Installation Instructions PowerFlex 700H, 700S, and 700AFE Drive Fan Systems Frames 9...
Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Summary of Changes This manual contains new and updated information. New and Updated Information This table contains the changes made to this revision. Topic Page Added information on parts availability to Phase 3 - Starts January 1, 2015 in the Energy-related Products Fan Efficiency Directive section. 13 Add spare part information for the frame 9 drive fan bracket.
Summary of Changes Notes: 4 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Table of Contents Preface Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Verify Your Drive Frame Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Energy-related Products Fan Efficiency Directive . . . . . . . . . . . . . . . . . . . Phase 1 - Starts January 1, 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Cross-plate Stirring Fan (20-PP01068) Removal and Installation . 51 Internal Stirring Fan (20-PP01068) Removal and Installation . . . . 52 Chapter 2 PowerFlex 700H and 700S Drives Frame 10 Procedures Frame 10 Fan System Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 AC Fan Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 DC Fan Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents AC to DC Fan System Retrofit Kit (SK-H1-DCFANRETROFITF11). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Main AC Fan Inverter Capacitor (SK-H1-FANCAP-F11) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Main AC Fan (20-PP01080) and Main DC Fan (SK-Y1-DCFAN1) Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Main AC Fan Inverter Capacitor (SK-H1-FANCAP-F1314) Removal and Installation (Converter Only). . . . . . . . . . . . . . . . . . . . 169 Main AC Fan Inverter Capacitor (SK-H1-FANCAP-F1314) Removal and Installation (Inverter Only) . . . . . . . . . . . . . . . . . . . . . . 170 Main AC Fan (20-FI13300) and Main DC Fan (SK-Y1-DCFAN1) Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents PowerFlex 700AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 Checking the Fan Inverter Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Checking Fuse Integrity with no Power Applied . . . . . . . . . . . . . . . 263 Checking Fuse Integrity with Power Applied . . . . . . . . . . . . . . . . . . 263 Checking the Main Fan Supply Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 10 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Preface Topic Page Who Should Use this Manual 11 Verify Your Drive Frame Size 11 What is Not in this Manual 12 How to Use this Manual 15 Fastener/Tool/Torque Information 16 General Precautions 17 This manual contains fan system service information for frame 9…14 PowerFlex 700H and PowerFlex 700S AC drives, and the frame 10 and 13 PowerFlex 700AFE.
Preface What is Not in this Manual This manual does not contain information about parts and functions of the drive that are not related to fan system service within the drive. For more information and service procedures for your particular drive, see the applicable publication in this table.
Preface Phase 2 - Starts January 1, 2013, and Ending December 31, 2014 According to the ErP Directive, delivering the existing AC fan systems as spare parts for PowerFlex 700H and 700S, frame 9 and larger, drives and PowerFlex 700AFE systems is allowed until the December 31, 2014 deadline within the EU. DC fan systems are available as spare parts. Phase 3 - Starts January 1, 2015 Use DC fan systems as spare part kits for PowerFlex 700H and 700S, frame 9 and larger, drives, and PowerFlex 700AFE systems.
Preface Fan System Replacement Recommendations This table provides recommendations for replacing a failed fan system on PowerFlex 700H and 700S frame 9 and larger drives and PowerFlex 700AFE systems. See Figure 1 on page 14 for more information. Frame Size Number of Fan Systems in the Drive 9 1 Always replace the failed AC fan system with a new DC fan system. 10 2 If one AC fan system fails, replace both existing AC fan systems with new DC fan systems.
Preface How to Use this Manual This manual contains a chapter for each drive type and frame size. 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.
Preface Fastener/Tool/Torque Information The disassembly illustrations contained in this manual identify the type of fastener, tool, and tightening torque used for disassembly/assembly of components in the drive. Fastener/Tool/Torque Information: PZ2 3.
Preface General Precautions Read the following precautions before you begin testing components, performing maintenance, or repairing the drive. Qualified Personnel ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.
Preface Notes: 18 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures This chapter contains spare part information and procedures for testing and replacing fan system components for frame 9 PowerFlex 700H and 700S drives. See Appendix A PowerFlex 700H and 700S Diagnostic Procedures on page 255 for additional component test procedures.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures AC Fan Systems Frame 9 Fan System Spare Parts See Available Fan System Kits starting on page 277 for an illustration of the spare part kit contents. Cat. No. Part Description Quantity Original Vendor and per Drive Model Number (3) 20-PP01049 50 mm cooling fan for fan inverter 20-PP01068 80 mm x 80 mm x 32 mm internal stirring fan assembly 1 2 or 3 (2) Sinwan SD5012PT-24H Japan Servo Co.
Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 Setting Off Off On Off Switch S1 S2 S3 S4 S1 - Setup Switch Off Off On Off S1-1 S1-2 S1-3 S1-4 230 V AC motor voltage 220 V AC motor voltage 50 Hz fan motor frequency Frame size 9…14 X3 X8 4 X5 X4 Install Jumper on 400/480V AC input drives only (Not present on fan inverter circuit boards, cat. no.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures Figure 3 - Frame 9 DC Fan System Wiring Schematic Diagram To Power Circuit Board X7 (Fan Control) 3 4 Main DC Fan X81 Fan Module X8 Isolated 48V DC Power Supply Circuit Board X3 X82 X2 DC + DC - Frame 9 Fan System Replacement Procedures 22 Replacement procedures for these frame 9 fan system parts are included in this chapter. Cat. No.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 Remove Power from the Drive ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing. Check the 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.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures Remove the Lower 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 lower protective cover to the drive and remove the cover. L1 L2 L3 L1 L2 L3 U/T1 V/T2 W/T3 U/T1 V/T2 W/T3 (8 Screws) PZ2 3.0 N•m (27 lb•in) Remove the Upper Protective Cover 1. Review the General Precautions on page 17.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 Removing the Main Fan Inverter Capacitor Bracket In order to test and/or replace other fan system components in the drive, you must first remove 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.
Chapter 1 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. X2 = X8 S1 NO 4 3 2 1 PZ2 1.3 N•m (11.
