Because most start-up difficulties are the result of incorrect wiring, take every precaution to verify that the wiring is completed as instructed. Read and understand all items before starting actual installation.

2-12

2-18

2-20

2-22

Page

ATTENTION:

The following information is merely a guide for proper installation. Rockwell Automation does not assume responsibility or liability for the compliance or 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.

Mounting Considerations Total Area Required for Drive Installation

Overall drive dimensions are shown in Figure 2.1

as an aid in calculating the total area required for installing Frame 2 drives.

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Frame 2 Installation

Figure 2.1 Frame 2 Drive Installation Dimensions

389.6

(15.34)

351.0

(13.82)

Dimensions are in millimeters and (inches).

See

DETAIL

566.1

(22.29)

Ground Terminal with 2 Clearance

Holes for M8 Stud

66.6

(2.62)

423.8

(16.68)

730.2

(28.75)

591.2

(23.28)

153.8

(6.06)

BACK VIEW

See

DETAIL

4x Ø

8.5 (0.33)

4x Ø

15.0 (0.59)

DETAIL A

16.0 (0.63)

Approximate Weight

186 kg (410 lb)

Motor

Output

Terminals

W/T3

V/T2

U/T1

955.7

(37.63)

3x Clearance

Hole for

M8 Stud

46.9

(1.85)

Coolant Inlet

37 Deg Flare -12

Coolant Outlet

37 Deg Flare -12

3x Clearance

Hole for

M8 Stud

SIDE VIEW

R/L1 S/L2 T/L3

AC Input Terminals

Stirring

Fan

Housing

FRONT VIEW

8.6 (0.34)

DETAIL B

14.9 (0.59)

Recommended Mounting Clearances

Specified vertical clearance requirements (

Figure 2.2

) are intended to be

from drive to drive. Other objects can occupy this space; however, reduced air flow may cause protection circuits to fault the drive. In addition, inlet air temperature must not exceed the product specification.

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Figure 2.2 Frame 2 Drive Minimum Mounting Clearances

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Frame 2 Installation

2-3

101.6 mm

(4.0 in.)

101.6 mm

(4.0 in.)

101.6 mm

(4.0 in.)

101.6 mm

(4.0 in.)

101.6 mm

(4.0 in.)

Equipment Lifting

Verifying Drive Input Ratings Match Supplied Power

It is important to verify that plant power meets the input power requirements

of the PowerFlex 700L Frame 2 drive circuitry. See Appendix A

for input power rating specifications. Be sure input power to the drive corresponds to the drive nameplate voltage and frequency.

This section explains how to lift the drive.

ATTENTION:

To guard against possible personal injury and/or equipment damage, observe the following:

• Do not allow any part of the drive or lifting mechanism to make contact with electrically charged conductors or components.

• At no time should a person or their limbs be directly underneath the items being lifted.

•

Do not subject the load to high rates of acceleration or deceleration.

• Inspect all lifting hardware for proper attachment before lifting any drive unit.

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Attaching the Lifting Feet to the Drive

Remove the four shipping bolts that hold the drive to the skid.

Attach the two lifting feet provided with the drive to the bottom drive

mounting holes as shown in Figure 2.3

Figure 2.3 Attaching Lifting Feet to the Drive

Attaching the Lifting Hardware to the Drive

Apply lifting hooks (see Figure 2.4

). Take precautions to verify that there

are lifting hooks secured in all four locations ( Figure 2.5

) on the drive.

Figure 2.4 Attaching Lifting Hardware to the Frame 2 Drive

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2-5

Connecting Lifting Hooks to Proper Locations

Locate all four lifting features on the drive (see

Figure 2.5

). All four

locations must be used to maintain the drive center of gravity when lifting.

Figure 2.5 Lifting Locations on the Frame 2 Drive

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Applying Strap Angles

TIP:

To ensure that this angle is greater than 60°, make the length of chain or cable between the center and the corners (B) longer than the distance between the opposite corners (A).

B > A

Min. 60°

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Rotating the Drive About the Board

Figure 2.6

shows the drive, with the lifting feet attached, on a skid. To avoid

damage to the drive input terminals when lifting the drive to a vertical position, do the following.

After the straps are in place (see

Applying Strap Angles on page 2-5 ),

carefully lift the drive to rotate it 90° to a vertical position.

Remove the lifting feet before installing the drive into the enclosure.

