Quick Start PowerFlex 700 Adjustable Frequency AC Drive When reading this document, look for this symbol “ Step x ” to guide you through the6 BASIC STEPS needed to install, start-up and program the PowerFlex 700.The information providedDoes Not replace the User Manual and is intended for qualified drive service personnel only. For detailed PowerFlex 700 information including applicationconsiderationsandrelatedprecautionsrefertothefollowing: Title Publication Available . . . PowerFlex 700 User Manual 20B-UM001x on the CD supplied with the drive PowerFlex Reference Manual PFLEX-RM001x or atwww.ab.com/manuals/dr Step 1 Read the General Precautions 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 may result if ESD control procedures are not followed. If you are not familiar with static control procedures, referenceA-Bpublication8000-4.5.2,“GuardingAgainstElectrostatic Damage” or any other applicable ESD protection handbook. ATTENTION: An incorrectly applied or installed drive can result in ! componentdamageorareductioninproductlife.Wiringorapplication errors, such as, undersizing the motor, incorrect or inadequate AC supply,orexcessiveambienttemperaturesmayresultinmalfunctionof the system. ATTENTION: Only qualified personnel familiar with adjustable ! frequency AC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may 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 +DC & –DC terminals of the Power Terminal Block (refer to the User Manual for location). The voltage must be zero. 2 PowerFlex 700 Adjustable Frequency AC Drive Quick Start 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“adjustfreq”portionofthebusregulatorfunction ! isextremelyusefulforpreventingnuisanceovervoltagefaultsresulting from aggressive decelerations, overhauling loads, and eccentric loads. Itforcestheoutputfrequencytobegreaterthancommandedfrequency while the drive's bus voltage is increasing towards levels that would otherwise cause a fault. However, it can also cause either of the following two conditions to occur. 1. Fast positive changes in input voltage (more than a 10% increase within6minutes)cancauseuncommandedpositivespeedchanges. Howeveran“OverSpeedLimit”faultwilloccurifthespeedreaches [MaxSpeed]+[OverspeedLimit].Ifthisconditionisunacceptable, action should 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). 2. Actual deceleration times can be longer than commanded deceleration times. However, a “Decel Inhibit” fault is generated if the drive stops decelerating altogether. If this condition is unacceptable,the“adjustfreq”portionofthebusregulatormustbe disabled (see parameters 161 and 162). In addition, installing a properly sized dynamic brake resistor will provide 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. 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. ATTENTION: If using Output Contactors, refer to the “Output ! Contactor Precaution” statement on page 1-12 of thePowerFlex 700 User Manual. PowerFlex 700 Adjustable Frequency AC Drive Quick Start 3 EMC Instructions CE Conformity Conformity with the Low Voltage (LV) Directive and Electromagnetic Compatibility (EMC) Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. PowerFlex Drives comply with the EN standards listed below when installed according to the User and Reference Manual. CE Declarations of Conformity are available online at: http://www.ab.com/certification/ce/docs. 