNECT ALL SOURCES OF POWER

BEFORE OPENING THE DOOR.

DANGER

ELECTRICAL SHOCK HAZARD FROM

ENERGY STORAGE CAPACITORS.

VERIFY LOW VOLTAGE DISCHARGE

BEFORE SERVICING.

SEE INSTRUCTION MANUAL.

Air

Outlet

16.8 (0.66)

450.7

(17.75)

Max.

425.5

(16.75)

287.0

(11.30)

140.0

(5.51)

13.5 (0.53) Dia. x 4

12.7 (0.50) Dia.

Lifting Holes

Mount with 0.50 in. UNC Grade 5 or higher screws or

M12 Material Class 5.6 or higher screws.

Use flat washer with each fastener.

Dimensions are in millimeters and (inches)

Approx. Weight

(1) kg (lbs.)

Description

5 Standalone

Drive

102.51 (226.0)

(1) Weights include HIM and Standard I/O.

Drive & Packaging

154.68 (341.0)

14

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Frame 5 – IP54, NEMA Type 12 Flange Mount (400…690V drives only)

11.0 (0.43)

219.5 (8.64)

500.0 (19.69)

196.5 (7.74)

478.0 (18.82)

12.7 (0.50) Dia. Lifting Holes x 4

Air

Outlet

1061.0

(41.77)

1039.0

(40.91)

SHLD

SHLD

127.6

(5.02)

449.6

(17.74)

BRAKE TERMINAL RATINGS

WIRE RANGE: 14-1/0 AWG (2.5-50 MM2)

TORQUE: 32 IN-LB (3.6 N-M)

STRIP LENGTH: 0.67 IN (17 MM)

GROUND TERMINAL RATINGS (PE)

WIRE RANGE: 6-1/0 AWG (18-35 MM2)

TORQUE: 44 IN-LB (5 N-M)

STRIP LENGTH: 0.83 IN (21 MM)

POWER & DC TERMINAL RATINGS

USE 75 C CU WIRE ONLY

WIRE RANGE: 4-3/0 AWG (18-70 MM2)

TORQUE: 133 IN-LB (15 N-M)

STRIP LENGTH: 1.02 IN (26 MM)

OUTPUT

6 MM HEX KEY

300 VDC EXT PWR SPLY TERM (PS+, PS-)

WIRE RANGE: 22-10 AWG (0.5-4 MM2)

TORQUE: 5.3 IN-LB (0.6 N-M)

STRIP LENGTH: 0.35 IN (9 MM)

INPUT AC

6 MM HEX KEY

DANGER

RISK OF ELECTRIC

SHOCK AND DEATH

DANGER

FIELD INSTALLED OPTIONS

194.0

(7.60)

53.2

(2.09)

5.5 (0.22) Dia. x 40

11.0 (0.43)

303.6

(11.95)

2.3 (0.09)

Compressed

Gasket

97.0

(3.82)

42.0 (1.65)

Ground

M5 PEM Nut

384.0 (15.12)

185.0

(7.30)

Dimensions are in millimeters and (inches)

Approx. Weight

(1) kg (lbs.)

Description

5 Flange Mount

Drive

61.69 (136.0)

(1) Weights include HIM and Standard I/O.

Drive & Packaging

81.65 (180.0)

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

15

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Frame 5 – Flange Mount Cutout

4.00 (0.157) Dia. x 40, minimum 14

GA. (1.9) steel mounting surface.

Deburr Pilot Holes and Drive Cutout.

10.0

(0.39)

1039.0

(40.91)

1026.5 (40.41)

948.5 (37.34)

870.5 (34.27)

792.5 (31.20)

714.5 (28.13)

636.5 (25.06)

558.5 (21.99)

480.5 (18.92)

402.5 (15.85)

324.5 (12.78)

246.5 (9.71)

168.5 (6.63)

90.5

(3.56)

12.5 (0.49)

59.0 (2.32)

131.0 (5.16)

203.0 (7.99)

275.0 (10.83)

347.0 (13.66)

419.0 (16.50)

478.0 (18.82)

458.0 (18.03)

Cutout

Dimensions are in millimeters and (inches)

1019.0

(40.12)

10.0

(0.39)

16

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

Frame 6 – IP20, NEMA/UL Type 1

49.6 (1.95)

403.9 (15.90)

360.6 (14.20)

300.0 (11.81)

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

8.5 (0.33)

18.0 (0.71)

275.5 (10.85)

850.0

(33.46)

825.0

(32.48)

126.3

(4.97)

Old Style Junction Box

13.5

(0.53)

New Style Junction Box

Junction Box can be removed if drive is mounted in a cabinet

8.5

(0.33)

Lifting Holes x 4

12.7 (0.50) Dia.

Dimensions are in millimeters and (inches)

Approx. Weight

(1) kg (lbs.)

Drive

6 71.44 (157.5)

Drive & Packaging

100.9 (222.0)

(1) Weights include HIM and Standard I/O. Add 13.60 kg (30.0 lbs.) for; 20BB260, 20BC260 and 20BD248.

56.2 (2.21)

45.6 (1.80)

34.9 (1.37) Dia.

3 Places

62.7 (2.47) Dia.

3 Places

22.2 (0.87) Dia.

4 Places

Removable Junction Box

242.0

(9.53)

222.3

(8.75)

148.5

(5.85)

116.6

(4.59)

47.1 (1.85)

52.1 (2.05)

69.1 (2.72)

130.1 (5.12)

230.1 (9.06)

280.1 (11.03)

330.1 (13.00)

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

151.8

(5.98)

185.4

(7.30)

219.0

(8.62)

17

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Frame 6 – IP54, NEMA Type 12 Standalone (400…690V drives only)

24.1 (0.90)

123.6 (4.90)

711.3 (28.00)

663.1 (26.10)

1828.8

(72.00)

1279.5

(50.40)

1795.2

(70.70)

16.8 (0.66)

487.8

(19.20) Max.

13.5 (0.53) Dia. x 4

12.7 (0.50) Dia.

Lifting Holes

283.3

(11.20)

Mount with 0.50 in. UNC Grade 5 or higher screws or

M12 Material Class 5.6 or higher screws.

Use flat washer with each fastener

Dimensions are in millimeters and (inches)

8.0

(0.30)

Approx. Weight

(1)

kg (lbs.)

Description

6 Standalone

Drive

176.90 (390.0)

(1) Weights include HIM and Standard I/O.

Drive & Packaging

229.07 (505.0)

18

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Frame 6 – IP54, NEMA Type 12 Flange Mount (400…690V drives only)

201.0 (7.90)

584.0 (23.00)

556.0 (21.90)

14.0 (0.60)

105.8

(4.17)

1100.0

(43.30)

1078.0

(42.40)

763.3

(30.0)

11.0 (0.43)

294.7

(11.60)

2.4 (0.10)

Compressed

Gasket

131.6

(5.20)

57.9 (2.30)

BR2 BR1 DC+ DCU

T1

V

T2

W

T3

OUTPUT

USE 75C COPPER WIRE ONLY, TORQUE 52 IN-LB (6 N-M)

PE PE R

L1

S

L2

T

L3

Ground - M5 PEM Stud

137.2

(5.40)

127.3

(5.00)

5.5 (0.22) Dia. x 44

468.2 (18.40)

193.7

(7.60)

Dimensions are in millimeters and

(inches)

Description

6 Flange Mount

Approx. Weight

(1)

kg (lbs.)

Drive

99.79 (220.0)

(1) Weights include HIM and Standard I/O.

Drive & Packaging

119.75 (264.0)

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

19

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Frame 6 – Flange Mount Cutout

4.00 (0.157) Dia. x 44, minimum

14 GA. (1.9) steel mounting surface.

Deburr pilot holes and drive cutout.

12.0

(0.50)

1078.0 (42.40)

1043.0 (41.10)

971.0 (38.20)

899.0 (35.40)

827.0 (32.60)

755.0 (29.70)

683.0 (26.90)

611.0 (24.10)

539.0 (21.20)

467.0 (18.40)

395.0 (15.60)

323.0 (12.70)

251.0 (9.90)

179.0

(7.00)

107.0

(4.20)

44.0 (1.70)

122.0 (4.80)

200.0 (7.90)

278.0 (10.90)

356.0 (14.00)

434.0 (17.10)

512.0 (20.20)

532.0

(20.90)

Cutout

Dimensions are in millimeters and (inches)

1054.0

(41.5)

35.0

(1.40)

12.0

(0.50)

20

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

Step 3: Wire the Drive –

Power

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Special Considerations

PowerFlex 700 drives are suitable for use on a circuit capable of delivering up to a maximum of 200,000 rms symmetrical amperes.

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 on page 33 .

If a system ground fault monitor (RCD) is to be used, only Type B (adjustable) devices must be used to avoid nuisance tripping.

Unbalanced, Ungrounded, Resistive or B Phase Grounded Distribution Systems

If phase to ground voltage exceeds 125% of normal line to line voltage or the supply system is ungrounded, refer to the Wiring and Grounding Guidelines for

Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001 .

ATTENTION:

To guard against drive damage, PowerFlex 700 drives contain protective MOVs and common mode capacitors that are referenced to ground.

These devices must be disconnected if the drive is not installed on a solidly grounded system. See page 43 for details.

Input Power Conditioning

Certain events on the power system supplying a drive can cause component damage or shortened product life. These conditions are divided into 2 basic categories:

1. All drives

•

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.

2. 5 Hp or Less Drives (in addition to “ 1 ” above)

•

The nearest supply transformer is larger than 100 kVA or the available short circuit (fault) current is greater than 100,000A.

•

The impedance in front of the drive is less than 0.5%.

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 by using the information supplied in Wiring and Grounding

Guidelines for Pulse Width Modulated (PWM) AC Drives, publication

DRIVES-IN001 .

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

21

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

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 can result in personal injury and/or equipment damage.

EMC Compliance

Refer to page 7 for details.

CabIe Trays and Conduit

If cable trays or large conduits are to be used, refer to the guidelines presented in the Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC

Drives, publication DRIVES-IN001.

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 must be disabled. This helps minimize the possible shock hazard from “cross coupled” motor leads.

Motor Cable Lengths

Typically, motor lead lengths less than 30 meters (100 feet) are acceptable.

However, if your application dictates longer lengths, refer to the Wiring and

Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001 or the PowerFlex 700 Technical Data, publication

20B-TD001 .

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 °C. 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 and must not have large variations in insulation concentricity.

22

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Shielded/Armored 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 must be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other devices that can 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 can also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable can help extend the distance that the motor is from the drive without the addition of motor protective devices such as terminator networks. Refer to the Reflected

Wave topic in the Wiring and Grounding Guidelines for Pulse Width Modulated

(PWM) AC Drives, publication DRIVES-IN001 .

Consideration must 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 must 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 can limit the allowable cable length. Particularly, some of the newer cables bundle 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. See Table 3 .

Table 3 - Recommended Shielded Wire

Location Rating/Type

Standard

(Option 1)

600V, 90 °C (194 °F)

XHHW2/RHW-2 Anixter

B209500-B209507, Belden

29501-29507, or equivalent

Standard

(Option 2)

Tray rated 600V, 90 °C

(194 °F) RHH/RHW-2 Anixter

OLF-7xxxxx or equivalent

Class I & II;

Division I &

II

Tray rated 600V, 90 °C

(194 °F) RHH/RHW-2 Anixter

7V-7xxxx-3G or equivalent

Description

• 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.

• 5 mil single helical copper tape (25% overlap min.) 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 on #10 AWG and smaller.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

23

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Single-Phase Input Power

The PowerFlex 700 drive is typically used with a three-phase input supply. Singlephase operation is possible with output current derated by 50% (at maximum ambient temperature of 25 °C) of the three-phase ratings. Refer to tables 4 through 6 .

AC Input Phase Selection (Frames 5…6 Only)

ATTENTION:

To avoid a shock hazard, ensure that all power to the drive has been removed before performing the following.

Moving the “Line Type” jumper on the Precharge Board (see below) allows single or three-phase operation.

IMPORTANT

When selecting single-phase operation, input power must be applied to the

R (L1) and S (L2) terminals. This ensures that the fan is properly powered.

Typical Location - Phase Select Jumper

JP3 JP2 JP1

AC Input

Precharge

Board

3-PH 1-PH

LINE

TYPE

SPARE 1

SPARE 2

24

Table 4 - 208/240 Volt Single-Phase AC Input Ratings

Drive

Catalog

Number e Hp

Rating

20BB2P2 0 0.25

20BB4P2 0 0.5

20BB6P8 1 1

20BB9P6 1 1.5

20BB015 1 2.5

20BB022 1 3.75

20BB028 2 5

20BB042 3 7.5

20BB052 3 10

20BB070 4 12.5

20BB080 4 15

20BB104 5 20

20BB130 5 25

20BB154 6 30

20BB192 6 37.5

20BB260 6 50

240V Single-Phase AC Input

5.1

7.2

11.9

17.3

Input

Amps

1.5

2.8

Three-Phase

Output

V AC Amps

0-230 1.1

0-230 2.1

0-230 3.4

0-230 4.8

0-230 7.7

0-230 11

22.2

33.4

41.3

55.6

0-230 14

0-230 21

0-230 26

0-230 35

63.6

84.6

0-230

0-230

40

52

105.7

0-230 65

125.2

0-230 77

156.1

0-230 96

211.4

0-230 130

208V Single-Phase AC Input

Drive

Catalog

Number e Hp

Rating

20BB2P2 0 0.25

20BB4P2 0 0.5

20BB6P8 1 1

20BB9P6 1 1.5

20BB015 1 2.5

20BB022 1 3.75

20BB028 2 5

20BB042 3 7.5

20BB052 3 10

20BB070 4 12.5

20BB080 4 15

20BB104 5 20

20BB130 5 25

20BB154 6 30

20BB192 6 37.5

20BB260 6 50

25.7

38.5

44.6

62.3

73.3

97.9

106.1

144.4

180.3

212.1

5.9

8.3

13.6

19.9

Input

Amps

1.7

3.2

Three-Phase

Output

V AC

Temp.

Amps °C

0-200 1.3

0-200 2.4

25

25

0-200 3.9

0-200 5.5

0-200 8.8

0-200 12.7

25

25

25

25

0-200 16.1

0-200 24.2

0-200 28

0-200 39.1

0-200 46

0-200 60

0-200 65

0-200 88.5

0-200 110.5

25

0-200 130 25

25

25

25

25

25

25

25

25

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Table 5 - 380…480 Volt Single-Phase AC Input Ratings

Drive

Catalog

Number e Hp

Rating

20BD1P1 0 0.25

20BD2P1 0 0.5

20BD3P4 0 1

20BD5P0 0 1.5

20BD8P0 0 2.5

20BD011 0 3.75

20BD014 1 5

20BD022 1 7.5

20BD027 2 10

20BD034 2 12.5

20BD040 3 15

20BD052 3 20

20BD065 3 25

20BD077 4 30

20BD096 5 37.5

20BD125 5 50

– – –

20BD156 6 62.5

20BD180 6 75

20BD248 6 100

480V Single-Phase AC Input

41.3

51.6

62.6

78.1

17.3

21.4

27

31.8

Input

Amps

0.7

1.4

2.3

3.4

6

8.2

10.9

Three-Phase

Output

V AC

0-460

0-460

0-460

0-460

0-460

0-460

0-460

0-460

0-460

0-460

0-460

0-460

0-460

0-460

0-460

Amps

0.6

1.1

1.7

2.5

4

5.5

7

11

13.5

17

20

26

32.5

38.5

48

101.6

0-460 62.5

– – –

126.8

0-460 78

146.4

0-460 90

201.6

0-460 124

380…400V Single-Phase AC Input

Drive

Catalog

Number e kW

Rating

20BC1P3 0 0.2

20BC2P1 0 0.4

20BC3P5 0 0.75

20BC5P0 0 1.1

20BC8P7 0 2

20BC011

20BC015

0 2.75

1 3.75

20BC022

20BC030

20BC037

20BC043

1 5.5

2 7.5

2 9.25

3 11

20BC056 3 15

20BC072 3 18.5

20BC085 4 22.5

20BC105 5 27.5

20BC125 5 27.5

20BC140 5 37.5

20BC170 6 45

20BC205 6 55

20BC260 6 66

45.9

59.7

70.5

87

17.8

24.6

30.3

35.2

103.6

117.4

142.6

171.9

220.6

Input

Amps

1

1.6

2.7

3.9

6.9

9.3

12.5

Three-Phase

Output

V AC

Temp.

Amps °C

0-400 0.7

0-400 1.1

0-400 1.8

25

25

25

0-400 2.5

0-400 4.4

0-400 5.8

0-400 7.7

0-400 11

0-400 15

0-400 18.5

0-400 21.5

25

25

25

25

25

25

25

25

0-400 28

0-400 36

0-400 42.5

0-400 52.5

0-400 62.5

0-400 70

0-400 85 25

0-400 102.5

25

0-400 130 25

25

25

25

25

25

25

Table 6 - 600…690 Volt Single-Phase AC Input Rating

Drive

Catalog

Number e Hp

Rating

20BE1P7 0 0.5

20BE2P7 0 1

20BE3P9 0 1.5

20BE6P1 0 2.5

20BE9P0 0 3.75

20BE011 1 5

20BE017 1 7.5

20BE022 2 10

20BE027 2 12.5

20BE032 3 15

20BE041 3 20

20BE052 3 25

20BE062 4 30

20BE077 5 37.5

20BE099 5 50

20BE125 6 62.5

20BE144 6 75

600V Single-Phase AC Input

32.6

41.3

50.4

62.6

13.3

17.5

21.4

25.4

2.6

4.6

6.7

8.5

Input

Amps

1.1

1.8

Three-Phase

Output

V AC

0-575 0.9

0-575 1.4

0-575 2

0-575 3.1

0-575 4.5

0-575 5.5

0-575

0-575

0-575

0-575

0-575

0-575

0-575

0-575

Amps

8.5

11

13.5

16

20.5

26

31

38.5

80.5

0-575 49.5

101.6

0-575 62.5

117.1

0-575 72

–

–

–

–

–

20BF052

20BF060

20BF082

–

–

–

–

–

–

Drive

Catalog

Number

20BF098

20BF119

20BF142

– –

– –

– –

– –

– –

5 22.5

5 27.5

5 37.5

e kW

Rating

– –

– –

– –

– –

– –

– –

5 45

6 55

6 66

690V Single-Phase AC Input

–

43.1

49.9

68.4

–

–

–

–

–

–

–

–

–

–

Input

Amps

–

–

–

–

–

–

Three-Phase

Output

V AC

Temp.