Figure 2.6 Frame 2 Drive on Skid

Input Terminals

Lifting Feet

Mounting Requirements

Skid

The PowerFlex700L Frame 2 drive is a single integrated assembly consisting of a filter section and a power section. The filter section provides the mounting feet and represents greater than 50% of the approximate 186 kg (410 lb) total weight. Follow these mounting requirement guidelines.

Mount the Frame 2 drive into an enclosure that is designed according to

Electrical Equipment Pollution Degree 2 requirements.

Size and fasten any enclosure mounting panel appropriately to accommodate for the weight of the drive.

The Frame 2 drive is designed to use eight M8 x 1.25 fasteners in mounting slots shown in Detail A and Detail B of

Figure 2.1

The M8 x 1.25 fasteners must be class 5.8 or greater.

Use a lock washer or similar mechanism to prevent the fasteners from loosening after mounting.

All M8 x 1.25 fastener threads must engage a steel panel with 6 to 7 full threads or a permanent backing nut such as a weld nut or a self-clinching PEM

® (1)

nut with 4 full threads.

Tighten the M8 x 1.25 fasteners to 11.3 ± 2.8 N

• m (100 ± 25 lb

• in) unless the lock washer mechanism requires a different torque. If this is

(1) the case, the holding force must be equivalent.

PEM is a registered trademark of PennEngineering.

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Frame 2 Installation

2-7

Verifying the Drive’s Watts

Loss Rating

When mounting the drive inside of an enclosure, determine the watts loss rating of the drive from

Table A.E on page A-6 . This table lists the typical

full load power loss watts value at 4 kHz (rated carrier frequency). Make sure that the enclosure is adequately ventilated with 0…50 °C (32…122 °F) ambient air based on the drive’s watts loss rating.

Removing the Drive Cover

(5 Captive Screws)

Removing the Active

Converter Control Cassette

The Frame 2 regenerative-type drive is equipped with an Active Converter control cassette.

Figure 2.7

shows the location and removal of this cassette

to access its terminal blocks for control wiring. See the PowerFlex 700

Active Converter Power Module User Manual, publication PFLEX-UM002, for control wiring details.

Figure 2.7 Removing the Frame 2 Active Converter Control Cassette

Detail

Synchronization Cable

(For use with 700S Phase II Control only)

40-Pin

Ribbon Cable

Pin 1

Internal DPI Cable

Synchronization Cable

(For use with 700 Vector Control only)

Communications

Adapter Option

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Frame 2 Installation

Removing the Inverter

Control Cassette

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For Frame 2 drives, the Inverter is equipped with either the standard

PowerFlex 700 Vector Control cassette or an optional PowerFlex 700S

Phase II Control cassette. In either case, the cassette is removed in the same way.

PowerFlex 700 Vector Control Cassette (standard)

Figure 2.8

shows the location and removal of the drive’s standard

PowerFlex 700 Vector Control cassette to access its terminal blocks for control wiring. See the PowerFlex 700 Adjustable Frequency AC Drive

User Manual - Series B, publication 20B-UM002, for control wiring details.

Figure 2.8 Removing the Standard PowerFlex 700 Vector Control Cassette

Pin 1

Detail

Communications

Adapter Option

PowerFlex 700S Phase II Control Cassette (optional)

Figure 2.9

shows the location and removal of the drive’s optional PowerFlex

700S Phase II Control cassette to access its terminal blocks for control wiring. See the PowerFlex 700S High Performance AC Drive - Phase II

Control User Manual, publication 20D-UM006, for control wiring details.

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2-9

Figure 2.9 Removing the Optional PowerFlex 700S Phase II Control Cassette

Detail

TB2 Terminals

TB1 Terminals

Communications

Adapter Option

Determining Wire Routing for Control, Ground, Drive

Input, and Motor Output

All wiring should be installed in conformance with the applicable local, national, and international codes (for example, NEC/CEC). Signal wiring, control wiring, and power wiring must be routed in separate conduits to prevent interference with drive operation. When hubs are not provided, use grommets to guard against wire chafing.

ATTENTION:

Do not route signal and control wiring with power wiring in the same conduit. This can cause interference with drive operation. Failure to observe this precaution can result in damage to, or destruction of, the equipment.

Do not route more than three sets of motor leads through a single conduit.

This minimizes cross-talk that can reduce the effectiveness of noise reduction methods. If more than three drive/motor connections per conduit are required, shielded cable must be used. If possible, each conduit should contain only one set of motor leads.