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 • 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. • Themotorcableshouldbekeptasshortaspossibleinordertoavoid electromagnetic emission as well as capacitive currents. • Use of line filters in ungrounded systems is not recommended. • PowerFlexdrivesmaycauseradiofrequencyinterferenceifusedina residential or domestic environment. The user 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. More information regarding harmonic emissions can be found in the PowerFlex Reference Manual. 4 PowerFlex 700 Adjustable Frequency AC Drive Quick Start Essential Requirements for CE Compliance Conditions 1-6 listed belowmust be satisfied for PowerFlex drives to meet the requirements ofEN61800-3. 1. Standard PowerFlex 700 CE compatible Drive. 2. Review important precautions/attention statements throughout this document before installing the drive. 3. Grounding as described on page 1-4 of theUser 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 should terminate with the proper shielded connector. 6. Conditions inTable A. Table A PowerFlex 700 EN61800-3 EMC Compatibility Second Environment First Environment me Restrict Motor Cable to 30 m (98 ft.) Restricted Distribution a Fr Any Drive and Option 0 ✔ Refer to 1 ✔ PowerFlex Reference Manual 2 ✔ 3 ✔ Step 2 Mount the Drive – Minimum Requirements 101.6 mm 101.6 mm 101.6 mm 101.6 mm (4.0 in.) (4.0 in.) (4.0 in.) (4.0 in.) SPTWSR SPTWSR No Adhesive Label SPTWSR SPTWSR (see below) 50.8 mm PMNNOEEOTTRD TAB PMNNOEEOTTRD TAB PMNNOEEOTTRD TAB (2.0 in.) PMNNOEEOTTRD TAB With Adhesive Label (see below) 101.6 mm 101.6 mm Refer to Figures1-3 for 101.6 mm 101.6 mm (4.0 in.) (4.0 in.) detailed dimension (4.0 in.) (4.0 in.) information. Operating Temperatures PowerFlex 700 drives are designed to operate at 0°to 40°C ambient. To operate in installations between 41° and 50° C, seeTable B. PowerFlex 700 Adjustable Frequency AC Drive Quick Start 5 Table B Acceptable Surrounding Air Temperature & Required Actions Required Action . . . IP 20, NEMA IP 20, NEMA IP 00, NEMA Type 1 Type Open Type Open Drive Catalog No Action Remove Top RemoveTopLabel Number Required Label & Vent Plate(1) AllExcept 20BC072 40°C 50°C NA 20BC072 40°C 45°C 50°C (1) Toremoveventplate(seeFigure3onpage8forlocation),lifttopedgeof plate from the chassis. Rotate the plate out from the back plate. Important: Removing the adhesive label from the drive changes the NEMA enclosure rating from Type 1 to Open type. Dimensions Figure 1 PowerFlex 700 Frames 0-3(0 Frame Shown) A 15.0 (0.59) D 5.8 (0.23) dia. see below C E B HOT surfCacAesU caTnI cOauNse severe burns 5.5 (0.22) - Frames 0-1 8.0 7.0 (0.28) - Frames 2-3 (0.31) 3 Places Dimensions are in millimeters and (inches). C) Weight(1) kg (lbs.) Frame(Table A B C D E Drive DParicvkea &ging 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) 500.0 (19.69) 18.55 (40.9) 