PowerFlex 700H and 700S Drives - Frame 9 Procedures IMPORTANT Chapter 1 Mark all connections and wires before removing to avoid incorrect wiring during reassembly. 5. Remove the fuses from the fuse holder. 6. Disconnect the four fuse power wires (black and red pairs) from the top and bottom of the fuse holder. 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. 7.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures 8. Remove the two M5 x 10 mm Phillips head screws that secure the fan capacitor, 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’. X2 X8 Series A Assembly Shown S1 NO 4 3 2 1 X7 X5 X1 X4 X6 8 9 P2 4.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 Main Fan Fuses (20-PP20202) and Fuse Holder (20-PP20300) Removal and Installation The main fan fuses and fuse holder are located on the fan inverter capacitor bracket below the fan inverter 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 lower protective cover from the drive. See Remove the Lower Protective Cover on page 24. 4.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures Main Fan Inverter Cooling Fan (20-PP01049) Removal and Installation Note: This spare part kit includes a fan mounted on a piece of sheet metal. Remove the fan from the sheet metal and discard the sheet metal. Follow these steps to remove and replace the main fan inverter cooling fan. IMPORTANT Note the orientation of the air flow direction arrow on the cooling fan housing before removal.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 Main AC Fan Inverter Capacitor (SK-H1-FANCAP-F9) Removal and Installation Note: The AC fan inverter capacitor replacement kit (SK-H1-FANCAP-F9) contains a new sheet metal bracket, hardware 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).
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures 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 Remove the Removing the Main Fan Inverter Capacitor Bracket on page 25. 5. Remove the main AC fan inverter cooling fan from the bracket. Save the fan for reuse. See Main Fan Inverter Cooling Fan (20-PP01049) Removal and Installation on page 30. 6.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 Main AC Fan Inverter Circuit Board Assembly (20-VB00299) Removal and Installation See Checking the Main AC Fan Inverter Circuit Board Diagnostic LEDs on page 268 for test procedures used to determine if the circuit board requires replacement. Follow these steps to replace the main AC fan inverter circuit board. 1. Review the General Precautions on page 17. 2. Remove power from the drive. See Remove Power from the Drive on page 23. 3.
Chapter 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. Fan Inverter Circuit Board PZ2 3.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 9. Install the new fan inverter assembly in the reverse order of removal. IMPORTANT If you are servicing a 400V/480V Frame 9 drive, insert the jumper on connector X3 as shown here. Connect Jumper to Connector X3 X8 X2 IMPORTANT Verify that dip switch S1 on the new fan iverter board is properly configured, as shown below.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures Main DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1) Removal and Installation Note: You can retrofit an existing AC fan system or replace a DC fan system with a new DC fan system. See Energy-related Products Fan Efficiency Directive on page 12 for 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.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 5. Disconnect the stirring fan power wires. 6. Disconnect the DC supply wire from fan inverter connector 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.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures 11. 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. PZ2 2.3 N•m (20.4 lb•in) 12. Install the main DC fan power supply system in the reverse order of removal. IMPORTANT 38 If you are servicing a 400V/480V Frame 9 drive, insert the jumper on connector X3.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 AC to DC Fan System Retrofit Kit (SK-H1-DCFANRETROFIT-F9) The frame 9 AC to DC main fan system retrofit kit contains the following parts: Item Number Description Quantity 1 DC fan assembly 1 2 DC fan supply assembly 1 3 M4 x 8 mm POZIDRIV screw 2 4 M5 x 10 mm POZIDRIV screw 4 Follow these steps to remove the main AC fan inverter system and replace it with a main DC fan inverter system. 1.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures 7. Remove the main AC fan from the drive and discard the old AC fan and bracket assembly. See Main AC Fan (20-PP01080) and Main DC Fan (SK-Y1-DCFAN1) Assembly Removal and Installation on page 43. Note: You do not need to complete the steps to measure the resistance of the fan supply wires or removing the main fan from the fan bracket. 8. Remove the main AC fan inverter output transformer assembly from the drive and discard the assembly.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 13. Using a 9 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. 13 T20 3.0 N•m (27 lb•in) 14. Install the four rubber bushings in the four holes in the drive chassis.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures 15. Insert the DC fan inverter assembly into the fan inverter compartment and secure the assembly to the drive using the two M4 x 8 mm POZIDRIV screws. PZ2 2.3 N•m (20.4 lb•in) 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.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 21. Secure the fan inverter cover to the drive using the M4 x 8 mm POZIDRIV screw. X2 X8 S1 NO 4 3 2 1 Series A Cover Shown X7 PZ2 1.3 N•m (11.5 lb•in) X5 X1 X4 X6 22. Install the lower protective cover in the reverse order of removal. See Remove the Lower Protective Cover on page 24. 23. Remove the backing from the drive modification label and attach the label, in a clearly visible location, to the front of the drive. 24.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures 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. IMPORTANT Verify that the upper mounting bolts are secure and properly torqued so that they will hold the drive to the wall of the system enclosure. 4. Remove the lower mounting bolts from the bottom of the frame. 5.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 7. Disconnect the main fan motor power connector from the output transformer.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures 8. Using the appropriate table below, 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.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 9. Using the 9 cm long T20 hexalobular screwdriver, loosen (approximately 12 full screw rotations), but do not remove the four screws (accessible through the holes vacated by the rubber bushings) so that the fan assembly can be removed from the drive. Note: These screws secure a sheet metal plate against the fan assembly inside the drive chassis, effectively sealing the fan plenum chamber. 9 T20 3.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures 10 PZ2 4.0 N•m (35 lb•in) 11. Remove the four screws that secure the main fan to the fan bracket and discard the fan. The sheet metal bracket must be reused. 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 bracket. The DC fan uses four M5 x 10 mm screws that are spaced 65 mm apart on the bracket.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 Main AC Fan Inverter Output Transformer (20-PP09055) Removal and Installation Follow these steps to remove and replace the main AC fan inverter output transformer. 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.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures 8. Remove the two M5 x 10 POZIDRIV screws that secure the output transformer to the drive frame. 8 PZ2 4.0 N•m (35 lb•in) 9. While pushing the output transformer wires and rubber bushing through the hole in the back of the fan inverter compartment, remove the output transformer from the bottom of the drive. 10. Install the new output transformer assembly in the reverse order of removal.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 5. Remove the two M5 x 45 mm POZIDRIV screws that secure the protective metal grate and stirring fan to the control frame and remove the fan. 5 PZ2 3.0 N•m (27 lb•in) 6. Install the chassis stirring fan 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.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures 5. Remove the two M4 x 40 mm POZIDRIV screws that secure the fan to the cross-plate and remove the fan. Retain the fan grill plate for reuse. 4 5 PZ2 3.0 N•m (27 lb•in) 6. Install the fan in the reverse order of removal. Internal Stirring Fan (20-PP01068) Removal and Installation Follow these steps to remove and replace the internal stirring fan located on the drive frame in the lower part of the drive. 1.
PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 6. Push the power wires on terminals U/T1, V/T2, and W/T3 to the side in order to gain 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. 8 PZ2 3.0 N•m (27 lb•in) 7 9. Install the fan in the reverse order of removal. Refer to the motor terminal wire placement diagrams below during reassembly.
