The PowerFlex 700H is a series of normal-duty and heavy-duty adjustable frequency AC drives from Rockwell Automation. The drives are designed to provide outstanding performance, space optimization, and application flexibility in an easy-to-use structure. They are ideal for high-power motor control applications requiring accurate open-loop speed regulation. Target applications include speed control of three-phase induction motors used in industrial fans, conveyors, pumps, simple extruders, mixers, and stamping presses.

Additionally, PowerFlex 700H AC drives provide excellent torque at low motor speeds, and motor control algorithms (Volts-per-Hertz and Sensorless Vector Control) are configurable for a wide variety of demanding speed control applications. This makes the drive series a cost-effective solution for high-performance, variable-speed applications. The drives also feature a slot-based architecture that lets users customize their motion control systems with available PowerFlex 700H power, control, communication, I/O, and packaging options based on their specific application needs. Some PowerFlex 700H drives also include an ATEX-certified safety option for use in potentially explosive industrial environments.

Heavy Duty rated PowerFlex 700H AC drives are available with the following power ratings:

• 205 to 1940 Amps, 110 to 1100 kW/148 to 1475 Hp output at 400V, 50Hz AC input
• 205 to 1940 Amps, 150 to 1700 kW/201 to 2280 Hp output at 480V, 60Hz AC input
• 144 to 1900 Amps, 150 to 2000 kW/201 to 2682 Hp output at 600V, 60Hz AC input
• 144 to 1900 Amps, 132 to 1900 kW/177 to 2548 Hp output at 690V, 50Hz AC input

Note: Normal Duty (ND) rated PowerFlex 700H AC drives cannot be used in heavy-duty motion control applications. Similarly, Heavy Duty (HD) rated PowerFlex 700H AC drives cannot be used in normal-duty motion control systems, regardless of the ratings indicated on the component nameplate. Generally, the drive system ratings provided on the system nameplate supersede any information/ratings provided on a component nameplate. This article focuses on PowerFlex 700H AC drives rated for heavy-duty performance.

Key Drive Features and Benefits

Heavy Duty rated PowerFlex 700H AC drives are available with a vast array of features that allow users to easily configure them for most application needs. The features include:

Space-Saving Hardware Components

• Integral EMC Filter: It is designed to limit the transmission of high-frequency currents and voltages between the mains power supply and PowerFlex 700H drive. This helps reduce Electromagnetic Interference (EMI) in the drive’s electronic components. The filter also serves as a low-cost solution to ensure compliance with EMC regulations.  
• A Built-in Common Mode Choke: A passive electromagnetic device that allows desired electrical signals to pass through power or data lines while filtering out unwanted/high-frequency noise signals from external sources (e.g., motors, inverters, and unshielded electronics) or other circuits in a PowerFlex 700H drive system.
• Internal NetLinx Communication Options: These options allow users to easily and seamlessly integrate PowerFlex 700H AC drives into manufacturing processes. The status indicators for all PowerFlex 700H communication options are provided on the front cover for simplified configuration and proper monitoring of drive communications.
• Embedded I/O: Heavy-duty PowerFlex 700H AC drives incorporate six digital inputs, two analog inputs, three relay outputs, two analog outputs, and one Positive Temperature Coefficient (PTC) input as standard I/O.
• Optional I/O: Available as 115V AC or 24V DC I/O option kits. PowerFlex 700H I/O option kits include:
• 20C-DA1-A: The kit provides
• 6 24V DC digital inputs along with analog I/O
• 20C-DA1-B: It features six 115V AC digital inputs along with analog I/O
• 20C-DO1: It contains three 115V AC digital outputs
• Integral Brake Transistor (IGBT): A dynamic braking transistor that is incorporated in Frame 9 PowerFlex 700H AC drives. It provides a simple and low-cost solution for switching regenerative energy without the need for costly external braking/chopper circuits.
• AC Input Line Reactor: An AC reactor that is installed between the incoming AC supply and PowerFlex 700H AC drive to improve the drive’s functionality and protection. It protects the AC drive from transient overvoltage conditions and power surges on the input power line.
• Pull-apart Control Terminal Blocks: They allow for simplified system wiring and quick I/O wiring disconnection.
• Easy-to-remove Control Module: The module is common across all PowerFlex 700H drive ratings. It allows for simultaneous installation and programming of PowerFlex 700H drives, saving time.

