Step 5. 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 5 I/O Wiring
Important points to remember about I/O wiring:
• 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.
• Wire with an insulation rating of 600V or greater is recommended.
• Control and signal wires should be separated 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.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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I/O Terminals
Figure 10 shows the drive Main Control Board and its terminal block locations. The Main Control Board includes the drive control firmware, I/O terminal block, and optional encoder board.
Figure 10 Drive Main Control Board and I/O Control Terminal Blocks
Pin 1
Pin 1
BR1
Main Control Board
Terminal Details
➊ ➋
Table 8 I/O Terminal Block Specifications
No. Name
➋
Encoder (optional)
Terminal Block
Description
➊
I/O Terminal Block Signal and control connections
Encoder power and signal connections
Wire Size Range
(1)
Torque
Maximum Minimum Maximum Recommended
2.1 mm
2
0.30 mm
2
0.6 N•m 0.6 N•m
(14 AWG)
0.75 mm
2
(18 AWG)
(22 AWG)
0.196 mm
(24 AWG)
2
(5.2 lb•in)
0.6 N•m
(5.2 lb•in)
(5.2 lb•in)
0.6 N•m
(5.2 lb•in)
(1)
Maximum/minimum that the terminal block will accept - these are not recommendations.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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Table 9 Vector Control Option I/O Terminal Designations
1
16
32
No. Signal
1 Analog In 1 (–)
2 Analog In 1 (+)
3 Analog In 2 (–)
4 Analog In 2 (+)
(1)
(1)
(1)
(1)
5 Pot Common
6 Analog Out 1 (–)
7 Analog Out 1 (+)
8 Analog Out 2 (–)
9 Analog Out 2 (+)
10 HW PTC Input 1
Factory
Default
(2)
—
(2)
Description
Isolated
(3)
, bipolar, differential,
±
10V/
0…20 mA, 11 bit and sign. For 0-20 mA, a jumper must be installed at terminals 17 and 18 (or 19 and 20). 88k ohm input impedance when configured for volt and
95.3 ohm for current
Related
Parameters
320… 327
For (+) and (–) 10V pot references
Single-ended bipolar (current output is not bipolar),
±
10V/0…20 mA, 11 bit and sign,
Voltage mode - limit current to 5 mA.
Current mode - max. load is 400 ohms.
340…347
11 Digital Out 1 – N.C.
(4)
12 Digital Out 1 Common
13 Digital Out 1 – N.O.
(4)
14 Digital Out 2 – N.C.
(4)
15 Digital Out 2/3 Com.
16 Digital Out 3 – N.O.
(4)
17 Current In Jumper
(1)
–
18
Analog In 1
19 Current In Jumper
(1)
–
20
Analog In 2
21 –10VDC Pot Ref.
22 +10VDC Pot Ref.
23 HW PTC Input 2
24 +24VDC
(5)
25 Digital In Common
26 24V Common
(5)
27 Digital In 1
(6)
28 Digital In 2
(6)
29 Digital In 3
(6)
30 Digital In 4
(6)
31 Digital In 5
(6)
32 Digital In 6/Hardware
Enable
(6)
, see
—
Fault
NOT Fault
NOT Run
Run
1.8k ohm PTC, Internal 3.32k ohm pull-up resistor
238, 259
Max. Resistive Load:
240V AC/30V DC – 1200VA, 150 W
Max. Current: 5 A, Min. Load: 10 mA
Max. Inductive Load:
240V AC/30V DC – 840VA, 105 W
Max. Current: 3.5 A, Min. Load: 10 mA
Placing a jumper across terminals 17 and
18 (or 19 and 20) will configure that analog input for current.
380…391
320…327
—
—
—
—
Speed Sel 1
Speed Sel 2
Speed Sel 3
2k ohm minimum load
See above
Drive-supplied logic input power
(5)
—
— Common for internal power supply
Stop - CF 115V AC, 50/60 Hz - Opto isolated
Start
Low State: less than 30V AC
Auto/Man.
High State: greater than 100V AC, 5.7 mA
361…366
24V DC - Opto isolated
Low State: less than 5V DC
High State: greater than 20V DC, 10 mA
DC Digital Input Impedance: 21k ohm
(1)
(2)
(3)
(4)
(5)
(6)
Important: 0…20 mA operation requires a jumper at terminals 17 and 18 (or 19 and 20). Drive damage may occur if jumper is not installed.