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures Notes: 54 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures This chapter contains spare part information and procedures for testing and replacing fan system components for frame 10 PowerFlex 700H and PowerFlex 700S drives. See Appendix A PowerFlex 700H and 700S Diagnostic Procedures on page 255 for additional component test procedures.
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures Frame 10 Fan System Spare Parts AC Fan Systems See Available Fan System Kits starting on page 277 for an illustration of the spare part kit contents. Cat. No.
Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 Setting Off Off On Off S1 S2 S3 S4 F2 F1 (-) X2-1 (-) X2-1 Frame size 9…14 230 V AC motor voltage 220 V AC motor voltage 50 Hz fan motor frequency To indicate the following: Off Off On Off Setup Switch 1 2 3 4 (+) X2-3 Off Off On Off Setup Switch 1 2 3 4 (+) X2-3 Fan Frequency Converter DC/AC Fan Frequency Converter DC/AC 2 X3 X8 X3 X8 X5-1 X5-1 BLK 1 BLK 2 BLK 1 X4-1 BLK 2 X4-1 4 4 Jumper V1 U1
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures Figure 5 - Frame 10 DC Fan System Wiring Schematic Diagram To ASIC Circuit Board X11 (Fan Control) 3 4 Main DC Fan DC- DC+ X81 X8 Isolated 48 VDC Power Supply Circuit Board Fan Module X3 X82 X2 4 Main DC Fan X81 Fan Module X8 Isolated 48 VDC Power Supply Circuit Board X2 58 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 X3 X82
PowerFlex 700H and 700S Drives - Frame 10 Procedures Frame 10 Fan System Replacement Procedures Chapter 2 Replacement procedures for these frame 10 fan system parts are included in this chapter. Cat. No.
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures Move the Control Frame and Remove the Air Flow Plate and Protective Covers You must move the control frame and remove the air flow plate and protective covers from 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.
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 6 5 T20 3.
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures 7. Remove the four M5 x 16 mm 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. 9 7 9 8 7 PZ2 1.5 N•m (13.
PowerFlex 700H and 700S Drives - Frame 10 Procedures Chapter 2 Remove the Main AC or DC Fan Power Supply Assemblies You must remove the main fan power supply assemblies from the drive in order to replace the AC or DC fan power supply circuit board, AC fan inverter output transformer, and AC fan inverter capacitor. Follow these steps to remove the main fan power supply assemblies.
Chapter 2 PowerFlex 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. AC fan system 5 5 PZ2 2.3 N•m (20.4 lb•in) PZ2 2.3 N•m (20.4 lb•in) DC fan system 5 5 PZ2 2.3 N•m (20.4 lb•in) PZ2 2.3 N•m (20.
PowerFlex 700H and 700S Drives - Frame 10 Procedures 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. All screws: PZ2 2.3 N•m (20.
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures 8. For the right-side fan power 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. Right-side AC fan power supply Note: Series A capacitor shown X3 (jumper installed) X8 X2 Right-side DC fan power supply 10. Carefully remove the fan power supply assemblies by pulling them out of the front of the drive.
PowerFlex 700H and 700S Drives - Frame 10 Procedures Chapter 2 Main AC Fan Inverter Circuit Board (20-VB00299) and AC Fan Output Transformer Assembly [20-FR10844 (Left) or 20-FR10845 (Right)] Removal and Installation PowerFlex 700H and 700S frame 10 drives have two fan inverters. You can replace a fan inverter circuit board, or replace an output transformer assembly (includes the output transformer and fan capacitor on the assembly).
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures 6. Remove two M5 x 10 mm POZIDRIV screws from the bottom of the assembly that secure the AC fan inverter board to the assembly and remove the AC fan inverter circuit board. Right-side AC fan inverter assembly shown PZ2 2.3 N•m (20.4 lb•in) 6 7.
PowerFlex 700H and 700S Drives - Frame 10 Procedures Chapter 2 Main DC Fan Power Supply System (SK-H1-DCFANBD1) Removal and Installation Note: PowerFlex 700H and 700S frame 10 drives have two fan power supplies. You can retrofit an existing AC fan system or replace a DC fan system with a new DC fan system. See Energy-related Products Fan Efficiency Directive on page 12 for guidelines on replacing an existing fan system with a new DC fan system.
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures 5. Install the new DC fan power supply assembly in the reverse order of removal, using the existing sheet metal housing. IMPORTANT If you are replacing a right-side DC fan power supply assembly, install the jumper on connector X3. For right-side DC fan assemblies, install jumper on connector X3.
PowerFlex 700H and 700S Drives - Frame 10 Procedures Chapter 2 Follow these steps to remove the main AC fan system and replace it with a main 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 protective covers from the drive. See Move the Control Frame and Remove the Air Flow Plate and Protective Covers on page 60. 4.
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures 5. Remove the two M6 x 20 mm hexalobular screws that secure each of the main AC fan housings to the drive 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.
PowerFlex 700H and 700S Drives - Frame 10 Procedures Chapter 2 7. Install the new DC fan assemblies in the reverse order of removal as instructed in step 4, using the connection locations identified in Table 1. 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 supply wire to DC fan extension wire connector 8.
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures Main AC Fan Inverter Capacitor (SK-H1-FANCAP-F1012) Removal and Installation Note: The AC fan inverter capacitor replacement kit (SK-H1-FANCAP-F1012) contains a new sheet metal bracket, hardware 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).
PowerFlex 700H and 700S Drives - Frame 10 Procedures Chapter 2 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 appropriate main fan 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.
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures 9. If the original, defective capacitor being replaced is series B, continue with the next step. If the original, defective capacitor being replaced is series A, secure the new fan 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.
PowerFlex 700H and 700S Drives - Frame 10 Procedures Chapter 2 10. Secure the new (series B) AC fan capacitor to the new AC fan capacitor bracket using the M12 nut and lock washer provided in the kit. 19 mm 5 N•m (44 lb•in) Nut Washer Bracket Capacitor 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. Note: AC Fan System Shown PZ2 4 N•m (35 lb•in) 11 12.
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures Main AC Fan (20-PP01080) and Main DC Fan (SK-Y1-DCFAN1) Assembly Removal 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: • The fan replacement kit only contains the fan motor and impeller assembly. Therefore, the sheet metal housing for the fan must be reused.
PowerFlex 700H and 700S Drives - Frame 10 Procedures Chapter 2 5. Using the appropriate table below, 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.
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures 6. Remove the two M6 x 20 mm hexalobular screws that secure each of the fan assembly 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.