Amps °C

–

–

–

–

–

0-690

0-690

0-690

–

–

–

–

–

–

–

–

–

–

–

26

30

41

82

100

0-690

0-690

49

59.5

120.2

0-690 71

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

25

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Selecting/Verifying Fan Voltage (Frames 5…6 Only)

ATTENTION:

To avoid a shock hazard, ensure that all power to the drive has been removed before performing the following.

26

IMPORTANT

Frames 5 & 6 utilize a fan transformer to power the internal fan(s). This transformer is sized specifically for the internal fan(s) and must not be used to power other circuitry.

If your line voltage is different than the voltage class specified on the drive nameplate, it can be necessary to change transformer taps as described. DC input drives require user supplied 120 or 240V AC to power the cooling fans. The power source is connected between “0 VAC” and the terminal corresponding to your source voltage.

Table 7 - Frames 5…6 Fan Connections

Drive

Type Enclosure

DC

Input

IP00, NEMA/UL

Type Open

AC

Input

IP20, NEMA/UL

Type 1

IP54, NEMA/UL

Type 12

IP00, NEMA/UL

Type Open

IP20, NEMA/UL

Type 1

IP54, NEMA/UL

Type 12

Rating

(120VAC)

100 VA

(Frame 5)

138 VA

(Frame 6)

100 VA

(Frame 5)

138 VA

(Frame 6)

100 VA

(Frame 5)

138 VA

(Frame 6)

100 VA

(Frame 5)

138 VA

(Frame 6)

No. of

Fans Connect at …

1 Power Terminal Block

Requires user supplied 120 or 240V AC. See page 29 for TB locations and terminal designations.

1

1

1

N/A (Connected internally)

A transformer matches the input line voltage to the internal fan voltage. If line voltage is different than the voltage class specified on the drive nameplate, the transformer taps may require changing.

The transformer is behind the Power Terminal Block. Access is gained by releasing the terminal block from the rail and removing the transformer cover plate.

1. Locate the small metal tab at the bottom of the end terminal block.

2. Press the tab-in and pull the top of the block out. Repeat for the next block if desired.

3. Remove the transformer cover plate.

4. Select the appropriate transformer tap.

5. Replace cover and terminal block.

Primary

P3

P2

P1

Fuse

3.5A, 250V

Red

Secondary

115V

Red

Primary

400/480V

600/690V

Terminal

P2

P3

P2

P3

Voltage

400

600

480

690

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Auxiliary Control Power Supply

If desired, an auxiliary control power supply can be used with certain drives to keep the control logic up when the main AC power is removed. An auxiliary control power supply can only be used with:

•

400/480 and 600/690 Volt drives with Vector Control (15 th

position of the catalog number string equals “C,” or “D”).

Using an auxiliary control power supply requires the use of some type of AC line monitoring, as well as control of the Precharge Enable signal. Consult the factory for additional guidance.

ATTENTION:

An Auxiliary Control Power Supply Must Not be used with any

PowerFlex 700 Standard Control drive or 200/240 Volt Vector Control drive.

Using the power supply with these drives causes equipment/component damage.

Refer to page 29 for terminal block locations.

Power supply must provide

UL Installation 300V DC, ±10%

Non UL Installation 270…600V DC, ±10%

Frames 0…3: 40 W, 165 mA,

Frame 5: 80 W, 90 mA

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

27

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Power Terminal Blocks

No.

Name Frame

➊

Power

Terminal

Block

0…1

2

3

4

5

75Hp,480V

100Hp,600V

5

100Hp

6

Wire Size Range

(2)

Torque

Description

Input power and motor connections

Input power and motor connections

Input power and motor connections

BR1, 2 terminals

Input power and motor connections

10.0 mm

2

(8 AWG)

35.0 mm

2

(2 AWG)

50.0 mm

2

(1/0 AWG)

Input power, DC+,

DC–, BR1, 2, PE, motor connections

Input power, DC+,

DC– and motor

70.0 mm

2

(2/0 AWG)

BR1, 2, PE terminals 50.0 mm

2

(1/0 AWG)

Input power, DC+,

DC–, BR1, 2, PE, motor connections

150.0 mm

2

(300 MCM) see Note

(3)

Maximum Minimum Maximum Recommended

4.0 mm

2

(12 AWG)

0.5 mm

2

(22 AWG)

1.7 N•m

(15 lb•in)

0.8 N•m

(7 lb•in)

10.0 mm

2

(8 AWG)

25.0 mm

2

(3 AWG)

0.8 mm

2

(18 AWG)

2.5 mm

2

(14 AWG)

1.7 N•m

(15 lb•in)

3.6 N•m

(32 lb•in)

1.4 N•m

(12 lb•in)

1.8 N•m

(16 lb•in)

0.8 mm

2

(18 AWG)

10.0 mm

2

(8 AWG)

4.0 mm

2

(12 AWG)

1.7 N•m

(15 lb•in)

4.0 N•m

(35 lb•in)

See Note

(4)

1.4 N•m

(12 lb•in)

4.0 N•m

(35 lb•in)

10.0 mm

(8 AWG)

4.0 mm

2.5 mm

2

(12 AWG)

2

(14 AWG)

2

6.0 N•m

(52 lb•in)

6.0 N•m

(52 lb•in)

➋

SHLD

Terminal

➌

AUX

Terminal

Block

0…6

0…4

5…6

Terminating point for wiring shields

— — 1.6 N•m

(14 lb•in)

1.6 N•m

(14 lb•in)

Auxiliary Control

Voltage

PS+, PS–

(1)

1.5 mm

2

(16 AWG)

4.0 mm

2

(12 AWG)

0.2 mm

2

(24 AWG)

0.5 mm

2

(22 AWG)

—

0.6 N•m

(5.3 lb•in)

—

0.6 N•m

(5.3 lb•in)

➍

Fan

Terminal

Block

5…6 User Supplied Fan

Voltage

4.0 mm

2

(12 AWG)

0.5 mm

2

(22 AWG)

0.6 N•m

(5.3 lb•in)

(1) 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. Refer to the User Manual for further information.

(2)

Maximum/minimum wire sizes that the terminal block accepts

- these are not recommendations.

(3) If can be necessary to connect multiple wires in parallel to these terminals by using multiple lugs.

(4) Refer to the terminal block label inside the drive.

0.6 N•m

(5.3 lb•in)

28

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Typical Terminal Block Location

➌

DANGER

Use 75C Wire Only

#10-#14 AWG

Torque to 7 in-lbs

BR1

BR2

DC+

DC–

PE

U/T1

V/T2

W/T3

R/L1

S/L2

T/L3

➊

➋

Frames 0…1

➌

➊

AUX IN+ AUX OUT–

BR1 B

Optional

Communications

Module

V/T2 W/T3

WIRE

STRIP

1.4 N-M

75C Cu Wire

6 AWG [10MM

12 IN. LBS.

] Max.

} TORQUE

PE R/L1 S/L2 T/L3

SHLD SHLD

Frame 2

➋

Optional

Communications

Module

PE B

PE A

➊

➌

/

PE

SHLD

WIRE

STRIP

BR1 BR2

75C Cu Wire

6 AWG [10MM2] Max.

12 IN. LBS.

} TORQUE

1.4 N-M

75C Cu Wire

2

3 AWG [25MM ] Max.

16 IN. LBS.

1.8 N-M } TORQUE

AUX IN

+ –

BR1 BR2 DC+ DC- U/T1 V/T2 W/T3 R/L1 S/L2 T/L3

PE

SHLD

➋

Frames 3…4

Frame 5 Frame 6

➋

Optional

Communications

Module

➋

Optional

Communications

Module

POWER TERMINAL RATINGS

WIRE RANGE: 14-1/0 AWG (2.5-35 MM2)

TORQUE: 32 IN-LB (3.6 N-M)

STRIP LENGTH: 0.67 IN (17 MM)

USE 75 C CU WIRE ONLY

GROUND TERMINAL RATINGS (PE)

WIRE RANGE: 6-1/0 AWG (16-35 MM2)

TORQUE: 44 IN-LB (5 N-M)

STRIP LENGTH: 0.83 IN (21 MM)

17

OUTPUT

21

300 VDC EXT PWR SPLY TERM (PS+, PS-)

WIRE RANGE: 22-10 AWG (0.5-4 MM2)

TORQUE: 5.3 IN-LB (0.6 N-M)

STRIP LENGTH: 0.35 IN (9 MM)

9

INPUT AC

➌

➊

Junction Box supplied on:

37 kW, 208V (50 Hp, 240V)

75 kW, 400V (100 Hp, 480V)

90kW, 690V (100 Hp, 600V)

For item number descriptions, see page 28 .

➌

22-10

AWG

5.3 IN-LB

(0.6 N-M)

BR2 BR1 DC+

USE 75C COPPER WIRE ONLY, TORQUE 52 IN-LB (6 N-M)

DC–

➊

➍

DC Input Drives

Only

USE 75C

COPPER WIRE

ONLY

TORQUE

52 IN-LB

(6 N-M)

T1 T2

OUTPUT

T3 L1 L2

INPUT

L3

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

29

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Terminal Block Details

Frame Power Terminal Blocks

0…1

BR1

BR2

DC+

DC–

PE

U (T1)

V (T2)

W (T3)

R (L1)

S (L2)

T (L3)

2

BR1 BR2 DC+ DC– U

(T1)

V

(T2)

W

(T3)

PE R

(L1)

S

(L2)

T

(L3)

3…4

Notes:

Shaded BR1 & BR2 Terminals are only present on drives ordered with the Brake Option.

➊

Precharge Resistor Fuse – DCT12-2

(DC input drives w/precharge only)

➋

M8 Stud (All Terminals)

Max. Lug Width = 25.4 mm (1 in.)

➌

M8 Stud (All Terminals)

Max. Lug Width = 31.8 mm (1.25 in.)

5

BR1 BR2 DC+ DC– U

(T1)

V

(T2)

W

(T3)

R

(L1)

S

(L2)

T

(L3)

AC Input (Ratings are Normal Duty)

240V, 40 Hp 480V, 75 Hp 690V, 45…90 kW

400V, 55 kW 600V, 75 Hp

BR2*

BR1*/

DC+

DC+

DC–

U/T1

V/T2

W/T3 PE

PS–

PE R/L1 S/L2 T/L3

DC Input (Ratings are Normal Duty)

240V, 40 Hp 480V, 75 Hp 690V, 45…90 kW

400V, 55 kW 600V, 75 Hp

PS–

BR2*

BR1*/

DC+

DC+ DC– U/T1 V/T2 W/T3 PE

0

VAC

240

VAC

PE

PS+

240V, 50 Hp 480V, 100 Hp

400V, 75 kW 600V, 100 Hp

PS–

BR2*

BR1*/

DC+

DC+ DC– U/T1 V/T2 W/T3

PE PE

R/L1 S/L2 T/L3

PS+

120

VAC

➊

240V, 50 Hp 480V, 100 Hp

400V, 75 kW 600V, 100 Hp

U/T1 V/T2 W/T3

PE

0

VAC

240

VAC

PE

PS–

BR2*

BR1*/

DC+ DC+ DC–

6

PS+

125…200 Hp

➌

PS+

125…200 Hp

➊

➋

120

VAC

22-10

AWG

5.3 IN-LB

(0.6 N-M)

BR2 BR1 DC+ DC–

USE 75 C COPPER WIRE ONLY, TORQUE 52 IN-LB (6 N-M)

22-10

AWG

5.3 IN-LB

(0.6 N-M)

BR2 BR1 DC+ DC–

USE 75 C COPPER WIRE ONLY, TORQUE 52 IN-LB (6 N-M)

➊

USE 75 C

COPPER WIRE

ONLY

TORQUE

52 IN-LB

(6 N-M)

U

T1

V

T2

OUTPUT

W

T3

PE PE R

L1

S

L2

INPUT

T

L3

USE 75 C

COPPER WIRE

ONLY

TORQUE

52 IN-LB

(6 N-M)

U

T1

V

T2

OUTPUT

W

T3

PE PE

22-10 AWG

5.3 IN-LB

(0.6 N-M)

30

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

R

S

T

U

V

W

DC+

DC–

PE

PS+

PS–

Terminal

BR1

BR2

Description

DC Brake (+)

DC Brake (–)

U (T1)

V (T2)

W (T3)

R (L1)

S (L2)

T (L3)

DC Bus (+)

DC Bus (–)

PE Ground

AUX (+)

AUX (–)

Motor Ground

Notes

DB Resistor Connection -

Important:

Only one DB resistor can be used with Frames

0…3. Connecting an internal & external resistor could cause damage.

Twisted pair wiring must be used from these terminals to the resistor. Wiring must be routed separately from other cabling.

DC Input/Brake Connections (chopper and resistor).

Refer to page 29

To Motor/Load

for location on Frame 3 drives

Auxiliary Control Voltage

Refer to page 29 for location on Frame 3 drives

AC Line Input Power

Three-Phase = R, S & T

Single-Phase = R & S Only (refer to User Manual for details)

Power and Ground Wiring

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. Periodically check the integrity of all ground connections.

For installations within a cabinet, a single safety ground point or ground bus bar connected directly to building steel must be used. All circuits including the AC input ground conductor must be grounded independently and directly to this point/bar.

Typical Grounding

R (L1)

S (L2)

T (L3)

U (T1)

V (T2)

W (T3)

PE

SHLD

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.

IMPORTANT

Do Not discard or replace grounding hardware.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

31

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Shield Termination

Shield termination at “SHLD” provides a grounding point for the motor cable shield. The

motor cable

shield must be connected to this terminal on the drive

(drive end) and the motor frame (motor end). A shield terminating cable gland can also be used.

When shielded cable is used for

control and signal wiring

, the shield must be grounded at the source end only, not at the drive end.

RFI Filter Grounding

Using an optional RFI filter can 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 must not include any form of plug or socket that permits inadvertent disconnection. Some local codes can require redundant ground connections. Periodically check the integrity of all connections. Refer to the instructions supplied with the filter.

Motor Overload Protection

Drives with Standard Control

PowerFlex 700 drives with standard control, identified by an N, A, or B in position 15 of the catalog number, only provide Class 10 motor overload protection according to NEC article 430. They do not provide speed sensitive overload protection, thermal memory retention and motor over-temperature sensing according to NEC article 430.126 (A) (2). If such protection is needed in the end-use product, it must be provided by additional means.

Drives with Vector Control

PowerFlex 700 drives with vector control, identified by a C or D in position 15 of the catalog number, provide class 10 motor overload protection according to

NEC article 430 and motor over-temperature protection according to NEC article 430.126 (A) (2). UL 508C File E59272.

32

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Drive, Fuse & Circuit Breaker Ratings

The PowerFlex 700 can be installed with input fuses or an input circuit breaker.

National and local industrial safety regulations and/or electrical codes can determine additional requirements for these installations.

ATTENTION:

The PowerFlex 700 does not provide branch short circuit protection. Specifications for the recommended fuse or circuit breaker to provide protection against short circuits are provided on pages 34 through

41

.

The tables on the following pages provide recommended AC line input fuse and circuit breaker information. See Fusing and Circuit Breakers below for UL and

IEC requirements. Sizes listed are the recommended sizes based on 40 °C (104

°F) and the U.S. NEC. Other country, state, or local codes can require different ratings. Tables with DC link fuse recommendations for DC input drives are also provided.

Fusing

The recommended fuse types are listed below. If available current ratings do not match those listed in the tables provided, choose the next higher fuse rating.

•

IEC – BS88 (British Standard) Parts 1 & 2, EN60269-1, Parts 1 & 2

(1)

, type gG or equivalent must be used.

•

UL - UL Class CC, T, RK1 or J must be used.

Circuit Breakers

The “non-fuse” listings in the following tables include inverse time circuit breakers, instantaneous trip circuit breakers (motor circuit protectors) and 140M self-protected combination motor controllers. If one of these is chosen as the desired protection method, the following requirements apply:

•

IEC – Both types of circuit breakers and 140M self-protected combination motor controllers are acceptable for IEC installations.

•

UL - Only inverse time circuit breakers and the specified 140M selfprotected combination motor controllers are acceptable for UL installations.

(1) Typical designations include, but may not be limited to the following; Parts 1 & 2: AC, AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG,

GH.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

33

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

208 Volt AC Input Protection Devices

Hp

Rating

PWM

Freq.

Temp.

(11)

Input

Ratings

Drive

Catalog

Number ND HD kHz °C

20BB2P2 0 0.5

0.33 4 50

Amps kVA Cont. 1 Min. 3 Sec. Min.

1.9

0.7

Output Amps

2.5

2.8

3.8

Dual Element

Time Delay

Fuse

3

(1)

Max.

6

(2)

Non-Time Delay

Fuse

Min.

(1)

3

Max.

(2)

10

Circuit

Breaker

(3)

Max.

15

(8)

Motor

Circuit

Protector

(4)

Max.

3

(8)

140M Motor Protector with Adjustable Current

Range

(5)(6)

Available Catalog Numbers -

140…

(7)

M-C2E-B25 M-D8E-B25 –

Min. Enclosure

Vol. (in.

