2025-04-29

The PowerFlex 700S AC drive series is built to deliver high-performance motor control and integration flexibility, thanks to Phase II control technology and DriveLogix software. By combining a powerful Logix engine with top-tier drive performance, the 700S offers a cost-effective, reliable control solution for industrial applications. With wide power ratings and versatile control options, the PowerFlex 700S series supports everything from basic to highly demanding operations.

In this guide, we'll walk you through using the PowerFlex 700S, from installation and wiring to start-up procedures, configuration, and fault management—ensuring your drives run efficiently and reliably.

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PowerFlex 700S Overview

The PowerFlex 700S series supports:

• Voltage Ratings: 200-240V AC (up to 100 HP), 380-480V AC (up to 1250 HP), 500-600V AC (up to 1600 HP), and 690V AC (up to 1500 kW).

• Inputs: Supports 3-phase and 6-pulse inputs; single-phase input at 50% current capacity.

• Control Options: LCD HMI, remote keypads, or computer-based tools.

• Networking: Ethernet, ControlNet, SynchLink fiber-optic synchronization, serial communication.

• Motor Feedback Options: Incremental encoders, resolvers, high-res encoders, Stahl SSI, and Temposonics interfaces.

• Certifications: ATEX, CE, C-Tick, and UL.

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Mounting Clearances

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Proper mounting and environmental controls are critical for efficient operation:

• Maintain recommended clearances for airflow around the drive.

• Monitor operating temperatures:

  • 0°C to 50°C for open and IP20 drives.

  • 0°C to 40°C for IP56 and NEMA/UL Type 1 enclosures.

• Exceeding temperature or clearance guidelines can cause premature drive wear or degraded performance.

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AC Supply Source and Power Conditioning

Stable and clean power is essential:

• Use grounded, balanced distribution networks.

• Employ isolation transformers or line reactors to minimize voltage spikes and harmonics.

• Proper grounding mitigates electrical noise and protects sensitive components.

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Grounding and Shield Termination Requirements

Ensure safe and stable system operation:

• Follow grounding practices recommended in the user manual.

• Terminate shields at the SHLD terminal to prevent radio-frequency interference (RFI).

• Always bond RFI filters properly to ground to ensure full compliance with EMC directives.

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Power Wiring, Cables, and Terminal Blocks

Proper wiring is vital for performance and safety:

• Choose motor and input cables rated for 200V–600V.

• Observe maximum motor cable lengths listed in the installation manual.

• Ensure firm connections at all terminal blocks.

• Remove access panels to inspect and seat cables before applying power.

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I/O Wiring and Configuration for Main Control Board

Streamline your integration process:

• Configure I/O terminals for critical functions such as hard-enable circuits and auxiliary power supplies.

• Follow CE conformity guidelines for wiring in EMC-sensitive installations.

• Use status LEDs on the control board for real-time wiring and setup verification.

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Preparing for Drive Start-Up

Prior to start-up:

• Tighten and verify all electrical connections.

• Confirm that environmental conditions (temperature, humidity) are within limits.

• Inspect mounting clearances and input power quality.

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Initial Power Application and Assisted Start-Up

Upon first energizing the drive:

• Observe LED indicators for signs of readiness or faults.

• Utilize the Assisted Start-Up feature to guide setup—this will prompt you to:

  • Select motor type and control mode.

  • Set voltage, frequency, and acceleration/deceleration parameters.

  • Configure safety and protection settings.

This step-by-step assistance ensures correct and safe operation from the start.

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Understanding PowerFlex 700S Drive Parameters

Parameters are the backbone of drive configuration:

• Set operational characteristics: motor torque, speed, fault reactions, and more.

• Fine-tune drive behavior for your specific application.

• Modify safety protocols, such as automatic fault response or torque limits.

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Organization of Parameters

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The parameters are logically grouped:

• Motor Control: Settings related to speed, torque, acceleration, and deceleration.

• Fault Management: Configure alarms, auto-restart behavior, and fault thresholds.

• Diagnostics: Monitor system health and performance metrics.

Use the Linear List to browse sequentially or the Cross-Reference by Name feature for fast alphabetical searches.

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Diagnosing Faults and Alarms

Understanding the difference:

• Faults: Immediate critical issues (e.g., overcurrent, overvoltage) that halt operation.

• Alarms: Warnings for non-critical issues that need attention before they escalate.

Promptly addressing alarms can often prevent faults and unexpected downtime.

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Analyzing Drive Status and LED Indications

Key status indicators:

• Running, Stopped, and Faulted drive states.

• Color-coded LEDs:

  • Green for normal operation.

  • Red for faults.

  • Flashing for active precharge, undervoltage, or pending alarms.

These indicators provide a fast and easy way to monitor health at a glance.

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Using the Human Interface Module (HIM) and Manual Fault Clearing

The HIM display shows:

• Fault/alarm codes.

• Explanations of the issue.

• Suggested corrective actions.

Once the root issue is resolved:

• Perform Manual Fault Clearing via the HIM to reset the system and resume operation quickly.

Thorough error descriptions help even non-specialist operators troubleshoot confidently.

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Conclusion

In conclusion, the PowerFlex 700S Series provides high-performance motor control capabilities designed for flexible integration and dependable industrial operation. By following best practices for installation, start-up, wiring, grounding, and parameter configuration, users can unlock the full potential of these drives while minimizing downtime and maximizing efficiency.

Understanding drive parameters, diagnostic indicators, and leveraging tools like the HIM module ensures smooth operations, whether you're working with basic conveyors or complex high-performance systems.

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At Do Supply, we offer a complete selection of PowerFlex 700S models ready for immediate shipment, backed by expert technical support.
Whether you're installing new drives or upgrading an existing system, our team is here to help you find the right solution.
Call or email us today to get started—or check out our blog comparing the PowerFlex 7 series drives if you’d like to learn even more!

Need help troubleshooting or replacing a drive? Contact PLG Automation today:
Email: sales@plgautomation.com
Phone: 800-906-9271