ATTENTION:

Unused wires in conduit must be grounded at both ends to avoid a possible shock hazard caused by induced voltages. Also, if a drive sharing a conduit is being serviced or installed, disable all drives using this conduit to eliminate the possible shock hazard from cross-coupled motor leads. Failure to observe these precautions can result in bodily injury.

Figure 2.10

shows locations for Frame 2 control wire routing, ground, drive input, motor output, DPI communication ports/cable routing, and coolant connections.

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Frame 2 Installation

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Figure 2.10 Frame 2 Drive Locations for Control Wire Routing, DPI Communication

Port, and Coolant Connections

28.0

(1.10)

Dimensions are in millimeters and (inches).

DPI Communications

Port

Control Wire

Conduit Plug

62.7 (2.47) Dia.

Coolant Inlet

223.2

(8.79)

280.5

(11.04)

222.0

(8.74)

152.0

(5.98)

112.0

(4.41)

72.0

(2.83)

Coolant Outlet

Bottom View of Drive

R/L1

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257.1

(10.12)

S/L2

199.9

(7.87)

T/L3

12.6

(0.50)

Control Wire

Conduit Plug

22.2 (0.87) Dia.

Bottom Drive Cover

245.8

(9.68)

290.4

(11.43)

481.8

(18.97)

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Frame 2 Installation

2-11

ATTENTION:

The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution can result in damage to, or destruction of, the equipment.

The customer must supply a grounding conductor between the ground lug of the drive and the ground lug in the cabinet. For PE ground terminal location, see Figure 2.15

. Tighten the ground connection to the recommended torque shown in

Table 2.B

Ungrounded or Resistive

Grounded Installations

PowerFlex 700L Frame 2 drives are equipped with a common mode input filter capacitor and MOV that are referenced to ground. If the drive is installed on a resistive ground or ungrounded distribution system, disconnect this capacitor and MOV to prevent drive damage.

Disconnecting the Common Mode Capacitor

To disconnect the 1 µF common mode capacitor from the circuit, see

Figure 2.11

and perform the following steps.

Disconnect the Faston wire from the 1 µF common mode capacitor.

Insulate the wire end by applying a wire nut or electrical tape.

Tie wrap the disconnected wire to keep it away from any electrical connections.

Disconnecting the MOV from Ground

To disconnect the MOV from ground, see

Figure 2.11

and perform the following steps.

Unbolt the ground wire lug from the MOV’s ground connection point.

Screw the bolt back into the panel.

Cut the lug off the disconnected ground wire and apply a wire nut to its end.

Tie wrap the disconnected ground wire to keep it away from any electrical connections.

For more information on ungrounded distribution systems, see Wiring and

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

Note:

Removing the Common Mode capacitor and input MOVs makes the drive more vulnerable to high voltage line spikes.

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Frame 2 Installation

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Figure 2.11 Removing Common Mode Capacitor and MOV

Common Mode

Capacitor Removal

Industry Automation

MOV Removal

Side View of Drive

Power Wiring

This section describes incoming line components and how to install them, and provides instructions on wiring input power, output contactors, motor overload protection, and output wiring to the motor.

Installing Transformers and Reactors (Not Recommended)

Frame 2 drives may be used on distribution systems with 200,000 amps or less symmetrical fault current capacity. The drive input components consist of a 3% line reactor and a harmonic line filter. Additional input inductance is not recommended.

Selecting and Verifying Control Transformer Voltage

A control transformer is used to match the input line voltage of the drive to the 115V control voltage. If your line voltage is different than the voltage class specified on the drive nameplate, it may be necessary to change transformer taps as described in the following steps.

Unfasten seven screws and remove the bottom drive cover

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Figure 2.12

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Figure 2.12 Removing the Bottom Drive Cover

Industry Automation

Frame 2 Installation

2-13

Remove the power section stirring fan.

Unfasten two bracket screws.

Disconnect the fan power leads (two fastons).

Lift the fan from the drive (

Figure 2.13

Figure 2.13 Removing the Power Section Stirring Fan

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Depending on the supplied AC line voltage used to power the drive, see

Table 2.A

to determine which transformer tap to use.

Table 2.A Control Transformer Tap Usage

AC Line Voltage Transformer Tap To Use

380V AC

400V AC

440V AC

400V

460V AC

480V AC

480V

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Pull the faston from the present tap and push it onto the appropriate tap.

Verify that the faston is fully seated on the tap.

TIP:

Do not bend the faston. A straight blade screwdriver helps to remove the faston by carefully prying on the bottom edge of the faston.

Figure 2.14 Control Transformer Voltage Taps

690V 600V

480V 400V

Reinstall the power section stirring fan.

