Rockwell Automation Allen-BradleyPowerFlex 700AFE Installation Instructions Manual Download

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PowerFlex 700H, 700S, and 700AFE Drive Fan Systems

Frames 9...14 Drives

Installation Instructions

Summary of Contents for Allen-BradleyPowerFlex 700AFE

Page 1: ...PowerFlex 700H 700S and 700AFE Drive Fan Systems Frames 9 14 Drives Installation Instructions ...

Page 2: ...or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Labels may also be on or inside the equipment to provide specific precautions Allen Bradley PowerFlex Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to R...

Page 3: ...ply kit 191 Updated the LCL Filter Section table to include the new LCL filter fan DC power supply kit 214 Added the LCL Filter DC Fan Power Supply Kit SK Y1 DCPS2 F10 Removal and Installation procedures for the new kit 219 Added the LCL Filter DC Fan Power Supply Circuit Board SK H1 DCFANBD1 Removal and Installation procedures for the new kit 225 UpdatedtheLCLFilterMainDCFan SK Y1 DCFAN1 Assembly...

Page 4: ...4 Rockwell Automation PublicationPFLEX IN029B EN P August 2014 Summary of Changes Notes ...

Page 5: ...r Frame 9 Fan System Repairs 20 Frame 9 Schematic Diagrams 21 Frame 9 Fan System Replacement Procedures 22 Remove Power from the Drive 23 Remove the Lower Protective Cover 24 Remove the Upper Protective Cover 24 Removing the Main Fan Inverter Capacitor Bracket 25 Main Fan Fuses 20 PP20202 and Fuse Holder 20 PP20300 Removal and Installation 29 Main Fan Inverter Cooling Fan 20 PP01049 Removal and In...

Page 6: ...nstallation 69 AC to DC Fan System Retrofit Kit SK H1 DCFANRETROFIT F10 70 Main AC Fan Inverter Capacitor SK H1 FANCAP F1012 Removal and Installation 74 Main AC Fan 20 PP01080 and Main DC Fan SK Y1 DCFAN1 Assembly Removal and Installation 78 ASIC Circuit Board Assembly Cooling Fan 20 PP01096 Removal and Installation 82 AC or DC Fan System Fuses 20 PP20202 and Fuse Holder 20 PP20300 Removal and Ins...

Page 7: ...Systems 124 Tools Needed for Frame 13 Fan System Repairs 125 Frame 13 AFE Schematic Diagrams 125 Frame 13 Fan System Replacement Procedures 134 Remove Power from the Drive 134 MovetheControlFrame andRemovetheScreens AirflowPlates and Protective Covers 135 Remove the Voltage Feedback Circuit Board Assembly Inverter Only 138 ASIC Circuit Board Assembly Cooling Fan 20 PP01096 Removal and Installation...

Page 8: ...rts 187 AC Fan Systems 187 DC Fan Systems 188 Tools Needed for Frame 10 AFE Fan System Repairs 188 Frame 10 AFE Fan System Schematic Diagrams 189 Frame 10 AFE Fan System Replacement Procedures 192 Power Structure Section 192 LCL Filter Section 214 Chapter8 PowerFlex700AFEDrive Frame13 Procedures Frame 13 AFE Drive Configurations 236 Frame 13 AFE Fan System Spare Parts 238 AC Fan Systems 238 DC Fan...

Page 9: ...65 Frame 9 PowerFlex 700H and 700S Drives 265 Frames 10 and 12 PowerFlex 700H and 700S Drives 265 Frame 11 PowerFlex 700H and 700S Drives 267 Frames 13 and 14 PowerFlex 700H and 700S Drives 268 Frames 10 and 13 PowerFlex 700AFE 268 Checking the Main AC Fan Inverter Circuit Board Diagnostic LEDs 268 AC Fan System LEDs 269 DC Fan System LEDs 269 Fan System Wiring and Operation 270 Testing the Main F...

Page 10: ...10 Rockwell Automation Publication PFLEX IN029B EN P August 2014 Table of Contents ...

Page 11: ...al 15 Fastener Tool Torque Information 16 General Precautions 17 Cat No 20D J 300 N 0 NNNBNNNN UL Open Type IP00 540V 650V Normal Duty Power 160 kW 132 kW 250 kW 200 kW Heavy Duty Power DC Voltage Range 462 594 350 583 713 350 Amps Input DC AC Voltage Range 0 400 50 Hz 0 460 60 Hz Base Hz default Output 3 Phase 0 320Hz Continuous Amps 300 245 330 368 300 245 330 368 1 Min Overload Amps 2 Sec Overl...

Page 12: ...lex 700H and 700S drive fan systems this directive will be implemented in multiple phases Phase 1 Starts January 1 2013 New products delivered within the EU with a power structure manufacture date of January 1 2013 and later will have a DC fan system installed Phase I includes PowerFlex 700H and 700S frame 9 and larger drives and PowerFlex 700AFE systems DC fan system kits have been developed to s...

Page 13: ...l be used as a replacement spare part kit Fan System Replacement FAQs Typical questions and solutions to fan system replacements can include Question Solution DoallACfansinadriveneedtobereplacedwithanewDC fan if only one has failed It is recommended that a power structure always contains the same type of fan system either all AC or all DC If only one AC fan inverter circuit board fails can I repla...

Page 14: ...with new DC fan systems 12 4 If one AC fan system fails replace the existing two AC fan systems contained in the power structure that contains the failedAC fan system with new DC fan systems 13 5 or 6 IfoneACfansystemfails replaceallexistingACfansystemswithnew DC fan systems 14 9 12 If one AC fan system fails replace allexisting AC fan systems contained in the power structure that contains the fai...

Page 15: ...ize Use this table to locate a list of available spare parts and the procedures for replacing fan system components for a specific drive and frame size Drive Type Frame Size Chapter Appendix Page Number PowerFlex 700H and 700S 9 1 19 10 2 55 11 3 87 12 4 117 13 5 121 14 6 179 PowerFlex 700AFE 10 7 185 13 8 235 PowerFlex 700H 700S and 700AFE 9 14 A 255 B 277 ...

Page 16: ... registered trademarks of the Phillips Screw Company Tool Type and Size F Flat nose screw driver Px Phillips screw driver bit and size PZx POZIDRIV screw driver bit and size Txx Hexalobular screw driver bit and size xx mm Hexagonal socket wrench Tightening Torque Fastener Type Flat head screw Hexagonal bolt Hexagonal nut or standoff Hexagonal screw Hexalobular head screw Phillips head screw 1 POZI...

Page 17: ...ay be at a potentially fatal voltage if not properly grounded If an oscilloscope is used to measure high voltage waveforms use appropriately rated differential voltage probes Be sure that they are set to the highest voltage scaling in order to achieve safe measurement resolution Verify that the oscilloscope chassis is correctly grounded to an earth ground ATTENTION The sheet metal cover and mounti...

Page 18: ...18 Rockwell Automation PublicationPFLEX IN029B EN P August 2014 Preface Notes ...

Page 19: ...Cover 24 Removing the Main Fan Inverter Capacitor Bracket 25 Main Fan Fuses 20 PP20202 and Fuse Holder 20 PP20300 Removal and Installation 29 Main Fan Inverter Cooling Fan 20 PP01049 Removal and Installation 30 Main AC Fan Inverter Capacitor SK H1 FANCAP F9 Removal and Installation 31 Main AC Fan Inverter Circuit Board Assembly 20 VB00299 Removal and Installation 33 MainDCFanPowerSupplyCircuitBoar...

Page 20: ...ndor 20 PP01049 50 mm cooling fan for fan inverter 1 Sinwan SD5012PT 24H 20 PP01068 80 mm x 80 mm x 32 mm internal stirring fan assembly 2 or 3 2 2 2 for PowerFlex 700H drives and 3 for PowerFlex 700S drives Japan Servo Co LTD PUDC24H4C 049 20 PP01080 230 W Main AC fan assembly 1 20 PP09055 Output transformer for main fan inverter 1 20 PP20202 Fuse for fansystem 2 Ferraz Shawmut ATQ8 4 4 The facto...

Page 21: ...1 3 Off S1 4 S1 Setup Switch F1 From Power Board X10 From Power Board X7 M1 Brown Black Blue Main Fan M Black 6 Black 5 Black 4 Black 3 Black 2 Black 1 X4 X5 2 2 µf 10 MΩ 2 2 µf 10 MΩ Yellow Green 7 µf X3 Install Jumper on 400 480V AC input drives only Not present on fan inverter circuit boards cat no VB00399 Switch Setting To indicate the following S1 Off 50 Hz fan motor frequency S2 Off 220 V AC...

Page 22: ...Page 20 PP20202 Fuse for fan system 29 20 PP20300 Fuse holder for main fan system fuses 29 20 PP01049 50 mm cooling fan for fan inverter 30 SK H1 FANCAP F9 Main AC fan capacitor 7 μF 31 20 VB00299 Main AC fan inverter circuit board 33 SK H1 DCFANBD1 Main DC fan powersupply circuitboard 36 SK H1 DCFANRETROFIT F9 AC to DC fan system retrofit kit 39 SK Y1 DCFAN1 Main DC fan assembly 43 20 PP01080 230...

Page 23: ... servicing Checkthe DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc may occur An elect...

Page 24: ...DRIV screws that secure the lower protective cover to the drive and remove the cover Remove the Upper Protective Cover 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 23 3 Remove the eight M4 x 8 mm POZIDRIV screws that secure the upper protective cover to the drive and remove the cover 8 Screws L1 L2 L3 L1 L2 L3 U T1 V T2 W T3 U T1...

Page 25: ... the main fan inverter cooling fan capacitor bracket from the drive The main fan inverter compartment is located in the bottom left hand corner of the drive under the connection plate Follow these steps to remove the main fan inverter capacitor bracket 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 23 3 Remove the lower protective ...

Page 26: ... PowerFlex 700H and 700S Drives Frame 9 Procedures 4 Remove the M4 x 8 mm POZIDRIV screw that secures the fan inverter cover to the drive frame and remove the cover 1 2 3 4 O N X6 X1 X4 X5 X7 S1 X2 X8 PZ2 1 3 N m 11 5 lb in Series A Cover Shown Series B Cover Series A Cover ...

Page 27: ...ires black and red pairs from the top and bottom of the fuse holder 7 Disconnect the stirring fan power wires IMPORTANT Mark all connections and wires before removing to avoid incorrect wiring during reassembly IMPORTANT Note that the red wires connect to the left side terminal on the fuse holder and the black wires connect to the right side terminal on the fuse holder 6 6 5 7 Red Black Red Black ...

Page 28: ...pacitor fuse holder and cooling fan bracket to the drive frame and lift the bracket out of the drive Note that the fan capacitor is still connected to the drive circuitry 9 Disconnect the fan capacitor wires from the connectors labeled Blue and Brown 1 2 3 4 O N X6 X1 X4 X5 X7 S1 X2 X8 9 8 P2 4 0 N m 35 lb in Series A Assembly Shown Series A Assembly Series B Assembly Note the Larger Capacitor ...

Page 29: ...ve power from the drive See Remove Power from the Drive on page 23 3 Remove the lower protective cover from the drive See Remove the Lower Protective Cover on page 24 4 Remove the main fan inverter capacitor bracket See Removing the Main Fan Inverter Capacitor Bracket on page 25 5 Remove and replace the fuses if necessary See Checking the Fan Inverter Fuses on page 263 6 If necessary remove the tw...

Page 30: ...ve See Remove Power from the Drive on page 23 3 Remove the lower protective cover from the drive See Remove the Lower Protective Cover on page 24 4 Remove the main fan inverter capacitor bracket See Removing the Main Fan Inverter Capacitor Bracket on page 25 5 Remove the two M4 x 16 mm POZIDRIV screws that secure the cooling fan to the bracket and remove and discard the fan 6 Install the new cooli...

Page 31: ... If a series A capacitor is currently installed always replace it with the new series B capacitor Follow these steps to remove test and replace the main AC fan inverter capacitor 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 23 Photo ID Part Description Quantity 1 Fan capacitor 1 2 Fan capacitor fuse holder and fan bracket 1 3 Fan...

Page 32: ...er for reuse 7 If a series A capacitor is installed continue with the next step If a series B capacitor is installed measure the value of the capacitor If the value of the capacitor is less than 7 μF continue with the next step 8 Remove the M12 nut and lock washer that secures the capacitor to the bracket and remove the capacitor 9 Install the new capacitor If replacing a smaller series A capacito...

Page 33: ...ve power from the drive See Remove Power from the Drive on page 23 3 Remove the lower protective cover from the drive See Remove the Lower Protective Cover on page 24 4 Remove the main AC fan inverter capacitor bracket See Removing the Main Fan Inverter Capacitor Bracket on page 25 5 Reach into the fan inverter compartment and disconnect the isolation transformer wires from X4 and X5 on the fan in...

Page 34: ...er 1 PowerFlex 700H and 700S Drives Frame 9 Procedures 8 Remove the three M4 x 8 mm POZIDRIV screws that hold the fan inverter assembly to the drive and remove the fan inverter assembly 1 2 3 4 O N X6 X1 X4 X5 X7 S1 X2 X8 Fan Inverter Circuit Board PZ2 3 0 N m 27 lb in 8 ...

Page 35: ...80VFrame9drive insertthejumperonconnector X3 as shown here Connect Jumper to Connector X3 X8 X2 IMPORTANT VerifythatdipswitchS1onthenewfaniverterboardisproperlyconfigured as shown below X 6 X 1 X 4 X 5 X 7 S1 X 2 X 8 1 ON 2 3 4 S1 1 ON 2 3 4 S1 1 S1 2 S1 3 S1 4 Off Off On Off Switch Setting To Indicate the Following S1 Off 50 Hz Fan Motor Frequency S2 Off 220 V AC Motor Voltage S3 On 230 V AC Moto...

Page 36: ...guidelines on replacing an existing fan system with a new DC fan system Follow these steps to remove and replace a DC fan system 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 23 3 Remove the lower protective cover from the drive See Remove the Lower Protective Cover on page 24 4 Remove the M4 x 8 mm POZIDRIV screw that secures the...

Page 37: ...nnector X2 7 Disconnect the fan supply wire from fan inverter connector X8 8 Disconnect the DC fan power supply wire from connector X81 9 Disconnect the four fuse power wires black and red pairs from the top and bottom of the fuse holder 10 Remove the two M5 x 10 mm Phillips head screws that secure the fuse holder cooling fan bracket to the frame and left the bracket out of the drive 5 6 7 9 8 10 ...

