Open-Chassis Style (IP00) - Frame 2: Intended to be installed in an enclosure. Frame 3: Input filter and power modules, when purchased individually, are intended to be mounted in an enclosure.

•

Type 1 (IP20) - Frame 3: Drive is mounted in a separate NEMA/UL Type

1 enclosure to obtain this rating.

PowerFlex 700L Liquid-Cooled AC drives must be placed in an enclosure.

See the catalog string on page

P-5 for fully assembled NEMA/UL Type 1

drive options.

PowerFlex 700L Liquid-Cooled AC drives are suitable for use on a circuit capable of delivering up to a maximum of 200,000 rms symmetrical amperes. For the PowerFlex 700L Frame 3A or 3B complete drive, a circuit breaker with shunt trip with the appropriate kAIC rating must always be used upstream of the power module. See Table 1.A

for details.

PowerFlex 700L Liquid Cooled AC drives should not be used on undersized or high-impedance supply systems. The supply system kVA should be equal to or greater than the drive-rated kW, and the system impedance should be less than 10%. Operation outside these limits could cause instability resulting in drive shutdown.

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General Installation Information

The kVA of all PowerFlex 700L drives on the distribution system and the system impedance of upstream transformers should be taken into account.

ATTENTION:

To guard against personal injury and/or equipment damage caused by improper circuit breaker selection, use only the recommended circuit breakers specified in Table 1.A

Unbalanced, Ungrounded or Resistive Grounded Distribution Systems

If phase-to-ground voltage will exceed 125% of normal or the supply system is ungrounded, see Wiring and Grounding Guidelines for Pulse

Width Modulated (PWM) AC Drives, publication DRIVES-IN001, for more information.

ATTENTION:

PowerFlex 700L Liquid Cooled Frame 2, 3A, and 3B drives contain protective MOVs and a common mode capacitor that are referenced to ground. (The protective MOVs and common mode capacitor in Frame 3A and 3B drives are mounted in the Input Filter Bay.) These devices must be disconnected if the drive is installed on a resistive grounded distribution system or an ungrounded distribution system.

Drive Frame Size

3A or 3B

See Ungrounded or Resistive

Grounded Installations on...

Page 2-11

Page 3-22

Input Power Conditioning

Certain events on the power system supplying a drive can cause component damage or shortened product life. These events include the following:

•

The power system has power factor correction capacitors switched in and out of the system, either by the user or by the power company.

•

The power source has intermittent voltage spikes in excess of 6000 volts.

These spikes could be caused by other equipment on the line or by events such as lightning strikes.

•

The power source has frequent interruptions.

General Grounding Requirements

The drive Safety Ground - PE must be connected to system ground.

Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked.

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

Figure 1.1 Typical Grounding

(L1)

(L2)

(L 3 )

PE U

(T1)

(T2)

(T 3 )

–

BR1 BR2

Re qu ired

Inp u t F us ing

Re qu ired Br a nch

Circ u it Di s connect

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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 or joist), a floor ground rod, or bus bar (

Figure 1.1

). Grounding points must comply with national

and local industrial safety regulations and/or electrical codes.

Shield Termination - SHLD

The Shield terminal provides a grounding point for the motor cable shield.

It must be connected to an earth ground by a separate continuous lead. The

motor cable

shield should be connected to this terminal on the drive (drive end) and the motor frame (motor end). Use a shield terminating or EMI clamp to connect shield to this terminal.

When shielded cable is used for

control and signal wiring

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

Wiring Requirements for the Drive

Certain drive requirements should be checked before continuing with the drive installation. Wire sizes, branch circuit protection, encoder feedback

(for FVC regulation), and wiring to disable the drive are all areas that need to be evaluated.

Operation of the drive can be disabled in two locations. The Gate Enable terminal block on the front of the power structure can be used to disable the firing of inverter IGBTs. When the Gate Enable signal is opened, inverter

IGBTs are disabled independent of any software control. This action also generates fault 207 in the Inverter Power Module to enunciate this condition. As a result of this fault, the Active Converter Power Module is also turned off, but this is done via software operation. The firing of IGBTs in the Active Converter Power Module can be disabled independently of any software control by opening the connection between terminals 13 and 14 on

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General Installation Information the Active Converter Power Module control cassette PCB assembly terminal block P1. This action also generates a fault in the Inverter Power

Module to enunciate this condition.

Input Line Branch Circuit Protection

ATTENTION:

Most codes require that upstream branch circuit protection be provided to protect input power wiring.