7269

3

)

(14)

20BB4P2 0 1 0.75 4

20BB6P8 1 2 1.5

4

20BB9P6 1 3 2 4

20BB015 1 5 3 4

20BB022 1 7.5

5 4

20BB028 2 10 7.5

4

20BB042 3 15 10 4

20BB052 3 20 15 4

50

50

50

50

50

50

50

50

3.7

6.8

9.5

15.7

23

29.6

1.3

2.4

3.4

5.7

8.3

4.8

7.8

11

17.5

25.3

10.7 32.2

5.6

10.4

12.1

19.3

27.8

38

7

13.8

17

26.3

38

50.6

6

10

12

20

30

40

44.5

16 48.3

53.1

72.5

60

51.5

17.1 56 64 86 80

10

15

20

35

50

70

100

125

6

10

12

20

30

40

60

80

17.5

30

40

70

100

125

175

200

15

30

40

70

100

125

175

200

7

15

15

30

30

50

70

100

–

–

–

–

M-C2E-B63 M-D8E-B63 – 7269

M-C2E-C10 M-D8E-C10 M-F8E-C10 7269

M-C2E-C16 M-D8E-C16 M-F8E-C16 7269

M-C2E-C20 M-D8E-C20 M-F8E-C20 7269

M-D8E-C25 M-F8E-C25 7269

–

–

–

M-F8E-C32 7269

M-F8E-C45 13630

– –

20BB070 4 25 20 4

20BB080 4 30 25 4

20BB104

(12)

5 40 – 4

20BB130

(12)

– 30 4

5 50 – 4

20BB154

(12)

– 40 4

6 60 – 4

20BB192

(12)

– 50 4

6 75 – 4

– 60 4

20BB260

(12)

6 100 – 2

– 75 2

50

50

50

50

50

50

50

50

50

50

45

50

72

84.7

113

25.9 78.2

30.5 92

93

117

40.7 120 132

124

156

175

90

110

150

84.7

30.5 92 138 175 125

141 44.1 130 143 175 175

113 35.3 104 156 175 125

167 60.1 177 195 266 225

141 50.9 150 225 300 200

208 75 221 243 308 300

167

255

199

60.1 177

91.9 260

71.7 205

266

286

305

308

390

410

225

300

225

175

200

250

200

275

225

350

300

450

350

575

450

90

110

150

125

175

125

225

200

300

225

300

225

300

350

475

350

500

400

500

500

600

500

750

600

300

350

350

300

375

300

500

450

600

500

750

600

100

150

150

150

250

150

250

250

400

250

400

400

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

See page 38 for notes.

240 Volt AC Input Protection Devices

Drive

Catalog

Number

Hp Rating

PWM

Freq.

ND HD kHz °C

20BB2P2 0 0.5

0.33 4

20BB4P2 0 1 0.75 4

Temp.

(11)

50

50

Input

Ratings

1.7

3.3

0.7

1.4

Output Amps

2.2

4.2

2.4

4.8

3.3

6.4

Dual Element

Time Delay Fuse

Amps kVA Cont. 1 Min. 3 Sec. Min.

3

5

(1)

Max.

6

8

(2)

Non-Time Delay

Fuse

Min.

3

5

(1)

Max.

10

15

(2)

Circuit

Breaker

(3)

Max.

15

15

(8)

Motor

Circuit

Protector

(4)

140M Motor Protector with Adjustable Current

Range

(5)(6)

Max.

3

7

(8)

Available Catalog Numbers -

140…

(7)

M-C2E-B25 M-D8E-B25 –

M-C2E-B63 M-D8E-B63 –

Min. Enclosure

Vol. (in.

7269

7269

3

)

(14)

20BB6P8 1 2 1.5

4

20BB9P6 1 3 2 4

20BB015 1 5 3

20BB022 1 7.5

5

4

4

20BB028 2 10 7.5

4

20BB042 3 15 10 4

20BB052 3 20 15 4

50

50

50

50

50

50

50

5.9

2.4

6.8

9 12 10

8.3

3.4

9.6

10.6

14.4

12

13.7

5.7

15.3

16.8

23

19.9

8.3

22 24.2

33

25.7

10.7 28 33 44

38.5

16 42 46.2

63

47.7

19.8 52 63 80

20

25

35

50

60

15

20

30

50

60

90

100

10

12

20

25

35

50

60

25

35

60

80

100

150

200

25

35

60

80

100

150

200

15

15

30

30

50

50

100

–

–

M-C2E-C10 M-D8E-C10 M-F8E-C10 7269

M-C2E-C10 M-D8E-C10 M-F8E-C10 7269

M-C2E-C16 M-D8E-C16 M-F8E-C16 7269

– M-D8E-C25 M-F8E-C25 7269

–

–

–

–

M-F8E-C32 7269

M-F8E-C45 13630

– –

20BB070 4 25 20 4

20BB080 4 30 25 4

20BB104

(12)

5 40 – 4

– 30 4

20BB130

(12)

20BB154

(12)

5 50 – 4

– 40 4

6 60 – 4

– 50 4

20BB192

(12)

6 75 – 4

20BB260

(12)

6

– 60 4

100 – 2

– 75 2

See page 38 for notes.

50

50

50

50

50

50

50

50

50

50

45

50

64.2

26.7 70 78

98

180

145

233

169

40.6 104

74.9 192

60.1 154

96.7 260

70.1 205

156

211

231

286

305

105 90

73.2

30.5 80 105 140 100

98 40.6 104 115 175 125

73 30.5 80 120 160 100

122 50.7 130 143 175 175

175

288

308

390

410

125

145 60.1 154 169 231 200

122 50.7 130 195 260 175

225

200

300

225

150

180

225

175

275

225

300

275

400

300

575

450

90

100

125

100

175

125

200

175

225

200

300

225

275

300

400

300

500

400

600

500

600

600

750

600

275

300

300

300

375

300

450

375

575

450

750

600

100

100

150

100

250

150

250

250

250

250

300

250

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

34

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

400 Volt AC Input Protection Devices kW

Rating

PWM

Freq. Temp.

Drive

Catalog

Number

20BC1P3 0

20BC2P1 0

ND HD kHz °C

0.37 0.25 4

0.75 0.55 4

50

(11)

50

(11)

20BC3P5 0

20BC5P0 0

20BC8P7 0

20BC011 0

1.5

2.2

4

5.5

0.75 4

1.5

2.2

4

4

4

4

50

(11)

50

(11)

50

(11)

50

(11)

20BC015 1

20BC022 1

20BC030 2

20BC037 2

20BC043 3

20BC056 3

20BC072 3

20BC085

(12)

4

7.5

11

15

5.5

7.5

11

18.5 15

22

30

37

45

18.5 4

22

30

–

4

4

4

4

4

4

4

50

(11)

50

(11)

50

(11)

50

(11)

50

(11)

50

(11)

50

(10)(11)

45

(11)

20BC105

(12)

20BC125

(12)

20BC140

(12)

20BC170

(12)

5

5

5

6

–

55

–

55

–

75

–

90

37

–

45

–

45

–

55

–

4

4

4

4

4

4

4

4

50

(9)

40

(9)

40

(9)

50

(9)

45

(11)

50

(9)

50

(9)

50

(9)

20BC205

(12)

20BC260

(12)

6

6

–

110 –

–

132 –

–

75

90

4

4

4

2

110 2

50

(9)

40

(9)

40

(9)

45

(9)

50

(9)

Input

Ratings Output Amps

Dual Element

Time Delay Fuse

Amps kVA Cont. 1 Min. 3 Sec. Min.

(1)

1.1

1.8

0.77 1.3

1.3

2.1

1.4

2.4

1.9

3.2

3.2

2.2

3.5

4.5

6

4.6

3.2

5

7.9

10.8

5.5

7.5

8.7

11.5

5.5

9.9

13

7.5

13.2

17.4

3

3

6

6

15

15

14.4

10 15.4

17.2

23.1

20

20.6

14.3 22 24.2

33

28.4

35

19.7 30

24.3 37

33

45

40.7

28.2 43 56

53

68.9

81.4

36.7 56

47.8 72

56.4 85

64

84

94

45

60

74

86

112

128

30

35

45

60

70

90

110

68.9

47.8 72 108 144 90

100.5 69.6 105 116 158 125

81.4

56.4 85

121.1 83.9 125

128

138

170

163

110

150

91.9

63.7 96 144 168 125

136 93.9 140 154 190 200

101

164

69.6 105

126 170

157

187

190

255

150

250

136 103 140 210 280 200

199 148 205 220 289 250

164

255

126

177

170

260

255

286

313

390

250

350

199 138 205 308 410 250

Max.

3

6

7

10

17.5

25

30

45

60

80

90

125

150

200

175

225

175

275

200

300

225

375

300

450

375

550

450

(2)

Non-Time Delay

Fuse

Min.

3

3

6

6

15

15

20

30

35

45

60

70

90

110

90

125

110

150

125

200

150

250

200

250

250

350

250

(1)

Max.

6

8

12

20

30

45

60

80

120

125

150

200

250

300

275

400

300

500

375

400

300

600

550

600

600

750

600

(2)

Circuit

Breaker

(3)

Max.

15

15

15

20

30

45

60

80

120

125

150

200

250

300

300

300

300

375

375

400

300

500

400

600

500

750

600

(8)

3

3

7

7

15

15

20

30

50

50

60

100

100

150

100

150

150

250

150

250

150

250

250

400

250

400

400

Motor

Circuit

Protector

(4)

Max.

(8)

140M Motor Protector with Adjustable Current

Range

(5)(6)

Available Catalog Numbers -

140…

(7)

Min. Enclosure

Vol. (in.

3

)

(14)

M-C2E-B16 –

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

M-C2E-B25 M-D8E-B25 –

M-C2E-B40 M-D8E-B40 –

M-C2E-B63 M-D8E-B63 –

M-C2E-C10 M-D8E-C10 M-F8E-C10 7269

M-C2E-C16 M-D8E-C16 M-F8E-C16 7269

M-C2E-C20 M-D8E-C20 M-F8E-C20 7269

–

–

M-D8E-C25 M-F8E-C25 7269

–

–

M-F8E-C32 7269

M-F8E-C45 7269

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

7269

7269

7269

7269

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

See page 38 for notes.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

35

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

480 Volt AC Input Protection Devices

Hp

Rating

PWM

Freq. Temp.

Drive

Catalog

Number

20BD1P1 0

20BD2P1 0

ND HD kHz °C

0.5

1

0.33 4

0.75 4

50

(11)

50

(11)

20BD3P4 0

20BD5P0 0

20BD8P0 0

20BD011 0

2

3

5

7.5

1.5

2

3

5

4

4

4

4

50

(11)

50

(11)

50

(11)

50

(11)

20BD014 1

20BD022 1

20BD027 2

20BD034 2

20BD040 3

20BD052 3

20BD065 3

20BD077

(12)

4

10

15

20

25

30

40

50

60

7.5

10

15

20

25

30

40

–

4

4

4

4

4

4

4

4

50

(11)

50

(11)

50

(11)

50

(11)

50

(11)

50

(11)

50

(11)

50

(11)

20BD096

(12)

20BD125

(12)

20BD156

(12)

20BD180

(12)

5

5

6

6

–

75

–

50

–

60

100 –

– 75

125 –

– 100 4

150 –

4

4

4

4

4

4

4

50

(9)

50

(9)

50

(9)

50

(9)

50

(11)

50

(9)

50

(9)

50

(9)

20BD248

(12)

6

–

200 –

–

125 4

2

150 2

50

(9)

45

(9)

50

(9)

See page 38 for notes.

Input

Ratings Output Amps

0.9

0.7

1.1

1.2

1.6

3

1.6

1.4

2.1

2.4

3.2

3

Dual Element

Time Delay Fuse

Non-Time Delay

Fuse

Circuit

Breaker

(3)

Motor

Circuit

Protector

(4)

Amps kVA Cont. 1 Min. 3 Sec. Min.

(1)

Max.

3

6

(2)

Min.

(1)

3

3

Max.

(2)

6

8

Max.

15

15

(8)

Max.

3

3

(8)

140M Motor Protector with Adjustable Current

Range

(5)(6)

Available Catalog Numbers -

140…

(7)

Min. Enclosure

Vol. (in.

3

)

(14)

M-C2E-B16 –

M-C2E-B25 –

–

–

7269

7269

2.6

2.2

3.4

4.5

6

3.9

3.2

5 5.5

7.5

4

6

6.9

5.7

8 8.8

12 10

9.5

7.9

11 12.1

16.5

15

8

10

15

20

4

6

10

15

12

20

30

40

15

20

30

40

7

7

15

15

M-C2E-B40 M-D8E-B40 –

M-C2E-B63 M-D8E-B63 –

7269

7269

M-C2E-C10 M-D8E-C10 M-F8E-C10 7269

M-C2E-C16 M-D8E-C16 M-F8E-C16 7269

12.5

10.4 14 16.5

22

19.9

16.6 22 24.2

33

24.8

20.6 27 33 44

31.2

25.9 34 40.5

54

36.7

30.5 40 51

47.7

39.7 52 60

59.6

49.6 65 78

72.3

60.1 77 85

68

80

50

60

104 80

116 100

17.5

30

25 50

35

40

60

70

90

110

125

170

17.5

25

35

40

50

60

80

100

50

80

100

125

150

200

250

300

50

80

100

125

150

200

250

300

20

30

50

50

50

70

100

100

–

–

–

–

–

–

M-C2E-C16 M-D8E-C16 M-F8E-C16 7269

– M-D8E-C25 M-F8E-C25 7269

–

–

–

–

–

–

M-F8E-C32 7269

M-F8E-C45 7269

M-F8E-C45 13630

–

–

–

–

–

–

59.6

49.6 65 98 130 80

90.1

74.9 96 106 144 125

72.3

60.1 77 116 154 100

117 97.6 125 138 163 150

90.1

74.9 96 144 168 125

147 122 156 172 234 200

131 109 125 188 250 175

169 141 180 198 270 225

147 122 156 234 312 200

233 194 248 273 372 300

169 141 180 270 360 225

125

200

170

250

200

350

250

400

350

550

400

80

125

100

150

125

200

175

225

200

300

225

250

350

300

500

350

600

500

600

600

700

600

250

350

300

375

350

450

375

500

450

700

500

100

125

100

150

125

250

250

250

250

400

250

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

36

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

600 Volt AC Input Protection Devices

(13)

Hp

Rating

PWM

Freq.

Temp.

(11)

Input

Ratings

Drive

Catalog

Number ND HD kHz °C

20BE1P7 0 1 0.5 4 50 1.3

1.4

Output Amps

1.7

2 2.6

Dual Element

Time Delay

Fuse

Amps kVA Cont. 1 Min. 3 Sec. Min.

2

(1)

Max.

(2)

4

Non-Time Delay

Fuse

Min.

(1)

2

Circuit

Breaker

(3)

Max.

(2)

Max.

(8)

6 15

20BE2P7 0 2 1 4

20BE3P9 0 3 2 4

20BE6P1 0 5 3 4

50

50

50

2.1

3

2.1

2.7

3.6

4.8

3

3.1

3.9

4.3

5.9

6

5.3

5.5

6.1

6.7

9.2

9

6

9

12

3

6

9

10

15

20

15

15

20

20BE9P0 0 7.5

20BE011 1 10

20BE017 1 15

20BE022 2 20

20BE099

(12)

20BE125

(12)

–

5

10

15

75

6 125 –

4

7.5 4

4

4

20BE027 2 25 20 4

20BE032 3 30 25 4

20BE041 3 40 30 4

20BE052 3 50 40 4

20BE062 4 60 50 2

20BE077

(12)

5 75 – 2

– 60 2

5 100 – 2

2

2

20BE144

(12)

– 100 2

6 150 – 2

– 125 2

See page 38 for notes.

50

50

50

50

40

(9)

50

(9)

50

(9)

50

(9)

50

(9)

50

50

(9)

50

(9)

40

(9)

50

50

50

50

7.8

9.9

8.1

9

10.2 11

9.9

13.5

13.5

18

10

15

15.4

16 17 18.7

25.5

20

20.2

21 22 25.5

34

24.8

25.7 27 33 44

29.4

30.5 32 40.5

54

37.6

39.1 41 48 64

47.7

49.6 52 61.5

82

58.2

60.5 62 78

72.3

75.1 77 85

104

116

30

35

40

50

60

80

90

58.2

60.5 63 94 126 90

92.9

96.6 99 109 126 125

72.3

117

75.1 77

122 125

116

138

138

188

100

150

93 96.6 99 149 198 125

135 141 144 158 216 175

117 122 125 188 250 150

60

70

90

110

20

25

40

50

125

150

125

200

175

250

200

300

275

35

40

50

60

10

15

20

30

80

90

150

100

125

150

200

35

40

60

80

225

300

90 250

125 375

100

150

300

375

125 375

175 400

375

100

125

150

200

30

40

50

80

225

300

250

375

300

375

375

400

375

100

250

150

250

250

100

100

100

150

50

50

100

100

15

15

20

30

3

3

7

15

Motor

Circuit

Protector

(4)

140M Motor Protector with Adjustable Current

Range

(5)(6)

Max.

(8)

Available Catalog Numbers -

140…

(7)

Min. Enclosure

Vol. (in.

3

)

(14)

M-C2E-B16 –

M-C2E-B25 –

–

–

–

M-C2E-B40 M-D8E-B40 –

M-D8E-B63 –

7269

7269

7269

7269

–

–

–

–

–

–

–

–

–

–

–

–

M-D8E-C10 M-F8E-C10 7269

M-D8E-C10 M-F8E-C10 7269

M-D8E-C16 M-F8E-C16 7269

– M-F8E-C25 7269

M-F8E-C25 7269

M-F8E-C32 13630

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

Table 8 - 690 Volt AC Input Protection Devices

(13)

Drive

Catalog

Number

20BF052

(12)

20BF060

(12)

20BF082

(12)

20BF098

(12)

20BF119

(12)

20BF142

(12)

kW

Rating

PWM

Freq.

Temp.

5

ND HD kHz °C

45 – 4 50

(9)

5

–

55

37.5 4

– 4

50

(9)

50

(9)

5

5

–

75

–

90

45

–

55

–

4

2

2

2

50

(9)

50

(9)

50

(9)

40

(9)

6

6

–

110 –

–

132 –

–

75

90

2

2

2

2

110 2

40

(9)

50

(9)

50

(9)

50

(9)

50

(9)

(11)

See page 38 for notes.

Input

Ratings

46.9

46.9

79

79

115

94.7

138

115

Output Amps

56.1 52

56.1 52

94.4 82

94.4 82

137 119

113 98

165 142

137 119

57

40.1

48 46 69

57.7

68.9 60 66

78

90

123

131

147

156

179

78

92

90

104

123

140

179

196

213

238

Dual Element

Time Delay Fuse

Amps kVA Cont. 1 Min. 3 Sec. Min.

(1)

60

50

80

60

100

57.7

68.9 60 90 120 80

94.7

113 98 108 127 125

100

150

125

175

150

Max.