Page 38: ... Remove the two M4 x 8 mm fan inverter mounting screws and while turning the fan inverter slightly sideways remove the DC fan power supply assembly 12 Install the main DC fan power supply system in the reverse order of removal IMPORTANT Ifyouareservicinga400V 480VFrame9drive insertthejumperonconnector X3 PZ2 2 3 N m 20 4 lb in ...

Page 39: ...ve Cover on page 24 4 Remove the main AC fan inverter capacitor bracket See Removing the Main Fan Inverter Capacitor Bracket on page 25 5 Remove the AC fan inverter capacitor from the bracket and discard the capacitor See Main AC Fan Inverter Capacitor SK H1 FANCAP F9 Removal and Installation on page 31 6 Remove the main AC fan inverter circuit board assembly and discard the assembly See Main AC F...

Page 40: ...acket 8 Remove the main AC fan inverter output transformer assembly from the drive and discard the assembly See Main AC Fan Inverter Output Transformer 20 PP09055 Removal and Installation on page 49 9 Partially insert the new retrofit DC fan assembly into the bottom of the drive 10 Insert the DC fan supply cable into the hole inside the drive chassis that leads to the fan circuit board assembly lo...

Page 41: ... cm long T20 hexalobular screwdriver tighten approximately 12 full screw rotations the four screws accessible through the holes in the drive chassis to secure the fan plenum sheet metal bracket against the fan assembly inside the drive 14 Install the four rubber bushings in the four holes in the drive chassis 13 T20 3 0 N m 27 lb in 14 ...

Page 42: ...mbly to the drive using the two M4 x 8 mm POZIDRIV screws 16 Connect the stirring fan power wires 17 Connect the DC supply wire from fan inverter connector X2 18 Connect the fan supply wire from fan inverter connector X8 19 Connect the DC fan power supply wire from connector X81 20 Connect the four fuse power wires black and red pairs from the top and bottom of the fuse holder PZ2 2 3 N m 20 4 lb ...

Page 43: ...emoval and Installation Follow these steps to measure the resistance between the main fan supply wires and remove and replace the main fan if necessary Notes To identify which fan is installed in your drive see Fan Inverter System Block Diagrams on page 257 For AC fan systems the sheet metal bracket is available as a spare part SK H1 FR9BRKT See page 288 for details For DC fan systems the sheet me...

Page 44: ...Remove the Lower Protective Cover on page 24 4 Remove the lower mounting bolts from the bottom of the frame 5 Remove the four rubber bushings that cover the mounting screws for the main fan assembly Retain these bushings for reuse 6 Remove the rubber bushing from the hole that covers the main fan motor power connector at the bottom of the drive IMPORTANT Verify that the upper mounting bolts are se...

Page 45: ...omation PublicationPFLEX IN029B EN P August 2014 45 PowerFlex 700H and 700S Drives Frame 9 Procedures Chapter 1 7 Disconnect the main fan motor power connector from the output transformer 7 Note DC fan system shown ...

Page 46: ...s table replace the AC fan DC Fan If the measurements are not similar to those in this table replace the DC fan Connection wires Resistance 5 Black Brown 62 Ω Brown Blue 36 Ω Blue Black 27 Ω Green chassis 0 Ω Connection wires Resistance 5 Red Blue Ω Red White Ω White Yellow Ω Blue White Ω Blue Motor Pin 4 Green Yellow Ground Pin 1 Brown Motor Pin 3 Black Motor Pin 2 AC Fan Pinouts White Tach Outpu...

Page 47: ...to the bottom of the drive chassis and slide the fan assembly down and out of the drive If the fan assembly does not easily come out of the dive chassis loosen the front screws as instructed in step 9 another turn and attempt to remove the fan assembly again Continue loosening the screws until the fan assembly slides easily from the drive 9 T20 3 0 N m 27 lb in IMPORTANT The next step assumes that...

Page 48: ...are and hole dimensions The AC fan uses four M4 x 8 mm screws that are spaced 40 mm apart on the bracket The DC fan uses four M5 x 10 mm screws that are spaced 65 mm apart on the bracket Based on the manufacturing date the sheet metal mounting bracket was fabricated for either an AC fan a DC fan or both 12 Install the main fan in the reverse order of removal IMPORTANT Verify that the fan turns eas...

Page 49: ...emove the Lower Protective Cover on page 24 4 Remove the main AC fan inverter cooling fan fuses and capacitor bracket See Removing the Main Fan Inverter Capacitor Bracket on page 25 5 Remove the main AC fan inverter circuit board assembly See Main AC Fan Inverter Circuit Board Assembly 20 VB00299 Removal and Installation on page 33 6 Remove the main AC fan from the drive See Main AC Fan 20 PP01080...

Page 50: ...nstall the new output transformer assembly in the reverse order of removal Chassis Stirring Fan 20 PP01068 Removal and Installation Note The chassis stirring fan is only installed on PowerFlex 700S Phase II drives Follow these steps to remove and replace the chassis stirring fan 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 23 3 R...

Page 51: ... in the reverse order of removal Cross plate Stirring Fan 20 PP01068 Removal and Installation Follow these steps to remove and replace the stirring fan located on the cross plate in the lower part of the drive 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 23 3 Remove the lower protective cover from the drive See Remove the Lower P...

Page 52: ...ace the internal stirring fan located on the drive frame in the lower part of the drive 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 23 3 Remove the lower protective cover from the drive See Remove the Lower Protective Cover on page 24 4 Remove the covers or protective isolation barriers from the U T1 V T2 and W T3 power terminal...

Page 53: ...access to the stirring fan 7 Disconnect the stirring fan power wire connector 8 Remove the two M4 x 8 mm POZIDRIV screws that secure the fan to the drive frame and remove the fan 9 Install the fan in the reverse order of removal Refer to the motor terminal wire placement diagrams below during reassembly 7 8 PZ2 3 0 N m 27 lb in Lug Hex Nut Washer Bus Bar Power Wire U1 U2 V1 V2 W1 W2 13 mm 20 0 N m...

Page 54: ...54 Rockwell Automation PublicationPFLEX IN029B EN P August 2014 Chapter 1 PowerFlex 700H and 700S Drives Frame 9 Procedures Notes ...

Page 55: ...move Power from the Drive 59 Move the Control Frame and Remove the Air Flow Plate and Protective Covers 60 Remove the Main AC or DC Fan Power Supply Assemblies 63 Main AC Fan Inverter Circuit Board 20 VB00299 and AC Fan Output Transformer Assembly 20 FR10844 Left or 20 FR10845 Right Removal and Installation 67 Main DC Fan Power Supply System SK H1 DCFANBD1 Removal and Installation 69 AC to DC Fan ...

Page 56: ...n inverter left side 1 20 FR10845 Output transformer assembly for main AC fan inverter right side 1 20 PP01080 230 W Main AC fan assembly 2 20 PP01096 60 mm internal fan for ASIC board 1 Sinwan SD5012PT 24H 2 2 The partmay not contain wires connectors ormounting hardware when bought directly from vendor 20 PP20202 Fuse for fan system 2 Ferraz Shawmut ATQ8 3 3 The factory default fuses are Ferraz S...

Page 57: ...cy Converter DC AC BLK 1 BLK 2 3 BLK BLK 2 2uf 4 BLK 5 2 2uf 1 7uf BRN 10Meg 10Meg M1 Main Fan Left Side 230V AC 50 Hz 6 BLUE 2 BLK BLK 1 BLK 2 3 BLK BLK 2 2uf 4 BLK 5 2 2uf 7uf 10Meg 10Meg YLW GRN 4 6 BLK Jumper 2 4 F2 Fan Frequency Converter From DC Bus in Power Structure M2 Main Fan Right Side 230V AC 50 Hz Off Off 1 2 3 4 Off On Setup Switch Off Off M BLACK 3 YLW GRN 4 M 1 BRN BLUE 2 BLACK 3 S...

Page 58: ...Drives Frame 10 Procedures Figure 5 Frame 10 DC Fan System Wiring Schematic Diagram 3 To ASIC Circuit Board X11 Fan Control 4 Main DC Fan Fan Module DC DC Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 Main DC Fan Fan Module 4 ...

Page 59: ...DC fan system retrofit kit 70 SK H1 FANCAP F1012 Main AC fan capacitor 7 μF Kit 74 20 PP01080 230 W main AC fan assembly 78 SK Y1 DCFAN1 Main DC fan assembly 78 20 PP01096 60 mm internal fan for ASIC board 82 20 PP20202 Fuse for fan system 85 20 PP20300 Fuse holder for main fan system fuses 85 ATTENTION Toavoidanelectricshockhazard verifythatthevoltageonthebus capacitorshasdischarged completelybef...

Page 60: ...om the drive in order to access fan system components on the drive power structure Follow these steps to move the control frame and remove the air flow plate and protective covers 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 59 3 Loosen or remove the two hexalobular screws that secure the control frame to the drive enclosure 4 Sw...

Page 61: ...4 61 PowerFlex 700H and 700S Drives Frame 10 Procedures Chapter 2 5 Remove the four M5 x 12 mm hexalobular self tapping sheet metal screws that secure the air flow plate to the drive enclosure 6 Slide the air flow plate off the drive 5 5 T20 3 0 N m 27 lb in 6 ...

Page 62: ...m POZIDRIV screws that secure the top and bottom protective covers to the main cover and remove the top and bottom covers 8 Remove the four M5 x 16 mm POZIDRIV screws that secure the main protective cover to the drive power structure and remove the cover 9 Slide the two side protective covers out of the drive enclosure 7 7 8 9 PZ2 1 5 N m 13 3 lb in 9 ...

Page 63: ...te the steps for the side of the drive that contains that assembly When replacing a failed AC fan system with a DC fan system remove and replace both AC fan systems 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 59 3 Move the control frame and remove the air flow plate and protective covers from the drive See Move the Control Frame...

Page 64: ... 700H and 700S Drives Frame 10 Procedures 5 Remove the two M5 X 10 mm POZIDRIV screws that secure each of the fan assembly brackets to the front of the drive 5 5 PZ2 2 3 N m 20 4 lb in PZ2 2 3 N m 20 4 lb in AC fan system 5 5 DC fan system PZ2 2 3 N m 20 4 lb in PZ2 2 3 N m 20 4 lb in ...

Page 65: ...rocedures Chapter 2 6 Disconnect the fan motor cables from the bottom of the fan power supply assembly 7 Remove the four M5 x 10 mm POZIDRIV screws that secure the bottom of the fan power supply assemblies to the drive frame 7 7 7 6 PZ2 2 3 N m 20 4 lb in All screws Note Left side AC fan powersupply shown ...

Page 66: ...supply disconnect the cables from connectors X2 and X8 9 For the left side fan power supply disconnect the cables from connectors X2 X8 and X3 10 Carefully remove the fan power supply assemblies by pulling them out of the front of the drive X3 jumper installed Right side ACfan power supply X8 X2 Note Series A capacitor shown Right side DC fan power supply ...

Page 67: ...t board requires replacement Follow these steps to remove and replace a fan inverter circuit board or output transformer assembly 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 59 3 Move the control frame and remove the air flow plate and protective covers from the drive See Move the Control Frame and Remove the Air Flow Plate and ...

Page 68: ...bly install the existing fan inverter circuit board on the new AC fan output transformer assembly in the reverse order of removal 8 Install the AC fan inverter assembly in the reverse order of removal 6 PZ2 2 3 N m 20 4 lb in Right side AC fan inverter assembly shown IMPORTANT Verify that dip switch S1 on the new AC fan inverter board is properly configured as shown below IMPORTANT If you are repl...

Page 69: ... guidelines on replacing an existing fan system with a new DC fan system Note Retain the fan power supply sheet metal bracket for reuse Follow these steps to remove and replace an existing fan system with a new DC fan system 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 59 3 Move the control frame and remove the air flow plate and...

Page 70: ... Fan System Retrofit Kit SK H1 DCFANRETROFIT F10 The frame 10 main AC to DC fan system retrofit kit contains the following parts IMPORTANT If you are replacing a right side DC fan power supply assembly install the jumper on connector X3 Item Number Description Quantity 1 Main DC fan assembly 2 2 DC fan power supply assembly 1 3 M6 x 20 mm POZIDRIV screw 4 4 M5 x 10 mm POZIDRIV screw 12 For right s...

Page 71: ...m 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 59 3 Move the control frame and remove the air flow plate and protective covers from the drive See Move the Control Frame and Remove the Air Flow Plate and Protective Covers on page 60 4 Remove the main AC fan power supply assemblies See Remove the Main AC or DC Fan Power Supply Asse...

Page 72: ...mblies Note The back of the fan housing contains two holes in the sheet metal that fit onto positioning pins located on the drive frame To remove the main fan assemblies lower the front end of the assembly downward in order to clear the sheet metal on the frame and pull the fan assembly off the positioning pins and out of the drive 6 Install the new DC main fan assemblies in the reverse order of r...

Page 73: ...ations identified in Table 1 8 Remove the backing from the drive modification label and attach the label in a clearly visible location to the front of the drive 9 Write DC fan retrofit and the installation date on the label Table 1 DC Fan Inverter Connections Item Description 1 DC supply wire to connector X2 2 Fan control wire to connector X8 3 Fan control FB wire jumper to connector X3 4 Fan supp...

Page 74: ...these steps to remove test and replace the main AC fan inverter capacitor 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 59 Photo ID Part Description Quantity 1 AC Fan capacitor 1 2 AC Fan capacitor bracket 1 1 If a series B AC fan inverter assembly is currently installed in the drive the sheetmetal frame has been modified to accom...

Page 75: ...n inverter assembly See Remove the Main AC or DC Fan Power Supply Assemblies on page 63 5 Cut the cable ties securing the wires marked Brown and Blue 6 Disconnect the AC fan capacitor wire connectors marked Brown and Blue 7 If a series A capacitor is installed continue with the next step If a series B capacitor is installed measure the value of the capacitor If the value of the capacitor is less t...

Page 76: ...an capacitor adapter bracket to the AC fan inverter assembly using the new M8 x 16 mm hexagonal socket screw and washer provided in the replacement kit IMPORTANT Assemble the adapter bracket using the appropriate mounting hole as shown in the illustration below 6 mm 12 N m 106 lb in 9 Use this hole 1 when installing theadapter bracket on the right side AC fan inverter assembly Use this hole 2 when...

