Step 4. Allen-Bradley PowerFlex 700L Frame 1X Liquid-Cooled Adjustable Frequency AC Drive, PowerFlex 700L Frame 1X
Below you will find brief information for AC Drive PowerFlex 700L Frame 1X. This document provides a detailed guide for installing and performing a basic start-up of your PowerFlex 700L Frame 1X drive. It includes information on mounting, wiring, cooling loop connections, and start-up procedures. You'll also find helpful troubleshooting tips and specifications.
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Step 4
Drive Coolant Connections
For locations of the coolant inlet and outlet connections on PowerFlex 700L
Liquid-Cooled Frame 1X drives, refer to item 8 in
The rated working pressure of the Frame 1X drive is 6.89 bar (100 psi).
Coolant supply and return lines should be sized for 76 LPM (20 GPM) /
6.89 bar (100 psi) service with a maximum operating temperature of 60 °C
(140 °F). The required operating flow rate and pressure drop is specified in
Table 4 on page 13 .
Coolant inlet and outlet connections are 1/4-inch NPT female. Apply Teflon thread sealing tape or pipe thread sealant to the threads of the coolant pipe that is being connected to the drive. Tighten to prevent leaks, but do not overtighten.
Wire the Drive
!
ATTENTION: National Codes and standards (NEC, VDE, BSI etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.
Special Considerations
The PowerFlex 700L Frame 1X drive is suitable for use on a circuit capable of delivering up to a maximum of 200,000 rms symmetrical amperes, 480 volts with recommended fuses/circuit breakers.
!
ATTENTION: To guard against personal injury and/or equipment damage caused by improper fusing or circuit breaker selection, use only the recommended line fuses/circuit breakers specified in
If a Residual Current Detector (RCD) is used as a system ground fault monitor, only Type B (adjustable) devices should be used to avoid nuisance tripping.
Unbalanced, Ungrounded, Impedance or Phase-Grounded Distribution
Systems
If phase-to-ground voltage will exceed 125% of normal line-to-line voltage or the supply system is ungrounded, refer to Wiring and Grounding
Guidelines for PWM AC Drives (publication DRIVES-IN001).
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 should be installed. See Wiring and
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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16
Grounding Guidelines for PWM AC Drives (publication DRIVES-IN001) for more information on impedance grounded and ungrounded systems.
!
ATTENTION: The PowerFlex 700L Frame 1X drive contains protective MOVs and common mode capacitors that are referenced to ground. To guard against drive damage, these devices must be disconnected if the drive is installed on an ungrounded, impedance or phase-grounded distribution system.
See Table 7 on page 22 for recommended jumper configurations.
AC Line Reactor
There is no DC link reactor or AC input reactor built into the drive.
Therefore, a 3% three-phase line reactor must be installed at the AC input terminals of the drive.
Recommended Reactors
Enclosure Type
IP00 (Open Type)
Catalog Number
1321-3R200-B
IP11 (NEMA/UL Type 1) 1321-3RA200-B
Input Power Conditioning
Certain events on the power system supplying a drive can cause component damage or shortened product life. These conditions include:
• 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.
Cable 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 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 will help minimize the possible shock hazard from
“cross coupled” motor leads.
Motor Cable Lengths
Typically, motor lead lengths less than 91 meters (300 feet) are acceptable.
However, if your application requires longer lengths, refer to the Wiring and
Grounding Guidelines for PWM AC Drives, publication DRIVES-IN001.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Wire Recommendations
Type
Power
(1)(2)
Standard
Min. Insulation
Rating Wire Type(s)
600V, 90 °C (194 °F) XHHW2/RHW-2
Anixter B209500-B209507, Belden
29501-29507, or equivalent
Description
• Four tinned copper conductors with XLPE insulation.
• Copper braid/aluminum foil combination shield and tinned copper drain wire.
(8)
(7)
Signal
(3) (4)
Standard Analog I/O 300V,
75…90 °C
(167…194 °F)
(6)
Encoder/Pulse I/O:
<30 m (100 ft.)
(5)
(4)
Encoder/Pulse I/O:
30…152 m (100…500 ft.)
Signal: Belden 9730/9728
Power: Belden 8790
(6)
Combined: Belden 9892
(7)
0.196 mm
2
(24 AWG)
0.750 mm
2
(18 AWG)
0.330 mm
2
(18 AWG), power is 0.500 mm
2
(20 AWG)
0.196 mm
2
(24 AWG) Encoder/Pulse I/O:
(1)
(2)
(3)
Digital I/O
152…259 m (500…850 ft.)
Shielded
Power: Belden 8790
Combined: Belden 9773/9774 as Belden 8770 (or equivalent)
(8)
Multi-conductor shielded cable such
0.750 mm
2
0.750 mm
2
0.750 mm
2
(18 AWG)
(18 AWG)
(18 AWG),
3 conductor, shielded.
Control and signal wires should be separated from power wires by at least 0.3 meters (1 foot).