PowerFlex 700H and 700S Drives - Frame 10 Procedures Chapter 2 7. Remove the four M5 x 16 mm POZIDRIV screws that secure the finger guard and fan inlet ring to the fan housing and remove the guard and ring. 7 PZ2 1.9 N•m (16.8 lb•in) 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.
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures 9. Remove the three rubber bushings that hold the fan wiring to the sheet metal housing. 9 9 10. Slide the fan out of the sheet metal housing. Retain the sheet metal housing for reuse. 11. Install the new main fan in the reverse order of removal. Verify that the fan turns easily and does not make contact with the sheet metal housing before installing the fan assembly on the drive.
PowerFlex 700H and 700S Drives - Frame 10 Procedures Chapter 2 4. Remove the ASIC circuit board assembly from the drive: • For earlier drives, remove the four M4 x 8 mm hexalobular 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.
Chapter 2 PowerFlex 700H and 700S Drives - Frame 10 Procedures 5. Disconnect the cable from connector X1 on the ASIC board and remove the fan assembly from the drive. 5 6. For newer drives only, remove the M4 x 15 mm hexalobular screw that secures the fan to the bracket. 6 T20 3.0 N•m (27 lb•in) 7. Install the ASIC cooling fan and assembly in the reverse order of removal.
PowerFlex 700H and 700S Drives - Frame 10 Procedures Chapter 2 AC or DC Fan System Fuses (20-PP20202) and Fuse Holder (20PP20300) Removal and Installation The fan system fuses and fuse holder are located on the front of the drive, next to the gate driver board. Follow these steps to remove and replace the fan system 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.
Chapter 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. 7 PZ2 3.0 N•m (27 lb•in) 8. Install the new fan system fuses and fuse holder in the reverse order of removal.
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures This chapter contains spare part information and procedures for testing and replacing fan system components for frame 11 PowerFlex 700H and PowerFlex 700S drives. See Appendix A PowerFlex 700H and 700S Diagnostic Procedures on page 255 for additional component test procedures.
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures Frame 11 Fan System Spare Parts AC Fan Systems See Available Fan System Kits starting on page 277 for an illustration of the spare part kit contents. Cat. No.
Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 Setting Off Off On Off Switch S1 S2 S3 S4 Frame size 9…14 230 V AC motor voltage 220 V AC motor voltage 50 Hz fan motor frequency To indicate the following: F2 F1 (-) X2-1 (-) X2-1 DC/AC Fan Frequency Converter DC/AC Off Off On Off S1 - Setup Switch Fan Frequency Converter S1-1 S1-2 S1-3 S1-4 (+) X2-3 Off Off On Off S1 - Setup Switch S1-1 S1-2 S1-3 S1-4 (+) X2-3 Off Off On Off S1 - Setup Switch Fan Frequency Conv
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures Figure 7 - Frame 11 DC Fan System Wiring Schematic Diagram To ASIC Circuit Board X11 (Fan Control) 3 4 DC- DC+ Main DC Fan X81 W Phase Fan Module X8 X3 Isolated 48 VDC Power X82 Supply Circuit Board X2 4 Main DC Fan X81 V Phase Fan Module X8 Isolated 48 VDC Power Supply Circuit Board X3 X82 X2 4 Main DC Fan X81 U Phase Fan Module X8 Isolated 48 VDC Power X82 Supply Circuit Board X2 90 X3 Rockwell Automation Publication PFLEX
PowerFlex 700H and 700S Drives - Frame 11 Procedures Frame 11 Fan System Replacement Procedures Chapter 3 Replacement procedures for these frame 11 fan system parts are included in this chapter. Cat. No.
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures Move the Control Frame and Remove the Air Flow Plate and Protective Covers You must move the control frame and remove the air flow plate and protective covers from 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.
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. T20 3.
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures 6. Remove the four 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. PZ2 2.6 N•m (23.0 lb•in) 7 6 PZ2 1.9 N•m (16.
PowerFlex 700H and 700S Drives - Frame 11 Procedures Chapter 3 Removing the Main AC or DC Fan Power Supply Assemblies You must remove the main fan power supply assemblies from the drive in order to test and/or replace the AC or DC fan power supply circuit board, AC fan inverter output transformer, and/or AC fan inverter capacitor. Follow these steps to remove the main fan inverter assemblies.
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures 4. Using a 17mm wrench, loosen 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. Note: AC Fan System Shown 4 17 mm 40 N•m (354 lb•in) 5 6. Disconnect the four wires from the top and bottom of the fuse block (located on the center drive inverter assembly).
PowerFlex 700H and 700S Drives - Frame 11 Procedures Chapter 3 7. Remove the two M5 x 10 mm POZIDRIV screws 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. 7 All Screws: PZ2 2.3 N•m (20.
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures 10. For the right-side fan assembly, disconnect the cables from connectors X2 and X8 on the fan power supply circuit board. If an in-line connector is present (as shown in the image below), disconnect the main 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.
PowerFlex 700H and 700S Drives - Frame 11 Procedures Chapter 3 Main AC Fan Inverter Circuit Board (20-VB00299) and AC Output Transformer Assembly (20-FR10845) Removal and Installation PowerFlex 700H and 700S frame 11 drives have three fan inverters. You can replace an AC or DC fan inverter circuit board, or replace an AC output transformer assembly (includes the AC output transformer and AC fan capacitor on the assembly).
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures 6. Remove two M5 x 10 mm POZIDRIV screws from the bottom of the assembly that secure the AC fan inverter board to the assembly and remove the AC fan inverter circuit board. AC Fan System Shown 6 PZ2 2.3 N•m (20.4 lb•in) 7. On center AC fan inverter assemblies, remove the capacitor and fuse block bracket assembly. You will re-use the fuse block on the new assembly. 8.
PowerFlex 700H and 700S Drives - Frame 11 Procedures Chapter 3 9. Install the AC fan inverter assembly in the reverse order of removal. 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 voltage S4 Off Frame size 9 - 13 IMPORTANT Verify that dip switch S1 on the new AC fan inverter board is properly configured, as shown below.
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures 4. Remove 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 102 If you are replacing a left-side AC fan inverter circuit board, install the jumper on connector X3.
PowerFlex 700H and 700S Drives - Frame 11 Procedures Chapter 3 AC to DC Fan System Retrofit Kit (SK-H1-DCFANRETROFIT-F11) The frame 11 DC main fan system retrofit kit contains the following parts: Item Number Description Quantity 1 DC main fan assembly 3 2 DC fan power supply assembly 3 3 M6 x 20 mm hexalobular screw 6 4 M5 x 10 mm POZIDRIV screw 12 5 M8 spring washer 1 6 M8 x 16 mm socket head screw 1 Follow these steps to remove the main AC fan system and replace it with a main DC f
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures order to clear the sheet metal on the frame, and pull the fan assembly off the positioning pins and out of the drive. 4 5 T30 4.5 N•m (39.8 lb•in) 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.