110

90

125

110

200

125

200

200

250

200

300

250

(2)

100

150

125

175

150

50

80

60

100

80

125

Non-Time Delay

Fuse

Min.

(1)

Max.

(2)

60 175

Circuit

Breaker

(3)

Max.

(8)

Motor

Circuit

Protector

(4)

Max.

(8)

175

150

225

–

–

–

150

225

175

375

225

375

175

375

225

375

–

–

–

–

375

400

375

450

400

375

–

–

–

–

–

–

–

–

–

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

37

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Notes

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(12)

(13)

(14)

Minimum protection device size is the lowest rated device that supplies maximum protection without nuisance tripping.

Maximum protection device size is the highest rated device that supplies drive protection. For US NEC, minimum size is 125% of motor FLA. Ratings shown are maximum.

Circuit Breaker - inverse time breaker. For US NEC, minimum size is 125% of motor FLA. Ratings shown are maximum.

Motor Circuit Protector - instantaneous trip circuit breaker. For US NEC minimum size is 125% of motor FLA. Ratings shown are maximum.

Bulletin 140M with adjustable current range must have the current trip set to the minimum range that the device will not trip.

Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 208 Wye or Delta, 240 Wye or Delta, 480Y/277 or 600Y/

347. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground systems.

The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers can vary. See Bulletin 140M Motor Protection Circuit Breakers

Application Ratings .

Maximum allowable rating by US NEC. Exact size must be chosen for each installation.

UL Type 12/IP54 (flange mount) heat sink ambient temperature rating is 40° C/ambient of unprotected drive portion (inside enclosure) is 55° C. The ambient temperature for the UL Type 12/IP54 stand-alone drives is 40° C.

Must remove top label and vent plate, drive enclosure rating is IP00, NEMA/UL Type Open.

Drive frames 0…4 temperature rating is for NEMA/UL Type Open. The adhesive top label must be removed to operate drive at this temperature. Frames 5 & 6 do not have a top label.

Drives have dual current ratings; one for normal duty applications, and one for heavy duty applications. The drive can be operated at either rating.

Note: 600V class drives below 77 Amps (Frames 0…4) are declared to meet the Low Voltage Directive. It is the responsibility of the user to determine compliance to the EMC directive.

When using a Manual Self-Protected (Type E) Combination Motor Controller, the drive must be installed in a ventilated or nonventilated enclosure with the minimum volume specified in this column. Application specific thermal considerations can require a larger enclosure.

325 Volt DC Input Protection Devices

Drive Catalog

Number

20BB2P2

20BB4P2

20BB6P8

20BB9P6

e Hp Rating

ND HD kHz

0 0.5

0.33

4

0 1 0.75

4

1 2

1 3

1.5

2

PWM

Freq.

4

4

20BB015

20BB022

20BB028

20BB042

1

1

2

3

5

7.5

10

15

3

5

7.5

10

4

4

4

4

20BB052

20BB070

20BB080

20BN104

20BN130

(3)

(3)

3 20

4 25

4 30

5 40

–

5 50

–

6 60 20BN154

(3)

20BN192

20BN260

(3)

(3)

–

6 75

– 60

6 100 –

– 75

See page 41 for notes.

50

–

30

–

40

–

15

20

25

–

4

4

4

4

4

4

4

4

4

2

2

4

4

50

50

50

50

50

50

50

50

50

50

50

°C

50

50

45

50

50

50

50

50

50

50

Temp.

(1)

55

75.3

86.8

114.1

85.8

142.6

114.1

169

142.6

210.6

169

285.3

210.6

16

23.3

30

45

DC Input

Ratings Output Amps

Amps Cont.

1 Min.

3 Sec.

2

3.8

6.9

9.7

2.2

4.2

6.8

9.6

2.4

4.8

9

10.6

3.3

6.4

12

14.4

15.3

22

28

42

16.8

24.2

33

46.2

23

33

44

63

52

70

80

104

80

130

104

154

130

192

154

260

205

63

78

105

115

120

143

156

169

195

211

231

286

305

260

288

308

390

410

160

175

175

231

80

105

140

175

100

150

175

200

30

45

60

90

10

15

20

Fuse

5

300

350

350

400

400

200

200

200

300

HSJ100

HSJ150

HSJ175

HSJ200

HSJ200

HSJ200

HSJ200

HSJ300

Non-Time Delay

Fuse

(2) (11)

JKS-5

JKS-10

HSJ15

HSJ20

HSJ30

HSJ45

HSJ60

HSJ90

HSJ300

HSJ350

HSJ350

HSJ400

HSJ400

38

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

540 Volt DC Input Protection Devices

Drive Catalog

Number

20BC1P3

20BC2P1

20BC3P5

20BC5P0

20BC8P7

20BC011

20BC015

20BC022

20BC030

20BC037

20BC043

20BC056

20BC072

20BC085

(3)(5)

e kW Rating

ND HD

0 0.37

0.25

4

0 0.75

0.55

4

PWM

Freq.

kHz

0 1.5

0.75

4

0 2.2

1.5

4

0 4 3

0 5.5

4

4

4

1 7.5

5.5

1 11 7.5

2 15 11

2 18.5

15

3 22

3 30

3 37

4 45

18.5

4

22 4

30

–

4

4

4

4

4

4

20BH105

20BH140

20BH170

(3)(5)

(3)(5)

(3)(5)

20BH205

(3)(5)

–

5 55

–

5 75

–

6 90

– 75

6 110 –

55

–

37

–

45

–

20BH260

(3)(5)

– 90

6 132 –

– 110 2

4

2

See page 41 for notes.

4

4

4

4

4

4

4

4

Temp.

(1)

50

50

50

50

50

50

50

(7)

45

40

(4)

50

(4)

50

(4)

40

(4)

45

50

(4)

50

(4)

40

(4)

40

(4)

45

(4)

50

(4)

50

50

50

50

°C

50

50

47.5

61.9

80.5

95.1

16.8

24

33.2

40.9

1.3

2.1

3.7

5.3

9.3

12.6

DC

Input

Ratings Output Amps

Amps Cont.

1 Min.

3 Sec.

1.3

2.1

3.5

5

1.4

2.4

4.5

5.5

8.7

9.9

11.5

13

1.9

3.2

6

7.5

13.2

17.4

15.4

22

30

37

43

56

72

85

17.2

24.2

33

45

56

64

84

94

74

86

112

128

23.1

33

45

60

80.5

72 108

120.2

105 116

95.1

159

85 128

140 154

120.2

105 158

192.3

170 187

159

226

140 210

205 220

192.3

170 255

298 260 286

226 205 305

190

255

280

289

144

158

170

190

313

390

410

225

300

300

350

175

175

200

225

350

500

500

90

100

125

150

25

40

50

70

8

10

15

20

Fuse

3

6

HSJ175

HSJ175

HSJ200

HSJ225

HSJ225

HSJ300

HSJ300

HSJ350

HSJ350

HSJ500

HSJ500

HSJ25

HSJ40

HSJ50

HSJ70

HSJ90

HSJ100

HSJ125

HSJ150

Non-Time Delay

Fuse

(2) (11)

JKS-3

JKS-6

JKS-8

JKS-10

HSJ15

HSJ20

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

39

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

40

650 Volt DC Input Protection Devices

Drive Catalog

Number

20BD1P1

20BD2P1

20BD3P4

20BD5P0

20BD8P0

20BD011

20BD014

20BD022

20BD027

20BD034

20BD040

20BD052

20BD065

20BD077

(3)

2 20

2 25

3 30

3 40

3 50

4 60

–

5 75

e Hp Rating

PWM

Freq.

ND HD kHz

0 0.5

0.33

4

0 1 0.75

4

0 2

0 3

1.5

4

2 4

0 5 3

0 7.5

5

1 10

1 15

7.5

4

10 4

4

4

15

20

25

30

40

–

50

–

4

4

4

4

4

4

4

4

20BR096

(3)(6)

20BR125

(3)(6)

20BR156

(3)(6)

– 60

5 100 –

– 75

6 125 –

20BR180

20BR248

(3)(6)

(3)(6)

– 100 4

6 150 – 4

– 125 4

6 200 – 2

– 150 2

See page 41 for notes.

4

4

4

4

Temp.

(1)

50

50

50

50

50

50

50

50

50

50

50

(4)

50

(4)

50

(4)

45

(4)

50

(4)

50

50

(4)

50

(4)

50

(4)

50

(4)

50

(4)

50

50

50

°C

50

28.9

36.4

42.9

55.7

69.7

84.5

69.7

105.3

8.1

11.1

14.7

23.3

DC Input

Ratings

Amps

1.0

1.9

3.0

4.5

84.5

137.1

105.3

171.2

137.1

204

171.2

272

204

77 116

125 138

96 144

156 172

125 188

180 198

156 234

248 273

180 270

65

77

65

96

27

34

40

52

8.0

11

14

22

Output Amps

Cont.

1 Min.

3 Sec.

1.1

2.1

3.4

5.0

1.2

2.4

4.5

5.5

1.6

3.2

6.0

7.5

8.8

12.1

16.5

24.2

12

16.5

22

33

15

20

30

40

6

6

10

Fuse

3

33

40.5

51

60

78

85

98

106

44

54

68

80

104

116

130

144

100

150

150

175

50

60

80

90

250

270

312

372

360

154

163

168

234

300

400

400

400

400

175

200

200

300

HSJ175

HSJ200

HSJ200

HSJ300

HSJ300

HSJ400

HSJ400

HSJ400

HSJ400

HSJ50

HSJ60

HSJ80

HSJ90

HSJ100

HSJ150

HSJ150

HSJ175

Non-Time Delay

Fuse

(2) (11)

JKS-3

JKS-6

JKS-6

JKS-10

HSJ15

HSJ20

HSJ30

HSJ40

810 Volt DC Input Protection Devices

Drive Catalog

Number

20BE1P7

20BE2P7

20BE3P9

20BE6P1

20BE9P0

20BE011

20BE017

20BE022

20BE027

20BE032

20BE041

20BE052

20BE062

20BT099

(3)

20BT144

(3)

e Hp Rating

PWM

Freq.

ND HD kHz

0 1 0.75

4

0 2

0 3

1.5

2

0 5 3

0 7.5

5

4

4

4

4

0 10

1 15

2 20

2 25

7.5

10

15

20

4

4

4

4

3 30

3 40

3 50

4 60

25

30

40

50

5 100 –

– 75

6 150 –

– 125

2

2

2

2

4

4

4

2

See page 41 for notes.

40

40

50

50

50

50

50

50

50

50

50

50

°C

50

50

50

50

50

Temp.

(1)

34.3

43.9

55.7

68

11.5

18

23.6

29

2.4

3.5

6.2

9.1

DC Input

Ratings Output Amps

Amps

1.5

Cont.

1.7

1 Min.

2

3 Sec.

2.6

2.7

3.9

6.1

9

3.6

4.3

6.7

9.9

4.8

5.9

Fuse

3

6

6

9.2

10

13.5

15

108.6

84.5

158

137.1

11

17

22

27

32

41

52

62

99

77

13.5

18.7

25.5

33

40.5

48

61.5

78

109

116

144 158

125 188

18

34

44

54

64

20

25.5

30

40

50

60

70

82 90

104 125

126

138

216

250

150

150

250

250

HSJ60

HSJ70

HSJ90

HSJ125

HSJ150

HSJ150

HSJ250

HSJ250

Non-Time Delay

Fuse

(2) (11)

JKS-3

JKS-6

JKS-6

JKS-10

HSJ15

HSJ20

HSJ30

HSJ40

HSJ50

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

932 Volt DC Input Protection Devices

Drive Catalog

Number

20BW052

(3)

20BW098

(3)

20BW142

(3)

e kW Rating

PWM

Freq.

Temp.

(1)

5

ND HD kHz °C

45 – 2 50

(4)

5

6

–

90

–

132

–

37.5

–

75

–

110

2

2

2

2

2

50

(4)

50

(4)

50

(4)

50

(4)

40

(4)

DC Input

Ratings

Amps

58.2

46.9

110.7

92.3

162.2

134.9

Output Amps

Cont. 1 Min. 3 Sec.

52

46

98

82

57

69

108

123

78

92

127

140

142 156 213

119 179 238

Fuse

100

100

160

160

250

315

Non-Time Delay

Fuse

(2) (11)

170M3691

170M3691

170M3693

170M3693

170M3695

170M3696

Notes

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

Frames 0…4 temperature rating is for NEMA/UL Type Open. The adhesive top label must be removed to operate drive at this temperature. Frames 5 & 6 do not have a top label.

The power source to common bus inverters must be derived from AC voltages 600V or less, as defined in NFPA70; Art 430-18 (NEC).

Battery supplies or MG sets are not included. The following devices were validated to break current of the derived power DC Bus.

Disconnects: Allen-Bradley Bulletin 1494, 30-400A; 194, 30-400A; or ABB OESA, 600 & 800A; OESL, all sizes.

Fuses: Bussmann Type JKS, all sizes; Type 170M, Case Sizes 1, 2 and 3, or Ferraz Shawmut Type HSJ, all sizes. For any other devices, please contact the factory.

Drives have dual current ratings; one for normal duty applications, and one for heavy duty applications. The drive can be operated at either rating.

UL Type 12/IP54 (flange mount) heatsink ambient temperature rating is 40 °C/ambient of unprotected drive portion (inside enclosure) is 55 °C. The ambient temperature for the UL Type 12/IP54 stand-alone drives is 40 °C.

Also applies to “P” voltage class.

Also applies to “J” voltage class.

Must remove top label and vent plate, drive enclosure rating is IP00, NEMA/UL Type Open.

Two 630A Bussmann 170M6608 can also be used.

Two 700A Bussmann 170M6611 can also be used.

Bussmann or equivalent.

(11)

See Fuse Certification and Test Data in PowerFlex AC Drives in Common Bus Configurations Application Guidelines, publication DRIVES-AT002 , for fuse self-certification and test data for Bussmann 170M and JKS fuses recommended for the DC bus fusing.

Output Devices

Common mode cores are internal to the drive. For information on output contactors see page 42 . Other devices such as cable terminators and output reactors are discussed in Wiring and Grounding Guidelines for Pulse Width

Modulated (PWM) AC Drives, publication DRIVES-IN001.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

41

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

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 start and stop the motor. If an input device is used, operation must not exceed one cycle per minute or drive damage occurs.

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 can be required to remove the AC line to the drive. An auxiliary braking method can 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 can 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 is removed from the respective motor, but the drive continues 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 can cause the drive to fault. If any of these conditions are determined to be undesirable or unsafe, an auxiliary contact on the output contactor must be wired to a drive digital input that is programmed as “Enable.”

This causes the drive to execute a coast-to-stop (cease output) whenever an output contactor is opened.

Bypass Contactor Precaution

ATTENTION:

An incorrectly applied or installed bypass system can result in component damage or reduction in product life. The most common causes are:

•

Wiring AC line to drive output or control terminals.

•

Improper bypass or output circuits not approved by Allen-Bradley.

•

Output circuits that do not connect directly to the motor.

Contact Allen-Bradley for assistance with application or wiring.

42

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Disconnecting MOVs and Common Mode Capacitors

The Powerflex 700 drive contains protective MOVs and Common Mode

Capacitors referenced to ground (see below). To guard against unstable operation and/or damage, the drive must be properly configured as shown in Table 9 on page 44 .

MOV and AC EMI Capacitor Phase to Ground

R/L1

S/L2

T/L3

Common Mode Capacitor to Ground

DC+

DC–

Jumper-Wire

Jumper-Wire

IMPORTANT

All PowerFlex 700 drives are shipped with the DC bus common mode capacitors referenced to ground.

Before proceeding, ensure that all power to the drive has been removed.

ATTENTION:

Only qualified personnel familiar with adjustable frequency AC drives and associated machinery must perform maintenance/repair of the system. Failure to comply can 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 following points (refer to pages 29 through

30 for locations):

•

+DC and -DC terminals of the Power Terminal Block

•

+DC terminal of the Power Block and the chassis

•

-DC terminal of the Power Terminal Block and the chassis

The voltage must be zero for all three measurements.

ATTENTION:

The following information is merely a guide for proper installation. Rockwell Automation 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.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

43

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Table 9 - Recommended Power Jumper Configurations

Power Source Type

Solid Ground

(1)

• AC fed, solidly grounded

• DC fed from passive rectifier that has an AC source and solid ground

MOV/Input

Filter Caps

Connected

(2)

DC Bus

Common

Mode Caps

Connected

Benefits Of Correct Configuration on Power Source Type

• Reduced electrical noise,

• Most stable operation,

• EMC compliance,

• Reduced voltage stress on components and motor bearings.

Non-Solid Ground

• AC fed ungrounded

• Impedance grounded

• High resistive ground

• B phase ground

• Regenerative unit such as common

DC bus supply & brake

• DC fed from an active converter

Disconnected Disconnected • Helps avoid severe equipment damage when ground fault occurs.

(1) It is highly recommended to accurately determine the power source type and then configure appropriately.

(2) When MOVs are disconnected, the power system must have its own transient protection to ensure known and controlled voltages.

To connect or disconnect these devices, refer to pages 45 through 51 .

IMPORTANT

Common mode capacitors are used to conform with the EMC directives.

Removing these devices can withdraw the associated directive.

In addition, on an ungrounded distribution system where the line-to-ground voltages on any phase could exceed 125% of the nominal line-to-line voltage, an isolation transformer must be installed. See Wiring and Grounding Guidelines for PWM AC Drives, publication DRIVES-IN001 for more information on impedance grounded and ungrounded systems.

Jumper Installation, Removal and Storage

PowerFlex 700 drives utilize plug-in style jumpers and jumper wires. Most drives have a jumper storage area inside the front cover. Store extra jumpers or jumpers that have been removed in this location for use at a later time.

Insulating Jumper Wires

Some drives are designed to utilize nylon screws and spacers to insulate jumper wires from ground and secure them to the chassis.

The components must be installed as shown.

44

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Drive Identification

Refer to the drive nameplate and locate the “Voltage Code,” “Current Rating,”

“Frame,” and “UL Type” (Frames 5…6).

Use this information to locate the proper procedure in the following tables.