Before fastening the two bracket screws, connect power to the fan power leads.

Reinstall the bottom drive cover by fastening the six screws.

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Frame 2 Installation

2-15

Installing Input Power Wiring to the Drive

Use the following steps to connect AC input power to the drive.

ATTENTION:

Connect the three-phase AC input power leads (three-wire 380-480V

AC) to the R/L1, S/L2, and T/L3 input power terminals on the Frame 2 drive.

For terminal locations, see Figure 2.15

Tighten the AC input power terminal connections to the recommended

torque as shown in Table 2.B

Table 2.B Frame 2 Drive Power Terminal Specifications

Item Name

➊

Input Power Bus Bar

R/L1, S/L2, T/L3

(2)

Description

Input power

Recommended

Tightening

Torque (+10%)

40 N

• m

(354 lb

• in)

Terminal

Bolt Size

(1)

➋

Output Power Bus Bar

U/T1, V/T2, W/T3

(2)

Motor connections 40 N

• m

(354 lb

• in)

➌

PE, Motor Ground Bus Bar

(2)

Terminating point for wiring shields and grounds

40 N

• m

(354 lb

• in)

➍

DC Bus Test Point Socket

(2 Terminals; DC+, DC-)

(3)

4 mm socket for DC bus voltage measurement only

— —

(1)

(2)

These connections are bus bar type terminations and require the use of lug connectors.

(3)

Apply counter torque to the nut on the other side of terminations when tightening or loosening the terminal bolt to avoid damage to the terminal.

Use only to verify that DC bus capacitors are discharged before servicing the Power Module. No other external use is permitted.

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Figure 2.15 Frame 2 Drive Power Terminal Locations

➌

DC+

Testpoint

➍

DC-

Testpoint

W/T3

➋

V/T2

U/T1

A A

Section A-A

Industry Automation

R/L1 S/L2

➊

T/L3

Installing Mechanical Motor Overload Protection (Optional)

To provide the motor with overload protection, local, national, and international codes (for example, NEC/CEC) may require one of the following items:

•

A motor thermostat be installed internal to the motor.

•

A mechanical thermal motor overload relay, sized to protect the motor, be installed between the motor and the drive’s output terminals.

In multiple motor applications (only V/Hz regulation), each motor must have its own user-supplied overload and branch circuit protection.

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2-17

Installing Output Wiring from the Drive Output Terminals to the Motor

Important:

See the PowerFlex 700L Technical Data, publication

20L-TD001, for motor lead length restrictions.

Follow these steps to connect the AC output power wiring from the drive to the motor.

Route the three-phase AC output power motor leads to the drive power module.

Do not route more than three sets of motor leads through a single conduit. This minimizes cross-talk that can reduce the effectiveness of noise reduction methods. If more than three drive/motor connections per conduit are required, shielded cable must be used. If possible, each conduit should contain only one set of motor leads.

ATTENTION:

Do not route signal and control wiring with power wiring in the same conduit. This can cause interference with drive operation. Failure to observe these precautions can result in damage to, or destruction of, the equipment

ATTENTION:

Connect the three-phase AC power motor leads to the U/T1, V/T2, and

W/T3 output power terminals.

For terminal locations, see Figure 2.15

Tighten the AC output power terminal connections to the proper torque

as shown in Table 2.B

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Frame 2 Installation

This section provides details on control wiring to the drive.

Control Wiring

ATTENTION:

Risk of equipment damage exists. Do not use drive terminal blocks TB5-1 and TB5-3 to connect any type of power wiring for auxiliary equipment. These terminals are only for low amperage control wiring.

ATTENTION:

Connect wiring to terminals in accordance with Table 2.C

, Figure 2.16

, and

the Frame 2 drive schematic on page B-2

Item Name

➊

Active Converter Cassette

Terminal Blocks—P1 and P2

➋

SHLD Terminal

➌

Terminal Block—TB1

1b 5: +12/+24V Cooling Loop

1b 6: Cooling Loop Return

1b 7: +24V (digin)

1b 8: Gate Enable

Table 2.C Frame 2 Drive Control Wiring Terminal Specifications

Wire Size Range

(1)

Description

Maximum Minimum

Active Converter AC power and control wiring 3.3 mm

(#12 AWG)

0.3 mm

(#22 AWG)

Recommended

Tightening

Torque (+10%)

0.8 N

• m

(7 lb

• in)

Wire Strip

Length

8 mm

(0.31 in.)