Page 77: ...itor bracket using the M12 nut and lock washer provided in the kit 11 If necessary secure the new AC fan capacitor bracket assembly to the AC fan inverter assembly using the two M5 x 10 mm POZIDRIV screws provided in the kit 12 Install the AC fan inverter assembly in the reverse order of removal 19 mm 5 N m 44 lb in Nut Washer Bracket Capacitor PZ2 4 N m 35 lb in 11 Note AC Fan System Shown ...

Page 78: ...peller assembly Therefore the sheet metal housing for the fan must be reused To identify which fan is installed in your drive see Fan Inverter System Block Diagrams on page 257 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 59 3 Remove the bottom protective cover only from the drive See Move the Control Frame and Remove the Air Flo...

Page 79: ...is table replace the AC fan DC Fan If the measurements are not similar to those in this table replace the DC fan Connection wires Resistance 5 Black Brown 62 Ω Brown Blue 36 Ω Blue Black 27 Ω Green chassis 0 Ω Connection wires Resistance 5 Red Blue Ω Red White Ω White Yellow Ω Blue White Ω Blue Motor Pin 4 Green Yellow Ground Pin 1 Brown Motor Pin 3 Black Motor Pin 2 AC Fan Pinouts White Tach Outp...

Page 80: ... housings to the drive frame and remove the fan assemblies Note The back of the fan housing contains two holes in the sheet metal that fit onto positioning pins located on the drive frame To remove the main fan assemblies lower the front end of the assembly downward in order to clear the sheet metal on the frame and pull the fan assembly off the positioning pins and out of the drive 6 T30 3 0 N m ...

Page 81: ...Remove the four hexalobular screws on the back of the fan assembly Note The main AC and DC fans have different mounting hardware and hole dimensions The AC fan uses four M4 x 8 mm screws that are spaced 40 mm apart on the housing The DC fan uses four M5 x 10 mm screws that are spaced 65 mm apart on the housing Based on the manufacturing date the sheet metal housing was fabricated for either an AC ...

Page 82: ...with the sheet metal housing before installing the fan assembly on the drive ASIC Circuit Board Assembly Cooling Fan 20 PP01096 Removal and Installation The ASIC circuit board cooling fan is located on the ASIC board assembly on the upper left side of the drive Follow these steps to remove and replace the cooling fan 1 Review the General Precautions on page 17 2 Remove power from the drive See Rem...

Page 83: ...ar screws that secure the ASIC assembly cover to the drive and remove the cover For newer drives remove the two M3 x 5 mm POZIDRIV screws that secure the cooling fan assembly to the ASIC assembly and rotate the fan assembly out of the ASIC assembly IMPORTANT After removing the fan assembly from the ASIC board assembly the fan power cable will still be connected to the ASIC circuit board PZ2 3 0 N ...

Page 84: ... Procedures 5 Disconnect the cable from connector X1 on the ASIC board and remove the fan assembly from the drive 6 For newer drives only remove the M4 x 15 mm hexalobular screw that secures the fan to the bracket 7 Install the ASIC cooling fan and assembly in the reverse order of removal 5 6 T20 3 0 N m 27 lb in ...

Page 85: ...m fuse holder 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 59 3 Move the control frame and remove the air flow plate and protective covers from the drive See Move the Control Frame and Remove the Air Flow Plate and Protective Covers on page 60 4 Remove the fuses from the fuse holder 5 Check the fuses See Checking the Fan Inverter...

Page 86: ... 2 PowerFlex 700H and 700S Drives Frame 10 Procedures 7 Remove the M4 x 8 mm POZIDRIV screw that secures the fuse holder to the drive frame and remove the fuse holder 8 Install the new fan system fuses and fuse holder in the reverse order of removal 7 PZ2 3 0 N m 27 lb in ...

Page 87: ...edures 91 Remove Power from the Drive 91 Move the Control Frame and Remove the Air Flow Plate and Protective Covers 92 Removing the Main AC or DC Fan Power Supply Assemblies 95 Main AC Fan Inverter Circuit Board 20 VB00299 and AC Output Transformer Assembly 20 FR10845 Removal and Installation 99 MainDCFanPowerSupplyCircuitBoard SK H1 DCFANBD1 RemovalandInstallation 101 AC to DC Fan System Retrofit...

Page 88: ...ty per Drive Original Vendor and Model Number 20 FR10845 Output transformer assembly for main AC fan inverter right side 3 20 PP01080 230 W main AC fan assembly 3 20 PP01096 Cooling fan for ASIC board assembly 1 Sinwan SD5012PT 24H 1 1 The partmay not contain wires connectors ormounting hardware when bought directly from vendor 20 PP20202 Fuse for fan system 2 Ferraz Shawmut ATQ8 2 2 The factory d...

Page 89: ...1 X2 1 X2 3 BLK 300VAC 300VAC 1 BLK 2 3 BLK BLK 2 2 µf 4 BLK 5 2 2 µf 7µf 10 M Ω 10 M Ω 6 BLK 2 4 3 Jumper From DC Bus in Power Structure DC DC F1 F2 Off S1 1 Off S1 2 On S1 3 Off S1 4 S1 Setup Switch Off S1 1 Off S1 2 On S1 3 Off S1 4 S1 Setup Switch Off S1 1 Off S1 2 On S1 3 Off S1 4 S1 Setup Switch Fan Frequency Converter Fan Frequency Converter Main Fan W Phase 230V AC 50 Hz Main Fan V Phase 2...

Page 90: ...stem Wiring Schematic Diagram 3 To ASIC Circuit Board X11 Fan Control 4 Main DC Fan W Phase Fan Module DC DC Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 4 Main DC Fan V Phase Fan Module Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 4 Main DC Fan U Phase Fan Module Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 ...

Page 91: ...12 Main AC fan capacitor 7 μF kit 105 20 PP01080 230 W main AC fan assembly 110 SK Y1 DCFAN1 Main DC fan assembly 110 20 PP01096 60 mm cooling fan for the ASIC board assembly 113 20 PP20202 Fuse for fan system 115 20 PP20300 Fuse holder for main fan system fuses 115 ATTENTION Toavoidanelectricshockhazard verifythatthevoltageonthebus capacitorshasdischarged completelybefore servicing Checkthe DC bu...

Page 92: ...omponents on the drive power structure Follow these steps to move the control frame and remove the air flow plate and protective covers 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 91 3 If moving the control frame from a DC input drive with pre charge interlock disconnect the wiring from terminal strip X50 4 Loosen the two hexalo...

Page 93: ...st 2014 93 PowerFlex 700H and 700S Drives Frame 11 Procedures Chapter 3 5 Remove the four M5 x 12 mm hexalobular self tapping sheet metal screws that secure the air flow plate to the drive enclosure and slide the plate off the drive 5 T20 3 0 N m 27 lb in ...

Page 94: ... M5 x 16 mm POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers 7 Remove the four M5 x 16 mm POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover 6 PZ2 1 9 N m 16 8 lb in PZ2 2 6 N m 23 0 lb in 7 ...

Page 95: ...apacitor Follow these steps to remove the main fan inverter assemblies Note You only need to complete the steps necessary to remove the fan assembly left side center or right side you are testing or replacing 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 91 3 Move the control frame and remove the air flow plate and protective cove...

Page 96: ...oosen the three connections to the output terminal next to the inverter assembly 5 If applicable cut the cable tie that secures the cable to the capacitor and disconnect the cable 6 Disconnect the four wires from the top and bottom of the fuse block located on the center drive inverter assembly 4 17 mm 40 N m 354 lb in 5 Note AC Fan System Shown 6 ...

Page 97: ... that secure the fan power supply assembly to the front of the drive Tightening torque for reassembly is 1 9 N m 16 8 lb in 8 Disconnect the fan motor cable from the bottom of the fan power supply assembly 9 Remove the four M5 x 10 mm POZIDRIV screws that secure the bottom of the fan power supply assembly to the drive frame 9 9 9 8 PZ2 2 3 N m 20 4 lb in All Screws 7 ...

Page 98: ...in connector from the front of the drive 11 For the left side and center fan assemblies disconnect the cables from connectors X2 X8 and X3 If an in line connector is present as shown in the image below disconnect the main connector from the front of the drive 12 Carefully remove the fan power supply assemblies by pulling them out of the front of the drive In line Connector at Front of Drive X8 X2 ...

Page 99: ...Inverter on page 265 for test procedures used to determine if the circuit board requires replacement Follow these steps to remove and replace a main fan inverter circuit board or an AC output transformer assembly 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 91 3 Move the control frame and remove the air flow plate and protective ...

Page 100: ...lies remove the capacitor and fuse block bracket assembly You will re use the fuse block on the new assembly 8 Complete the appropriate installation If you are replacing the AC fan inverter circuit board install the new circuit board on the existing AC fan inverter assembly in the reverse order of removal If you are replacing the AC output transformer assembly install the existing AC fan inverter ...

Page 101: ...these steps to remove and replace an existing fan system with a DC fan system 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 91 3 Move the control frame and remove the air flow plate and protective covers from the drive See Move the Control Frame and Remove the Air Flow Plate and Protective Covers on page 92 IMPORTANT Verify that d...

Page 102: ...e the appropriate main fan power supply assembly See 95 on page Removing the Main AC or DC Fan Power Supply Assemblies 5 Install the new DC fan power supply in the reverse order of removal using the existing sheet metal housing IMPORTANT If you are replacing a left side AC fan inverter circuit board install the jumper on connector X3 ...

Page 103: ...See Move the Control Frame and Remove the Air Flow Plate and Protective Covers on page 92 4 Remove the main AC fan power supply assemblies See Removing the Main AC or DC Fan Power Supply Assemblies on page 95 5 Remove the two M6 x 20 mm hexalobular screws that secure each of the main fan housings to the drive Then remove the fan assemblies Note The back of the fan housing contains two holes in the...

Page 104: ...heet metal on the frame and pull the fan assembly off the positioning pins and out of the drive 6 Remove the M8 x 16 mm hexagonal socket screw that secures the fan capacitor and fuse holder adapter bracket to the Phase V AC fan inverter assembly and remove the bracket Save this bracket for reuse 4 5 T30 4 5 N m 39 8 lb in 8 mm 12 N m 106 lb in 6 ...

Page 105: ...are and fasteners and a series B capacitor identified in the table and shown below The series B capacitor 50 mm dia x 62 mm tall is larger than the series A capacitor 35 mm dia x 57 mm tall If a series A capacitor is currently installed always replace it with the new series B capacitor Photo ID Part Description Quantity 1 AC Fan capacitor 1 2 Fan capacitor bracket 1 1 If a series B AC fan inverter...

Page 106: ...w the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 91 3 Move the control frame and remove the air flow plate and protective covers from the drive See Move the Control Frame and Remove the Air Flow Plate and Protective Covers on page 92 4 Remove the appropriate main AC fan inverter assembly See Removing the Main AC or DC Fan Power Supply Assem...

Page 107: ... a series A capacitor is installed continue with the next step If a series B capacitor is installed measure the value of the capacitor If the value of the capacitor is not 7 μF continue with the next step 8 Unscrew and remove the fan capacitor from the AC fan inverter assembly 6 5 8 Series B Capacitor in a Right side AC Fan Inverter Assembly Shown Series A Capacitor in a Right side AC Fan Inverter...

Page 108: ... adapter bracket to the AC fan inverter assembly using the new M8 x 16 mm hexagonal socket screw and washer provided in the replacement kit 10 For the V phase AC fan inverter assembly the fuse holder and bracket to which it is secured must be installed on top of the new adapter bracket Phase U and W Fan Inverter Assemblies Phase V Fan Inverter Assembly New Adapter Bracket New Adapter Bracket Exist...

Page 109: ... using the M12 nut and lock washer provided in the kit 12 Secure the new capacitor bracket assembly to the AC fan inverter assembly using the two M5 x 10 mm POZIDRIV screws provided in the kit 13 Install the AC fan inverter assembly in the reverse order of removal Nut Washer Bracket Capacitor Bracket Front View 12 mm 5 N m 44 lb in 12 PZ2 4 N m 35 lb in Note AC Fan System Shown ...

Page 110: ...Block Diagrams on page 257 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 91 3 Remove the bottom protective cover only from the drive See Move the Control Frame and Remove the Air Flow Plate and Protective Covers on page 92 4 Disconnect the fan power supply cable from the bottom of the fan power supply for the main fan 5 Using the ...

Page 111: ...The back of the fan housing contains two holes in the sheet metal that fit onto positioning pins located on the drive frame To remove the main fan assemblies lower the front end of the assembly downward in order to clear the sheet metal on the frame and pull the fan assembly off the positioning pins and out of the drive Connection wires Resistance 5 Red Blue Ω Red White Ω White Yellow Ω Blue White...

Page 112: ...8 Remove the four hexalobular screws on the back of the fan assembly Note The Main AC and DC fans have different mounting hardware and hole dimensions The AC fan uses four M4 x 8 mm screws that are spaced 40 mm apart on the housing The DC fan uses four M5 x 10 mm screws that are spaced 65 mm apart on the housing Based on the manufacturing date the sheet metal housing was fabricated for either an A...

Page 113: ...with the sheet metal housing before installing the fan assembly on the drive ASIC Circuit Board Assembly Cooling Fan 20 PP01096 Removal and Installation The ASIC circuit board cooling fan is located on the ASIC board assembly on the upper left side of the drive Follow these steps to remove and replace the cooling fan 1 Review the General Precautions on page 17 2 Remove power from the drive See Rem...

Page 114: ...V screws that secure the cooling fan assembly to the ASIC assembly and rotate the fan assembly out of the ASIC assembly 5 Disconnect the cable from connector X1 on the ASIC board and remove the fan assembly from the drive 6 Remove the M4 x 15 mm screw s that secure the cooling fan to the ASIC assembly cover and remove the fan 7 Install the ASIC cooling fan in the reverse order of removal IMPORTANT...

Page 115: ...m the Drive on page 91 3 Move the control frame and remove the air flow plate and protective covers from the drive See Move the Control Frame and Remove the Air Flow Plate and Protective Covers on page 92 4 Remove the fuses from the fuse holder 5 Check the fuses See Checking Fuse Integrity with no Power Applied on page 263 6 Disconnect the four fuse power wires black and red pairs connected to the...