These inputs/outputs are dependant on a number of parameters (see “Related Parameters”).
Differential Isolation - External source must be maintained at less than 160V with respect to PE. Input provides high common mode immunity.
Contacts in unpowered state. Any relay programmed as Fault or Alarm will energize (pick up) when power is applied to drive and deenergize (drop out) when a fault or alarm exists. Relays selected for other functions will energize only when that condition exists and will deenergize when condition is removed.
150 mA maximum load designed to power digital inputs only. Not present on 115V versions.
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.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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
Analog Input Bipolar
Speed Reference
±
10V Input
Analog Voltage Input
Unipolar Speed Reference
0…10V Input
Common
+
3
4
• 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
Common
+
3
4
Analog Current Input
Unipolar Speed Reference
Vector
0…20 mA Input
Analog Current Input
Unipolar Speed Reference
Standard
4…20 mA Input
Common
+
3
4
19
20
19
20
Common
+
• Configure Input for Current:
Parameter 320 and add jumper at appropriate terminals
• Adjust Scaling:
Parameters 91/92 and 325/326
• View results: Parameter 002
• Configure Input for Current:
Parameter 320, bit 1 = “Current”
• Adjust Scaling:
Parameters 91/92 and 325/326
• View Results: Parameter 002
Ferrite
Bead
1
2
Analog Input, PTC
Vector
PTC OT set > 5V
PTC OT cleared < 4V
PTC Short < 0.2V
1.8k
PTC
5
22
• 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”
3.32k
Ohm
HW PTC Input
(2)
PTC OT set > 5V
PTC OT cleared < 4V
PTC Short < 0.2V
2-Wire Control
Non-Reversing
(3)
24V DC internal supply
1.8k
PTC
Ferrite
Bead
24
25
26
28
Stop-Run
23
2-Wire Control
External supply (I/O Board dependent)
10
Neutral/
Common
25
27
28
Run Fwd.
115V/
+24V
• 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”
• Disable Digital Input #1:
Parameter 361 = “0” (Not Used)
• Set Digital Input #2:
Parameter 362 = “7” (Run)
• Set Direction Mode:
Parameter 190 = “0” (Unipolar)
• Set Digital Input #1:
Parameter 361 = “8” (Run Forward)
• Set Digital Input #2:
Parameter 362 = “9” (Run Reverse)
Run Rev.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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Input/Output
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 will cause a type 2 alarm.
Digital Input
PLC Output Card (Board dependent). Resistors are recommended to dissipate leakage current.
Connection Example
24
25
26
27
28
Stop
25
27
28
Neutral/
Common
Start
115V/
+24V
25
Stop
27
28
Required Parameter Changes
• No changes required if parameters are at factory default settings
• No changes required if parameters are at factory default settings
Start
Neutral/
Common
10k Ohm, 2 Watt
Control from
Prog. Controller
• No changes required if parameters are at factory default settings
Digital Output
Relays shown in powered state with drive faulted. See
.
Vector Control:
2 relays at terminal 14…16
Power Source or
11
12
13
14
15
16
Fault
NOT Fault
Vector Control:
• Select Source to Activate:
Parameters 380/384/388
NOT Run
Run
Standard Control:
• Select Source to Activate:
Parameters 380/384
Standard Control:
1 relay at terminals 14…16
Enable Input
32
Vector Control
• Configure with Parameter 366.
For dedicated hardware Enable:
Remove Jumper J10 (see page 30
)
Standard Control:
• Configure with Parameter 366
(1)
(2)
(3)
Refer to the Attention statements on
page 24 for important bipolar wiring information.
A PTC (Positive Temperature Coefficient) device (motor thermistor), embedded in the motor windings, can be monitored by the drive for motor thermal protection.
Important: Programming inputs for 2 wire control (Run) deactivates all HIM Start buttons unless Parameter 192
[Save HIM Ref], bit 1 (Manual Mode) = “1.” This will allow the HIM to control Start and Jog.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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 used. This is done by removing a jumper and wiring the enable input to “Digital In 6.”