UL Type

Voltage Code

Current Rating

Series

Cat No. 20B

D xxx

x x xxxxxxx

UL TYPE 1/IP20

Normal Duty Power

Heavy Duty Power

Input: 3 Phase, 47-63Hz

AC Voltage Range

Amps xxx kW xxx kW

342-440 xxx

Output: 3 Phase, 0-400 Hz

AC Voltage Range

Base Hz (default)

Continuous Amps

1 Min Overload Amps

3 Sec Overload Amps

0-400

50 Hz xxx xxx xxx

Mfd. in 2007 on Aug 1

400V 480V xxx kW xxx kW

Series: B

I/O: 24VAC/DC (Standard)

Original Firmware V. x.xxx

432-528 xxx

c

U

®

L

Listed

Ind. Cont

Eq. 966X

US

0-460

60 Hz xxx xxx xxx

Frame:

3

Serial Number: xxxxxxx

N223

Made in the USA (TAC 1J)

Rockwell Automation, Mequon WI 53092-4400

Frame

Jumper Settings and Locations

Factory Default Jumper Settings

MOV/Input

Filter Caps

DC Bus Common

Mode Caps

0…1 All Drives

B…E All PE_B

Installed

PE_A

Installed

Power Source Type

PE A

MOV

PE B

CM Cap

U/T1

V/T2

W/T3

R/L1

S/L2

T/L3

BR1

BR2

DC+

DC–

PE

DANGER

Wir e O nly

Use 75C WG

Tor que t

Solid Ground

• Remove the I/O Cassette (see page 53 ). Verify that jumpers are installed at the “PE_A” and

“PE_B” locations on the Power Board.

Non-Solid Ground

• Remove the I/O Cassette (see page 53 ).

Remove jumpers at the “PE_A” and “PE_B” locations on the Power Board.

2 B…E All PE_MOV

Installed

PE_CAP

Installed

MOV

CM Cap

PE_CAP

PE_MOV

PE 2 PE 1

MOV-PE JMPR

PE 4 PE 3

AUX IN+ AUX OUT–

BR1 BR2 DC+ DC- U/T1 V/T2 W/T3

75C Cu Wire

6 AWG [10MM ] Max.

12 IN. LBS.

1.4 N-M } TORQUE

PE R/L1 S/L2 T/L3

WIRE

STRIP

SHLD SHLD

Solid Ground

• Verify that jumpers are installed at the

“PE_CAP” and “PE_MOV” locations.

Non-Solid Ground

• Remove jumpers at the “PE_CAP” and

“PE_MOV” locations.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

45

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

46

Factory Default Jumper Settings

MOV/Input

Filter Caps

(1) (2)

3…4 All Drives (continued)

DC Bus Common

Mode Caps

B…E All PE_MOV

Installed

PE-CAP

Installed

Power Source Type

CM Cap

PE_CAP

PE CAP

MOV

PE_MOV

PE MOV

Solid Ground

• Verify that jumpers are installed at the

“PE_CAP” and “PE_MOV” locations.

Non-Solid Ground

• Remove jumpers at the “PE_CAP” and

“PE_MOV” locations.

WIRE

STRIP

BR1 BR2

75C Cu Wire

6 AWG [10MM2] Max.

12 IN. LBS.

1.4 N-M } TORQUE

75C Cu Wire

3 AWG [25MM

2

] Max.

16 IN. LBS.

1.8 N-M

} TORQUE

AUX IN

+ –

BR1 BR2 DC+ DC- U/T1 V/T2 W/T3 R/L1 S/L2 T/L3

PE

SHLD

5 IP20, NEMA/UL Type 1 and Open Drives

B

J

N

P

R

C

D

H

All except

C140

Two green/ yellow wires connected to the

Power Terminal

Block rail

Green/yellow wire is connected to ground

CM Cap -

Older Drives

CM Cap - Newer Drives

Optional

Communications

Module

Solid Ground

1. CM Cap jumper wire must be connected to ground with a metal screw. Verify, and if necessary:

• Newer Drives - Remove the nylon screw/ spacer and insert a metal M5 x 8 screw.

Torque to 3.2 N•m (28 lb•in).

• Older Drives - Remove the I/O Cassette (see page 53 ). The green/yellow CM Cap jumper wire is on the back of chassis and must be connected to ground with a metal screw.

Remove the insulation from the wire terminal and connect to chassis with a metal M5 x 12 screw. Torque to 3.2 N•m (28 lb•in).

2. MOV/Input Filter Cap jumper wires must be connected to ground with a metal screw.

Verify, and if necessary, remove the nylon screw/spacer and insert a metal M5 x 12 screw.

MOV

POWER TERMINAL RATINGS

WIRE RANGE: 14-1/0 AWG (2.5-35 MM2)

TORQUE: 32 IN-LB (3.6 N-M)

STRIP LENGTH: 0.67 IN (17 MM)

USE 75 C CU WIRE ONLY

GROUND TERMINAL RATINGS (PE)

WIRE RANGE: 6-1/0 AWG (16-35 MM2)

TORQUE: 44 IN-LB (5 N-M)

STRIP LENGTH: 0.83 IN (21 MM)

17

OUTPUT

21

300 VDC EXT PWR SPLY TERM (PS+, PS-)

WIRE RANGE: 22-10 AWG (0.5-4 MM2)

TORQUE: 5.3 IN-LB (0.6 N-M)

STRIP LENGTH: 0.35 IN (9 MM)

9

INPUT AC

MOV / Input Filter Cap

Frame 5 continued on next page

(1) AC input drives only. MOV’s and input filter caps do not exist on DC input drives.

(2) When removing MOV’s, the input filter capacitor must also be removed.

Non-Solid Ground

1. CM Cap jumper wire must be insulated from ground. Verify, and if necessary:

• Newer Drives - Remove the metal screw and insert a M5 x 15 nylon screw/spacer.

• Older Drives - Remove the I/O Cassette (see page 53 ). Insulate/secure jumper wire to guard against unintentional contact with chassis or components.

2. MOV/Input Filter Cap jumper wires must be insulated from ground with a nylon screw/ spacer. Verify, and if necessary, remove the metal screw and insert a M5 x 20 nylon screw/ spacer.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Factory Default Jumper Settings

MOV/Input

Filter Caps

(1) (2)

DC Bus Common

Mode Caps

5 IP20, NEMA/UL Type 1 and Open Drives (continued)

C

F

W

140

052

060

Two green/yellow wires connected to the Power

Terminal Block rail

Green/yellow wire to

CM Cap Board is connected to ground

Optional

Communications

Module

Power Source Type

Solid Ground

1. CM Cap jumper wire must be connected to ground with a metal screw. Verify, and if necessary, remove the nylon screw/spacer and insert a metal M5 x 8 screw. Torque to 3.2 N•m

(28 lb•in).

2. MOV/Input Filter Cap jumper wires must be connected to ground with a metal screw.

Verify, and if necessary, remove the nylon screw/spacer and insert a metal M5 x 12 screw.

CM Cap

POWER TERMINAL RATINGS

WIRE RANGE: 14-1/0 AWG (2.5-35 MM2)

TORQUE: 32 IN-LB (3.6 N-M)

STRIP LENGTH: 0.67 IN (17 MM)

USE 75 C CU WIRE ONLY

GROUND TERMINAL RATINGS (PE)

WIRE RANGE: 6-1/0 AWG (16-35 MM2)

TORQUE: 44 IN-LB (5 N-M)

STRIP LENGTH: 0.83 IN (21 MM)

17

OUTPUT

21

300 VDC EXT PWR SPLY TERM (PS+, PS-)

WIRE RANGE: 22-10 AWG (0.5-4 MM2)

TORQUE: 5.3 IN-LB (0.6 N-M)

STRIP LENGTH: 0.35 IN (9 MM)

9

INPUT AC

MOV

Non-Solid Ground

1. CM Cap jumper wire must be insulated from ground with a nylon screw/spacer. Verify, and if necessary, remove the metal screw and insert a M5 x 15 nylon screw/spacer.

2. MOV/Input Filter Cap jumper wires must be insulated from ground with a nylon screw/ spacer. Verify, and if necessary, remove the metal screw and insert a

M5 x 20 nylon screw/spacer.

E

F

T

W

077

082

099

098

MOV / Input Filter Cap

Two green/yellow wires connected to chassis ground

Green/yellow wire to

CM Cap Board is connected to ground

Optional

Communications

Module

Solid Ground

1. CM Cap jumper wire must be connected to ground with a metal screw. Verify, and if necessary, remove the nylon screw/spacer and insert a metal M5 x 8 screw. Torque to 3.2 N•m

(28 lb•in).

2. MOV jumper wire must be connected to ground with metal screws. Verify, and if necessary, remove the nylon screw/spacers and insert a metal M5 x 12 screws.

3. Input Filter Cap jumper wire must be connected to ground with a metal screw.

Verify, and if necessary, remove the nylon screw/spacer and insert metal M5 x 8 screw.

CM Cap

POWER TERMINAL RATINGS

WIRE RANGE: 14-1/0 AWG (2.5-35 MM2)

TORQUE: 32 IN-LB (3.6 N-M)

STRIP LENGTH: 0.67 IN (17 MM)

USE 75 C CU WIRE ONLY

GROUND TERMINAL RATINGS (PE)

WIRE RANGE: 6-1/0 AWG (16-35 MM2)

TORQUE: 44 IN-LB (5 N-M)

STRIP LENGTH: 0.83 IN (21 MM)

17

OUTPUT

21

300 VDC EXT PWR SPLY TERM (PS+, PS-)

WIRE RANGE: 22-10 AWG (0.5-4 MM2)

TORQUE: 5.3 IN-LB (0.6 N-M)

STRIP LENGTH: 0.35 IN (9 MM)

9

PE

INPUT AC

MOV

Input Filter

Cap

MOV

Frame 5 continued on next page

(1) AC input drives only. MOV’s and input filter caps do not exist on DC input drives.

(2) When removing MOV’s, the input filter capacitor must also be removed.

Non-Solid Ground

1. CM Cap jumper wire must be insulated from ground with a nylon screw/spacer. Verify, and if necessary, remove the metal screw and insert a M5 x 15 nylon screw/spacer.

2. MOV jumper wire must be insulated from ground with a nylon screw/spacer. Verify, and if necessary, remove the metal screws and insert a M5 x 20 nylon screw/spacer.

3. Input Filter Cap jumper wire must be insulated from ground with a nylon screw/spacer. Verify, and if necessary, remove the metal screws and insert a M5 x 15 nylon screw/spacer.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

47

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Factory Default Jumper Settings

MOV/Input

Filter Caps

(1) (2)

5 IP54, NEMA Type 12 Drives

DC Bus Common

Mode Caps

P

R

C

D

All

CM Cap -

Older Drives

Two green/yellow wires connected to chassis ground

SHLD

SHLD

Green/yellow wire is connected to ground

CM Cap - Newer Drives

Power Source Type

Solid Ground

1. CM Cap jumper wire must be connected to ground with a metal screw. Verify, and if necessary:

• Newer Drives - Remove the nylon screw/ spacer and insert a metal M5 x 8 screw.

Torque to 3.2 N•m (28 lb•in).

• Older Drives - Remove the

I/O Cassette (see page 53 ). The green/ yellow CM Cap jumper wire is on the back of chassis and must be connected to ground with a metal screw. Remove the insulation from the wire terminal and connect to chassis with a metal M5 x 10 screw. Torque screw to 3.2 N•m (28 lb•in).

2. MOV/Input Filter Cap jumper wires must be connected to ground with a metal screw.

Verify, and if necessary, remove the nylon screw/spacer and insert a metal M5 x 12 screw.

MOV

BRAKE TERMINAL RATINGS

WIRE RANGE: 14-1/0 AWG (2.5-50 MM2)

TORQUE: 32 IN-LB (3.6 N-M)

STRIP LENGTH: 0.67 IN (17 MM)

GROUND TERMINAL RATINGS (PE)

WIRE RANGE: 6-1/0 AWG (18-35 MM2)

TORQUE: 44 IN-LB (5 N-M)

STRIP LENGTH: 0.83 IN (21 MM)

POWER & DC TERMINAL RATINGS

USE 75 C CU WIRE ONLY

WIRE RANGE: 4-3/0 AWG (18-70 MM2)

TORQUE: 133 IN-LB (15 N-M)

STRIP LENGTH: 1.02 IN (26 MM)

OUTPUT

6 MM HEX KEY

300 VDC EXT PWR SPLY TERM (PS+, PS-)

WIRE RANGE: 22-10 AWG (0.5-4 MM2)

TORQUE: 5.3 IN-LB (0.6 N-M)

STRIP LENGTH: 0.35 IN (9 MM)

INPUT AC

6 MM HEX KEY

DANGER

RISK OF ELECTRIC

SHOCK AND DEATH

DANGER

FIELD INSTALLED OPTIONS

MOV / Input Filter Cap

Frame 5 continued on next page

(1) AC input drives only. MOV’s and input filter caps do not exist on DC input drives.

(2) When removing MOV’s, the input filter capacitor must also be removed.

Non-Solid Ground

1. CM Cap jumper wire must be insulated from ground. Verify, and if necessary:

• Newer Drives - Remove the metal screw and insert a M5 x 15 nylon screw/spacer.

• Older Drives - Remove the

I/O Cassette (see page 53 ).Insulate/secure jumper wire to guard against unintentional contact with chassis or components.

2. MOV/Input Filter Cap jumper wires must be insulated from ground with a nylon screw/ spacer. Verify, and if necessary, remove the metal screw and insert a M5 x 20 nylon screw/ spacer.

48

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Factory Default Jumper Settings

MOV/Input

Filter Caps

(1) (2)

5 IP54, NEMA Type 12 Drives (continued)

DC Bus Common

Mode Caps

T

W

E

F

All Two green/yellow wires connected to chassis ground

Green/yellow wire to

CM Cap Board is connected to ground

CM Cap

SHLD

SHLD

BRAKE TERMINAL RATINGS

WIRE RANGE: 14-1/0 AWG (2.5-50 MM2)

TORQUE: 32 IN-LB (3.6 N-M)

STRIP LENGTH: 0.67 IN (17 MM)

GROUND TERMINAL RATINGS (PE)

WIRE RANGE: 6-1/0 AWG (18-35 MM2)

TORQUE: 44 IN-LB (5 N-M)

STRIP LENGTH: 0.83 IN (21 MM)

POWER & DC TERMINAL RATINGS

USE 75 C CU WIRE ONLY

WIRE RANGE: 4-3/0 AWG (18-70 MM2)

TORQUE: 133 IN-LB (15 N-M)

STRIP LENGTH: 1.02 IN (26 MM)

OUTPUT

6 MM HEX KEY

300 VDC EXT PWR SPLY TERM (PS+, PS-)

WIRE RANGE: 22-10 AWG (0.5-4 MM2)

TORQUE: 5.3 IN-LB (0.6 N-M)

STRIP LENGTH: 0.35 IN (9 MM)

INPUT AC

6 MM HEX KEY

DANGER

RISK OF ELECTRIC

SHOCK AND DEATH

DANGER

FIELD INSTALLED OPTIONS

MOV

Power Source Type

Solid Ground

1. CM Cap jumper wire must be connected to ground with a metal screw. Verify, and if necessary, remove the nylon screw/spacer and insert a metal M5 x 12 screw. Torque to 3.2

N•m (28 lb•in).

2. MOV/Input Filter Cap jumper wires must be connected to ground with a metal screw.

Verify, and if necessary, remove the nylon screw/spacer and insert a metal M5 x 12 screw.

Non-Solid Ground

1. CM Cap jumper wire must be insulated from ground with a nylon screw/spacer. Verify, and if necessary, remove the metal screw and insert a M5 x 20 nylon screw/spacer.

2. MOV/Input Filter Cap jumper wires must be insulated from ground with a nylon screw/ spacer. Verify, and if necessary, remove the metal screw and insert a M5 x 20 nylon screw/ spacer.

MOV / Input Filter Cap

(1) AC input drives only. MOV’s and input filter caps do not exist on DC input drives.

(2) When removing MOV’s, the input filter capacitor must also be removed.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

49

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Factory Default Jumper Settings

MOV/Input

Filter Caps

(1) (2)

6 IP20, NEMA/UL Type 1 and Open Drives

DC Bus Common

Mode Caps

P

R

J

N

D

H

B

C

All Two green/yellow wires connected to Power Terminal

Block “PE”

Green/yellow wire to

CM Cap Board is connected to Power

Terminal Block “PE”

Optional

Communications

Module

Power Source Type

Solid Ground

1. The green/yellow CM Cap jumper wire must be connected to “PE.”

2. The MOV/Input Filter Cap jumper wires must be connected to “PE.”

Non-Solid Ground

1. The green/yellow CM Cap jumper wire must be insulated from ground. Verify, and if necessary, remove the jumper wire from “PE” and insulate/secure it to guard against unintentional contact with chassis or components.

Important: Do Not Remove/

Disconnect the larger green/yellow wire

.

2. MOV/Input Filter Cap jumper wires must be insulated from ground. Verify, and if necessary, remove the jumper wires from “PE” and individually insulate/secure each jumper wire to guard against unintentional contact with chassis or components.

DO NOT

REMOVE

MOV

22-10

AWG

5.3 IN-LB

(0.6 N-M)

BR2 BR1 DC+

USE 75 C COPPER WIRE ONLY, TORQUE 52 IN-LB (6 N-M)

DC–

Input Filter Cap

USE 75 C

COPPER WIRE

ONLY

CM Cap

TORQUE

52 IN-LB

(6 N-M)

U V

T1 T2

OUTPUT

MOV

W

T3

PE PE R

L1

S

L2

INPUT

T

L3

PE PE

Frame 6 continued on next page

(1) AC input drives only. MOV’s and input filter caps do not exist on DC input drives.

(2) When removing MOV’s, the input filter capacitor must also be removed.

50

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Factory Default Jumper Settings

MOV/Input

Filter Caps

(1) (2)

DC Bus Common

Mode Caps

6

IP20, NEMA/UL Type 1 and Open Drives (continued)

T

W

E

F

DO NOT

All

REMOVE

Two green/yellow wires connected to Power Terminal

Block “PE” and chassis

Optional

Communications

Module

Green/yellow wire to

CM Cap Board is connected to Power

Terminal Block “PE”

Power Source Type

Solid Ground

1. The green/yellow CM Cap and MOV jumper wires must be connected to “PE.”

2. The Input Filter Cap jumper wire (top right) must be connected to chassis ground with a metal screw. Verify, and if necessary, remove the nylon screw/spacer and insert a metal M5 x 10 screw. Torque to 3.2 N•m (28 lb•in).