Page 116: ...116 Rockwell Automation PublicationPFLEX IN029B EN P August 2014 Chapter 3 PowerFlex 700H and 700S Drives Frame 11 Procedures Notes ...

Page 117: ...ives are essentially two parallel frame10 drives Therefore the spare parts are identical to the frame 10 with the exception that there are twice as many parts required The procedures for replacing frame 12 fan system components are also the same as those for frame 10 drives The spare parts for frame 12 drives are contained in this chapter See Chapter 2 PowerFlex 700H and 700S Drives Frame 10 Proce...

Page 118: ...PP01096 Cooling fan for ASIC board assembly 2 Sinwan SD5012PT 24H 2 2 The partmay not contain wires connectors ormounting hardware when bought directly from vendor 20 PP20202 Fuse for fan system 4 Ferraz Shawmut ATQ8 3 3 The factory default fuses are Ferraz Shawmut ATQ8 8 A fuses Older drives may contain Bussman 6 A fuses 20 PP20300 Fuse holder for main fan system fuses 2 Ferraz Shawmut 30322 20 V...

Page 119: ...LK 5 2 2uf 7uf 10Meg 10Meg 6 BLK BLK 1 BLK 2 3 BLK BLK 2 2uf 4 BLK 5 2 2uf 7uf 10Meg 6 BLK 2 4 F2 In Power Structure 2 Right Side Fan Frequency Converter FromASICBoard 1 X11 DC AC DC AC Fan Frequency Converter Fan Frequency Converter Jumper FromDCBusinPowerStructure FromDCBusinPowerStructure Off Off 1 2 3 4 Off On SetupSwitch Off Off 1 2 3 4 Off On SetupSwitch Off Off 1 2 3 4 Off On SetupSwitch Of...

Page 120: ...ft side Fan Module DC DC Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 4 Main DC Fan Right side Fan Module Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 3 To ASIC Circuit Board X11 Fan Control 4 Main DC Fan Left side Fan Module DC DC Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 4 Main DC Fan Right side Fan Module Isolated 48 VDC Power Supply Circuit Board...

Page 121: ...01096 Removal and Installation Inverter Only 139 AC or DC Fan System Fuses 20 PP20202 and Fuse Holder 20 PP20300 Removal and Installation 141 Remove the Main Fan Assembly 143 Removing the Main AC or DC Fan Power Supply Assemblies Inverter Only 145 Main AC Fan Inverter Circuit Board 20 VB00299 and DC Fan Power Supply Circuit Board SK H1 DCFANBD1 Removal and Installation Converter Only 148 Main AC F...

Page 122: ... and an inverter section as shown here For frame 13 drives the converter section has two or three rectifier sections depending on the power rating while the inverter section always has three power sections The converter converts ac fixed 50 60 Hz to dc voltage The inverter section inverts dc to variable ac frequency AC line AC DC DC AC DC bus Motor Converter section Inverter section Converter Inve...

Page 123: ...p 5 AC 1300 1450 Amp 6 20 PP20202 Fuse for fan system DC Input 6 Ferraz Shawmut ATQ8 2 AC 1150 Amp 10 AC 1300 1450 Amp 12 20 PP1096 Cooling fan for ASIC board assembly all 1 Sinwan SD5012PT 24H 3 600 690 20 FI13301 ACfaninverterassembly includescircuitboard fuses capacitor isolation transformer and mounting hardware DC Input 3 AC Input 5 20 VB00299 AC fan inverter circuit board DC Input 3 AC Input...

Page 124: ...DCFANRETROFIT F13B AC to DC fan system retrofit kit for frame 13 AC Input 1300A 1450 Amp 1 20 PP1096 Cooling fan for ASIC board assembly all 1 Sinwan SD5012PT 24H 4 600 690 SK 1 DCFANBD1 1 Main DC fan power supply circuit board DC Input 3 AC Input 5 SK Y1 DCFAN1 Main DC fan assembly DC Input 3 AC Input 5 20 PP20300 Fuse holder for fan system fuses DC Input 3 Ferraz Shawmut 30322 AC 1150 Amp 5 AC 1...

Page 125: ...can be configured with either AC or DC common bus input voltage applied The AC input drives have both converter and inverter sections while the DC input drives have only an inverter The schematics will change based on this hardware configuration Table 2 provides a list of schematic diagrams applicable to each drive configuration Table 2 Drive Configurations and Applicable Schematics Drive Input Vo...

Page 126: ...Phase F12 F13 DC DC DC DC F14 F15 5 25 26 21 22 23 X9 24V 0EVA X15 Charge Relay X2 Fan Gate Driver Measure L R X5 X4 X3 X11 Fan Gate Driver Measure L R Fan Gate Driver Measure L R Phase Module W Phase Module V Phase Module U X3 X8 X3 X8 X3 X8 X1 X1 X1 4 3 3 4 U T1 V T2 W T3 ASIC Board 1 The number of NFE s varies with the drive rating as shown in this table Voltage Class Amps of Reactors Reactor C...

Page 127: ...1 X3 U1 V1 X4 1 X5 1 X2 1 X2 3 BLK 300VAC 300VAC 1 BLK 2 3 BLK BLK 2 2uf 4 BLK 5 2 2uf 1 7uf Brown 10Meg 10Meg Black 3 Ylw Grn 4 M1 6 Blue 2 BLK F2 S1 1 S1 2 S1 3 S1 4 Off On S1 Setup Switch Off Off Fan Frequency Converter From previous NFE or U Phase Inverter Module M DC DC Switch Setting To indicate the following S1 Off 50 Hz fan motor frequency S2 Off 220 V AC motor voltage S3 On 230 V AC motor...

Page 128: ...14 Chapter 5 PowerFlex 700H and 700S Drives Frame 13 Procedures Figure 12 Frame 13 AC Input Drive Converter DC Fan System Rectifier Circuit Board X201 4 Main DC Fan Fan Module DC DC Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 X1 To Next Fan Module ...

Page 129: ...X3 V1 U1 X8 BLK 1 X5 1 BLK 2 X4 1 6 2 2uf 300VAC 3 BLK 2 2uf 300VAC 5 BLK 4 BLK 7uf 10Meg 10Meg BLK 4 X3 V1 U1 X8 BLK 1 X5 1 BLK 2 X4 1 6 2 2uf 300VAC 3 BLK 2 2uf 300VAC 5 BLK 4 BLK 7uf 10Meg 10Meg X2 3 X2 1 F1 Fan Frequency Converter DC AC F2 S1 1 S1 2 S1 3 S1 4 Off On S1 Setup Switch Off Off X2 3 X2 1 F1 Fan Frequency Converter DC AC F2 S1 1 S1 2 S1 3 S1 4 Off On S1 Setup Switch Off Off 3 To X51...

Page 130: ... To ASIC Circuit Board X11 Fan Control 4 Main DC Fan V Phase Fan Module Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 4 Main DC Fan W Phase Fan Module Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 4 Main Dc Fan U Phase Fan Module Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 X3 4 X3 X2 ASIC X1 NFE EndingTerminal in FI13 In Frame 13 Only DC DC ...

Page 131: ...ures Chapter 5 Figure 15 Frame 13 DC Input Drive Inverter Section X9 26 25 24V 0EVA X15 21 22 23 Charge Relay DC DC DC DC DC DC W T3 U T1 V T2 X11 ASIC Board Gate Driver Bd Fan Measure L R Phase Module V Phase Module U Phase Module W Gate Driver Bd Fan Measure L R Gate Driver Bd Fan Measure L R X8 X3 X8 X3 X8 X3 ...

Page 132: ...dule Main Fan 230Vac 50 Hz BLK 4 X3 V1 U1 X8 BLK 1 X5 1 BLK 2 X4 1 6 2 2uf 300VAC 3 BLK 2 2uf 300VAC 5 BLK 4 BLK 7uf 10Meg 10Meg BLK X3 V1 U1 X8 BLK 1 X5 1 BLK 2 X4 1 6 2 2uf 300VAC 3 BLK 2 2uf 300VAC 5 BLK 4 BLK 7uf 10Meg 10Meg X2 3 X2 1 F1 Fan Frequency Converter DC AC F2 S1 1 S1 2 S1 3 S1 4 Off On S1 Setup Switch Off Off X2 3 X2 1 F1 Fan Frequency Converter DC AC F2 S1 1 S1 2 S1 3 S1 4 Off On S...

Page 133: ...To ASIC Circuit Board X11 Fan Control 4 Main DC Fan V Phase Fan Module DC Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 4 Main DC Fan W Phase Fan Module Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 4 Main DC Fan U Phase Fan Module Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 DC X3 X3 Ending Terminal in FI13 In Frame 13 Only X2 ASIC X1 NFE 4 ...

Page 134: ...upply circuit board 153 SK Y1 DCFANRETROFIT F13 Fan system retrofit kit 154 SK H1 FANCAP F1314 Main AC fan capacitor 7 μF kit 170 20 FI3300 230 W main AC fan assembly 174 SK Y1 DCFAN1 Main DC fan assembly 174 ATTENTION Toavoidanelectricshockhazard verifythatthevoltageonthebus capacitorshasdischarged completelybefore servicing Checkthe DC bus voltage at the Power Terminal Block by measuring between...

Page 135: ...der to access fan system components on the drive power structure Follow these steps to move the control frame and remove the screens airflow plate and protective covers 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 134 3 If moving the control frame from a DC input drive with pre charge interlock disconnect the wiring from terminal...

Page 136: ...FLEX IN029B EN P August 2014 Chapter 5 PowerFlex 700H and 700S Drives Frame 13 Procedures 5 If the drive is installed inside an enclosure remove the screws that secure the protective screens to the enclosure and remove the screens 7 7 7 7 ...

Page 137: ...rame screens airflow plates and protective covers in the reverse order of removal 5 Converter unit Inverter unit Note AC input drive shown T20 3 0 N m 27 lb in DC BU S CO ND UC TO RS AN D CA PA CITO RS OP ER AT E AT HIGH VO LTAG E RE MO VE PO WER AN D WA IT 5 MI NU TE S BE FO RE SE RV ICING DANGER DC BU S CO ND UC TO RS AN D CA PA CITO RS OP ER AT E AT HIGH VO LTAG E RE MO VE PO WER AN D WA IT 5 M...

Page 138: ...Plates and Protective Covers on page 135 4 Disconnect the DC bus connection cable from connector J2 5 Disconnect the motor feedback connection cable from connector J1 6 Carefully unplug the fiber optic cables from sockets J4 and J5 and carefully move them aside 7 Remove the four M4 x 8 mm Phillips head screws that secure the voltage feedback circuit board assembly to the fan housing on the drive a...

Page 139: ...he ASIC circuit board 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 134 3 Move the control frame and remove the screens airflow plates and protective covers from the drive See Move the Control Frame and Remove the Screens Airflow Plates and Protective Covers on page 135 4 If you are accessing the electrical components within the V...

Page 140: ...re the cooling fan assembly to the ASIC circuit board assembly and rotate the fan assembly out of the assembly 6 Disconnect the cable from connector X1 on the ASIC board and remove the fan assembly from the drive IMPORTANT After removing the fan assembly from the ASIC board assembly the fan power cable will still be connected to the ASIC circuit board 5 PZ2 3 0 N m 26 5 lb in 6 ...

Page 141: ...cated on the front of the drive There is one set of fuses for each drive converter and inverter section Follow these steps to remove and replace the fan system fuse holder assemblies 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 134 3 Move the control frame and remove the screens airflow plates and protective covers from the drive...

Page 142: ...Note that the red wires DC are connected to the left side terminal and the black wires DC are connected to the right side terminals 7 Remove the M4 x 8 mm POZIDRIV screw that secures the fuse holder assembly 8 Install the AC or DC fan inverter fuses and fuse holder in the reverse order of removal 6 Converter Section Inverter Section 7 Insulator Fuse holder PZ2 3 0 N m 26 5 lb in Note Converter sec...

Page 143: ...main fan assembly 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 134 3 Move the control frame and remove the screens airflow plates and protective covers from the drive See Move the Control Frame and Remove the Screens Airflow Plates and Protective Covers on page 135 4 If necessary remove the voltage feedback circuit board assembly...

Page 144: ...emove the M8 x 20 mm hexagonal socket screw from the chassis in front of the fan housing in order to allow room for the fan housing to be removed from the unit 7 Remove the four M5 x 10 POZIDRIV screws that secure the main fan housing to the assembly and remove the fan housing 8 Install the main fan assembly in the reverse order of removal 5 7 6 5 5 mm or HOP6 bit 20 N m 177 lb in PZ2 3 5 N m 31 0...

Page 145: ...o determine if the fan inverter assembly requires replacement Follow these steps to remove and replace a main fan inverter assembly 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 134 3 Move the control frame and remove the screens airflow plates and protective covers from the drive See Move the Control Frame and Remove the Screens ...

Page 146: ...pter 5 PowerFlex 700H and 700S Drives Frame 13 Procedures 6 Remove the connectors by pinching the tabs together and sliding them out of the sheet metal bracket 7 Carefully push the rubber grommet with the fan wires and connectors through the hole in the drive chassis 8 ...

Page 147: ...pter 5 8 Cut the cable ties that secure the fan wires to the inside of the main fan housing 9 Remove the four M5 x 10 POZIDRIV screws that secure the fan power supply assembly to the fan housing and using the handle provided at the base of the assembly slide the fan assembly out of the housing 7 8 PZ2 3 5 N m 31 0 lb in ...

Page 148: ...page 17 2 Remove power from the drive See Remove Power from the Drive on page 134 3 Move the control frame and remove the screens airflow plates and protective covers from the drive See Move the Control Frame and Remove the Screens Airflow Plates and Protective Covers on page 135 4 Remove the four M4 x 8 mm POZIDRIV screws that secure the fan circuit board protection cover to the drive Press the r...

Page 149: ... drives with a DC fan system continue with step 6 For drives with an AC fan system complete steps a d a Disconnect the wires from connectors X2 X3 and X8 on the main AC fan circuit board b Disconnect the wires from connectors X4 and X5 on the AC fan circuit board 4 4 PZ1 0 9 N m 8 0 lb in Series A converter 4 4 4 Series B converter ...