The PowerFlex 700L Frame 2 drive does not provide input power short circuit protection. Specifications for the recommended fuse or circuit breaker to provide Frame 2 drive input power protection against short circuits are provided in

Table A.F

and Table A.G

Frame 3A and 3B complete drives include an input power circuit breaker. The value of the circuit breaker provided with the drive is listed in Table 1.A

Table 1.A AC Input Circuit Breaker Values for Frame 3A and 3B Complete Drives

Frame

Size

Input Voltage

400…480V AC

575…690V AC

400…480V AC

575…690V AC

Circuit Breaker

Provided

800 A

1500 A

Shunt Trip

Rating

65 kAIC

35 kAIC

100 kAIC

35 kAIC

Power Wiring

Because most start-up difficulties are the result of incorrect wiring, take every precaution to verify that the wiring is correct. Read and understand all items in this section before beginning installation.

ATTENTION:

The following information is merely a guide for proper installation. Rockwell Automation cannot assume responsibility for the compliance or noncompliance to any code, national, local, or otherwise for the proper installation of this drive or associated equipment. A risk of personal injury and/or equipment damage exists if codes are ignored during installation.

Cable Types Acceptable for 400-690 Volt Installations

ATTENTION:

National Codes and standards (NEC, VDE, BSI, and so forth) and local codes outline provisions for safely

PowerFlex 700L Frames 2, 3A, and 3B Liquid-Cooled AC Drives User Manual

installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.

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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 (167 °F). Do not reduce wire gauge when using higher temperature wire.

Unshielded Cable

THHN, THWN, or similar wire is acceptable for drive installation in dry environments provided adequate free air space and/or conduit fill rate limits are used.

Do not use THHN or similarly coated wire in wet areas

. Any wire chosen must have a minimum insulation thickness of 15 mils (0.4mm/

0.015 in.) and should not have large variations in insulation concentricity.

Shielded Cable

Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC Drive. Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches, and other devices that may be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations, or a high degree of communication/networking are also good candidates for shielded cable.

Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable may help extend the distance the motor can be located from the drive without the addition of motor protective devices such as terminator networks. See Chapter 5, “Reflected Wave” in Wiring and Grounding

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

DRIVES-IN001.

Consideration should be given to all of the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics, and chemical resistance. Additionally, a braided shield should be included and 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

29528 - 29532 (AWG-1 through AWG-410). This cable has three XLPE insulated conductors plus ground with a spiral copper shield surrounded by a PVC jacket.

Other types of shielded cable are available, but the selection of these types may limit the allowable cable length. Particularly, some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield.

This construction can greatly increase the cable charging current required,

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and reduce the overall drive performance. These cables are not recommended.

Armored Cable

Cable with continuous aluminum armor is often recommended in drive system applications or specific industries. It offers most of the advantages of standard shielded cable and also combines considerable mechanical strength and resistance to moisture. It can be installed in concealed and exposed manners and removes the requirement for conduit (EMT) in the installation. It can also be directly buried or embedded in concrete.

Because noise containment can be affected by incidental grounding of the armor to building steel when the cable is mounted, we recommend that the armor cable have an overall PVC jacket. For details, see Chapter 2, “Wire

Types” in Wiring and Grounding Guidelines for Pulse Width Modulated

(PWM) AC Drives, publication DRIVES-IN001.

Interlocked armor is acceptable for shorter cable runs, but continuous welded armor is preferred.

Best performance is achieved with three spaced ground conductors, but acceptable performance for drives below 200 HP is provided by way of a single ground conductor.

Table 1.B Recommended Shielded or Armored Wire

Location

Standard

(Option 1)

Standard

(Option 2)

Class I & II;

Division I & II

Rating/Type

1000V, 90 °C (194 °F)

XHHW2/RHW-2 Anixter

B29528-B29532, Belden

29528-29532, or equivalent

Tray rated 1000V, 90 °C

(194 °F) RHH/RHW-2

Anixter

OLFLEX-76xxx03 or equivalent

Tray rated 1000V, 90 °C

(194 °F) RHH/RHW-2

Anixter 7VFD-xxxx or equivalent

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.

• corrugated copper tape with three bare copper grounds in contact with shield.

•

PVC jacket.

•

Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor.

•

Black sunlight resistant PVC jacket overall.

•

Three copper grounds.

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Cable Trays and Conduit

If cable trays or large conduits are to be used, see the guidelines in 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 should be disabled. This helps to minimize the possible shock hazard from

“cross coupled” motor leads.

Compliance with the Low Voltage (LV) Directive and Electromagnetic

Compatibility Directive (EMC) has been demonstrated using harmonized

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

European Communities. PowerFlex 700L Liquid-Cooled AC drives comply with the EN standards listed below when installed according to this

PowerFlex 700L Liquid-Cooled AC Drive User Manual, PowerFlex 700

Active Converter User Manual, PowerFlex 70/700 Reference Manual and, depending on the equipped drive control option, either the PowerFlex 700 -

Series B User Manual or PowerFlex 700S Phase II Control User Manual.