Terminating point for control wiring shields on the drive

2.1 mm

(#14 AWG)

0.3 mm

(#22 AWG)

Drive control wiring:

Output dry contact (12V DC/24V DC, 2

Amps max.) indicating the drive is powered and has completed precharge.

Drive-supplied +24V DC

Enables the firing of the IGBTs.

Factory-installed jumper from terminal 1b

7 to terminal 1b 8 allows firing of the

IGBTs.

4.0 mm

(#10 AWG)

0.2 mm

(#24 AWG)

1.4 N

• m

(12 lb

• in)

0.9 N

• m

(8 lb

• in)

10 mm

(0.39 in.)

8 mm

(0.31 in.)

4.0 mm

(#12 AWG)

0.5 mm

(#22 AWG)

0.6 N

• m

(5.3 lb

• in)

➍

PS- Terminal

PS+ Terminal

300V DC Auxiliary Control voltage

(1)

Maximum/minimum sizes that the terminals will accept - these are not recommendations.

10 mm

(0.39 in.)

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Frame 2 Installation

2-19

Figure 2.16 Frame 2 Drive Control Wiring Terminal Locations

➊

S HLD

➋

TB4 (NOTE: On drives without TB4, there are additional terminals on TB1.)

➌ ➍

TB1

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➌

➍

C us tomer Connection S ide

TB1 When TB4 i s Pre s ent

PE2 PE1

PE1 PE2

C us tomer Connection S ide

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Frame 2 Installation

Synchronization

Connections

Coupled Power Modules

Frame 2 combined Converter/Inverter Power Modules are configured only as coupled power modules. Coupling the Converter and Inverter is achieved by using two factory-installed cables: a control synchronization cable and an inverter-to-converter DPI communication cable. The two cables are described in the next two subsections.

TB2 Header on

700 Vector

Control Cassette

Control Synchronization Cable

To enable synchronization between the Inverter control board and the

Converter control board, a factory-installed control synchronization cable connects each board. No user connection is required. However, the connection method is different for PowerFlex 700L drives with 700 Vector

Control than for 700S Phase II Control. The 700 Vector Control

synchronization cable connection is shown in Figure 2.17

. The 700S Phase

II Control synchronization cable connection is shown in Figure 2.18

Figure 2.17 Frame 2 700 Vector Control Synchronization Cable Connection

TB2-2

TB2-1

P1 Terminal Block on Active Converter

Control Cassette

P1-7

P1-8

Control Synchronization

Cable (Factory-Installed)

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2-21

Figure 2.18 Frame 2 700S Phase II Control Synchronization Cable Connection

P6 Header on

700S Phase II

Control Cassette

J9 Header on

Active Converter

Control Cassette

Control Synchronization

Cable (Factory-Installed)

Inverter-to-Converter DPI Communication Cable

To enable the Inverter and Converter section of the Frame 2 drive to communicate with each other, a factory-installed DPI communication cable is used. No user connection is required.

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Frame 2 Installation

DPI Connections for Frame

2 Drives

Drive Connection Points

The PowerFlex 700L Frame 2 drive provides a number of cable connection points as shown in

Figure 2.19

. If an additional external HIM is required for the application, the HIM can be connected to the DPI port on the bottom of the drive. Only one additional external HIM device may be connected. The use of two external HIM devices is not supported. If multiple external HIM devices are required, then install a user-supplied splitter cable or splitter box.

Figure 2.19 Frame 2 Drive DPI Connection Points

Extern a l

HIM Option

➋

➌

➎

Active

Converter

PCB

Drive

HIM Option

➊

Comm u nic a tion s

Ad a pter Option

➍

Extern a l

DPI C ab le

Bottom View of Drive

R/L1 S /L2 T/L 3

Item Connector

➊

DPI Port 1

Description

HIM connection when installed in the drive.

➋

DPI Port 2 Cable connection for handheld and remote options.

➌

DPI Port 3 or 2 Splitter cable connection to DPI Port 2 provides additional port.

➍

DPI Port 5

➎

DPI Port 6

Cable connection for communications adapter.

Internal DPI connection to Active Converter pcb.

External Door-Mounted HIM Connection (optional)

For a Frame 2 drive installed in a user-supplied enclosure, an optional external door-mounted HIM may be connected as an alternative to the external HIM option. The cable supplied with the door-mount HIM option

kit connects to the DPI port on the bottom of the drive (see Figure 2.19

). For

additional installation information, see the instructions provided with the door-mount HIM option kit.