Page 150: ...fully remove the circuit board d Continue with step 8 6 Disconnect the cable from connector X2 X3 X8 and X81 on the DC fan circuit board 7 Remove the two M4 x 8 mm POZIDRIV screws that secure the main DC fan circuit board to the drive frame and carefully remove the circuit board 8 Install the fan circuit board in the reverse order of removal c PZ2 3 0 N m 27 0 lb in 6 6 7 PZ2 3 0 N m 26 5 lb in Co...

Page 151: ...General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 134 3 Move the control frame and remove the screens airflow plates and protective covers from the drive See Move the Control Frame and Remove the Screens Airflow Plates and Protective Covers on page 135 4 Remove the main fan assembly from the drive See Remove the Main Fan Assembly on page 143 5 Rem...

Page 152: ...les from connectors X4 and X5 on the circuit board 9 Cut any cables ties as necessary 10 Remove the two M4 x 8 mm POZIDRIV screws that secure the fan inverter circuit board to the assembly and carefully remove the circuit board 11 Install the fan inverter circuit board in the reverse order of removal AC fan inverter assembly shown 10 PZ2 3 0 N m 26 5 lb in AC fan inverter assembly shown ...

Page 153: ... 2 Remove power from the drive See Remove Power from the Drive on page 134 3 Move the control frame and remove the screens airflow plates and protective covers from the drive See Move the Control Frame and Remove the Screens Airflow Plates and Protective Covers on page 135 4 Remove the main fan assembly from the drive See Remove the Main Fan Assembly on page 143 5 Remove the DC fan power supply as...

Page 154: ...etrofit Kits Cat No Item Description Qty Kit Contents SK Y1 DCFANRETROFIT F13 For DC input frame 13 drives 1 DC fan assembly 3 2 DC fan power supply assembly 3 3 Wire harness 1 4 M5 x 10 mm POZIDRIV screws 24 5 Wire ties 9 SK H1 DCFANRETROFIT F13A For AC input frame 13 drives w 2 NFEs 1 DC fan assembly 5 2 DC fan power supply assembly 1 3 3 DC fan power supply assembly 2 2 4 DC fan power supply wi...

Page 155: ... 10 mm hexagonal socket screws 36 9 Wire ties 27 10 Wire tie mounting clamps 3 13 Wire harness for 3 NFE 1 SK H1 DCFANRETROFIT F14A AC input frame 14 drives w 3 NFEs 1 DC fan assembly 9 2 DC fan power supply assembly 1 6 3 DC fan power supply assembly 2 3 4 DC fan power supply wire harness 1 3 5 DC fan power supply wire harness 2 3 6 DC chaining wire harness 2 7 M4 x 8 mm POZIDRIV screws 6 8 M5 x ...

Page 156: ...ETROFIT F14B For AC input frame 14 drives w 4 NFEs 1 DC fan assembly 10 2 DC fan power supply assembly 1 6 3 DC fan power supply assembly 2 4 4 DC fan power supply wire harness 1 4 5 DC fan power supply wire harness 2 4 6 DC chaining wire harness 2 7 M4 x 8 mm POZIDRIV screws 8 8 M5 x 10 mm hexagonal socket screws 64 9 Wire ties 42 10 Wire tie mounting clamps 4 12 Wire harness for 2 NFE 2 SK H1 DC...

Page 157: ...trol Frame and Remove the Screens Airflow Plates and Protective Covers on page 135 4 Remove the main fan assemblies See Remove the Main Fan Assembly on page 143 5 Remove the AC fan inverter assemblies See Removing the Main AC or DC Fan Power Supply Assemblies Inverter Only on page 145 6 For AC input standalone drives only remove the wire harness that connects the fans on the converter and inverter...

Page 158: ...d 700S Drives Frame 13 Procedures 7 Install the DC fan inverter assemblies in the drive using the four M5 x10 mm POZIDRIV screws supplied in the kit See Removing the Main AC or DC Fan Power Supply Assemblies Inverter Only on page 145 for details 7 PZ2 3 5 N m 31 0 lb in Inverter section shown ...

Page 159: ...Secure the power supply cables to the inside of the main fan housings using the cable ties supplied with the kit 9 Route the fan inverter power supply cables through the hole in the drive chassis and insert them into the connector support bracket on the front of the drive chassis 8 Inverter section shown 9 Inverter section shown ...

Page 160: ...wire DC is connected to the right side terminals 11 Install the new main DC fans in the fan housings using the M5 x 10 mm POZIDRIV screws supplied in the kit Final torque is 3 5 N m 31 0 lb in See Remove the Main Fan Assembly on page 143 for details 12 Install the M8 x 20 mm hexagonal socket screws supplied with the kit in the front of the main fans Final torque is 20 N m 177 lb in 13 Connect the ...

Page 161: ...he DC power supply and DC connectors from the DC fan inverter circuit board Note the phase markings U V W on the DC chaining wire connectors and verify they are connected to the correct phase 15 Remove the backing from the drive modification label and attach the label to the front of a main fan housing 16 Write DC fan retrofit and the installation date on the label 14 Inverter section shown ...

Page 162: ...er from the Drive on page 134 3 Move the control frame and remove the screens airflow plates and protective covers See Move the Control Frame and Remove the Screens Airflow Plates and Protective Covers on page 135 4 Remove the main fan assemblies See Remove the Main Fan Assembly on page 143 5 Disconnect the converter X1 wire harness 1 from the connector and fan extension wire 2 on the sheetmetal c...

Page 163: ...ain AC Fan Inverter Capacitor SK H1 FANCAP F1314 Removal and Installation Converter Only on page 169 9 Remove the M4 x 8 mm grounding screw 1 in image for the AC fan power conditioning capacitors from the drive 10 Remove the M4 x 25 mm mounting screw 2 in image for the AC fan power conditioning capacitors from the drive 11 Remove the M8 x 70 mm transformer mounting screw 3 in image 12 Remove the f...

Page 164: ...y Circuit Board SK H1 DCFANBD1 Removal and Installation Converter Only on page 148 for details 14 Install the main DC fans in the drive using the four M5 x 10 mm POZIDRIV screws 15 Install the M8 x 20 mm hexagonal socket screws supplied with the kit in front of the main fans 16 Connect the fan power supply cables to the connectors on the support brackets on the drive chassis 13 PZ2 3 5 N m 31 0 lb...

Page 165: ...00H and 700S Drives Frame 13 Procedures Chapter 5 FanWireHarnessInstallation 17 Modify the fan wire harness a Connect the 300 mm DC wire between connectors X1 pin 15 and connector X8 pin 5 b Connect the loose end of the 210 mm DC wire to connector X1 pin 1 X201 X8 X3 X6 X1 a b ...

Page 166: ... DC fan extension wire to the fan supply cable d Use two of the cable ties supplied in the retrofit kit to tie together the excess 48VDC fan extension wire e Connect the fan control FB wire to connector X3 on the fan power supply f Connect the fan control wire to connector X8 on the fan power supply g Use two of the cable ties supplied in the retrofit kit to tie together the wire harness and fan p...

Page 167: ... the cover 22 Modify and connect the converter external wire connections with the wires provided in the retrofit kit a Place the converter wire harness connector X1 on the sheet cover connector holder b Connect the wire harness DC wire on the fuse base c Use two of the cable ties supplied in the retrofit kit to tie together the wire harness and DC wires 4 4 PZ1 0 9 N m 8 0 lb in Series A converter...

Page 168: ...r units 24 Connect the additional DC wire on the new fan wire harness supplied in the retrofit kit to the DC terminal on the inverter fuse base and secure the wire using two tie wraps 25 Remove the backing from the drive modification label and attach the label to the front of a main fan housing 26 Write DC fan retrofit and the installation date on the label 23 Converter Section Inverter Section 24...

Page 169: ...a x 57 mm tall If a series A capacitor is currently installed always replace it with the new series B capacitor Follow these steps to remove and replace the main AC fan inverter capacitor 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 134 3 Move the control frame and remove the screens airflow plates and protective covers from the ...

Page 170: ...ue and Brown 7 Unscrew the capacitor from the drive frame and remove the capacitor 8 Install the main fan capacitor in the reverse order of removal Main AC Fan Inverter Capacitor SK H1 FANCAP F1314 Removal and Installation Inverter Only Note The AC fan inverter capacitor replacement kit SK H1 FANCAP F1314 contains a new sheet metal bracket hardware and fasteners and a series B capacitor identified...

Page 171: ...e drive See Move the Control Frame and Remove the Screens Airflow Plates and Protective Covers on page 135 4 Remove the main fan assemblies from the drive See Remove the Main Fan Assembly on page 143 5 Remove the AC fan inverter assemblies from the drive See Removing the Main AC or DC Fan Power Supply Assemblies Inverter Only on page 145 6 Cut the cable ties that secure the fan capacitor wires to ...

Page 172: ...14 Chapter 5 PowerFlex 700H and 700S Drives Frame 13 Procedures 7 Disconnect the fan capacitor wires from the connectors marked Brown and Blue 8 Unscrew and remove the existing fan capacitor from the inverter assembly 7 AC fan inverter shown AC fan inverter shown ...

Page 173: ...M8 x 12 mm hexagonal socket screw and spring washer provided Tightening torque is 20 N m 178 lb in Note Secure the capacitor in a position that allows the maximum amount of clearance possible between the transformer and capacitor ensuring that they DO NOT touch 11 Connect the new fan capacitor wires to the connectors marked Brown and Blue 12 Secure the fan capacitor wires to the fan wire bundle us...

Page 174: ...e the sheet metal housing for the fan must be reused To identify which fan is installed in your drive see Fan Inverter System Block Diagrams on page 257 1 Review the General Precautions on page 17 2 Remove power from the drive See Remove Power from the Drive on page 134 3 Move the control frame and remove the screens airflow plates and protective covers from the drive See Move the Control Frame an...

Page 175: ...fan 6 For AC fan systems install the new fan assembly in the reverse order of removal For DC fan systems complete the remaining steps Connection wires Resistance 5 Black Brown 62 Ω Brown Blue 36 Ω Blue Black 27 Ω Green chassis 0 Ω Connection wires Resistance 5 Red Blue Ω Red White Ω White Yellow Ω Blue White Ω Blue Motor Pin 4 Green Yellow Ground Pin 1 Brown Motor Pin 3 Black Motor Pin 2 AC Fan Pi...

Page 176: ...9B EN P August 2014 Chapter 5 PowerFlex 700H and 700S Drives Frame 13 Procedures 7 Remove the three M4 x 8 mm POZIDRIV screws from the front of the fan housing 8 Remove the two M4 x 5 mm flathead POZIDRIV screws and remove the sheet metal side 7 8 ...

Page 177: ... reuse Note The Main AC and DC fans have different mounting hardware and hole dimensions The AC fan uses four M4 x 8 mm screws that are spaced 40 mm apart on the housing The DC fan uses four M5 x 10 mm screws that are spaced 65 mm apart on the housing Based on the manufacturing date the sheet metal housing was fabricated for either an AC fan a DC fan or both 12 Install the new main DC fan in rever...

Page 178: ...178 Rockwell Automation PublicationPFLEX IN029B EN P August 2014 Chapter 5 PowerFlex 700H and 700S Drives Frame 13 Procedures Notes ...

Page 179: ...ves greater than 1500A there are 4 converter sections and 6 inverter sections Frame 14 Fan System Spare Parts Frame 14 PowerFlex 700H and PowerFlex 700S drives are essentially two parallel frame13 drives Therefore the spare parts are identical to the frame 13 with the exception that there are twice as many parts required The procedures for replacing frame 14 fan system components are also the same...

Page 180: ... 24 20 PP1096 Cooling fan for ASIC board assembly All 2 Sinwan SD5012PT 24H 4 600 690 20 FI13301 AC fan inverter assembly includes circuit board fuses capacitors isolation transformer and mounting hardware DC Input 6 AC 1500 Amp 9 AC 1900 2250 Amp 10 20 VB00299 AC fan inverter circuit board 1 DC Input 6 AC 1500 Amp 9 AC 1900 2250 Amp 10 20 FI13300 Main AC fan assembly DC Input 6 AC 1500 Amp 9 AC 1...

Page 181: ...Amp 2 20 PP1096 Cooling fan for ASIC board assembly All 2 Sinwan SD5012PT 24H 5 600 690 SK H1 DCFANBD1 1 Main DC fan power supply circuit board DC Input 6 AC 1500 Amp 9 AC 1900 2250 Amp 10 SK Y1 DCFAN1 Main DC fan assembly DC Input 6 AC 1500 Amp 9 AC 1900 2250 Amp 10 20 PP20300 Fuse holder for fan system fuses DC Input 6 Ferraz Shawmut 30322 AC 1500 Amp 9 AC 1900 2250 Amp 10 20 PP20202 Fuse for fa...

Page 182: ...ctions while the DC input drives have only parallel inverters The schematics will change based on this hardware configuration Table 4 provides a list of system diagrams applicable to each drive configuration Table 4 Drive Configurations and Applicable System Diagrams Please see Frame 13 AFE Schematic Diagrams on page 125 for more information Drive Input Voltage Drive Hardware Section AC Fan System...

Page 183: ...nverter Sections NFE 1 U T1 V T2 W T3 L1 L2 L3 X1 B B NFE 2 L1 L2 L3 X1 B B NFE 3 L1 L2 L3 X1 B B NFE 4 L1 L2 L3 X1 B B FI13 PM1 X3 X8 B B U T1 V T2 W T3 FI13 PM2 X3 X8 B B X11 on PM1 ASIC Board X11 on PM2 ASIC Board Power Structure 1 typical left side Power Structure 2 typical right side Converter Section Contains 3 or 4 modules based on the current rating Inverter Section ...

Page 184: ... and 700S Drives Frame 14 Procedures Figure 19 Frame 14 DC Input Drive Inverter Sections U T1 V T2 W T3 FI13 PM1 X3 X8 B B U T1 V T2 W T3 FI13 PM2 X3 X8 B B X11 on PM1 ASIC Board Power Structure 1 typical left side Power Structure 2 typical right side Inverter Section X11 on PM2 ASIC Board ...

Page 185: ...erter Fuses 20 PP20202 and Fuse Holder 20 PP20300 Removal and Installation 197 Remove the Main Fan Assembly 198 AC Fan Inverter Assembly 20 FI13301 Removal and Installation 199 Main AC Fan Inverter Circuit Board 20 VB00299 Removal and Installation 201 MainDCFanPowerSupplyCircuitBoard SK H1 DCFANBD1 RemovalandInstallation 202 AC to DC Main Fan System SK Y1 DCFANRETROFIT F10 Retrofit 203 Main AC Fan...