Outstanding Speed Control and Performance

PowerFlex 700H variable frequency drives are configurable for Sensorless Vector Control (SVC) or Volts-per-Hertz (V/Hz) control modes. The two motor control algorithms enable speed control and system performance that match up to the needs of a given application. They provide:

• Precise open-loop speed regulation with slip compensation
• Exceptional torque output at low motor speeds for demanding motion control applications

Volts-per-Hertz (V/Hz): This is a basic and low-cost technique for controlling the speed of three- or single-phase AC motors. It controls the motor speed by maintaining a constant ratio between the frequency and voltage applied to the motor. It is commonly used in simple pump and fan applications where high-precision speed control is not required. In V/Hz control mode, users can control multiple AC motors with a single PowerFlex 700H AC drive. With an additional “slip compensation” feature, the V/Hz can adjust the frequency reference when the motor load fluctuates to maintain the actual motor speed as close as possible to the desired speed.

Sensorless Vector Control (SVC): This is a flux vector motor control technique with slip compensation, in which the frequency, phase, and amplitude of the input voltage to an AC motor are regulated to obtain the desired motor speed. It improves upon the basic V/Hz control method by providing control for both the magnitude and angle between the motor current and voltage. Volts/Hertz AC drives control only the voltage magnitude. By controlling the voltage angle, SVC provides better motor speed regulation and improved torque control without the need for speed or position sensors. PowerFlex 700H drives configured for Sensorless Vector control are ideal for applications that require high starting torque over an extensive speed range. They also readily meet the high torque demands for low-speed motor operations, consequently improving heavy-duty performance.

Easy-to-Use Human Interface Module

PowerFlex 700H AC drives incorporate a full-featured LCD Human Interface Module that supports a variety of features and languages, simplifying drive programming. The module provides:

• Large and easy-to-read 21-character 7-line backlit LCD display
• Multiple languages, including German, Portuguese, French, English, Spanish, Dutch, and Italian
• Control keys for local speed, start, direction, and stop control
• Function keys that serve as an alternative for shortcuts to common drive programming tasks
• “Calculator-like” numeric keypad for quick and easy data entry. This feature is only available in Full Numeric PowerFlex 700H HIM versions.

Internal Communication Adapters

Allen-Bradley PowerFlex 700H drives include a wide selection of optional internal communication adapters that are provided as user-installed communication option kits. These adapters provide high-speed and efficient control capabilities and/or data exchange between PowerFlex 700H AC drives and host Logix controllers over common industrial communication protocols, including EtherNet/IP, DeviceNet, PROFIBUS, CANopen, ControlNet, Remote I/O, RS-485 Serial communications, INTERBUS, LonWorks, BACnet, Modbus/TCP, and other open communication and control networks.

Listed below are some of the available PowerFlex 700H internal communication adapters:

• 20-COMM-D: DeviceNet Communication Adapter
• 20-COMM-S: RS-485 DF1 Adapter
• 20-COMM-I: INTERBUS Communication Adapter
• 20-COMM-SMX3: RS-485 DF1 Adapter with conformal coating
• 20-COMM-E: EtherNet/IP Adapter
• 20-COMM-DMX3: DeviceNet Communication Adapter with conformal coating
• 20-COMM-C: ControlNet Adapter (Coax)
• 20-COMM-B: BACnet MS/TP RS-485 Adapter
• 20-COMM-R: Remote I/O Adapter
• 20-COMM-L: LonWorks Communication Adapter
• 20-COMM-P: PROFIBUS DP Adapter
• 20-COMM-RMX3: Remote I/O Adapter with conformal coating
• 20-COMM-K: CANopen Adapter
• 20-COMM-Q: ControlNet Adapter (Fiber)
• 20-COMM-EMX3: EtherNet/IP Adapter with conformal coating
• 20-COMM-H: HVAC Adapter
• 20-COMM-M: Modbus/TCP Adapter
• 20-COMM-CMX3: ControlNet Adapter (Coax) with conformal coating

Optional Safe Torque-Off Functionality

PowerFlex 700H AC drives are supplied with an optional ATEX-capable Safe Torque-Off (STO) module (Catalog No. 20C-DG1). The safety option is ideal for safety-related motor control applications that benefit from the removal of motion-producing power to the motor being controlled without disconnecting the incoming AC supply to the PowerFlex 700H drive. This provides an appropriate degree of operator safeguarding, allowing mechanical work to be performed on the PowerFlex 700H drive system.