CE Declarations of Conformity are available online at www.ab.com/ certification/ce/docs .

Low Voltage Directive (2006/95/EC)

EN50178 Electronic equipment for use in power installations.

EMC Directive (2004/108/EC)

EN61800-3 Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods.

General Notes

•

Without additional external filtering, PowerFlex 700L Liquid-Cooled

AC drives satisfy the 2nd Environment high-frequency emission limits of

EN61800-3. Without external mitigation, PowerFlex 700L

Liquid-Cooled drives are not intended to be used on a low-voltage public network which supplies residential or office premises; radio frequency interference is expected if used in such an environment.

•

The drive motor cabling should be kept as short as possible to minimize electromagnetic emission and capacitive currents.

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General Installation Information

•

Use of line filters in ungrounded systems is not recommended.

•

Conformity of the drive with CE EMC requirements does not guarantee an entire machine or installation complies with CE EMC requirements.

Many factors can influence total machine/installation compliance.

•

Non-regenerative PowerFlex 700L Liquid-Cooled AC drives generate conducted low frequency disturbances (harmonic emissions) on the AC supply system which may require mitigation in some applications. More information regarding harmonic emissions can be found in the

PowerFlex 70/700 Reference Manual, publication PFLEX-RM001.

•

When operated on a public supply system, it is the responsibility of the installer or user to make sure, by consultation with the distribution network operator and Rockwell Automation, if necessary, that applicable requirements have been met.

Essential Requirements for CE Compliance

Conditions 1 through 6 listed below

must be accomplished

for a

PowerFlex 700L drive installation to meet the requirements of EN61800-3.

Use a standard PowerFlex 700L Liquid-Cooled CE-compliant drive.

For the Frame 2 drive, kit Catalog Number SK-L1-CHK2-F2, which includes common mode chokes and shielded cable clamps, must be installed according to its included instructions, publication 20L-IN011.

For Frame 3A and 3B, the drive must be installed in a suitable enclosure which attenuates radio frequency emissions (Rittal TS 8 or equivalent).

System grounding as described on

page 1-2 .

Output power wiring to the motor, control (I/O) and signal wiring must use cable with a braided shield with coverage of 75% or greater, or cables must be contained in metal conduit, or equivalent shielding must be provided.

All control (I/O) and signal wiring to the drive must use cable with a braided shield providing 75% or greater coverage, or the cables be housed in a metal conduit, or equivalent shielding must be provided.

When shielded cable is used, only the drive end of the cable shield should be terminated with a low-impedance connection to earth.

The shields of all shielded cables must be terminated with the proper shielded connectors to chassis/earth.

Motor cables must not exceed 20 meters (65.6 feet) in length.

Motor cabling must be separated from control and signal wiring

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wherever possible.

Review important precautions and attention statements throughout this manual before installing the drive.

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Compliance of PowerFlex 700L Liquid-Cooled AC drives with the

Australian Radiocommunications Act of 1992 has been demonstrated through compliance with EN61800-3. Both the General Notes and the

Essential Requirements for CE Compliance provided above apply to C-Tick compliance for PowerFlex 700L Liquid-Cooled AC drives.

C-Tick Declarations of Compliance are available online at www.ab.com/ certification/c-tick/index.html

Input Contactor Precautions

ATTENTION:

A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage.

The drive is designed to use control input signals that will start and stop the motor. If an input device is used, operation must not exceed one cycle per minute or drive damage will occur.

ATTENTION:

The drive start/stop/enable control circuitry includes solid-state components. If hazards due to accidental contact with moving machinery, or unintentional flow of liquid, gas, or solids exist, an additional hard-wired stop circuit may be required to remove the AC line to the drive. An auxiliary braking method may be required.

Output Contactor Precaution

ATTENTION:

To guard against drive damage when using output contactors, the following information must be read and understood. One or more output contactors may be installed between the drive and motor(s) for the purpose of disconnecting or isolating certain motors/loads. If a contactor is opened while the drive is operating, power will be removed from the respective motor, but the drive will continue to produce voltage at the output terminals. In addition, reconnecting a motor to an active drive (by closing the contactor) could produce excessive current that may cause the drive to fault. If any of these conditions are determined to be undesirable or unsafe, an auxiliary contact on the output contactor should be wired to a drive digital input that is programmed as “Enable.” This will cause the drive to execute a coast-to-stop (cease output) whenever an output contactor is opened.

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