Page 186: ...his configuration is repackaged into a cabinet structure that is consistent with the system The IP20 NEMA UL Type 1 MCC enclosure finger safe and dripping water protection The IP21 NEMA UL Type 1 Rittal enclosure finger safe and no water protection The spare parts listed in this manual fit any of the cabinet types listed above The procedures contained in this document pertain to each drive configu...

Page 187: ...bly 1 20 FI13301 AC fan inverter assembly includes PCB fuses capacitor isolation transformer and mounting hardware 1 20 PP1096 Cooling fan for ASIC board assembly 1 Sinwan SD5012PT 24H 1 1 The partmay not contain wires connectors ormounting hardware when bought directly from vendor 20 PP20202 2 Fuse for fan system 2 Ferraz Shawmut ATQ8 2 2 The factory default fuses are Ferraz Shawmut ATQ8 8 A fuse...

Page 188: ...awmut 30322 20 PP20202 Fuse for fan system 2 Ferraz Shawmut ATQ8 4 4 The factory default fuses are Ferraz Shawmut ATQ8 8 A fuses Older drives may contain Bussman 6 A fuses SK Y1 DCFANRETROFIT F10 Retrofit fan kit for frame 10 AFE 1 20 PP1096 Cooling fan for ASIC board assembly 1 Sinwan SD5012PT 24H 5 5 The partmay not contain wires connectors ormounting hardware when bought directly from vendor LC...

Page 189: ... Frequency Converter Off S1 1 Off S1 2 On S1 3 Off S1 4 S1 Setup Switch F1 From Power Board X10 From ASIC Board X11 M1 Brown Black Blue Main Fan M Black 6 Black 5 Black 4 Black 3 Black 2 Black 1 X4 X5 2 2 µf 10 MΩ 2 2 µf 10 MΩ Yellow Green 7 µf X3 To X51 on the LCL Filter Fan Power Supply Circuit Board Switch Setting To indicate the following S1 Off 50 Hz fan motor frequency S2 Off 220 V AC motor ...

Page 190: ...00AFE Drive Frame 10 Procedures Figure 22 Frame 10 AFE Power Structure DC Fan System Wiring Schematic Diagram To ASIC Circuit Board X11 Fan Control 3 4 Main DC Fan Fan Module DC DC Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 ToX51ontheLCLFilter Power Supply Circuit Board ...

Page 191: ... Fuse X52 4 pin Pin 1 KLIXON Pin 4 KLIXON X1 Fan KLIXON X1 Fan DC Power Supply PCB AFE Power Structure X3 on AFE Power Structure DC Bus X3 LCL Filter X8 X53 3 pin Pin DC supply Pin DC supply X2 X51 4 pin Pin 4 16 5V Pin 3 fan control Pin 2 DC Pin 1 fan alarm Fuse X52 4 pin Pin 1 KLIXON Pin 4 KLIXON X1 Fan KLIXON X81 Fan DC Power Supply PCB AFE Power Structure DC Bus X3 on AFE Power Structure Pin 1...

Page 192: ...199 20 VB00299 Main AC fan inverter circuit board 201 SK H1 DCFANBD1 Main DC fan powersupply circuitboard 202 SK Y1 DCFANRETROFIT F10 AC to DC fan system retrofit kit 203 SK H1 FANCAPF1314 Main AC fan inverter capacitor 207 20 FI13300 Main AC fan assembly 210 SK Y1 DCFAN1 Main DC fan assembly 210 ATTENTION Toavoidanelectricshockhazard verifythatthevoltageonthebus capacitorshasdischarged completely...

Page 193: ...n system components on the power structure Follow these steps to move the control frame and remove the airflow plate and protective covers and screens 1 Review the General Precautions on page 17 2 Remove power from the AFE See Remove Power from the AFE on page 192 3 If moving the control frame from a DC input drive with pre charge interlock disconnect the wiring between terminals blocks X9 and X15...

Page 194: ...ll Automation PublicationPFLEX IN029B EN P August 2014 Chapter 7 PowerFlex 700AFE Drive Frame 10 Procedures 5 Remove the screws that secure the protective screens to the AFE enclosure Then remove the screens 6 6 ...

Page 195: ...Remove the four T8 hexalobular screws which secure the air flow plate to the AFE and slide the air flow plate off the AFE 7 Remove the four M5 x 16 mm POZIDRIV screws that secure the protective front cover and terminal cover to the power structure and remove the covers 7 7 T20 3 0 N m 27 lb in 8 8 PZ2 1 65 N m 14 6 lb in ...

Page 196: ...plicable move the control frame and remove the screens airflow plate and protective covers from the AFE See Move the Control Frame and Remove the Screens Airflow Plate and Protective Covers IP21 Rittal Enclosure on page 193 4 Remove the DC bus connection from the ASIC cover Note When reinstalling the ASIC board verify that the DC bus connection has been made 5 Remove the four screws that secure th...

Page 197: ...Move the control frame and remove the screens airflow plate and protective covers from the AFE See Move the Control Frame and Remove the Screens Airflow Plate and Protective Covers IP21 Rittal Enclosure on page 193 4 Remove the fuses from the fuse holder 5 Check the fuses See Checking the Fan Inverter Fuses on page 263 6 Disconnect the fan power supply wires from the top and bottom of the fuse hol...

Page 198: ...the Control Frame and Remove the Screens Airflow Plate and Protective Covers IP21 Rittal Enclosure on page 193 4 Disconnect the main fan supply connector from the connector on the support bracket and pull the connector out of the sheet metal support bracket 5 Remove the M8 x 20 mm hexagonal socket screw from the chassis in front of the fan housing in order to allow room for the fan housing to be r...

Page 199: ...move and replace an AC fan inverter assembly 1 Review the General Precautions on page 17 2 Remove power from the AFE See Remove Power from the AFE on page 192 3 If applicable move the control frame and remove the screens airflow plate and protective covers from the AFE See Move the Control Frame and Remove the Screens Airflow Plate and Protective Covers IP21 Rittal Enclosure on page 193 4 Remove t...

Page 200: ...nverter to the power structure 8 Remove the cable ties that secure the cables with black insulation to the power structure frame and remove the fan inverter assembly from the power structure 9 Install the AC fan inverter assembly in the reverse order of removal Fan Inverter 7 Wire harness is attachedtoframewith two cable ties PZ2 3 5 N m 31 0 lb in Inverter Sections Remove cable ties ...

Page 201: ...he control frame and remove the screens airflow plate and protective covers from the AFE See Move the Control Frame and Remove the Screens Airflow Plate and Protective Covers IP21 Rittal Enclosure on page 193 4 Remove the main fan assembly from the AFE See Remove the Main Fan Assembly on page 198 5 Remove the AC fan inverter assembly from the AFE See AC Fan Inverter Assembly 20 FI13301 Removal and...

Page 202: ...e Energy related Products Fan Efficiency Directive on page 8 for guidelines on replacing an existing fan system with a new DC fan system Follow these steps to remove and replace an existing fan system with a new DC fan system 1 Review the General Precautions on page 17 2 Remove power from the AFE See Remove Power from the AFE on page 192 3 If applicable move the control frame and remove the screen...

Page 203: ...the DC fan power supply circuit board and heatsink to the assembly carriage Then carefully remove the DC fan power supply board from the assembly 8 Install the DC fan power supply circuit board in the reverse order of removal ACtoDCMainFanSystem SK Y1 DCFANRETROFIT F10 Retrofit There are three different AC to DC fan retrofit kits available The correct kit is identified in Figure 24 Figure 24 SK Y1...

Page 204: ...nd protective covers See Move the Control Frame and Remove the Screens Airflow Plate and Protective Covers IP21 Rittal Enclosure on page 193 4 Remove the main fan assemblies See Remove the Main Fan Assembly on page 198 5 Remove the fan inverter assemblies See AC Fan Inverter Assembly 20 FI13301 Removal and Installation on page 199 6 Install the DC fan power supply assemblies in the drive using the...

Page 205: ...Secure the power supply cables to the inside of the main fan housings using the cable ties supplied with the kit 8 Route the fan power supply cables through the hole in the drive chassis and insert them into the connector support bracket on the front of the drive chassis 7 Inverter section shown 8 Inverter section shown ...

Page 206: ...the black wire DC is connected to the right side terminals 10 Install the new main DC fans in the fan housings using the M5 x 10 mm POZIDRIV screws supplied in the kit Final torque is 3 5 N m 31 0 lb in See Remove the Main Fan Assembly on page 198 for details 11 Remove the backing from the drive modification label and attach the label to the front of a main fan housing 12 Write DC fan retrofit and...

Page 207: ...it with the new series B capacitor Follow these steps to remove and replace the main AC fan inverter capacitor 1 Review the General Precautions on page 17 2 Remove power from the AFE See Remove Power from the AFE on page 192 3 If applicable move the control frame and remove the screens airflow plate and protective covers from the AFE See Move the Control Frame and Remove the Screens Airflow Plate ...

Page 208: ... the AFE See AC Fan Inverter Assembly 20 FI13301 Removal and Installation on page 199 6 Cut the cable ties that secure the fan capacitor wires to the wire bundle 7 Disconnect the fan capacitor wires from the connectors marked Brown and Blue 8 Unscrew and remove the existing fan capacitor from the inverter assembly 7 AC fan inverter shown AC fan inverter shown ...

Page 209: ... 12 mm hexagonal socket screw and spring washer provided Tightening torque is 20 N m 178 lb in Note Secure the capacitor in a position that allows the maximum amount of clearance possible between the transformer and capacitor ensuring that they DO NOT touch 11 Connect the new fan capacitor wires to the connectors marked Brown and Blue 12 Secure the fan capacitor wires to the fan wire bundle using ...

Page 210: ...he sheet metal housing for the fan must be reused To identify which fan is installed in your drive see Fan Inverter System Block Diagrams on page 257 1 Review the General Precautions on page 17 2 Remove power from the AFE See Remove Power from the AFE on page 192 3 If applicable move the control frame and remove the screens airflow plate and protective covers from the AFE See Move the Control Fram...

Page 211: ...r to those in this table replace the DC fan 6 For AC fan systems install the new fan assembly in the reverse order of removal For DC fan systems complete the remaining steps Connection wires Resistance 5 Black Brown 62 Ω Brown Blue 36 Ω Blue Black 27 Ω Green chassis 0 Ω Connection wires Resistance 5 Red Blue Ω Red White Ω White Yellow Ω Blue White Ω Blue Motor Pin 4 Green Yellow Ground Pin 1 Brown...

Page 212: ...IN029B EN P August 2014 Chapter 7 PowerFlex 700AFE Drive Frame 10 Procedures 7 Remove the three M4 x 8 mm POZIDRIV screws from the front of the fan housing 8 Remove the two M4 x 5 mm flathead POZIDRIV screws and remove the sheet metal side 7 8 ...

Page 213: ...ve the grommets from the holes in the sheet metal 11 Remove the four M5 x 10 POZIDRIV screws that secure the fan to the sheet metal housing and remove the fan Retain the sheet metal housing for reuse 12 Install the new main DC fan in reverse order Verify that the fan turns easily and does not make contact with the sheet metal housing or fan cable before installing the fan assembly in the drive 11 ...

Page 214: ... Precautions on page 17 2 Remove power from the AFE See Remove Power from the AFE on page 192 3 Remove the sixteen T25 Torx self tapping cover screws Cat No Part Description Page 20 PP20202 or SK Y1 F11 F10 Fuse for fan system 215 SK Y1 DCPS1 D460 DC fan power supply assembly 400 480V older version 215 SK Y1 DCPS1 F325 DC fan power supply assembly 600 690V older version 215 SK Y1 DCPS2 F10 DC fan ...

Page 215: ...er from the AFE on page 192 3 Install the LCL filter DC fan fuses in the reverse order of removal LCLFilterFanDCPowerSupply SK Y1 DCPS1 D460orSK Y1 DCPS1 F325 Removaland Installation Note It is not necessary to remove the fan assembly from the LCL filter but by doing so it may be easier to replace the fan DC power supply circuit board The LCL filter fan DC power supply wiring diagram is shown in F...

Page 216: ... Filter X8 X53 3 pin Pin DC supply Pin DC supply X4 X51 4 pin Pin 5 16 5V Pin 3 fan control Pin 1 fan alarm Fuse X52 4 pin Pin 1 KLIXON Pin 4 KLIXON X1 Fan KLIXON X1 Fan DC Power Supply PCB AFE Power Structure X3 on AFE Power Structure DC Bus IMPORTANT Beforedoinganywork disconnecttheAFEpowerstructurefromtheACsupply and wait until the fan stops and the indicators on the keypad turn off If a keypad...

Page 217: ...0 Procedures Chapter 7 4 Remove the two M4 x 10 mm POZIDRIV screws that secure the cover to the chassis and remove the cover 5 Disconnect the cables from connectors X1 X3 X4 and X8 Note Image for SK Y1 DCPS1 D460 or SK Y1 DCPS1 F325 X8 X3 X1 X4 Note Image for SK Y1 DCPS1 D460 or SK Y1 DCPS1 F325 ...

Page 218: ... August 2014 Chapter 7 PowerFlex 700AFE Drive Frame 10 Procedures 6 Remove the six fasteners that secure the DC power supply 7 Install the LCL filter fan DC power supply in the reverse order of removal Note Images for SK Y1 DCPS1 D460 or SK Y1 DCPS1 F325 ...

Page 219: ...shown in Figure 26 The diagram shows the connections to the AFE power structure and DC bus Figure 26 LCL Filter Fan DC Power Supply SK Y1 DCPS2 F10 Wiring Diagram X3 LCL Filter X8 X53 3 pin Pin DC supply Pin DC supply X2 X51 4 pin Pin 4 16 5V Pin 3 fan control Pin 2 DC Pin 1 fan alarm Fuse X52 4 pin Pin 1 KLIXON Pin 4 KLIXON X1 Fan KLIXON X81 Fan DC Power Supply PCB AFE Power Structure DC Bus X3 o...

Page 220: ...erFlex 700AFE Drive Frame 10 Procedures 1 Review the General Precautions on page 17 2 Remove power from the AFE See Remove Power from the AFE on page 192 3 Remove the LCL filter fan See LCL Filter Fan Assembly Removal and Installation on page 229 X51 X53 Image for SK Y1 DCPS2 F10 ...