Note: The STO feature does not offer electrical safety – hazardous voltages capable of causing electric shocks could still be present at the connected motor even with the feature enabled. It should also not be used as a control function for stopping or starting a PowerFlex 700H AC drive system.

In addition, the STO safety option offers the benefit of a quick machine start-up after a demand for the drive’s safety mechanism. It also helps minimize mechanical wear and tear on a PowerFlex 700H drive resulting from repetitive start-up. The Safe Torque-Off option for Frames 9 to 14, 400/480V, and 600/690V PowerFlex 700H AC drives are TÜV approved for use in safety applications rated up to and including:

• Safety Integrity Level (SIL) 2 in compliance with EN 62061 and IEC 61508 functional safety standards
• EN 954-1 Category 3(CAT 3)/ PL d (Performance Level d) in conformity with EN ISO 13849-1

Built-in Protective Features

PowerFlex 700H drives are available with the following inbuilt protective features:

• Common Mode Capacitors and Protective MOVs (Metal Oxide Varistors): Frame 10 to 14 PowerFlex 700H drives incorporate common mode capacitors and removable MOVs, which are referenced to ground. These devices help ensure compatibility with ungrounded power distribution systems. The capacitors filter out high-frequency interference signals from such systems, while the MOVs provide protection against overvoltage conditions and power surges. To avoid drive damage, the common mode capacitors and MOVs referenced to the ground have to be disconnected if the PowerFlex 700H drive is mounted on a resistive grounded or an ungrounded power distribution system.
• Ground Fault Protection: In PowerFlex 700H drives, ground fault protection is provided during startup and when the drive is running. It helps ensure reliable drive operation.
• 6 kV (kilovolts) Transient Protection: This is a surge protection mechanism that provides increased robustness for PowerFlex 700H drive systems rated for 380 to 480V AC operation.
• Electronic Motor Overload Protection: Heavy-duty PowerFlex 700H AC drives have an inbuilt electronic motor overload system for motor protection during across-the-line (bypass) operation. The system helps increase the service life of the connected motor.

Industry-standard mounting and Packaging Options

All PowerFlex 700H drives feature a modular design and high-power density structure with ratings equivalent to those of PowerFlex 700S AC drives. This results in reduced spare parts ordering and stocking. Frame 10 and larger PowerFlex 700H drives include floor-standing, Rittal TS-8 cabinet designs for multi-drive lineups or compact stand-alone drive applications.

In addition, packaged PowerFlex 700H AC drives are assembled in UL Type 12 or 1/ NEMA rated MCC style/Rittal enclosures with or without conformal coating. Each enclosure type is well suited to a specific type of environmental conditions and protection requirements, as detailed below.

• IP20, UL Type 1/NEMA 1: This enclosure provides a level of protection against electrical/thermal hazards and solid foreign objects such as falling dirt. It is used for conventional mounting of Frame 10 or larger PowerFlex 700H drives outside or inside a control cabinet. The enclosure’s conduit plate is removable, allowing easy drive installation and component replacement without disturbing the electrical conduit. 
• IP54, NEMA 12/UL Type 12: The enclosure offers a high degree of protection against dirt, dust particles, and splashing water. It is available for wall-mount, stand-alone Frame 10, or larger PowerFlex 700H drives intended for dust-tight applications.
• IP21, NEMA 1/UL Type 1: The enclosure is used for packaging Frame 9 PowerFlex 700H drives intended for indoor use. It provides protection against liquids and solid objects, like debris, dust, condensation, and moisture.
• Conformal Coating: The PowerFlex 700H drive is coated in a non-conducting substance or insulator that protects it from corrosion, fungus, abrasion, dust, moisture, and other environmental stresses induced by extremely polluted atmospheres. The coating improves the lifespan of the PowerFlex 700H drive even when it’s exposed to corrosive agents. It also helps maintain durable surface insulation resistance, ensuring the reliability and operational integrity of PowerFlex 700H drive systems.

At Do Supply, we carry a wide selection of drives, like the PowerFlex 700H, ready to be shipped to your automation solution. Whether you need something heavy-duty like the 700H or a bit lighter-weight like the PowerFlex 40 series, we have you covered. Give us a call today, and we can pair you with your next drive! If the 700H is too much drive for your needs, feel free to check out the rest of our PowerFlex 7 series drives compared here!