1. Remove the drive Main Control Board (see Figure 11 ).
Figure 11 Main Control Board Removal
Flathead Screw
M4 x 10 mm Long
2X
1.9 N
• m (17 lb
• in)
29
Flathead Screw
M4 x 10 mm Long
4X
1.9 N
• m (17 lb
• in)
U
T1
V
T2
OUTPUT
W
T3
V
U
W
T
S
R
Flathead Screw
M4 x 10 mm Long
1X
1.9 N
• m (17 lb
• in)
Flathead Screw
M4 x 12 mm Long
2X (apply Loctite to threads)
1.9 N
• m (17 lb
• in)
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
30
2. Locate and remove Jumper J10 on the Main Control Board (see
).
3. Re-install the Main Control Board into the drive.
4. Wire Enable to “Digital In 6” (see page 26
).
5. Verify that [Digital In6 Sel], Parameter 366 is set to “1” (Enable).
Figure 12 Hardware Enable Jumper Location
Main Control
Board Assembly
Optional
Encoder Board
Jumper J10 on
Main Control Board
=
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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Encoder Interface Option (Vector Control Only)
Table 10 Encoder Terminal Designations
See “Detail” in
Figure 10
8
1
3
2
1
6
5
No.
Description
8 +12V
(1)
DC Power
7 +12V
4
Encoder Z (NOT)
Encoder Z
Encoder B (NOT)
Encoder B
Encoder A (NOT)
Encoder A
Internal power source 250 mA.
Pulse, marker or registration input.
Quadrature B input.
(2)
Single channel or quadrature A input.
(1)
(2)
Jumper selectable +5/12V is available on 20B-ENC-1 Encoder Boards.
Z channel can be used as a pulse input while A and B are used for encoder.
Table 11 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° at 25 °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 will 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.
Figure 13 Encoder Board Jumper Settings
+12V
+5V
J3
Output
Configuration
+12V
+5V
J3
Output
Configuration
+12V
+5V
J2
Input
Configuration
5/12V
(20B-ENC-1, Series B)
5/12V
(20B-ENC-2)
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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Figure 14 Sample Encoder Wiring
I/O
Encoder Power – Internal Drive Power
Internal (drive) 12V DC, 250 mA
(1)
Encoder Signal – Single-Ended, Dual Channel
(2)
3
2
1
5
4
8
7
6
5
4
3
2
1
8
7
6
Connection Example
+12V DC
(250 mA)
Common to SHLD
(1) to Power Supply
Common
Z NOT to SHLD
(1)
Z
B NOT
B
A NOT
A
Encoder Power – External Power Source
External
Power
Supply to SHLD
(1)
Encoder Signal – Differential, Dual Channel
8
7
6
5
4
3
2
1
(1)
(2)
SHLD connection is on the drive chassis (item 4 in Figure 6 on page 19 )
Example applies to 20B-ENC-1 only.
to SHLD
(1)
Z NOT
Z
B NOT
B
A NOT
A
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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Resistance Temperature Detector (RTD) Board
Up to eight RTD or NTC (negative temperature coefficient) temperature sensors are supported by the RTD board in the PowerFlex 700L Frame 1X drive. The number of I/O connections required from an upper level controller to use the RTD board can be managed by selecting one of several configuration options.
Figure 15 RTD Board Location
Pin 1 Pin 6 Pin 1 Pin 12
RTD PC Board (Assembled In Enclosure)
U V W
Connections
Figure 16 RTD Board Connections
24 13
12
J2 - RTD Inputs
1
Gain
Mode
Time
1 2 3 1 2 3
12
S1 S2
6
J3 - I/O
1
7
J2
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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Table 12 J2 RTD Board I/O Function Settings
8
9
10
11
12
6
7
4
5
2
3
J2 Position
1
I/O Function
+24V COM
LOUT1 COM
LOUT2 COM
LOUT3 COM
LIN COM
AOUT COM
+24VDC
LOUT1 NO
LOUT2 NO
LOUT3 NO
LIN
AOUT
Important: A motor temperature sensor (RTD, NTC or thermocouple) should be considered equivalent to a motor thermostat and wired with the same considerations. Motor thermostat contacts are generally not isolated from the drive/controller digital inputs. Therefore, the sensor inputs will not be isolated on the
RTD board.