22.68 (50) (1) Weights include HIM and Standard I/O. 6 PowerFlex 700 Adjustable Frequency AC Drive Quick Start Figure 2 PowerFlex 700 Frame 5 6.5 (0.26) A 15.0 (0.59) 259.1 (10.20) Detail 37.6 (1.48) D C B E HOT surfCacAesU caTnI cOauNse severe burns 6.5 (0.26) Lifting Holes - 4 Places 12.7 (1.37) Dia. 12.5 (0.49) Dimensions are in millimeters and (inches). C) Approx. Weight(1) kg (lbs.) Frame(Table A(Max.) B C(Max.) D E Drive DParicvkea &ging 5 308.9 (12.16) 644.5 (25.37)(2) 275.4 (10.84) 225.0 (8.86) 625.0 (24.61) 37.19 (82.0) 42.18 (93.0) (1) Weights include HIM and Standard I/O. (2) When using the supplied junction box (100 HP drives Only), add an additional 45.1 mm (1.78 in.). Table C PowerFlex 700 Frames 208/240V AC Input 400V AC Input 480V AC Input Frame ND HP HD HP ND kW HD kW ND HP HD HP 0 0.5 0.33 0.37 0.25 0.5 0.33 1 0.75 0.75 0.55 1 0.75 2 1.5 1.5 0.75 2 1.5 3 2 2.2 1.5 3 2 – – 4 2.2 5 3 – – 5.5 4 7.5 5 1 5 3 7.5 5.5 10 7.5 7.5 5 11 7.5 15 10 2 10 7.5 15 11 20 15 – – 18.5 15 25 20 3 15 10 22 18.5 30 25 20 15 30 22 40 30 – – 37 30 50 40 5 – – 55 45 – – – – – – 75 60 – – – – 100 75 PowerFlex 700 Adjustable Frequency AC Drive Quick Start 7 Figure 3 Bottom View Dimensions Frame 0 Frame 1 96.0 (3.78) 108.5 (4.27) 75.0 (2.95) 87.5 (3.44) 55.0 (2.17) 67.5 (2.66) 35.0 (1.38) 22.2 (0.87) Dia. – 4 Places 47.5 (1.87) 22.2 (0.87) Dia. 28.6 (1.13) Dia. 3 Places 30.2 25.5 (1.19) (1.00) 187.5 185.0 187.6 185.1 (7.38) (7.28) (7.39) (7.29) 132.9 133.3 (5.23) (5.25) 41.9 (1.65) 43.0 (1.69) 56.1 (2.21) 70.0 (2.76) 75.9 (2.99) 75.9 (2.99) 96.0 (3.78) 96.0 (3.78) Frame 2 167.5 (6.59) 156.9 (6.18) 28.7 (1.13) Dia. 22.4 (0.88) Dia. 3 Places 2 Places 184.8 (7.28) 157.5 (6.20) 150.9 (5.94) 112.1 (4.41) 39.3 (1.55) 57.2 (2.25) 72.7 (2.86) 106.0 (4.17) 139.4 (5.49) 177.4 (6.98) Dimensions are in millimeters and (inches). 8 PowerFlex 700 Adjustable Frequency AC Drive Quick Start Figure 3 PowerFlex 700 Bottom View Dimensions (continued) Frame 3 – All Drives Frame 3 – 50 HP, 480V (37 kW, 400V) except 50 HP, 480V (37 kW, 400V) Normal Duty Drive 22.2 (0.87) Dia. 19045.7.3 ( (34.7.135)) 327 P.3la (c1e.s47) Dia. 19045.7.3 ((34.7.135)) 324 P.9la (c1e.s37) 42D6 iPa.7l.a (c1e.s84) Dia. 28.7 (1.13) Dia. 2 Places 28.7 (1.13) Dia. 2 Places (166.55.01) (178.42.65) (178.42.65) 160.1 165.1 (155.19.51)127.7 (6.30) (6.50) (166.300.1) (5.03) 127.7 (5.03) Vent Plate 22.7 (0.89) 29.0 (1.14) 66.0 (2.60) 22.7 (0.89) 97.0 (3.82) 29.0 (1.14) 137.2 (5.40) 66.0 (2.60) 187.0 (7.36) 130.0 (5.12) 186.0 (7.32) Frame 5 – 75 HP, 480V (55kW, 400V) Normal Duty Drive 93.2 (3.67) 34.9 (1.37) Dia. 104.0 (4.09) 2 Places 222 P.2la (c0e.s87) Dia. 62.7 (2.47) Dia. 2 Places 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) Frame 5 – 100 HP, 480V Normal Duty Drive 34.9 (1.37) Dia. 42.6 (1.68) 222 P.2la (c0e.s87) Dia. 622 P.7la (c2e.s47) Dia. 31.9 (1.26) Removable Junction Box 241.9 (9.52) Dimensions are in millimeters (282.830.5) and (inches) (178.482.5) 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) PowerFlex 700 Adjustable Frequency AC Drive Quick Start 9 Step 3 Power Wiring – Wire Recommendations 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.). SeeTable