PowerFlex 700H and 700S Drives - Frame 11 Procedures Chapter 3 7. Install the fan capacitor and fuse holder adapter bracket to the new Phase V DC fan power supply assembly. 8. Install the DC fan power supply assemblies in the reverse order of removal, using the hardware supplied in the kit. 9. Remove the backing from the drive modification label and attach the label to the front of a main fan housing. 10. Write “DC fan retrofit” and the installation date on the label.
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures 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 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.
PowerFlex 700H and 700S Drives - Frame 11 Procedures Chapter 3 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 not 7 μF, continue with the next step. 8. Unscrew and remove the fan capacitor from the AC fan inverter assembly.
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures 9. If the original, defective capacitor being replaced is series B, continue with the next step. If the original, defective capacitor being replaced is series A, secure the new fan 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.
PowerFlex 700H and 700S Drives - Frame 11 Procedures Chapter 3 11. Secure the new AC fan capacitor to the new bracket using the M12 nut and lock washer provided in the kit. Nut Washer Bracket 12 mm 5 N•m (44 lb•in) Capacitor Bracket Front View 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. Note: AC Fan System Shown PZ2 4 N•m (35 lb•in) 12 13.
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures Main AC Fan (20-PP01080) and Main DC Fan (SK-Y1-DCFAN1) Assembly Removal 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: • The fan replacement kit only contains the fan motor and impeller assembly. Therefore, the sheet metal housing for the fan must be reused.
PowerFlex 700H and 700S Drives - Frame 11 Procedures Chapter 3 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 DC Fan Pinouts White (Tach Output) Pin 3 Blue (-) Pin 4 Red (+) Pin 1 Yellow (Control Output) Pin 2 6. Remove the two M6 x 20 mm hexalobular screws that secure the fan to the drive. Then remove the fan.
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures 7. Remove the four M5 x 16 mm POZIDRIV screws that secure the finger guard and fan inlet ring to the fan housing and remove the guard and ring. 7 PZ2 2.6 N•m (23.0 lb•in) 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.
PowerFlex 700H and 700S Drives - Frame 11 Procedures Chapter 3 9. Remove the three rubber bushings that hold the fan wiring to the sheet metal housing. 9 9 9 10. Slide the fan out of the sheet metal housing. Retain the sheet metal housing for reuse. 11. Install the new main fan in the reverse order of removal. Verify that the fan turns easily and does not make contact with the sheet metal housing before installing the fan assembly on the drive.
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures 4. Remove the ASIC circuit board assembly from the drive: • For earlier drives, remove the four M4 x 8 mm hexalobular 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.
PowerFlex 700H and 700S Drives - Frame 11 Procedures Chapter 3 AC or DC Fan System Fuses (20-PP20202) and Fuse Holder (20PP20300) Removal and Installation The fan system fuses and fuse holder are located on the V phase on the front of the drive. Follow these steps to remove and replace the fan system fuse holder. 1. Review the General Precautions on page 17. 2. Remove power from the drive. See Remove Power from the Drive on page 91. 3.
Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures Notes: 116 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Chapter 4 PowerFlex 700H and 700S Drives - Frame 12 Procedures This chapter contains spare part information and procedures for testing and replacing fan system components for frame 12 PowerFlex 700H and PowerFlex 700S drives. See Appendix A PowerFlex 700H and 700S Diagnostic Procedures on page 255 for additional component test procedures.
Chapter 4 PowerFlex 700H and 700S Drives - Frame 12 Procedures AC Fan System Spare Parts See Available Fan System Kits starting on page 277 for an illustration of the spare part kit contents. Cat. No.
PowerFlex 700H and 700S Drives - Frame 12 Procedures Frame 12 Schematic Diagrams Figure 8 - Frame 12 AC Fan System Wiring Schematic Diagram From DC Bus in Power Structure DC+ DC- F1 F2 Chapter 4 Drive Bay 1 From ASIC Board #2 - X11 3 X2-3 (+) X2-1 (-) X8 U1 X4-1 BLK 2 DC/AC V1 1 2 3 4 Off Off On Off Setup Switch X5-1 BLK 1 Fan Frequency Converter 2 BLUE 6 BLK 5 BLK 4 BLK 2.2uf 2.
Chapter 4 PowerFlex 700H and 700S Drives - Frame 12 Procedures Figure 9 - Frame 12 DC Fan System Wiring Schematic Diagram To ASIC Circuit Board X11 (Fan Control) 3 4 Drive Bay 1 Main DC Fan DC- DC+ X8 X3 X82 Isolated 48 VDC Power Supply Circuit Board X2 X81 Left-side Fan Module 4 Main DC Fan To ASIC Circuit Board X11 (Fan Control) X8 X3 X82 Isolated 48 VDC Power Supply Circuit Board X2 X81 Right-side Fan Module 3 Drive Bay 2 4 Main DC Fan DC- DC+ X8 X3 X82 Isolated 48 VDC Power Supply Cir
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures This chapter contains spare part information and procedures for testing and replacing fan system components for frame 13 PowerFlex 700H and PowerFlex 700S drives. See Appendix A PowerFlex 700H and 700S Diagnostic Procedures on page 255 for additional component test procedures.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures Frame 13 Drive Configurations Frame 13 drives consist of a converter section and an inverter section, as shown here. AC line AC DC DC bus Converter section DC Motor AC Inverter section 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.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Frame 13 Fan System Spare Parts AC Fan Systems See Available Fan System Kits starting on page 277 for an illustration of the spare part kit contents.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures DC Fan Systems See Available Fan System Kits starting on page 277 for an illustration of the spare part kit contents.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Tools Needed for Frame 13 Fan System Repairs Frame 13 AFE Schematic Diagrams • • • • • • • • • • Chapter 5 #2 POZIDRIV screwdriver 19 mm socket wrench 5.5 mm hex key or HOP6 bit T20 and T25 hexalobular screwdriver Multi meter Fuse puller Needle-nose pliers Wire cutter Cable ties Optional: PowerFlex 700H and 700S maintenance stand (cat. No.