Input Filter Cap

MOV

Non-Solid Ground

1. The green/yellow CM Cap and MOV jumper wires must be insulated from ground. Verify, and if necessary, remove them from “PE” and individually insulate/secure each jumper wire to guard against unintentional contact with chassis or components.

Important: Do Not

Remove/Disconnect the larger green/ yellow wire

.

2. The Input Filter Cap jumper wire (top right) must be insulated from ground with a nylon screw/spacer. Verify, and if necessary, remove the metal screw and insert a M5 x 15 nylon screw/spacer.

22-10

AWG

5.3 IN-LB

(0.6 N-M)

BR2 BR1 DC+

USE 75 C COPPER WIRE ONLY, TORQUE 52 IN-LB (6 N-M)

DC–

CM Cap

USE 75 C

COPPER WIRE

ONLY

TORQUE

52 IN-LB

(6 N-M)

U V

T1 T2

MOV

W

T3

PE PE R

L1

S

L2

INPUT

T

L3

PE PE

6 IP54, NEMA Type 12 Drives

All Two green/yellow wires connected to Power Terminal

Block “PE”

T

W

P

R

E

F

C

D

Green/yellow wire to

CM Cap Board is connected to Power

Terminal Block “PE”

DO NOT

REMOVE

CM Cap

PE PE

T1

V

T2

OUTPUT

MOV

W

T3

PE PE R

L1

S

L2

INPUT

T

L3

Solid Ground

1. The green/yellow CM Cap jumper wire must be connected to “PE.”

2. The MOV/Input Filter Cap jumper wires must be connected to “PE.”

Non-Solid Ground

1. The green/yellow CM Cap jumper wire must be insulated from ground. Verify, and if necessary, remove the jumper wire from “PE” and insulate/secure it to guard against unintentional contact with chassis or components.

Important: Do Not Remove/

Disconnect the larger green/yellow wire

.

2. MOV/Input Filter Cap jumper wires must be insulated from ground. Verify, and if necessary, remove the jumper wires from “PE” and individually insulate/secure them to guard against unintentional contact with chassis or components.

(1) AC input drives only. MOV’s and input filter caps do not exist on DC input drives.

(2) When removing MOV’s, the input filter capacitor must also be removed.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

51

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Step 4: I/O Wiring

Important points to remember about I/O wiring:

•

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.

•

Wire with an insulation rating of 600V or greater is recommended.

•

Separate control and signal wires 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.

ATTENTION:

Configuring an analog input for 0…20 mA 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.

Wire Recommendations

Type

Signal

(1) (2) (3)

Encoder/Pulse I/O

<30 m (100 ft.)

Encoder/Pulse I/O

30 to 152 m

(100 to 500 ft.)

Encoder/Pulse I/O

152 to 259 m

(500 to 850 ft.)

Wire Type(s)

Standard Analog I/O Belden 8760/9460 (or equivalent)

Belden 8770 (or equivalent)

Combined: Belden 9730

(4)

Signal: Belden 9730/9728

(4)

Power: Belden 8790

(5)

Combined: Belden 9892

(6)

Signal: Belden 9730/9728

(4)

Power: Belden 8790

(5)

Combined: Belden 9773/9774

(7)

Multi-conductor shielded cable such as Belden 8770

(or equivalent)

Description

0.750 mm

2

(18AWG), twisted pair, 100% shield with drain.

0.750 mm

2

(18AWG), 3 conductor, shielded for remote pot only.

0.196 mm

2

(24AWG), individually shielded

0.196 mm

2

(24AWG), individually shielded

0.750 mm

2

(18AWG)

0.330 mm

2

(22AWG) or 0.500 mm

2

(20AWG)

0.196 mm

2

(24AWG), individually shielded

0.750 mm

2

(18AWG)

0.750 mm

2

(18AWG), individually shielded

0.750 mm

2

(18AWG), 3 conductor, shielded.

Min.

Insulation

Rating

300V,

75…90 °C

(167…194 °F)

Digital I/O

(1)(2)(3)

Shielded 300V,

60 °C (140 °F)

Unshielded Per US NEC or applicable national or local code –

(1) Separate control and signal wires from power wires by at least 0.3 meters (1 foot).

(2) If the wires are short and contained within a cabinet that has no sensitive circuits, the use of shielded wire can not be necessary, but is always recommended.

(3) 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.

(4) 9730 is 3 individually shielded pairs (2 channel + power). If 3 channel is required, use 9728.

(5) 8790 is 1 shielded pair.

(6) 9892 is 3 individually shielded pairs (3 channel) + 1 shielded pair for power.

(7) 9773 is 3 individually shielded pairs (2 channel + power). If 3 channel is required, use 9774.

52

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

I/O Terminals

The figure below shows the I/O Control Cassette and terminal block locations.

The cassette provides a mounting point for the various PowerFlex 700

I/O options. To remove the cassette, follow the steps below. Cassette removal is similar for all frames (Frame 0 drive shown).

Step Description

A

B

C

D

Disconnect the two cable connectors shown below.

Loosen the two screw latches shown below.

Slide the cassette out.

Remove screws securing cassette cover to gain access to the boards.

PowerFlex 700 Typical Cassette & I/O Terminal Blocks

B

C

➌

➋

B

➊

Pin 1

A

D

Detail

L2

R/L1

W/T3

V/T2

U/T1

PE

DC-

DC+

BR2

BR1

=

I/O Terminal Block Specifications

Wire Size Range

(1)

Torque

No.

Name

➊

I/O Cassette

Description

Removable I/O Cassette

Maximum Minimum Maximum Recommended

➋

➌

I/O Terminal Block

Encoder Terminal

Block

Signal & control connections

Encoder power & signal connections

2.5 mm

2

(14 AWG)

0.75 mm

2

(18 AWG)

0.30 mm

(22 AWG)

(24 AWG)

(1) Maximum/minimum that the terminal block accepts - these are not recommendations.

2

0.196 mm

2

0.6 N•m

(5.3 lb•in)

0.6 N•m

(5.3 lb•in)

0.6 N•m

(5.3 lb•in)

0.6 N•m

(5.3 lb•in)

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

53

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

54

Vector Control Option I/O Terminal Designations

1

No. Signal

1 Analog In 1 (–)

(1)

2 Analog In 1 (+)

(1)

3 Analog In 2 (–)

(1)

4 Analog In 2 (+)

(1)

5 Pot Common

6 Analog Out 1 (–)

Factory

Default Description

(4)

Isolated

(5)

, bipolar, differential, ±10V/0-20 mA, 11 bit & sign. For 0-20 mA, a jumper must be installed at terminals 17 & 18 (or 19 & 20). 88k ohm input impedance when configured for volt. & 95.3 ohm for current

Related

Param.

320 -

327

16

32

–

(4)

For (+) and (–) 10V pot references.

Single-ended bipolar (current output is not bipolar),

±

10V/0-20 mA, 11 bit & sign, Voltage mode - limit current to 5 mA. Current mode - max. load is 400 ohms.

340 -

347

7 Analog Out 1 (+)

8 Analog Out 2 (–)

9 Analog Out 2 (+)

10 HW PTC Input 1

11 Digital Out 1 – N.C.

(2)

–

Fault

1.8k ohm PTC, Internal 3.32k ohm pull-up resistor

Max. Resistive Load:

240V AC/30V DC – 1200VA, 150W

Max. Current: 5A, Min. Load: 10 mA

Max. Inductive Load:

240V AC/30V DC – 840VA, 105W

Max. Current: 3.5A, Min. Load: 10 mA

238 259

380 -

391

12 Digital Out 1 Common

13 Digital Out 1 – N.O.

(2)

14 Digital Out 2 – N.C.

(2)

15 Digital Out 2/3 Com.

16 Digital Out 3 – N.O.

(2)

17 Current In Jumper

(1)

–

Analog In 1

18

19 Current In Jumper

(1)

–

Analog In 2

20

21 –10VDC Pot Ref.

22 +10VDC Pot Ref.

NOT Fault

NOT Run

Run

Placing a jumper across terminals 17 & 18 (or 19 &

20) configures that analog input for current.

320 -

327

–

–

2k ohm minimum load.

23 HW PTC Input 2

24 +24VDC

(6)

–

–

See above

Drive supplied logic input power.

(6)

25 Digital In Common

26 24V Common

(6)

27 Digital In 1

28 Digital In 2

29 Digital In 3

30 Digital In 4

31 Digital In 5

(3)

(3)

(3)

(3)

(3)

–

– Common for internal power supply.

Stop - CF 115V AC, 50/60 Hz - Control & I/O Cat. No. option D

Opto isolated

Start

Low State: less than 30V AC

Auto/Man.

High State: greater than 100V AC, 5.7 mA

Speed Sel 1

Speed Sel 2

Speed Sel 3

24V DC - Control & I/O Cat. No. option C

Opto isolated

Low State: less than 5V DC

High State: greater than 20V DC, 10 mA DC Digital

Input Impedance: 21k ohm

361 -

366

32 Digital In 6/Hardware

Enable

(3)

, see pg. 57

(1)

Important:

0…20 mA operation requires a jumper at terminals 17 & 18 (or 19 & 20). Drive damage can occur if jumper is not installed.

(2) Contacts in unpowered state. Any relay programmed as Fault or Alarm energizes (picks up) when power is applied to drive and deenergize

(drop out) when a fault or alarm exists. Relays selected for other functions energize only when that condition exists and deenergizes when condition is removed.

(3) A 10k ohm, 2 watt burden resistor must be installed on each digital input when using a triac type device. The resistor is installed between each digital input and neutral /common.

(4) These inputs/outputs are dependant on a number of parameters (see “Related Parameters”).

(5) Differential Isolation - External source must be maintained at less than 160V with respect to PE. Input provides high common mode immunity.

(6) 150 mA maximum load designed to power digital inputs only. Not present on 115V versions.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Standard Control Option I/O Terminal Designations

1

16

32

No. Signal

1 Anlg Volts In 1 (–)

2 Anlg Volts In 1 (+)

3 Anlg Volts In 2 (–)

4 Anlg Volts In 2 (+)

5 Pot Common

6 Anlg Volts Out 1 (–)

7 Anlg Volts Out 1 (+)

8 Anlg Current Out 1 (–)

9 Anlg Current Out 1 (+)

10 Reserved for Future Use

11 Digital Out 1 – N.C.

(1)

12 Digital Out 1 Common

13 Digital Out 1 – N.O.

(1)

14 Digital Out 2 – N.C.

(1)

15 Digital Out 2 Common

16 Digital Out 2 – N.O.

(1)

17 Anlg Current In 1 (–)

18 Anlg Current In 1 (+)

19 Anlg Current In 2 (–)

20 Anlg Current In 2 (+)

Factory

Default

(2)

(2)

–

(2)

(2)

Fault

NOT Fault

NOT Run

Run

(2)

(2)

Description

Isolated

(3)

, bipolar, differential, ±10V, 11 bit & sign,

88k ohm input impedance.

Isolated

88k ohm input impedance.

For (+) and (–) 10V pot references.

Isolated

Isolated

(4)

, bipolar, differential, ±10V, 11 bit & sign,

Related

Param.

320 -

327

Bipolar,

±

10V, 11 bit & sign, 2k ohm minimum load.

340 -

4-20mA, 11 bit & sign, 400 ohm maximum load.

Max. Resistive Load:

240V AC/30V DC – 1200VA, 150W

Max. Current: 5A, Min. Load: 10mA

Max. Inductive Load:

240V AC/30V DC – 840VA, 105W

Max. Current: 3.5A, Min. Load: 10mA

(3) impedance.

(4)

, 4-20 mA, 11 bit & sign, 124 ohm input

, 4-20 mA, 11 bit & sign, 124 ohm input impedance.

344

380 -

387

320 -

327

21 –10VDC Pot Ref.

22 +10VDC Pot Ref.

–

–

2k ohm minimum.

23 Reserved for Future Use

24 +24VDC

(5)

25 Digital In Common

26 24V Common

(5)

–

–

Drive supplied logic input power.

(5)

– Common for internal power supply.

27

28

29

30

31

32

Digital In 1

Digital In 2

Digital In 3

Digital In 4

Digital In 5

Digital In 6

Stop - CF 115V AC, 50/60 Hz - Control & I/O Cat. No. option B

Opto isolated

Start

Low State: less than 30V AC

Auto/Man.

High State: greater than 100V AC, 5.0 mA

Speed Sel 1

Speed Sel 2

Speed Sel 3

24V AC/DC, 50/60 Hz- Control & I/O Cat. No. option A

Opto isolated

Low State: less than 5V AC/DC

High State: greater than 20V AC/DC

11.2 mA DC

Digital Input Impedance: 35k ohm

361 -

366

(1) Contacts in unpowered state. Any relay programmed as Fault or Alarm energizes (picks up) when power is applied to drive and deenergize

(drop out) when a fault or alarm exists. Relays selected for other functions energize only when that condition exists and deenergizes when condition is removed.

(2) These inputs/outputs are dependant on a number of parameters. See “Related Parameters.”

(3) Differential Isolation - External source must be maintained at less than 160V with respect to PE. Input provides high common mode immunity.

(4) Differential Isolation - External source must be less than 10V with respect to PE.

(5) 150 mA maximum load designed to power digital inputs only. Not present on 115V versions.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

55

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

56

I/O Wiring Examples

Input/Output

Potentiometer Unipolar

Speed Reference

(1)

10k Ohm Pot. Recommended

(2k Ohm Minimum)

Connection Example

3

4

5

Required Parameter Changes

• Adjust Scaling:

Parameters 91/92 and 325/326

• View Results:

Parameter 002

22

Joystick Bipolar Speed

Reference

(1)

±10V Input

Analog Input Bipolar

Speed Reference

±10V Input

Analog Voltage Input

Unipolar Speed Reference

0 to +10V Input

Analog Current Input

Unipolar Speed Reference

0-20 mA Input

Analog Input, PTC

PTC OT set > 5V

PTC OT cleared < 4V

PTC Short < 0.2V

HW PTC Input

PTC OT set > 5V

PTC OT cleared < 4V

PTC Short < 0.2V

Analog Output

±10V, 0-20 mA Bipolar

+10V Unipolar (shown)

2-Wire Control Non-

Reversing

(2)

24V DC internal supply

3

5

Common

+

Common

+

Common

+

3

4

3

4

3

4

1.8k

PTC

Ferrite

Bead

1

2

5

3.32k

Ohm

Ferrite

Bead

1.8k

PTC

10

+ –

21

22

24

25

26

28

Stop-Run

19

20

22

23

• Set Direction Mode:

Parameter 190 = “1, Bipolar”

• Adjust Scaling:

Parameters 91/92 and 325/326

• View Results:

Parameter 002

• Set Direction Mode:

Parameter 190 = “1, Bipolar”

• Adjust Scaling:

Parameters 91/92 and 325/326

• View Results:

Parameter 002

• Configure Input with parameter 320

• Adjust Scaling:

Parameters 91/92 and 325/326

• View results:

Parameter 002

• Configure Input for Current:

Parameter 320 and add jumper at appropriate terminals

• Adjust Scaling:

Parameters 91/92 and 325/326

• View results:

Parameter 002

• Set Fault Config 1:

Parameter 238, bit 7 = “Enabled”

• Set Alarm Config 1:

Parameter 259, bit 11 = “Enabled”

• View Status Drive Alarm 1:

Parameter 211, bit 11 = “True”

• Set Fault Config 1:

Parameter 238, bit 13 = “Enabled”

• Set Alarm Config 1:

Parameter 259, bit 18 = “Enabled”

• View Status: Drive Alarm 1:

Parameter 211, bit 18 = “True”

• Configure with Parameter 340

• Select Source Value:

Parameter 380, [Digital Out1 Sel]

• Adjust Scaling:

Parameters 343/344

• Disable Digital Input:#1:

Parameter 361 = “0, Unused”

• Set Digital Input #2:

Parameter 362 = “7, Run”

• Set Direction Mode:

Parameter 190 = “0, Unipolar”

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Input/Output

2-Wire Control

Reversing

(1)

External supply

(I/O Board dependent)

3-Wire Control

Internal supply

3-Wire Control

External supply (I/O Board dependent). Requires 3-wire functions only ([Digital In1

Sel]). Using 2-wire selections causes a type 2 alarm.

Digital Input

PLC Output Card (Board dependent).

Connection Example

Neutral/

Common

25

27

28

Run Fwd.

115V/

+24V

Run Rev.

24

25

26

27

28

Stop

Required Parameter Changes

• Set Digital Input:#1:

Parameter 361 = “8, Run Forward”

• Set Digital Input #2:

Parameter 362 = “9, Run Reverse”

• No Changes Required

25

27

28

Start

Neutral/

Common

115V/

+24V

25

27

28

Stop

• No Changes Required

Start

Neutral/

Common

10k Ohm, 2 Watt

Control from

Prog. Controller

• No Changes Required

Digital Output

Relays (two at terminals

14…16) shown in powered state with drive faulted. See page 54 and page 55 .

Power Source or

11

12

13

14

15

16

Enable Input

Fault

NOT Fault

NOT Run

Run

• Select Source to Activate:

Parameters 380/384

• Configure with parameter 366

For dedicated hardware Enable:

Remove Jumper J10 (see below)

32

(1) Refer to the Attention statement on page 52 for important bipolar wiring information.

(2)

Important:

Programming inputs for 2 wire control deactivates all HIM Start buttons unless parameter 192, [Save HIM Ref], bit 1

[Manual Mode] = “1.” This allows the HIM to control Start and Jog.

Hardware Enable Circuitry (Vector Control Only)

By default, the user can program a digital input as an Enable input. The status of this input is interpreted by drive software. If the application requires the drive to be disabled without software interpretation, a “dedicated” hardware enable configuration can be utilized. This is done by removing a jumper and wiring the enable input to “Digital In 6.”

1.

Remove the I/O Control Cassette & cover as described on page 53 .