Page 221: ...blicationPFLEX IN029B EN P August 2014 221 PowerFlex 700AFE Drive Frame 10 Procedures Chapter 7 4 Remove the two M4 x 8 mm POZIDRIV screws that secure the cover to the chassis and remove the cover 4 Image for SK Y1 DCPS2 F10 ...

Page 222: ...dures 5 Remove the three M5 x 10 mm hexalobular screws that secure the assembly to the fan housing Then shift the assembly sufficient to remove the X51 and X53 connectors 6 Disconnect the X1 fan cable from the connector on the fan sheet metal housing X51 X53 Image for SK Y1 DCPS2 F10 5 6 Image for SK Y1 DCPS2 F10 ...

Page 223: ...rom the sheet metal fan housing 8 Disconnect the cable from X51 on the LCL filter fan power supply and X3 on the AFE power unit and discard the cable 9 Connect the new cable to X51 on the LCL filter fan power supply and X3 on the AFE power module The extra flying lead connects to the DC bus terminal as shown here 7 Image for SK Y1 DCPS2 F10 ...

Page 224: ...all the new LCL filter fan power supply using the one M4 x 12 mm and two M5 x 10 mm screws provided 11 Connect the X51 and X53 connectors to the fan power supply circuit board 12 Insert the X1 fan cable connector into the receptacle on the fan sheet metal housing X51 X53 Image for SK Y1 DCPS2 F10 12 Image for SK Y1 DCPS2 F10 ...

Page 225: ...ter already has a new fan power supply kit SK Y1 DCPS2 F10 installed the DC fan power supply circuit board SK H1 DCFANBD1 can be installed as a replacement part Note See Appendix B on page 277 to verify the version of the DC fan power supply circuit board installed in your system 1 Review the General Precautions on page 17 2 Remove power from the AFE See Remove Power from the AFE on page 192 3 Rem...

Page 226: ...erFlex 700AFE Drive Frame 10 Procedures 4 Remove the two M4 x 8 mm POZIDRIV screws that secure the cover to the chassis and remove the cover 5 Disconnect the cables from connectors X2 X3 and X8 at the top of the board 4 Image for SK Y1 DCPS2 F10 X8 X2 X3 Image for SK H1 DCFANBD1 ...

Page 227: ...l Automation PublicationPFLEX IN029B EN P August 2014 227 PowerFlex 700AFE Drive Frame 10 Procedures Chapter 7 6 Disconnect the cable from connector X81 at the bottom of the board X81 Image for SK H1 DCFANBD1 ...

Page 228: ... the M4 x 8 mm hexalobular screw that secures the DC power supply circuit board to the sheet metal support 8 Remove the four fasteners that secure the DC power supply board to the chassis and remove the board 9 Install the new DC fan power supply circuit board in the reverse order of removal 7 Image for SK H1 DCFANBD1 8 8 8 8 ...

Page 229: ...ion Note The fan replacement kit only contains the fan motor and impeller assembly Therefore the sheet metal housing for the fan must be reused 1 Review the General Precautions on page 17 2 Remove power from the AFE See Remove Power from the AFE on page 192 3 Disconnect terminal blocks X51 and X53 X51 X53 Note Image for SK Y1 DCPS1 D460 or SK Y1 DCPS1 F325 ...

Page 230: ...n page 219 8 Install the LCL filter fan assembly in the reverse order of removal LCLFilterMainDCFan SK Y1 DCFAN1 AssemblyRemovalandInstallation Follow these steps to measure the resistance between the main fan supply wires and remove and replace the main fan if necessary Note The DC fan replacement kit only contains the fan motor and impeller assembly Therefore the sheet metal housing for the fan ...

Page 231: ...rom the AFE See LCL Filter Fan Assembly Removal and Installation on page 229 4 Disconnect the X1 connector from the sheet metal housing 5 Measure the resistance between the fan supply wires DC Fan If the measurements are not similar to those in this table replace the DC fan Connection wires Resistance 5 Red Blue Ω Red White Ω White Yellow Ω Blue White Ω 4 Image for SK Y1 DCPS2 F10 White Tach Outpu...

Page 232: ...014 Chapter 7 PowerFlex 700AFE Drive Frame 10 Procedures 6 Remove the M5 x 16 mm hexalobular screw that secures the fan power cable to the fan housing 7 Remove the grommets from the holes in the sheet metal 6 Image for SK Y1 DCPS2 F10 7 Image for SK Y1 DCPS2 F10 ...

Page 233: ...and hole dimensions The AC fan uses four M4 x 8 mm screws that are spaced 40 mm apart on the housing The DC fan uses four M5 x 10 mm screws that are spaced 65 mm apart on the housing Based on the manufacturing date the sheet metal housing was fabricated for either an AC fan a DC fan or both 9 Install the new main DC fan in reverse order Verify that the fan turns easily and does not make contact wi...

Page 234: ...234 Rockwell Automation PublicationPFLEX IN029B EN P August 2014 Chapter 7 PowerFlex 700AFE Drive Frame 10 Procedures Notes ...

Page 235: ...ed for Frame 13 AFE Fan System Repairs 239 Frame 13 AFE Schematic Diagrams 240 Frame 13 AFE Fan System Replacement Procedures 243 Power Structure Section 243 LCL Filter Section 243 Removing the LCL Filter Protective Cover 244 LCL Filter DC Fan Fuses 20 PP20202 Removal and Installation 245 LCL Filter DC Fan Power Supply SK Y1 DCPS1 D1K3 or SK Y1 DCPS1 E1K0 Removal and Installation 245 LCL Filter Fa...

Page 236: ...a LCL filter section and a converter section The converter section is an inverter section designed to either supply DC bus voltage or regenerate power back to the AC line For clarity of instructions the converter will be referred to as a power structure throughout this chapter Figure 27 Frame 13 AFE System IP21 NEMA UL Type 1 Rittal Cabinet LCL Filter DC Fan Fuses Inverter Fan Fuses ...

Page 237: ...binet structure that is consistent with the system The IP20 NEMA UL Type 1 MCC enclosure finger safe and dripping water protection The IP21 NEMA UL Type 1 Rittal enclosure finger safe and no water protection The spare parts listed in this manual fit any of the cabinet types listed above The procedures contained in this document pertain to each drive configuration listed above Only the enclosure an...

Page 238: ...ly 3 20 FI13301 Fan inverter assembly includes PCB fuses capacitor isolation transformer and mounting hardware 3 20 PP1096 Cooling fan for ASIC board assembly 1 Sinwan SD5012PT 24H 1 1 The partmay not contain wires connectors ormounting hardware when bought directly from vendor 20 PP20202 2 Fuse for fan system 2 Ferraz Shawmut ATQ8 2 2 The factory default fuses are Ferraz Shawmut ATQ8 8 A fuses Ol...

Page 239: ...202 2 Fuse for fan system 2 Ferraz Shawmut ATQ8 4 4 The factory default fuses are Ferraz Shawmut ATQ8 8 A fuses Older drives may contain Bussman 6 A fuses SK Y1 DCFANRETROFIT F13 Retrofit fan kit for frame 13 AFE 1 20 PP1096 Cooling fan for ASIC board assembly 1 Sinwan SD5012PT 24H 5 5 The partmay not contain wires connectors ormounting hardware when bought directly from vendor LCL Filter SK Y1 DC...

Page 240: ... 50 Hz BLK 4 X3 V1 U1 X8 BLK 1 X5 1 BLK 2 X4 1 6 2 2uf 300VAC 3 BLK 2 2uf 300VAC 5 BLK 4 BLK 7uf 10Meg 10Meg BLK 4 X3 V1 U1 X8 BLK 1 X5 1 BLK 2 X4 1 6 2 2uf 300VAC 3 BLK 2 2uf 300VAC 5 BLK 4 BLK 7uf 10Meg 10Meg X2 3 X2 1 F1 Fan Frequency Converter DC AC F2 S1 1 S1 2 S1 3 S1 4 Off On S1 Setup Switch Off Off X2 3 X2 1 F1 Fan Frequency Converter DC AC F2 S1 1 S1 2 S1 3 S1 4 Off On S1 Setup Switch Off...

Page 241: ...IC Circuit Board X11 Fan Control 4 Main DC Fan V Phase Fan Module DC DC Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 4 Main DC Fan W Phase Fan Module Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 4 Main DC Fan U Phase Fan Module Isolated 48 VDC Power Supply Circuit Board X81 X8 X3 X82 X2 To X51 on the LCL Filter Fan Power Supply Circuit Board ...

Page 242: ... Fuse X52 4 pin Pin 1 KLIXON Pin 4 KLIXON X1 Fan KLIXON X1 Fan DC Power Supply PCB AFE Power Structure X3 on AFE Power Structure DC Bus X3 LCL Filter X8 X53 3 pin Pin DC supply Pin DC supply X2 X51 4 pin Pin 4 16 5V Pin 3 fan control Pin 2 DC Pin 1 fan alarm Fuse X52 4 pin Pin 1 KLIXON Pin 4 KLIXON X1 Fan KLIXON X81 Fan DC Power Supply PCB AFE Power Structure DC Bus X3 on AFE Power Structure Pin 1...

Page 243: ...s of this publication as they become available Enter PFLEX IN029 in the Search field on the Rockwell Automation Literature Library at http www rockwellautomation com literature Cat No Part Description Page 20 PP01096 60 mm cooling fan for the ASIC board assembly 139 20 PP20202 Fuse for fan system 141 20 PP20300 Fuse holder for main fan system fuses 141 20 FR13301 Main AC fan inverter assembly 151 ...

Page 244: ...ng screws that secure the front bracket shown in Figure 32 This bracket holds the LCL filter in the cabinet 4 Remove the vented cover from the bottom of the LCL filter to access the DC fan fuses fan and DC power supply Figure 32 Removing LCL Filter Protective Covers 5 Install the protective covers in the reverse order of removal Front Bracket Front View IP21 NEMA UL Type 1 Rittal Cabinet Shown Sho...

Page 245: ...fan power supply circuit board The LCL filter DC fan power supply wiring diagram is shown in Figure 33 The diagram shows the connections to the AFE power structure and DC bus Figure 33 LCL Filter Fan DC Power Supply Wiring Diagram 1 Review the General Precautions on page 17 2 Remove power from the AFE See Remove Power from the AFE on page 192 IMPORTANT Use only ATQ8 Ferraz Shawmut fuses X3 X3 LCL ...

Page 246: ...Assembly Removal and Installation on page 252 5 Remove the two M4 x 10 mm POZIDRIV screws that secure the cover to the drive and remove the cover 6 Remove the connectors X1 X3 X4 and X8 7 Loosen the five nylon fasteners and remove the M4 x 8 mm hexalobular screw that secures the DC power supply to the fan housing and remove the DC power supply 8 Install the LCL filter fan DC power supply in the re...

Page 247: ...n assembly from the LCL filter but by doing so it may be easier to replace the fan DC power supply circuit board The LCL filter fan DC power supply wiring diagram is shown in Figure 34 The diagram shows the connections to the AFE power structure and DC bus Figure 34 LCL Filter Fan DC Power Supply SK Y1 DCPS2 F13 Wiring Diagram Newer Version X3 LCL Filter X8 X53 3 pin Pin DC supply Pin DC supply X2...

Page 248: ...nect the X51 and X53 connectors from the fan power supply 6 Remove the three M5 x 16 mm hexalobular screws that secure the assembly to the fan housing 7 Disconnect the cable from X51 on the LCL filter fan power supply and X3 on the AFE power unit and discard the cable IMPORTANT Beforedoinganywork disconnecttheAFEpowerstructurefromtheACsupply and wait until the fan stops and the indicators on the k...

Page 249: ...ded See step 6 for details 10 Connect the X51 and X53 connectors to the fan power supply circuit board 11 Insert the X1 fan cable connector into the receptacle on the fan sheet metal housing 12 If necessary install the LCL filter fan in the reverse order of removal LCLFilterFanDCPowerSupplyCircuitBoard SK H1 DCFANBD1 RemovalandInstallation If the LCL filter already has a new fan power supply kit S...

Page 250: ... that are spaced 65 mm apart on the bracket Based on the manufacturing date the sheet metal mounting bracket was fabricated for either an AC fan a DC fan or both 1 Review the General Precautions on page 17 2 Remove power from the AFE See Remove Power from the AFE on page 192 3 Remove the LCL filter fan assembly from the AFE See LCL Filter Fan Assembly Removal and Installation on page 252 4 Remove ...

Page 251: ...Procedures Chapter 8 7 Remove the M4 x 8 mm hexalobular screw that secures the circuit board to the sheet metal support 8 Remove the four fasteners that secure the DC power supply 9 Install the new DC fan power supply circuit board in the reverse order of removal 7 Image for SK H1 DCFANBD1 8 8 8 8 ...

Page 252: ...4 Disconnect terminal blocks X51 and X53 5 Remove the three M4 x 8 mm hexalobular screws that secure the fan housing to the chassis Note Support the front of the fan housing as you remove the screws 6 Lower the front of the fan assembly slide it forward to remove the alignment tabs on the sheet metal housing from the slots on the back wall and pull the fan assembly out of the chassis 7 Install the...

Page 253: ...C fan replacement kit only contains the fan motor and impeller assembly Therefore the sheet metal housing for the fan must be reused 1 Review the General Precautions on page 17 2 Remove power from the AFE See Remove Power from the AFE on page 192 3 Remove the LCL filter protective covers See Removing the LCL Filter Protective Cover in page 244 4 Remove the LCL filter fan assembly from the AFE See ...

Page 254: ...AC and DC fans have different mounting hardware and hole dimensions The AC fan uses four M4 x 8 mm screws that are spaced 40 mm apart on the housing The DC fan uses four M5 x 10 mm screws that are spaced 65 mm apart on the housing Based on the manufacturing date the sheet metal housing was fabricated for either an AC fan a DC fan or both 10 Install the new main DC fan in reverse order Verify that ...

Page 255: ...er specific fan system components require replacement Topic Page Fan Inverter System Block Diagrams 257 Checking the Fan Inverter Fuses 263 Checking the Main Fan Supply Wires 264 Checking the AC Fan Inverter Capacitor 265 Isolating a Faulty Fan Inverter 265 Checking the Main AC Fan Inverter Circuit Board Diagnostic LEDs 268 Testing the Main Fan Inverter Circuit Board Diagnostic LEDs 274 ...