600 600 600 400 400 400 2 3 3 2 2 2 1030 1180 X3 X3 X2 X2 X2 X3 2 2 2 3 3 2 # of Reactor # of Reactors Connection NFEs 1150 1300 1450 920 Voltage Class Amps (1) The number of NFE’s varies with the drive rating as shown in this table: L3 L2 L1 L3 L2 L1 L3 L2 L1 X3 X8 (1) X3 X8 X3 X8 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 X1 DC- DC+ DC- DC+ DC- DC+ X1 X1 F15 F14 F13 F12 F11 F10 Fan Supply Connection (Located on the front of each Converter)
DC- DC+ F2 F1 (-) X2-1 DC/AC V1 U1 X8 S1 Setup Switch Fan Frequency Converter X3 Off Off On Off S1-1 S1-2 S1-3 S1-4 (+) X2-3 X13 X5-1 BLK 1 X4-1 BLK 2 X6 Rectifier Board 6 BLK 5 BLK 4 BLK 3 BLK 7uf 2.2uf 300VAC 10Meg 2.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures Figure 12 - Frame 13 AC Input Drive Converter DC Fan System 4 Rectifier Circuit Board X201 Main DC Fan To Next Fan Module X81 X1 Fan Module X8 Isolated 48 VDC Power Supply Circuit Board X2 DC + DC - 128 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 X3 X82
DC+ DC- From DC Bus Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 F2 F1 F2 F1 F2 F1 (-) X2-3 X2-1 DC/AC V1 U1 X8 (-) X2-1 DC/AC V1 U1 (-) X2-1 DC/AC V1 U1 X8 3 3 2 X5-1 X5-1 4 2.2uf 300VAC 2.2uf 300VAC 7uf 10Meg 10Meg BLK 1 BLK 1 3 BLK 5 BLK 4 BLK 6 BLK 3 BLK 5 BLK 4 BLK 6 BLK 2.2uf 300VAC 2.2uf 300VAC 2.2uf 300VAC 2.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures Figure 14 - Frame 13 AC Input Drive Inverter DC Fan System To ASIC Circuit Board X11 (Fan Control) 3 4 DC- DC+ Main DC Fan X81 V Phase Fan Module X8 X3 Isolated 48 VDC Power X82 Supply Circuit Board X2 4 Main DC Fan X81 W Phase Fan Module X8 X3 Isolated 48 VDC Power X82 Supply Circuit Board X2 4 4 Main Dc Fan X3 X81 U Phase Fan Module X8 X3 Isolated 48 VDC Power X82 Supply Circuit Board X2 X3 Ending Terminal in FI13 X1 / NFE
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 Figure 15 - Frame 13 DC Input Drive Inverter Section DC+ Phase Module U DC- Measure L/R Gate Driver Bd. X8 X3 Fan DC+ U / T1 Phase Module V DC- V / T2 W / T3 Measure L/R Gate Driver Bd. X8 X3 Fan DC+ Phase Module W DC- Measure L/R Gate Driver Bd.
DC+ DC- From DC Bus Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 F2 F1 F2 F1 F2 F1 (-) X2-3 X2-1 DC/AC V1 U1 X8 (-) X2-3 X2-1 DC/AC V1 U1 (-) X2-1 DC/AC V1 U1 2 BLK 1 X5-1 4 4 X5-1 BLK 1 X4-1 BLK 2 4 BLK 1 X4-1 BLK 2 4 X8 2 X3 X8 3 S1 Setup Switch Fan Frequency Converter X3 Off Off On Off S1-1 S1-2 S1-3 S1-4 (+) X2-3 S1 Setup Switch Fan Frequency Converter Off Off On Off S1-1 S1-2 S1-3 S1-4 (+) 4 X5-1 X4-1 BLK 2 Jumper 2 S1 Setup Swi
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 Figure 17 - Frame 13 AC Input Drive Inverter DC Fan System To ASIC Circuit Board X11 (Fan Control) 3 4 DC+ DC– Main DC Fan X81 X8 X3 Isolated 48 VDC Power X82 Supply Circuit Board V Phase Fan Module X2 4 Main DC Fan X81 W Phase Fan Module X8 X3 Isolated 48 VDC Power X82 Supply Circuit Board X2 4 4 Main DC Fan X3 X81 U Phase Fan Module X8 X3 Isolated 48 VDC Power X82 Supply Circuit Board X2 X3 Ending Terminal in FI13 X2 / ASIC
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures Frame 13 Fan System Replacement Procedures Replacement procedures for these frame 13 fan system parts are included in this chapter. Cat. No.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 Move the Control Frame, and Remove the Screens, Airflow Plates, and Protective Covers You may need to move the control frame based on the mounting location. You must remove the screens, air flow plate and protective covers from 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 screens, airflow plate and protective covers. 1.
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.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 6. Remove the four hexalobular screws that secure the air flow plate to the drive enclosure and slide the plate off the drive. Inverter unit Note: AC input drive shown Converter unit T20 3.0 N•m (27 lb•in) 5 7. If necessary, remove the four M5 x 16 mm POZIDRIV screws that secure the two or three protective covers to the drive, then remove the covers. PZ2 1.65 N•m (14.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures Remove the Voltage Feedback Circuit Board Assembly (Inverter Only) The PowerFlex 700S drive has a voltage feedback circuit board assembly located on the fan housing of the V phase inverter section. It must be removed to service the fan inverter circuit board and fans. Follow these steps to remove the voltage feedback circuit board assembly. 1. Review the General Precautions on page 17. 2. Remove power from the drive.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 8. Install the voltage feedback circuit board assembly in the reverse order of removal. ASIC Circuit Board Assembly Cooling Fan (20-PP01096) Removal and Installation (Inverter Only) PowerFlex 700H and 700S drives have an ASIC circuit board located on the V phase inverter section. It may need to be removed to service the fan inverter circuit board and cooling fans. Follow these steps to remove the ASIC circuit board. 1.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures 5. Remove the two M3 x 5 mm POZIDRIV screws that secure the cooling fan assembly to the ASIC circuit board assembly and rotate the fan assembly out of the assembly. After removing the fan assembly from the ASIC board assembly, the fan power cable will still be connected to the ASIC circuit board. IMPORTANT 5 PZ2 3.0 N•m (26.5 lb•in) 6. Disconnect the cable from connector X1 on the ASIC board and remove the fan assembly from the drive.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 7. Remove the M4 x 15 mm hexalobular screw that secures the fan to the bracket. 7 T20 3.0 N•m (27 lb•in) 8. Install the ASIC circuit board cooling fan and assembly in the reverse order of removal. AC or DC Fan System Fuses (20-PP20202) and Fuse Holder (20PP20300) Removal and Installation The fan system fuses and fuse holder are located on the front of the drive. There is one set of fuses for each drive converter and inverter section.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures 6. Disconnect the fan power supply wires from the top and bottom of the fuse holder. 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. Converter Section Inverter Section 6 7. Remove the M4 x 8 mm POZIDRIV screw that secures the fuse holder assembly. Note: Converter section shown Insulator PZ2 3.0 N•m (26.5 lb•in) 7 Fuse holder 8.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 Remove the Main Fan Assembly The main fan assembly must be removed to gain access to the fan power supply circuit board. Follow these steps to remove the 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.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures 5. Disconnect the main fan power supply connector from the connector on the support bracket and pull the connector out of the sheet metal support bracket. 6. 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 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.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 Removing the Main AC or DC Fan Power Supply Assemblies (Inverter Only) You must remove the main fan power supply assemblies from the drive in order to test and/or replace the AC or DC fan power supply circuit board, AC fan inverter output transformer, and/or AC fan inverter capacitor. Follow these steps to remove the main fan inverter assemblies.