Hardware
The hardware consists of a single PC board with two wired connectors, one for temperature sensors and the second for power and I/O signals.
RTD/NTC Sourcing
A 2-wire RTD or NTC temperature sensor may be used. A chassis connection is available for each sensor for use with shielded cable. Each channel requires up to three connections.
Multiplexer and Amplifier
An analog multiplexer sequentially connects the temperature sensors one at a time to the analog output. The active sensor channel is indicated by a 3-bit output (A0…A2). When using an RTD or NTC, a simple voltage divider is formed and the device is probed differentially.
The sensor voltages are amplified using a high-quality, rail-to-rail instrumentation amplifier with gain adjustment. To accommodate a variety of sensors and temperature ranges, an amplifier boosts the analog sensor voltage in order to increase the temperature resolution. Discrete gains of x10 through x80 are selectable through DIP switch settings. A 4th order low pass filter rejects normal-mode noise at the analog input with a cutoff frequency of approximately 16 Hz.
To determine the proper gain setting:
1. Determine R
MAX
, the maximum resistance of the sensor over the temperature range to be measured.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
2. Determine the maximum voltage across R
MAX using the following equation:
V
MAX
= 1.00V x R
MAX
/ (R
MAX
+ 998)
3. Select the largest gain that results in V
MAX
* Gain (x10, x20, or x40), being less than 10 volts.
Example:
Using a 100 Ohm Pt RTD (a = 0.00385) to measure temperatures from
0…200 °C, the maximum resistance occurs at 200 °C and is approximately
177 Ohm. The maximum voltage across the sensor is 151 mV. If the x40 gain is used, the output voltage at 200 °C is 6.04 Volts.
Figure 17 Scaled Analog Output for RTD Board
A0
A1
A2
Analog Multiplexer
Channel
Address
4th Order Low Pass Filter
FC = 16 Hz
NTC/RTD
Sourcing
SA (1 of 8)
SB (1 of 8)
DA
DB
MAX4194
Instrumentation Amp
Rail-to-Rail
Gain Adjustable
5V
S1
50K
12V x10
100K
11.1K
F
F
100K 100K
100K 100K
F
Gain Adjust
DIP Switch Settings, S1
(overall gain) up down x10 x20
LMC6484
Quad Op Amp
Railt-to-Rail
MAX4194
Rg x30
Gain = 1 + 50K/Rg x40 x50 x60 x70 x80
F
12V
0.01
F
10
10
Analog Out
0-10V
Digital I/O
The digital outputs are isolated with solid state relays. The outputs are internally short circuit protected. The digital input is optically isolated.
Microcontroller Software
A microcontroller monitors three DIP switches to determine the operational mode of the RTD board. A single “Mode” switch determines whether the board uses an internal timebase or the digital input as a clock to step through the eight analog input channels. When using the internal timebase, the other two DIP switches select one of four clock periods.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
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36
When the “Mode” switch is up (open) the board uses the digital input as an enable/reset. When the board’s digital input is inactive (open or ground), the analog output is held at the first channel. When the digital input is active
(24V), the microcontroller sequentially cycles through the eight temperature sensor channels. Each channel is available at the analog output for the selected period of time. After the eighth channel is completed, the cycle begins again with the first channel. Deactivating the digital input will asynchronously reset the sequence back to the first channel. The “Time” jumpers/DIP switches select one of four time periods between temperature sensor channels.
Table 13 Microcontroller Settings
Time Period
1 second
10 seconds
30 seconds
60 seconds
S2-2
Down
Up
Down
Up
S2-3
Down
Down
Up
Up
When the “Mode” switch (S2-1) is down (closed), the board uses the digital input as an external clock to sequentially cycle through the eight temperature sensor channels. The analog output channel advances with both the rising and falling edges of the digital input. In both modes, the active channel is output as a 3-bit binary address on the RTD board’s digital outputs. An inactive output (open) indicates a “0.” When using the digital input as an external clock, it may be necessary to monitor the address lines in order to maintain synchronization with the controller. When using the internal clock mode, the digital outputs may be ignored to reduce the required number of I/O. In either mode, the board’s digital input is debounced with a period of 50 milliseconds.
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