2.

Locate & remove Jumper J10 on the Main

Control Board (see diagram).

3.

Re-assemble cassette.

4.

Wire Enable to “Digital In 6” (see page 54 ).

5.

Verify that [Digital In6 Sel], parameter 366 is set to “1, Enable.”

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

57

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Encoder Interface Option (Vector Control Only)

Encoder Terminal Designations

See “Detail” on page 53

8

6

5

No.

Description

8 +12V

(1)

DC Power

7 +12V

(1)

DC Return (Common)

Encoder Z (NOT)

Encoder Z

1

4

3

Encoder B (NOT)

Encoder B

2 Encoder A (NOT)

1 Encoder A

(1) Jumper selectable +5/12V is available on 20B-ENC-1 Encoder Boards.

(2) Z channel can be used as a pulse input while A & B are used for encoder.

Internal power source

250 mA.

Pulse, marker or registration input.

(2)

Quadrature B input.

Single channel or quadrature A input.

Encoder Specifications

Type:

Supply:

Quadrature:

Duty Cycle:

Incremental, dual channel

12V, 250 mA. 12V, 10 mA minimum inputs isolated with differential transmitter, 250 kHz maximum.

90°, ±27 degrees at 25 degrees C.

50%, +10%

Requirements: Encoders must be line driver type, quadrature (dual channel) or pulse (single channel), 8…15V DC output (3.5…6V DC when jumpers are in 5V position), single-ended or differential and capable of supplying a minimum of 10 mA per channel. Maximum input frequency is 250 kHz. The Encoder

Interface Board accepts 12V DC square-wave with a minimum high state voltage of 7.0V DC. With the jumpers in the 5V position, the encoder accept a 5V DC square-wave with a minimum high state voltage of 3.1V DC. In either jumper position, the maximum low state voltage is 0.4V DC.

Encoder Board Jumper Settings

+12V

+12V

J3

Output

Config.

+5V

+12V

+5V

J3

Output

Config.

+5V

J2

Intput

Config.

5/12V

(20B-ENC-2)

5/12V

(20B-ENC-1, Series B)

58

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Sample Encoder Wiring

I/O

Encoder Power

–Internal Drive

Power

Internal (drive)

12V DC,

250mA

(1)

Encoder Signal

–Single-Ended,

Dual

Channel

(2)

Connection Example

8

7

6

5

4

3

2

1

6

5

8

7

4

3

2

1

+12V DC

(250 mA)

Common to SHLD

(1) to Power Supply

Common

Z NOT to SHLD

(1)

Z

B NOT

B

A NOT

A

(1) SHLD connection is on drive chassis (see page 29 ).

(2) Example applies to 20B-ENC-1 only.

I/O

Encoder Power

–External

Power Source

Connection Example

External

Power

Supply to

SHLD

(1)

Encoder Signal

–Differential,

Dual Channel

8

7

6

5

2

1

4

3

Z NOT

Z

B NOT

B

A NOT

A to SHLD

(1)

Reference Control

Auto Speed Sources

The drive speed command can be obtained from a number of different sources.

The source is determined by drive programming and the condition of the Speed

Select digital inputs, Auto/Manual digital inputs or reference select bits of a command word.

The default source for a command reference (all speed select inputs are open— the default setting) is the selection programmed in [Speed Ref A Sel]. If any of the speed select inputs are closed, other parameters are used as the speed command source.

Manual Speed Sources

The manual source for speed command to the drive can be selected several ways:

•

The HIM can provide the manual source when:

–

manual control is requested from the HIM (see ALT Functions on page 67 ) or …

–

the I/O terminal block requests manual control through a digital input programmed for “Auto/Manual.” [TB Man Ref Sel] is then set to one of the DPI ports with a HIM connected to it.

(1)

•

The I/O terminal block analog input can provide the manual source when a digital input is programmed for “Auto/Manual” when active. [TB Man

Ref Sel] is set to “Analog Input.”

(1) Requires drive firmware v7.001 or greater and a Series B HIM with firmware v5.004 or greater.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

59

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Changing Speed Sources

The selection of the active Speed Reference can be made through digital inputs,

DPI command, jog button or Auto/Manual HIM operation.

Torque Reference Source

The torque reference is normally supplied by an analog input or network reference. Switching between available sources while the drive is running is not available. Digital inputs programmed as “Speed Sel 1,2,3” and the HIM Auto/

Manual function (see above) do not affect the active torque reference when the drive is in Vector Control Mode.

Speed Reference Selection Chart

(1)

= Default

Auto Speed Ref Options

Speed Ref A Sel, Parameter 090

Speed Ref B Sel, Parameter 093

Preset Speed 2, Parameter 102

Preset Speed 3, Parameter 103

Preset Speed 4, Parameter 104

Preset Speed 5, Parameter 105

Preset Speed 6, Parameter 106

Preset Speed 7, Parameter 107

DPI Port Ref 1-6, See Parameter 209

Trim

[Digital Inx Select]:

Speed Sel

3 2 1

0 0 0

0 0 1

0 1 0

0 1 1

1 0 0

1 0 1

1 1 0

1 1 1

DPI Command

Manual Speed Ref Options

HIM Requesting Auto/Manual

TB Man Ref Sel, Parameter 096

Jog Speed, Parameter 100

Digital Input

Jog Command

Speed Adders

PI Output

Slip Compensation

None

[Speed Mode]:

2 "Process Pi"

1 "Slip Comp"

0 "Open Loop"

PI Exclusive Mode

[PI Configuration]:

Bit 0, Excl Mode = 0

Auto

Man

Drive Ref Rslt

Pure Reference to follower drive for

Frequency Reference

Mod Functions

(Skip, Clamp,

Direction, etc.)

Min/Max Speed

Commanded

Frequency

Acc/Dec Ramp and

S Curve

Post Ramp to follower drive for

Frequency Reference

Output Frequency

Auto/Manual Examples

PLC = Auto, HIM = Manual

A process is run by a PLC when in Auto mode and requires manual control from the HIM during set-up. The Auto speed reference is issued by the PLC through a communications module installed in the drive. Since the internal communications is designated as Port 5, [Speed Ref A Sel] is set to “DPI Port 5” with the drive running from the Auto source.

•

Attain Manual Control

–

Press ALT then Auto/Man on the HIM. When the HIM attains manual control, the drive speed command comes from the HIM speed control keys.

•

Release to Auto Control

–

Press ALT then Auto/Man on the HIM again. When the HIM releases manual control, the drive speed command returns to the PLC.

60

(1) To access Preset Speed 1, set parameter 090 or 093 to “Preset Speed 1.”

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

PLC = Auto, Terminal Block = Manual

A process is run by a PLC when in Auto mode and requires manual control from an analog potentiometer wired to the drive terminal block. The auto speed reference is issued by the PLC through a communications module installed in the drive. Since the internal communications is designated as Port 5, [Speed Ref A

Sel] is set to “DPI Port 5” with the drive running from the Auto source. Since the

Manual speed reference is issued by an analog input (“Analog In 1 or 2”), [TB

Man Ref Sel] is set to the same input. To switch between Auto and Manual,

[Digital In3 Sel] is set to “Auto/Manual.”

•

Attain Manual Control

–

Close the digital input.

With the input closed, the speed command comes from the pot.

•

Release to Auto Control

–

Open the digital input.

With the input open, the speed command returns to the PLC.

PLC = Auto, Terminal Block = Manual, with speed reference from the HIM

IMPORTANT

Requires drive firmware v7.001 or greater and a Series B HIM with firmware v5.004 or greater.

A process is run by a PLC when in Auto mode and requires manual control from the terminal block with the speed reference provided by the HIM.

The auto speed reference is produced by the PLC and transmitted to the drive through a communications module installed in the drive. Since the internal communications is designated as Port 5, [Speed Ref A Sel] is set to “DPI Port 5" with the drive running from the Auto source.

When Manual mode is requested through the terminal block digital input, the drive evaluates if Manual mode can be granted.

If [TB Man Ref Sel], parameter 96 is set to a DPI Port and [Man Ref Preload], parameter 193 is enabled, the drive transfers the last value of the automatic speed reference to the HIM. The HIM is now the speed reference source. The terminal block has exclusive control based on [Save HIM Ref ], parameter 192, bit 1

(Manual Mode).

If [TB Man Ref Sel] is set to a DPI Port and [Man Ref Preload] is disabled, the

HIM is now the speed reference source. The terminal block has exclusive control based on [Save HIM Ref ], bit 1 (Manual Mode).

If [TB Man Ref Sel] is set to one of the DPI Ports, a HIM must be connected on the DPI Port selected.

IMPORTANT

The HIM does not enter Manual mode, it is only the reference source for the terminal block.

Rockwell Automation Publication 20B-IN019E-EN-P - July 2013

61

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

•

Attain Manual Control

–

Close the digital input.

With the input closed, the speed command comes from the HIM.

•

Release to Auto Control

–

Open the digital input.

With the input open, the speed command returns to the PLC.

Auto/Manual Notes

1.

Manual control is exclusive. If a HIM or terminal block takes manual control, no other device can take manual control until the controlling device releases manual control.

2.

If a HIM has manual control and power is removed from the drive, the drive returns to Auto mode when power is reapplied.

3.

Parameter 192 - [Save HIM Ref ], bit 1 can enable Manual mode to allow starts and jogs from the HIM in 2-wire mode.

Step 5: Start-Up Check List

•

This check list supports the Basic Start-Up menu option. See page 67 for information on other start-up routines.

•

A Human Interface Module (HIM) is required to run the Basic Start-Up routine.

•

The Basic Start-Up routine can modify parameter values for Analog and

Digital I/O. Refer to Common I/O Programming Changes on page 71 .

ATTENTION:

Power must be applied to the drive to perform the following start-up procedure. Some of the voltages present are at incoming line potential.

To avoid electric shock hazard or damage to equipment, only qualified service personnel must perform the following procedure. Thoroughly read and understand the procedure before beginning.

Prepare For Drive Start-Up

1.

Confirm that all inputs are connected to the correct terminals and are secure.

2.

Verify that AC line power at the disconnect device is within the rated value of the drive.

3.

Verify that control power voltage is correct.

4.

The remainder of this procedure requires that a

HIM be installed. Connect a Human Interface

Module (HIM) to Drive Peripheral Interface (DPI)

Port 1 or 2. Use remote devices to start up the drive, if an operator interface is not available.

DPI Ports

➊

and

➋

Lang Auto / Man Remove

Alt

1

.

Exp

7

4

2

0

8

5

3

+/-

Param #

9

6

Jog

CAUTION

HOT surfaces can cause severe burns

PORT

MOD

NET A

NET B

POWER

STS

➋

➊

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PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

IMPORTANT

When power is first applied, the HIM can require approximately 5 seconds until commands are recognized (including the Stop key). An explanation of the LED indicators can be found on page 75.

5.

Apply AC power and control voltages to the drive.

If any of the six digital inputs are configured to “Stop – CF”

(CF = Clear Fault) or “Enable,” verify that signals are present or reconfigure [Digital Inx Sel], parameters 361…366. If an I/O option is not installed (i.e. no I/O terminal block), verify that [Digital Inx Sel] is not configured to “Stop – CF” or “Enable.” If this is not done, the drive does not start. Refer to Abbreviated Fault Listing on page 72 for a list of potential digital input conflicts.

If the STS LED is not flashing green at this point, refer to Drive Status

Indicators on page 70 .

6.

When prompted, select a display language. The PowerFlex 700 Start-Up

Screen displays.

7.

Press the Enter key to display the Start-Up Menu.

8.

Use the Arrow keys to highlight “2. Basic”.

9.

Press the Enter key. Follow the menu by using the Enter key to step you through the Start-Up routine.

The Basic Start-Up routine asks simple questions and prompts you to input required information. See also Common I/O Programming

Changes on page 71 .

Information About Start-Up Motor Tests

Control schemes vary based on the Start/Jog Source selected in Step 3. Motor

Tests.

Start/Jog Source

Digital Inputs

Local Human Interface Module

(HIM)–Port 1

Remote HIM

Control Source Description

Digital In 1 = Stop / Digital In 2 = Start / Digital In 3 = Jog

Human Interface Module (HIM) connected to DPI Port 1 controls Stop / Start / Jog

Digital In 1…6 are temporarily disabled during motor tests.

Human Interface Module (HIM) connected to DPI Port 2 controls Stop / Start / Jog

Digital In 1…6 are temporarily disabled during motor tests.

During motor tests and tuning procedures, the drive can modify certain parameter values for proper Start Up operation. These values are then reset to their original values when Start Up is complete. The affected parameters are: 053,

080, 276, 278 and 361…366. If power is removed from the drive during the tests without aborting the auto-tune procedure, these parameters can not reset to their original value. If this situation occurs, reset the drive to factory defaults (see page 71 ) and repeat the Start Up procedure.

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PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

First Powerup Menu Structure

English?

Français?

Español?

Italiano?

Deutsch?

Português?

Nederlands?

Not Selected

Main Menu:

Diagnostics

Parameter

Device Select

Memory Storage

Start-Up

Preferences

PowerFlex 700

Start-Up

Startup consists of several steps to configure a drive for basic applications.

PowerFlex 700

Start-Up

Make a selection

1. SMART

2. Basic

3. Detailed

4. More info

PowerFlex 700

Start-Up

Complete these steps in order:

1. Motor Control

2. Motr Data/Ramp

3. Motor Tests

4. Speed Limits

5. Speed/Trq Cntl

6. Start/Stop/I/O

7. Done/Exit

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PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Supplemental Information Using PowerFlex Drives w/Regen Units

If a Regenerative unit (for example, 1336 REGEN) is used as a bus supply or brake, the common mode capacitors must be disconnected as described on page 43 .

Connections to the 1336 REGEN

Regen Brake Mode

Frame(s)

0…4

5…6

Terminals

1336 REGEN

DC+

DC–

DC+

DC–

PowerFlex 700

BR1

DC–

DC+

DC–

Regenerative Bus Supply Mode

Frame(s)

0…4

5…6

Terminals

1336 REGEN

DC+

DC–

DC+

DC–

PowerFlex 700

DC+

DC–

DC+ of Common Bus Drives

DC– of Common Bus Drives

DC Input (Common Bus) and Precharge Notes

The following notes must be read and understood. Also refer to pages 26 through

30 for additional DC input information.

Important Application Notes

1.

If drives without internal precharge are used (Frames 5 & 6 only), then: a. precharge capability must be provided in the system to guard against possible damage, and b. 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.

2.

If drives with internal precharge (Frames 0…6) are used with a disconnect switch to the common bus, then: a. an auxiliary contact on the disconnect must be connected to a digital input of the drive. The corresponding input (parameter 361…366) must be set to “30, Precharge Enable.” This provides the proper precharge interlock, guarding against possible damage to the drive when connected to a common DC bus.

b. the drive must have firmware version 2.002 or above.

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PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Human Interface Module (HIM) Overview

LCD Display Elements

Display Description

F-> Power Loss

0.0

Hz

Main Menu:

Diagnostics

Parameter

Device Select

Auto

Direction

⎥

Drive Status

⎥

Alarm

⎥

Auto/Man

⎥

Information

Commanded or Output Frequency

Programming / Monitoring / Troubleshooting

Human Interface Module (HIM) Key Functions

Key

Esc

Sel

Description

Exit a menu, cancel a change to a parameter value, or acknowledge a fault/alarm.

Select a digit, select a bit, or enter edit mode in a parameter screen.

Scroll through options, increase a value, or toggle a bit.

Scroll through options, decrease a value, or toggle a bit.

ALT

Enter a menu, enter edit mode in a parameter screen, or save a change to a parameter value.

Access the function associated with a programming or numeric key. Refer to the drive user manual for more information.

Start the drive.

S.M.A.R.T.

Esc

View

Sel

Lang Auto / Man Remove

Alt

1

.

Exp

7

4

8

5

2

0

9

6

3

+/-

Param #

Jog

Human Interface Module (HIM)

Stop the drive or clear a fault.

Jog

Jog the drive.

Change direction.

Increase speed.

Decrease speed.

These keys are active only when the HIM is granted Manual Control or

Param. 090 [Speed Ref A Sel] / 093 [Speed Ref B Sel] is set to:

Option 18 “DPI Port 1” for a HIM installed in the drive cover or

Option 19 “DPI Port 2” for a HIM connected by cable for handheld or remote installation option

Human Interface Module (HIM) Main Menu

Main Menu Screen

F-> Power Loss

0.0

Hz

Main Menu:

Diagnostics

Parameter

Device Select

Auto

Menu Selections

Main Menu:

Diagnostics

Parameter

Device Select

Memory Storage

Start-Up

Preferences

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PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

ALT Functions

To use an ALT function, start at the Main Menu and press the ALT key, release it, then press the programming key associated with one of the following functions:

ALT Key then

ALT

Esc

Esc

Sel

Sel

Function

S.M.A.R.T.

Function Description

Displays the S.M.A.R.T. screen. This function allows the drive parameter values to be quickly programed by directly accessing the most frequently used drive functions. Refer to the User Manual for more information.

Log In/Out Log in to change parameter settings.

Log out to protect parameter settings.

Change a password.

View

Device

Allows the selection of how parameters are viewed or detailed information about a parameter or component.

Select a connected adapter for editing.

+/–

Lang

Auto/Man Switches between Auto and Manual Modes. If the Human Interface Module (HIM) requests Manual Mode, the Speed Reference source is transferred to the Human

Interface Module (HIM).

Remove

Displays the language selection screen. The LCD Human Interface Module (HIM) on an architecture class drive allows you to change the display language any time.

Allows Human Interface Module (HIM) removal without causing a fault if the

Human Interface Module (HIM) is not the last controlling device and does not have Manual control of the drive.

Param # Allows entry of a parameter number for viewing/editing.

Start-Up Routines

The PowerFlex 700 start up routines allow the user to commission the drive more quickly and accurately. If you have an LCD HIM, two methods are provided.

• S.M.A.R.T. Start

This routine is accessible by using the “ALT” function key on the LCD

HIM. This keystroke brings up a list of parameters needed to program the eight most commonly adjusted drive functions. These include Start, Stop,

Minimum Speed, Maximum Speed, Acceleration Time, Deceleration

Time, Reference source (speed command) and Electronic Overload setting for the motor. No knowledge of parameter organization or access is required. S.M.A.R.T. Start can commission the drive in just a few minutes.