The use of shielded wire for AC input power may not be necessary but is always recommended.
300V,
60 °C (140 °F)
If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessary, but is always recommended.
Signal: Belden 9730/9728
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.
Belden 9730 is 3 individually shielded pairs (2 channel + power). If 3 channel is required, use Belden 9728.
Belden 8790 is 1 shielded pair.
• PVC jacket.
Belden 8760/9460 (or equivalent) 0.750 mm
2
(18 AWG), twisted pair,
100% shield with drain.
Belden 8770 (or equivalent) 0.750 mm
2
(18 AWG), 3 conductor, shielded for remote pot only.
Combined: Belden 9730
(5)
0.196 mm
2
(24 AWG)
Belden 9892 is 3 individually shielded pairs (3 channel) + 1 shielded pair for power.
Belden 9773 is 3 individually shielded pairs (2 channel + power). If 3 channel is required, use Belden 9774.
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PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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General Grounding Requirements
The drive Safety Ground - PE must be connected to system ground.
Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked.
For installations within a cabinet, a single safety ground point or ground bus bar connected directly to building steel should be used. All circuits including the AC input ground conductor should be grounded independently and directly to this point/bar.
Figure 5 Typical Grounding
R (L1)
S (L2)
T (L3)
Drive
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.
Shield Termination
The Shield terminal (PE) provides a grounding point for the motor cable shield. The motor cable shield should be connected to this terminal on the drive (drive end) and the motor frame (motor end). A shield terminating cable gland may also be used.
When shielded cable is used for control and signal wiring, the shield should be grounded at the source end only, not at the drive end.
RFI Filter Grounding
Using an RFI filter (user supplied) may result in relatively high ground leakage currents. Therefore, any filter must only be used in installations
with grounded AC supply systems and be permanently installed and
solidly grounded (bonded) to the building power distribution ground.
Ensure that the incoming supply neutral is solidly connected (bonded) to the same building power distribution ground. Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection. Some local codes may require redundant ground connections. The integrity of all connections should be periodically checked. Refer to the instructions supplied with the filter.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Power Wiring
Figure 6 Power Terminal Locations
➍
➍
➋
R
S
T
➍
Table 5 Power Terminal Specifications
Item Name Description
➊
Input
Power
R (L1), S (L2), and T (L3) connections
Wire Size Range
(1)
Maximum Minimum
70 mm
2
50 mm
2
(2/0 AWG) (1 AWG)
➋
Output
Power
➌
Brake
Resistor
U (T1), V (T2), and W (T3) connections
70 mm
2
(2/0 AWG)
BR1 (DC Brake +) and BR2
(DC Brake -) connections
35 mm
2
(2 AWG)
50 mm
2
(1 AWG)
25 mm
2
(4 AWG)
Recommended Terminal
Torque (±10%)
Bolt Size
7.9 N•m
(70 lb•in)
M6
3.95 N•m
(35 lb•in)
3.95 N•m
(35 lb•in)
➍
Ground PE and motor ground connections
(1)
70 mm
2
(2/0 AWG)
50 mm
2
(1 AWG)
7.9 N•m
(70 lb•in)
Maximum/minimum sizes that the terminal block will accept - these are not recommendations.
M5
M5
M6
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
➊
➌
19
20
Drive, Fuse, and Circuit Breaker Ratings
The PowerFlex 700L Frame 1X drive includes input fuses. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations. Refer to
for recommended fuses/circuit breakers.
!
ATTENTION: The PowerFlex 700L Frame 1X drive does not provide branch short circuit protection. Specifications for the recommended fuse or circuit breaker to provide protection
against short circuits are provided in Table 6 .
provides drive ratings (including continuous, 1 minute and 3 second) and recommended AC line input fuse and circuit breaker information. Both types of short circuit protection are acceptable for UL and IEC requirements. Sizes listed are the recommended sizes based on
40 °C and the U.S. NEC. Other country, state or local codes may require different ratings.
Fusing
If fuses are chosen as the desired protection method, refer to the recommended types listed below. If available amp ratings do not match the tables provided, the closest fuse rating that exceeds the drive rating should be chosen.
• IEC – BS88 (British Standard) Parts 1 & 2
(1)
, EN60269-1, Parts 1 & 2, type gG or equivalent should be used.
• UL – UL Class CC, T, RK1 or J must be used.
Circuit Breakers
The “non-fuse” listings in the following tables include both circuit breakers
(inverse time or instantaneous trip) and 140M Self-Protecting Motor
Starters. If one of these is chosen as the desired protection method, the following requirements apply.
• IEC and UL – Both types of devices are acceptable for IEC and UL installations.
Table 6 480 Volt AC Input Protection Devices
Drive
Catalog Number
480 Volt AC Input
HP Rating
ND HD
PWM
Freq. Temp.
kHz
CNMD180W0ENNNC1 150 —
— 125
4
4
°C
50
50
Input
Ratings Output Amps
Amps
169
147
Cont. 1 Min. 3 Sec. Min.