Chapter 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.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 8. Cut the cable ties that secure the fan wires to the inside of the main fan housing. 7 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. 8 PZ2 3.5 N•m (31.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures AC Fan Inverter Assembly DC Fan power Supply Assembly Main AC Fan Inverter Circuit Board (20-VB00299) and DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1) Removal and Installation (Converter Only) Follow these steps to remove and replace the main AC fan inverter or DC fan power supply 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.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Series A converter Chapter 5 Series B converter 4 4 PZ1 0.9 N•m (8.0 lb•in) 4 4 4 5. For 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.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures c. Remove the two M4 x 8 mm POZIDRIV screws that secure the AC fan circuit board to the drive frame and carefully remove the circuit board. c. PZ2 3.0 N•m (27.0 lb•in) 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.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 Main AC Fan Inverter Circuit Board (20-VB00299) Removal and Installation (Inverter Only) Although not recommended, you may replace just the circuit board in the AC fan inverter assembly. Follow these steps to remove and replace the main AC fan inverter 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.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures 7. Disconnect the cable from connector X3. AC fan inverter assembly shown. 8. Disconnect the cables 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. AC fan inverter assembly shown. = 10 PZ2 3.0 N•m (26.5 lb•in) 11.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 Main DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1) Removal and Installation (Inverter Only) PowerFlex 700H and 700S frame 13 drives have multiple fans power supplies. You can retrofit an existing AC fan system or replace a DC fan system with a new DC fan system. See Energy-related Products Fan Efficiency Directive on page 12 for guidelines on replacing an existing fan system with a new DC fan system.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures AC to DC Main Fan System (SK-x1-DCFANRETROFIT-F13x and -14x) Retrofit Table 3 lists the six AC to DC fan retrofit kits available for installation in frame 13 and 14 drives. See DC Fan Systems on page 124 to identify the correct kit for your drive. Table 3 - Available AC to DC Main Fan Inverter Systems Retrofit Kits Cat. No.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 Table 3 - Available AC to DC Main Fan Inverter Systems Retrofit Kits (Continued) Cat. No.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures Table 3 - Available AC to DC Main Fan Inverter Systems Retrofit Kits (Continued) Cat. No.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 Inverter Units 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. 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.
Chapter 5 PowerFlex 700H and 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. Inverter section shown 7 PZ2 3.5 N•m (31.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 8. Secure the power supply cables to the inside of the main fan housings using the cable ties supplied with the kit. Inverter section shown 8 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.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures 10. Connect the fan inverter power supply wires to the bottom of the fuse holders. Note that the red wire (+DC) is connected to the left side terminal and the black wire (-DC) is connected to the right side terminals. 5 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.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 14. Connect the DC- chaining wire set provided in the kit between the 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. Inverter section shown 14 15. Remove the backing from the drive modification label and attach the label to the front of a main fan housing. 16.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures Converter Units 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. 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.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 6. Remove the wire harness that connects the fans on the converter and inverter units. Converter Section Inverter Section 6 7. Remove the AC fan inverter assemblies. See Main AC Fan Inverter Circuit Board (20-VB00299) and DC Fan Power Supply Circuit Board (SK-H1DCFANBD1) Removal and Installation (Converter Only) on page 148. 8. Remove the AC fan capacitor from the converter.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures 13. Install the DC fan inverter assemblies in the converter using the two M4 x 8 mm POZIDRIV screws supplied in the kit. See Main AC Fan Inverter Circuit Board (20-VB00299) and DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1) Removal and Installation (Converter Only) on page 148 for details. DC Fan System 13 PZ2 3.5 N•m (31.0 lb•in) 14. Install the main DC fans in the drive using the four M5 x 10 mm POZIDRIV screws. 15.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 Fan Wire Harness Installation 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. b. X6 X201 X1 X3 a.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures 18. Modify the converter internal wire connections. a. Connect the 48V DC fan extension wire supplied in the retrofit kit to connector X81 on the fan power supply. b. Connect the DC supply wire to connector X2 on the fan power supply. c. Connect the 48V 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.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 21. Install the fan circuit board protection cover using the four M4 x 8 mm POZIDRIV screws. Insert the rubber grommet into the hole in the cover. Series A converter Series B converter 4 4 PZ1 0.9 N•m (8.0 lb•in) 4 4 4 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.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures 23. Connect the wire harness supplied in the retrofit kit that connects the fans on the converter and inverter units. Converter Section Inverter Section 23 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. Note: Converter section shown 24 24 24 25.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 Main AC Fan Inverter Capacitor (SK-H1-FANCAP-F1314) Removal and Installation (Converter 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 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).
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures 4. Remove the main fan circuit board from the drive. See Main AC Fan Inverter Circuit Board (20-VB00299) and DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1) Removal and Installation (Converter Only) on page 148. 5. Cut the cable ties that secure the fan capacitor wires to the wire bundle. 6. Disconnect the capacitor wires from the connectors marked “Blue” and “Brown”. 7. Unscrew the capacitor from the drive frame and remove the capacitor.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 Photo ID# Part Description Quantity 1 Fan capacitor 1 2 Fan capacitor bracket 1 3 Bracket lock washer (M12) 1 4 Bracket nut (M12) 1 5 Bracket spring washer 1 6 Bracket hexagonal socket screw (M8 x 12 mm) 1 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.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures 7. Disconnect the fan capacitor wires from the connectors marked “Brown” and “Blue.” AC fan inverter shown. 7 8. Unscrew and remove the existing fan capacitor from the inverter assembly. AC fan inverter shown.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 9. Secure the new fan capacitor to the bracket using the M12 hexagonal nut and lock washer provided. 12 mm 5.0 N•m (44.2 lb•in) 10. If necessary, secure the fan capacitor bracket (and capacitor) to the drive chassis using the M8 x 12 mm hexagonal socket screw and spring washer provided. Tightening torque is 20 N•m (178 lb•in).