See page 69 .

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PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

• Assisted Start Up

Three levels of Assisted Start Up (Basic, Detailed and Application) aid the user in commissioning the drive asking simple Yes/No or “Enter Data” questions. The user is guided through the Start Up to reduce the amount of time necessary to get the drive “up and running.” The following are included in startup:

–

Input Voltage Ratings

–

Motor Data

–

Motor Tests & Auto-tuning

–

Speed/Torque Control & Direction Limits

–

Speed Reference

–

Start & Stop Modes

–

Ramp Setup

–

Digital and Analog I/O

–

Application Set-up (TorqProve, Oil Well Pumps, Positioning/Speed

Profiling)

See page 70 for details.

IMPORTANT

Power must be applied to the drive when viewing or changing parameters.

Previous programming can affect the drive status and operation when power is applied. If the I/O Cassette has been changed, a Reset Defaults operation must be performed.

Torque Proving applications can use the Assisted Start Up to tune the motor.

However, it is recommended that the motor be disconnected from the hoist/ crane equipment during the routine. If this is not possible, refer to the manual tuning procedure in the User Manual.

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PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Start-Up

Continue

Start Over

Intro

Selection:

1. SMART

2. Basic

3. Detailed

4. Application

Start Up Menu

Motor Control

Select

Configures

Motor Control

Method

Selection:

1. Torq Prove

2. Pos/Spd Profile

3. Oil Well Pumps

Motor Data and

Ramp Times

Enter Motor NP

Data, Stop Mode,

Accel/Decel

Ramp Times

Motor Control

Select

Configures

Motor Control

Method

Motor Tests

(1)

Optimize Torque and

Verify Direction

Motor Data and

Ramp Times

Enter Motor NP

Data, Stop Mode,

Accel/Decel

Ramp Times

Speed Limits

Set Min/Max

Speed and

Direction Control

Motor Tests

Optimize Torque and

Verify Direction

Speed/Torque

Control

Configure

Source, Value and Scale for

Speed References

Speed Limits

Set Min/Max

Speed and

Direction Control

Basic

Done /

Exit

Start/Stop/I/O

Detailed

Configure

Control Method

(2 Wire/3 Wire),

I/O, Digital I/O

& Analog Outputs

Pos/Spd Profile

Pos/Spd Profile

Application

Configure for a

Specific Application such as; Auto Restart,

Flying Start, etc.

Done /

Exit

Done /

Exit

Torq Proving

Speed/Torque

Control

Configure

Source, Value and Scale for

Speed References

Torq Proving

Done /

Exit

Well Pump

Type

Motor Data and

Ramp Times

Enter Motor NP

Data, Stop Mode,

Accel/Decel

Ramp Times

Pump Data

Enter Pump

Data

Start/Stop/I/O

Configure

Control Method

(2 Wire/3 Wire),

I/O, Digital I/O

& Analog Outputs

Motor Tests

Optimize Torque and

Verify Direction

Speed/Torque

Control

Configure

Source, Value and Scale for

Speed References

Torque Alarm Process Display

Done /

Exit

(1)

During Motor Tests and tuning procedures, the drive can modify certain parameter values for proper Start Up operation. These values are then reset to their original values when Start Up is complete.

The affected parameters are: 053, 080, 276, 278 and 361…366. If power is removed from the drive during the tests without aborting the auto-tune procedure, these parameters can not be reset to their original value. If this situation occurs, reset the drive to factory defaults and repeat the Start Up procedure.

Running S.M.A.R.T. Start

During a Start Up, the majority of applications require changes to a few parameters. The LCD HIM on a PowerFlex 700 drive offers S.M.A.R.T. start, which displays the most commonly changed parameters. With these parameters, you can set the following functions:

S - Start Mode and Stop Mode

M - Minimum and Maximum Speed

A - Accel Time 1 and Decel Time 1

R - Reference Source

T - Thermal Motor Overload

To run a S.M.A.R.T. start routine:

Key(s) Step

1. Press ALT and then Esc (S.M.A.R.T). The

S.M.A.R.T. start screen appears.

2. View and change parameter values as desired. For HIM information, see

Appendix B in the User Manual.

3. Press Esc to exit the S.M.A.R.T. start.

ALT

Esc

Esc

Example LCD Displays

F-> Stopped

0.0

Hz

SMART List:

Auto

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PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Running an Assisted Start Up

IMPORTANT

This start-up routine requires an LCD HIM.

The Assisted start-up routine prompts you to input required information. Access

Assisted Start Up by selecting “Start Up” from the Main Menu.

To perform an Assisted Start-Up

Step

1. In the Main Menu, press the Up Arrow or

Down Arrow to scroll to “Start Up”.

2. Press Enter.

Key(s) Example LCD Displays

F-> Stopped

0.0

Hz

Main Menu:

Memory Storage

Start Up

Preferences

Auto

IMPORTANT

Done/Exit must be selected upon completion of the Start Up routine in order for any Start Up/Autotune data to be saved.

Drive Status Indicators

Name

POWER

Color

Green

State

Steady

Description

Illuminates when power is applied to the drive.

STS

PORT

MOD

NET A

NET B

Green

Yellow

Flashing

Steady

Flashing, Drive

Stopped

Flashing, Drive

Running

Red

Steady,

Drive Running

Flashing

Steady

Refer to the Communication

Adapter User Manual.

Drive ready, but not running and no faults are present.

Drive running, no faults are present.

An inhibit condition exists, the drive cannot be started. Check parameter 214 [Start Inhibits].

An intermittent type 1 alarm condition is occurring.

Check parameter 211 [Drive Alarm 1].

A continuous type 1 alarm condition exists.

Check parameter 211 [Drive Alarm 1].

A fault has occurred.

A non-resettable fault has occurred.

Status of DPI port internal communications (if present).

Status of communications module (when installed).

Status of network (if connected).

Status of secondary network (if connected).

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PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Common I/O Programming Changes

Your application needs may require changing parameters from their factory default settings.

Speed Reference A

Change Speed Reference A from Analog In 2 to Analog In 1 to connect an external potentiometer.

1.

Set Param. 090 [Speed Ref A Sel] to option 1 “Analog In 1”

This sets the speed reference input to I/O terminals 1 & 2. For 4…20 mA operation, a jumper must be placed between terminals 17 & 18.

2.

Set Param. 096 [TB Man Ref Sel] to option 9 “MOP Level”

This eliminates a potential Conflict alarm condition. Analog In 2 is not a valid Speed Reference source if selected for any of the following:

–

117 [Trim In Select]

–

126 [PI Reference Sel]

–

128 [PI Feedback Sel]

–

147 [Current Lmt Sel]

–

179 [Sleep-Wake Ref ]

3.

Set Param. 091 [Speed Ref A Hi] to the upper value of the desired speed reference range in Hz

4.

Set Param. 092 [Speed Ref A Lo] to the lower value of the desired speed reference range in Hz

Control Scheme

Change from 3 Wire Start/Stop to 2 Wire Run/Not Run at Digital In 1 &

Digital In 2.

IMPORTANT

This disables the Start button on the HIM.

1.

Set Param. 361 [Digital In1 Sel] to option 7 “Run” or 9 “Run Reverse”

2.

Set Param. 362 [Digital In2 Sel] to another option such as 8 “Run

Forward” or 10 “Jog”

See I/O Wiring Examples beginning on page 56 .

Restoring Factory Defaults

From the Human Interface Module (HIM) Main Menu select: Memory Storage

/ Reset To Defaults

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PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Troubleshooting

For a complete listing of Faults and Alarms, refer to the PowerFlex 700 User

Manual, publication 20B-UM002 .

Table 10 - Abbreviated Fault Listing

Fault

Auxiliary

Input

2

Decel Inhibit 24

Description

➀

Auxiliary input interlock is open.

Action

Check remote wiring.

➂

The drive is not following a commanded deceleration because it is attempting to limit bus voltage.

1. Verify input voltage is within drive specified limits.

2. Verify system ground impedance follows proper grounding techniques.

3. Disable bus regulation and/or add dynamic brake resistor and/or extend deceleration time.

Refer to page 6 for further info.

4. Disable with parameter 238.

1. Reprogram [Motor NP FLA] with the correct motor nameplate value.

2. Repeat Autotune.

FluxAmpsRef

Rang

78 The value for flux amps determined by the

Autotune procedure exceeds the programmed [Motor NP FLA], parameter

042.

➀

The drive output current has exceeded the hardware current limit.

HW

OverCurrent

12 Check programming. Check for excess load, improper DC boost setting, DC brake volts set too high or other causes of excess current.

IR Volts

Range

Motor

Overload

OverSpeed

Limit

OverVoltage 5

SW

OverCurrent

77

7

25

36

“Calculate” is the autotune default and the value determined by the autotune procedure for IR Drop Volts is not in the range of acceptable values.

➀

➂

Internal electronic overload trip.

Enable/Disable with [Fault Config 1].

Re-enter motor nameplate data.

An excessive motor load exists. Reduce load so drive output current does not exceed the current set by [Motor NP FLA].

➀

Functions such as Slip Compensation or Bus

Regulation have attempted to add an output frequency adjustment greater than that programmed in [Overspeed Limit], parameter 083.

Remove excessive load or overhauling conditions or increase [Overspeed Limit].

➀

DC bus voltage exceeded maximum value.

Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration.

Extend the decel time or install dynamic brake option.

➀

Drive output current has exceeded the 1ms current rating. This rating is greater than the

3 second current rating and less than the hardware overcurrent fault level. It is typically 200…250% of the drive continuous rating.

Check for excess load, improper DC boost setting. DC brake volts set too high.

(1) See the User Manual for a description of fault types.

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PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Table 11 - Abbreviated Alarm Listing

Alarm

Dig In

ConflictA

17

Description

➁

Digital input functions are in conflict. Combinations marked with a “ ” cause an alarm.

Acc2/Dec2 Accel 2 Decel 2 Jog 1/2 Jog Fwd Jog Rev Fwd/Rev

Acc2/Dec2

Accel 2

Decel 2

Jog 1/2

Jog Fwd

Jog Rev

Fwd/Rev

Dig In

ConflictB

18

➁

A digital Start input has been configured without a Stop input or other functions are in conflict.

Combinations that conflict are marked with a “ ” and cause an alarm.

Start Stop-CF Run Run Fwd Run Rev Jog 1/2 Jog Fwd Jog Rev Fwd/Rev

Start

Stop-CF

Run

Run Fwd

Run Rev

Jog 1/2

Jog Fwd

Jog Rev

Fwd/Rev

Dig In

ConflictC

TB Man

Ref Cflct

19

30

➁

More than one physical input has been configured to the same input function. Multiple configurations are not allowed for the following input functions.

Forward/Reverse Run Reverse

Speed Select 1 Jog Forward

Speed Select 2

Speed Select 3

Run Forward

Jog Reverse

Run

Stop Mode B

Bus Regulation Mode B

Acc2 / Dec2

Accel 2

Decel 2

➁

Occurs when:

•

“Auto/Manual” is selected (default) for [Digital In3 Sel], parameter 363

and

•

[TB Man Ref Sel], parameter 96 has been reprogrammed.

No other use for the selected analog input can be programmed.

Example: If [TB Man Ref Sel] is reprogrammed to “Analog In 2,” all of the factory default uses for “Analog In 2” must be reprogrammed (such as parameters 90, 117, 128 and 179). Refer to the Auto/Manual Examples section of the PowerFlex 700 User Manual.

To correct:

•

Verify/reprogram the parameters that reference an analog input

or

•

Reprogram [Digital In3] to another function or “Unused.”

(1) See the User Manual for a description of alarm types.

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PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

74

Common Symptoms and Corrective Actions

Drive does not Start from Start or Run Inputs wired to the terminal block.

Cause(s)

Drive is Faulted

Indication

Flashing red status light

Corrective Action

Clear fault.

• Press Stop

• Cycle power

• Set [Fault Clear] to 1

• “Clear Faults” on the HIM Diagnostic menu.

Wire inputs correctly and/or install jumper.

Incorrect input wiring. Refer to the wiring examples starting on page 56 .

• 2 wire control requires Run, Run Forward,

Run Reverse or Jog input.

• 3 wire control requires Start and Stop inputs.

• Jumper from terminal 25 to 26 is required.

Incorrect digital input programming.

• Mutually exclusive choices have been made (i.e., Jog and Jog Forward).

• 2 wire and 3 wire programming can be conflicting.

• Exclusive functions (i.e, direction control) can have multiple inputs configured.

• Stop is factory default and is not wired.

None

None

Flashing yellow status light and “DigIn CflctB” indication on LCD HIM.

[Drive Status 2] shows type 2 alarm(s).

Program [Digital Inx Sel], parameters

361…366 for correct inputs.

Start or Run programming can be missing.

Program [Digital Inx Sel] to resolve conflicts.

Remove multiple selections for the same function.

Install stop button to apply a signal at stop terminal.

Drive does not Start from Human Interface Module (HIM).

Cause(s)

Drive is programmed for 2 wire control. HIM

Start button is disabled for 2 wire control unless param. 192, bit 1 = “1.”

Indication

None

Corrective Action

If 2 wire control is required, no action needed.

If 3 wire control is required, program

[Digital Inx Sel] for correct inputs.

Drive does not respond to changes in speed command.

Cause(s)

No value is coming from the source of the command.

Indication

LCD HIM Status Line indicates “At Speed” and output is 0 Hz.

Incorrect reference source has been programmed.

None

Incorrect Reference source is being selected via remote device or digital inputs.

None

Corrective Action

1. If the source is an analog input, check wiring and use a meter to check for presence of signal.

2. Check [Commanded Speed], parameter

002 for correct source.

3. Check parameter 213, [Speed Ref

Source] for the source of the speed reference.

4. Reprogram parameter 090, [Speed Ref

A Sel] for correct source.

5. Check parameter 209, [Drive Status 1], bits 12 & 13 for unexpected source selections.

6. Check parameter 216 [Dig In Status] to see if inputs are selecting an alternate source.

7. Reprogram digital inputs to correct

“Speed Sel x” option.

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PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Motor and/or drive do not accelerate to commanded speed.

Cause(s)

Acceleration time is excessive.

Excess load or short acceleration times force the drive into current limit, slowing or stopping acceleration.

Indication

None

None

Speed command source or value is not as expected.

Programming is preventing the drive output from exceeding limiting values.

None

None

Corrective Action

Reprogram [Accel Time x].

Check [Drive Status 2], bit 10 to see if the drive is in Current Limit.

Remove excess load or reprogram [Accel

Time x].

Check for the proper Speed Command by using Steps 1 through 7 above.

Check [Maximum Speed] and [Maximum

Freq] (parameters 082 and 055) to assure that speed is not limited by programming.

Motor operation is unstable.

Cause(s) Indication

Motor data was incorrectly entered or Autotune was not performed.

None

Corrective Action

1. Correctly enter motor nameplate data.

2. Perform “Static” or “Rotate” Autotune procedure.

Drive does not reverse motor direction.

Cause(s)

Digital input is not selected for reversing control.

Digital input is incorrectly wired.

Indication

None

Direction mode parameter is incorrectly programmed.

None

None

Motor wiring is improperly phased for reverse. None

A bipolar analog speed command input is incorrectly wired or signal is absent.

None

Corrective Action

Check [Digital Inx Sel]. Choose correct input and program for reversing mode.

Check input wiring.

Reprogram [Direction Mode] for analog

“Bipolar” or digital “Unipolar” control.

Switch two motor leads.

1. Use meter to check that an analog input voltage is present.

2. Check wiring.

Positive voltage commands forward direction. Negative voltage commands reverse direction.

Stopping the drive results in a Decel Inhibit fault.

Cause(s)

The bus regulation feature is enabled and is halting deceleration due to excessive bus voltage. Excess bus voltage is normally due to excessive regenerated energy or unstable AC line input voltages.

Internal timer has halted drive operation.

Indication

LCD Status Line indicates

“Faulted”.

Corrective Action

Decel Inhibit fault screen.

1. See Attention statement on page 6 .

2. Reprogram parameters 161/162 to eliminate any “Adjust Freq” selection.

3. Disable bus regulation (parameters 161 &

162) and add a dynamic brake.

4. Correct AC input line instability or add an isolation transformer.

5. Reset drive.

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PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

Manually Clearing Faults

Step

1. Press Esc to acknowledge the fault. The fault information is removed so that you can use the

Human Interface Module (HIM).

2. Address the condition that caused the fault.

The cause must be corrected before the fault can be cleared.

3. After corrective action has been taken, clear the fault by one of these methods:

• Press Stop

• Cycle drive power

• Set parameter 240 [Fault Clear] to “1.”

• “Clear Faults” on the Human Interface Module (HIM) Diagnostic menu.

Key(s)

Esc

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Notes:

PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6

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77

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Rockwell Automation provides technical information on the Web to assist you in using its products.

At http://www.rockwellautomation.com/support , you can find technical manuals, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. You can also visit our Knowledgebase at http://www.rockwellautomation.com/knowledgebase for FAQs, technical information, support chat and forums, software updates, and to sign up for product notification updates.

For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer

TechConnect

SM

support programs. For more information, contact your local distributor or Rockwell Automation representative, or visit http://www.rockwellautomation.com/support/ .

Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running.

United States or Canada 1.440.646.3434

Outside United States or Canada Use the Worldwide Locator at http://www.rockwellautomation.com/support/americas/phone_en.html

, or contact your local Rockwell

Automation representative.

New Product Satisfaction Return

Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.

United States

Outside United States

Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor to complete the return process.

Please contact your local Rockwell Automation representative for the return procedure.

Documentation Feedback

Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete this form, publication RA-DU002 , available at http://www.rockwellautomation.com/literature/ .

U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, E-mail: [email protected]

Online: www.ab.com/support/abdrives

Allen-Bradley, Rockwell Software, Rockwell Automation, PowerFlex, RSLinx, DriveExplorer, DriveExecutive, ControlFLASH, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

*PN-211781*

PN-211781

Publication 20B-IN019E-EN-P - July 2013

Supersedes Publication 20B-IN019D-EN-P - June 2013

PN-211781

Copyright © 2013 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.