180
156
198
234
270
312
Dual Element
Time Delay Fuse
225
200
(1)
Max.
400
350
(2)
Non-Time
Delay Fuse
Min.
Max.
225
200
600
600
Circuit
Breaker
(3)
Motor Circuit
Protector
(4)
Maximum Maximum
500
450
250
250
(1)
Minimum protection device size is the lowest rated device that supplies maximum protection without nuisance tripping.
(2)
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.
(3)
Circuit Breaker - inverse time breaker. For US NEC, minimum size is 125% of motor FLA. Ratings shown are maximum.
(4)
Motor Circuit Protector - instantaneous trip circuit breaker. For US NEC, minimum size is 125% of motor FLA. Ratings shown are maximum.
(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.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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 will start and stop the motor. If an input device is used, operation must not exceed one cycle per minute or drive damage will occur.
ATTENTION: The drive start/stop/enable control circuitry includes solid state components. If hazards due to accidental contact with moving machinery or unintentional flow of liquid, gas or solids exist, an additional hardwired stop circuit may be required to remove the AC line to the drive. An auxiliary braking method may be required.
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.
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 which do not connect directly to the motor.
Contact Allen-Bradley for assistance with application or wiring.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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22
Disconnecting MOVs and Common Mode Capacitors
The PowerFlex 700L Frame 1X drive contains protective MOVs and common mode capacitors that are referenced to ground. To guard against drive damage and/or operation problems, these devices must be properly configured according to Table 7 .
Figure 7 MOV and AC EMI Capacitor Phase to Ground
R/L1
S/L2
T/L3
2 3 4
2 3 4
1
1
PE–A PE–C
Figure 8 Common Mode Capacitors to Ground
DC+
DC–
PE–B
!
!
ATTENTION: The PowerFlex 700L Frame 1X drive contains protective MOVs and common mode capacitors that are referenced to ground. To guard against drive damage, these devices must be disconnected if the drive is installed on an ungrounded, impedance or phase-grounded distribution system.
See Table 7 for recommended jumper configurations.
ATTENTION: PE-A, PE-B, and PE-C jumpers must be configured according to the recommendations in Table 7 . The
PE-D and PE-E power jumpers must always remain connected.
Table 7 Recommended Power Jumper Configurations
Power Source Type
(1)
Unknown
• AC fed Solidly Grounded
• DC fed from passive rectifier which has a Solidly Grounded
AC source
MOV
(PE-A)
(2)
Connected
(3)
DC Bus
Common Mode
Caps (PE-B)
Disconnected
(3)
Connected Connected
Input Filter
Caps (PE-C)
Connected
(3)
Connected
Bridge
Circuit Bd
Gnd (PE-D)
Connected
(3)
RTD Circuit
Bd Ground
(PE-E)
Connected
(3)
Benefits Of Correct
Configuration on Power
Source Type
See below.
UL compliance,
Reduced electrical noise,
Most stable operation,
EMC compliance,
Reduced voltage stress on components and motor bearings
• AC fed Ungrounded Disconnected Disconnected Disconnected Helps avoid severe equipment damage when ground fault
• Impedance Grounded occurs
• DC fed from an active converter
(1)
(2)
(3)
It is highly recommended to accurately determine the power source type and then configure appropriately.
When MOVs are disconnected, the power system must have its own transient protection to insure known and controlled voltages.
This is the factory default configuration. NOTE: The PE-D and PE-E power jumpers must be connected regardless of the power source type.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before connecting/ disconnecting the MOV, EMI Snubber Board, and common mode capacitor wires. Measure the DC bus voltage at the DC+ and
The power jumpers PE-A, PE-C, PE-D, and PE-E are factory connected to ground using one of the two screws shown in Figure 9 . Jumpers PE-D and
PE-E must remain connected.
To connect or disconnect the drive’s protective MOVs and common mode capacitors, refer to Table 7 and Figure 9 . Then:
1. Remove the appropriate screw(s) from the drive flange that connect the wire(s).
2. Cut the lugs off the ground wire(s) to be disconnected. Apply wire nuts to the end(s) of the disconnected wires.
3. Tie wrap the disconnected ground wires to keep them away from any electrical connections.
4. Gather together the wire lugs of the remaining ground wires to be connected. Using the screw(s), fasten the ground wires to the drive flange. Torque to 3.2 N
• m (28 lb
• in).
5. Tuck the wires back into the drive flange.
Figure 9 Protective Circuit Connections for Grounded Drive Distribution Systems
Labeled ground wires PE-A, PE-B,
PE-C, PE-D, and
PE-E
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009

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Key features
- Liquid-Cooled
- Adjustable Frequency
- Basic Start-Up Routine
- Cooling Loop Connection
- Wiring Instructions
- Troubleshooting Tips
- CE Compliant