D. Unshielded THHN,THWNorsimilarwireisacceptablefordriveinstallationindry environments provided adequate free air space and/or conduit fill rates limitsareprovided.DonotuseTHHNorsimilarlycoatedwireinwet areas.Anywirechosenmusthaveaminimuminsulationthicknessof15 Mils and should not have large variations in insulation concentricity. Shielded/Armored Cable Shielded cable is recommended if sensitive circuits or devices are connected or mounted to the machinery driven by the motor. SeeTable D. For further information on acceptable and unacceptable cable types, refer to “Power Wiring” in thePowerFlex 700 User Manual. Table D Recommended Shielded Cable Type Wire Type(s) Description Power Standard 600V, 90°C (194°F) • Four tinned copper conductors with XLP (Option 1) XHHW2/RHW-2 insulation. Anixter B209500-B209507, • Copper braid/aluminum foil combination Belden 29501-29507, or shield and tinned copper drain wire. equivalent • PVC jacket. Standard Trayrated600V,90°C(194°F) • Three tinned copper conductors with (Option 2) RHH/RHW-2 XLPE insulation. Anixter OLF-7xxxxx or • 5 mil single helical copper tape (25% equivalent overlap min.) with three bare copper grounds in contact with shield. • PVC jacket. Class I & II; Trayrated600V,90°C(194°F) • ThreebarecopperconductorswithXLPE DivisionI&II RHH/RHW-2 insulation and impervious corrugated Anixter 7V-7xxxx-3G or continuously welded aluminum armor. equivalent • Black sunlight resistant PVC jacket overall. • Three copper grounds on #10 AWG and smaller. 10 PowerFlex 700 Adjustable Frequency AC Drive Quick Start Table E Power Terminal Block Specifications Wire Size Range(1) Torque Name Frame Description Maximum Minimum Maximum Recommended Power Terminal 0 & 1 Input power and 4.0 mm2 0.5 mm2 1.7 N-m 0.8 N-m Block motor connections (10 AWG) (22 AWG) (15 lb.-in.) (7 lb.-in.) 2 Input power and 10.0 mm2 0.8 mm2 1.7 N-m 1.4 N-m motor connections (6 AWG) (18 AWG) (15 lb.-in.) (12 lb.-in.) 3 Input power and 25.0 mm2 2.5 mm2 3.6 N-m 1.8 N-m motor connections (3 AWG) (14 AWG) (32 lb.-in.) (16 lb.-in.) BR1, 2 terminals 10.0 mm2 0.8 mm2 1.7 N-m 1.4 N-m (6 AWG) (18 AWG) (15 lb.-in.) (12 lb.-in.) 5 Input power, BR1, 35.0 mm2 2.5 mm2 3.6 N-m 3.6 N-m (75 HP) 2, DC+, DC– and (1/0 AWG) (14 AWG) (32 lb.-in.) (32 lb.-in.) motor connections PE 35.0 mm2 16.0 mm2 5 N-m 5 N-m (1/0 AWG) (6 AWG) (44 lb.-in.) (44 lb.-in.) 5 Input power, DC+, 70.0 mm2 16.0 mm2 15 N-m 15 N-m (100 DC– and motor (3/0 AWG) (4 AWG) (133 lb.-in.) (133 lb.-in.) HP) connections BR1, 2, terminals 35.0 mm2 2.5 mm2 3.6 N-m 3.6 N-m (1/0 AWG) (14 AWG) (32 lb.-in.) (32 lb.-in.) PE 35.0 mm2 16.0 mm2 5 N-m 5 N-m (1/0 AWG) (6 AWG) (44 lb.-in.) (44 lb.-in.) AUX Terminal 0-3 Auxiliary Control 1.3 mm2 0.2 mm2 — — Block Voltage(2) (16 AWG) (24 AWG) 5 4.0 mm2 0.5 mm2 0.6 N-m 0.6 N-m (10 AWG) (22 AWG) (5.3 lb.-in.) (5.3 lb.-in.) (1) Maximum/minimum sizes that the terminal block will accept - these are not recommendations. (2) 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. Power & Ground Wiring R S T PE U V W DC DC BR1 BR2 (L1) (L2) (L3) (T1) (T2) (T3) + – Required Input Fusing Required Branch Circuit Disconnect