Page 256: ...from improper usage of a multimeter and other test equipment The multimeter chassis may be at a potentially fatal voltage if not properly grounded If a multimeter is used to measure high voltage waveforms use appropriately rated differential voltage probes Be sure that they are set to the highest voltage scaling in order to achieve safe measurement resolution Verify that the multimeter chassis is ...

Page 257: ...PowerFlex 700H and PowerFlex 700S Drives The frame size for PowerFlex 700H and PowerFlex 700S drives determines the number of fan systems as listed here Frame 9 drives one fan system Frame 10 drives two fan systems Frame 11 drives three fan systems Frame 12 drives four fan systems where the topology is parallel frame 10 drives DC Bus Fuse ASIC Circuit Board Fan Inverter CircuitBoard Power Conditio...

Page 258: ...ems for standalone AC input drives Frame 14 drives six fan systems for common DC bus drives nine ten or twelve fan systems for standalone AC input drives This drive topology and fan system distribution is shown here DC Bus Fuse ASIC Circuit Board Fan Inverter CircuitBoard Fan X2 X8 X3 X11 Fan Inverter Circuit Board Fan X2 X8 X3 Fan Inverter CircuitBoard Fan X2 X8 X3 Frame 9 Frame 10 12 Frame 11 13...

Page 259: ... the PWM switching waveform onthe fan motor and fan capacitor N A Fan capacitor A 7 uF capacitor provides aphase shift that helps tostart the fan motor and then to regulate the fan motor speed N A Fan control circuit board Fan inverter circuit board where the DC input voltage in converted toa50HzPWMsignalforcontrollingthefanspeed Thiscircuitboard also contains the on off fan control signal and fan...

Page 260: ... PowerFlex 700H and 700S Diagnostic Procedures Figure 36 Frame 10 AFE Fan System Topology New Style DC Bus Fuse Fuse DC Fan ASIC Circuit Board X2 X8 X81 X3 X11 DC Fan DC Fan Power Supply Circuit Board LCL Filter Section DC Fan Power Supply Circuit Board powerStructure Section ...

Page 261: ...Capacitor AC Fan Power Conditioning Fan Capacitor AC Fan DC Bus ASIC Circuit Board Fuse Fuse DC Fan Power Conditioning Fan Capacitor AC Fan X11 X2 X8 X4 X5 X3 X2 X8 X4 X5 X3 AC Fan Inverter Circuit Board Power Structure Section X2 X8 X4 X5 X3 DC Fan Power SupplyCircuitBoard LCL Filter Section AC Fan Inverter Circuit Board Power Structure Section AC Fan Inverter Circuit Board Power Structure Sectio...

Page 262: ...ogy as the PowerFlex 700H 700S drives In addition there is a DC fan system in the LCL filter of each frame DC Bus ASIC Circuit Board Fuse Fuse DC Fan X11 X2 X8 X81 X3 X2 X8 X3 X2 X8 X3 DC Fan Power Supply Circuit Board Power Structure Section X81 X81 DC Fan DC Fan DC Fan DC Fan Power Supply Circuit Board LCL Filter Section DC Fan Power Supply Circuit Board Power Structure Section DC Fan Power Supp...

Page 263: ...ds less than 1 Ω across the metal ferrule ends If a higher reading is measured replace both fuses Checking Fuse Integrity with Power Applied Using a voltmeter measure the DC bus voltage across the fuse pair top and bottom to be the same voltage OR measure across the body of each fuse to have no voltage drop If a voltage drop exists across the fuse body replace both fuses IMPORTANT This procedure r...

Page 264: ...d measure the resistance between the fan supply wires AC Fan If the measurements are not similar to those in this table replace the AC fan DC Fan If the measurements are not similar to those in this table replace the DC fan Connection wires Resistance 5 Black Brown 62 Ω Brown Blue 36 Ω Blue Black 27 Ω Green chassis 0 Ω Connection wires Resistance 5 Red Blue Ω Red White Ω White Yellow Ω Blue White ...

Page 265: ...IC board to X8 on the left side fan inverter board X3 on the left side fan inverter to X8 on the right side fan inverter X3 on the right side fan inverter is terminated by a jumper For more details see Frame 10 AC Fan System Wiring Schematic Diagram on page 57 Frame 10 DC Fan System Wiring Schematic Diagram on page 58 Frame 12 AC Fan System Wiring Schematic Diagram on page 119 Frame 12 DC Fan Syst...

Page 266: ...R10845 Right Removal and Installation on page 67 For DC fan systems see Main DC Fan Power Supply System SK H1 DCFANBD1 Removal and Installation on page 69 IsolatetheRight sideFanInverter 8 Connect all cables in the original configuration 9 Disconnect the cable from connector X8 on the right side fan inverter 10 Disconnect the cable from connector X8 on the left side fan inverter and connect it to ...

Page 267: ...4 If the W phase fan inverter faults then replace the W phase fan inverter circuit board For AC fan systems see Main AC Fan Inverter Circuit Board 20 VB00299 and AC Output Transformer Assembly 20 FR10845 Removal and Installation on page 99 For DC fan systems see Main DC Fan Power Supply Circuit Board SK H1 DCFANBD1 Removal and Installation on page 101 5 Restore original wiring configuration Checki...

Page 268: ... 700AFE For more details see Frame 10 AFE Fan System Schematic Diagrams on page 189 Frame 13 AFE Schematic Diagrams on page 240 Additional procedures will be added to future revisions of this publication as they become available Enter PFLEX IN029 in the Search field on the Rockwell Automation Literature Library at http www rockwellautomation com literature Checking the Main AC Fan Inverter Circuit...

Page 269: ...wer supply and control circuitry DC Fan System LEDs Each DC fan inverter has a red yellow and green diagnostic LED The diagnostic LEDs can be used to determine whether the DC fan inverter board must be replaced These LEDs can only be viewed when the DC fan inverter board is removed from the drive and energized with an external power supply and control circuitry ATTENTION The inverter LEDs are only...

Page 270: ... P August 2014 Appendix A PowerFlex 700H and 700S Diagnostic Procedures Fan System Wiring and Operation The following block diagrams show the logic power fault detection control PWM gate drive and fan power sections of the AC and DC fan inverter boards ...

Page 271: ...PWM 2 Iso 18V 3 Next Fan Control 4 Next Fan Alarm X3 is also used as the loopback pin set When used as a loopback a jumper connects Pins 2 and 4 For PowerFlex 700H 700S drives the jumper occurs on Fr 9 First board Fr 10 12 Second board Fr 11 13 14 Third board For the PowerFlex 700AFE the jumper occurs on Fr 10 First board Fr 13 Third board SMPS 18V DC 5V 18V µP Temp Bov Ioc I 2 t Fault Detect NTC ...

Page 272: ...oard ASIC Circuit Board X11 X8 of Next Fan X8 X3 X2 1 DC 3 DC 1 Fan PWM 2 Iso 18V 3 Fan Control 4 Fan Alarm Fr9 5 DC Ref 6 Fan Alarm Fr8 7 Fan Alarm Fr10 OPTO OPTO OPTO 1 Next Fan PWM 2 Iso 18V 3 Next Fan Control 4 Next Fan Alarm dc dc Converter Fault Detect Driver X81 Blue X81 Red DC DC Isolation PWM Contoller DC 18V Ifdbk Temp OPTO _ X81 Yellow X81 White Rotate 48V DC Fan Vfdbk Control ...

Page 273: ...l Fan control The fan control signal originates on the ASIC circuit board and enters at X8 pin 3 and is optically isolated before being routed to the microprocessor When the fan control signal X8 pin 3 is pulled low the next fan control X3 pin 1 is also pulled low and the microprocessor fan control is enabled For the AC fan inverter system the fan control is defined by the switch states as a 50 Hz...

Page 274: ...herefore if the drive is used as the DC voltage source the board common reference will be at DC bus voltage and NOT at earth ground ATTENTION If the fan motor and plenum chamber is removed from the drive for this test it must be properly secured to the test fixture to ensure it will not move or shift when the fan is commanded to rotate ATTENTION Severe injury or death can result from electrical sh...

Page 275: ...V DC source 5 Evaluate the AC fan inverter circuit board in each of the switch configurations and view the LED status and fan rotation against the states listed in Table 5 If the LED status and fan rotation is NOT consistent with the table the circuit board is not functioning and must be replaced If the LED status and fan rotation agrees with the table the circuit board should be ok and can be use...

Page 276: ...er circuit board in each of the switch configurations and view the LED status and fan rotation against the states in Table 6 If the LED status and fan rotation is NOT consistent with the table the circuit board is not functioning and must be replaced If the LED status and fan rotation agrees with the table the circuit board should be ok and can be used or further evaluated Table 6 DC Fan System LE...

Page 277: ...E systems Spare Part Kit Contents The following table describes and shows the contents of each available fan system spare part kit For the number of kits to purchase see the fan system spare part tables in the chapter corresponding with your drive frame size Frame 9 Fan System Spare Parts on page 20 Frame 10 Fan System Spare Parts on page 56 Frame 11 Fan System Spare Parts on page 88 Frame 12 Fan ...

Page 278: ...s Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated 20 PP01049 50 mm Cooling fan for fan inverter 9 20 PP01068 80 mm x 80 mm x 32 mm internal stirring fan assembly 9 20 PP01096 60 mm internal fan for ASIC board 10 11 12 13 14 10 AFE Power Strctr 13 AFE Power Strctr ...

Page 279: ... 14 10 AFE LCL Power Strctr 13 AFE LCL Power Strctr 20 PP20300 Fuse holder for main fan system fuses 9 10 11 12 13 14 10 AFE LCL Power Strctr 13 AFE LCL Power Strctr 20 VB00299 AC fan inverter frames 9 12 9 10 11 12 13 14 10 AFE Power Strctr 13 AFE Power Strctr Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated ...

Page 280: ...0 PP01080 230 W main AC fan assembly 9 10 11 12 20 PP09055 Output transformer for AC fan inverter 9 SK H1 DCFANBD1 Main DC fan power supply circuit board 9 10 11 12 13 14 10 AFE Power Strctr LCL 13 AFE Power Strctr LCL Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated ...

Page 281: ...tput transformer assembly for AC fan inverter left 10 12 20 FR10845 Output transformer assembly for AC fan inverter right 10 11 12 SK Y1 DCFAN1 Main DC fan assembly 9 10 11 12 13 14 10 AFE LCL Power Strctr 13 AFE LCL Power Strctr Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated ...

Page 282: ...13301 AC fan inverter fan inverter includes circuit board capacitor isolation transformer and mounting hardware 13 14 10 AFE Power Strctr 13 AFE Power Strctr SK Y1 DCPS1 E1K0 DC fan power supply assembly for a 600 690V PowerFlex 700AFE older version Replaced by kit cat no SK Y1 DCPS2 F13 see page 286 13 AFE LCL Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated...

Page 283: ...400 480V PowerFlex 700AFE older version Replaced by kit cat no SK Y1 DCPS2 F13 see page 286 13 AFE LCL SK Y1 DCPS1 D460 DC fan power supply assembly for a 400 480V PowerFlex 700AFE LCL filter older version Replaced by kit cat no SK Y1 DCPS2 F10 see page 285 10 AFE LCL Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated ...

Page 284: ... power supply assembly for a 600 690V PowerFlex 700AFE LCL filter older version Replaced by kit cat no SK Y1 DCPS2 F10 see page 285 10 AFE LCL SK Y1 HF1 DF Fan power supply wire kit for a PowerFlex 700AFE LCL filter older version 10 AFE LCL Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated ...

Page 285: ...t 2014 285 Available Fan System Kits Appendix B SK Y1 DCPS2 F10 DC fan power supply circuit board upgrade kit for a PowerFlex 700AFE LCL filter newer version 10 AFE LCL Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated ...

Page 286: ...F13 Fan power supply circuit board upgrade kit for a PowerFlex 700AFE LCL filter newer version 13 AFE LCL SK Y1 F11 F10 same as 20 PP20202 on page 279 Fan power supply fuse for a PowerFlex 700AFE LCL filter 10 AFE LCL 13 AFE LCL Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated ...

Page 287: ...ugust 2014 287 Available Fan System Kits Appendix B SK H1 FANCAP F9 AC fan capacitor kit 7 µF PF700H S 9 SK H1 FANCAP F1012 AC fan capacitor kit 7 µF PF700H S 10 12 Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated ...

Page 288: ...em Kits SK H1 FANCAP F11 AC fan capacitor kit 7 µF PF700H S 11 SK H1 FANCAP F1314 AC fan capacitor kit 7 µF PF700H S 13 14 10 AFE Power Strctr 13 AFE Power Strctr SK H1 FR9BRKT Main fan support bracket short 9 Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated ...

Page 289: ...014 289 Available Fan System Kits Appendix B SK H1 DCFANRETROFIT F9 AC to DC fan system retrofit kit 9 SK H1 DCFANRETROFIT F10 AC to DC fan system retrofit kit 10 12 Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated Qty 2 ...

Page 290: ...endix B Available Fan System Kits SK H1 DCFANRETROFIT F11 AC to DC fan system retrofit kit 11 SK Y1 DCFANRETROFIT F10 AC to DC fan system retrofit kit 10 AFE Power Strctr Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated Qty 3 Qty 3 ...

Page 291: ...ndix B SK Y1 DCFANRETROFIT F13 AC to DC fan system retrofit kit for DC input drives 13 AFE Power Strctr and 13 14 DC Input SK H1 DCFANRETROFIT F13A AC to DC fan system retrofit kit for AC input 1150 A drives 13 Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated ...

Page 292: ...o DC fan system retrofit kit for AC input 1300 1450 A drives 13 SK H1 DCFANRETROFIT CONV AC to DC fan system retrofit kit for 2700 A AC input converter 13 14 SK H1 DCFANRETROFIT F14A AC to DC fan system retrofit kit for AC input 1500 A drives 14 Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated ...

Page 293: ...29B EN P August 2014 293 Available Fan System Kits Appendix B SK H1 DCFANRETROFIT F14B AC to DC fan system retrofit kit for AC input 1770 2150 A drives 14 Kit Cat No Description in Spare Parts Catalog Drive Frame Size Kit Contents Illustrated ...

Page 294: ...294 Rockwell Automation PublicationPFLEX IN029B EN P August 2014 Appendix B Available Fan System Kits Notes ...

Page 295: ......

Page 296: ...stallation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow...

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