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures 13. Complete the remaining installation in the reverse order of removal as detailed in the previous steps for the Inverter unit. AC fan inverter system shown. IMPORTANT: Verify that the fan capacitor does not touch the fan transformer.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 AC Fan: If the measurements are not similar to those in this table, replace the AC fan. Connection wires Resistance ±5% Black-Brown 62 Ω Brown-Blue 36 Ω Blue-Black 27 Ω Green-chassis 0Ω AC Fan Pinouts Blue (Motor) Pin 4 Brown (Motor) Pin 3 Green/Yellow (Ground) Pin 1 Black (Motor) Pin 2 DC Fan: If the measurements are not similar to those in this table, replace the DC fan.
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. 7 8. Remove the two M4 x 5 mm flathead POZIDRIV screws and remove the sheet metal side.
PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 9. Cut the tie wraps that secure the fan cable to the sheet metal housing. 10. Remove the grommets from the holes in the sheet metal. 11. Remove the four screws that secure the fan to the sheet metal housing and remove the fan. Retain the sheet metal housing for 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.
Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures Notes: 178 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Chapter 6 PowerFlex 700H and 700S Drives - Frame 14 Procedures This chapter contains spare part information and procedures for testing and replacing fan system components for frame 14 PowerFlex 700H and PowerFlex 700S drives. See Appendix A PowerFlex 700H and 700S Diagnostic Procedures on page 255 for additional component test procedures.
Chapter 6 PowerFlex 700H and 700S Drives - Frame 14 Procedures AC Fan Systems See Available Fan System Kits starting on page 277 for an illustration of the spare part kit contents.
PowerFlex 700H and 700S Drives - Frame 14 Procedures Chapter 6 DC Fan Systems See Available Fan System Kits starting on page 277 for an illustration of the spare part kit contents.
Chapter 6 PowerFlex 700H and 700S Drives - Frame 14 Procedures Frame 14 System Diagrams The PowerFlex 700H and PowerFlex 700S frame 14 drive can be configured with either AC or DC (common bus) input voltage applied. The AC input drives have both parallel converter and parallel inverter sections, 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.
PowerFlex 700H and 700S Drives - Frame 14 Procedures Chapter 6 Figure 18 - Frame 14 AC Input Drive Converter and Inverter Sections Converter Section (Contains 3 or 4 modules based on the current rating) L1 Inverter Section B+ NFE 1 L2 B- L3 B+ Power Structure 1 (typical left side) FI13 PM1 U/T1 V/T2 B- W/T3 X8 X1 X3 X11 on PM1 ASIC Board L1 B+ NFE 2 L2 B- L3 X1 L1 B+ NFE 3 B+ FI13 PM2 Power Structure 2 (typical right side) L2 B- L3 U/T1 V/T2 B- W/T3 X8 X1 X3 X11 on PM2 ASIC
Chapter 6 PowerFlex 700H and 700S Drives - Frame 14 Procedures Figure 19 - Frame 14 DC Input Drive Inverter Sections Inverter Section B+ Power Structure 1 (typical left side) FI13 PM1 U/T1 V/T2 B- W/T3 X8 X3 X11 on PM1 ASIC Board B+ FI13 PM2 Power Structure 2 (typical right side) U/T1 V/T2 B- W/T3 X8 X3 X11 on PM2 ASIC Board 184 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures This chapter contains spare part information and procedures for testing and replacing fan system components for frame 10 PowerFlex 700AFE drives. See Appendix A PowerFlex 700H and 700S Diagnostic Procedures on page 255 for additional component test procedures.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures Frame 10 AFE Drive Configurations The frame 10 AFE drive consists mainly of a LCL filter section and a converter section. The converter section is actually 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.
PowerFlex 700AFE Drive - Frame 10 Procedures Frame 10 AFE Fan System Spare Parts Chapter 7 AC Fan Systems See Available Fan System Kits starting on page 277 for an illustration of the spare part kit contents. Voltage Cat. No.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures DC Fan Systems See Available Fan System Kits starting on page 277 for an illustration of the spare part kit contents. Voltage Cat. No.
Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 Setting Off Off On Off Switch S1 S2 S3 S4 S1 - Setup Switch Off Off On Off S1-1 S1-2 S1-3 S1-4 X2 - Fan Frequency Converter Frame size 9…14 230 V AC motor voltage 220 V AC motor voltage 50 Hz fan motor frequency To indicate the following: + F1 X3 X8 4 From ASIC Board X11 Black 1 Black 2 To X51 on the LCL Filter Fan Power Supply Circuit Board X5 X4 Black 3 Black 4 Black 5 Black 6 2.2 µf 2.
Chapter 7 PowerFlex 700AFE 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 To X51 on the LCL Filter Power Supply Circuit Board Main DC Fan X81 Fan Module X8 Isolated 48 VDC Power Supply Circuit Board X2 DC + DC - 190 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 X3 X82
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 Figure 23 - Frame 10 AFE (LCL Filter Section) DC Fan System Wiring Schematic Diagram -L1 L1 L2 X52 1 L3 2 3 4 X53 + - M X51 1 3 5 U V W (Older version of X51 connections shown) PE LCL Filter DC Fan System Wiring -Older Version LCL Filter X1 KLIXON Fan X1 Fuse X53 (3-pin) + Pin = DC+ (supply) - Pin = DC- (supply) X4 Fan DC Power Supply PCB X3 X8 X3 X52 (4-pin) Pin 1 = KLIXON Pin 4 = KLIXON AFE Power Structure DC Bus X51 (4-pin)
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures Frame 10 AFE Fan System Replacement Procedures Replacement procedures for these frame 10 fan system parts are included in this chapter. Power Structure Section Replacement procedures for these frame 10 AFE power structure fan system parts are included in this chapter. Cat. No.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 Move the Control Frame, and Remove the Screens, Airflow Plate, and Protective Covers (IP21 Rittal Enclosure) You may need to move the control frame based on the mounting location. You must remove the screens, air flow plate and protective covers from the AFE in order to access fan 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.
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.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 6. 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 7 T20 3.0 N•m (27 lb•in) 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. 8 8 PZ2 1.65 N•m (14.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures ASIC Circuit Board Assembly Cooling Fan (20-PP01096) Removal and Installation PowerFlex 700AFE frame 10 drives have an ASIC circuit board located in the inverter section. Follow these steps to remove and replace the ASIC circuit board. 1. Review the General Precautions on page 17. 2. Remove power from the AFE. See Remove Power from the AFE on page 192. 3.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 AC or DC Fan Inverter Fuses (20-PP20202) and Fuse Holder (20-PP20300) Removal and Installation The fan inverter fuses and fuse holder are located on the front of the inverter section. See Figure 20 on page 186 for details. Follow these steps to remove and replace the fan inverter fuse holder 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.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures Remove the Main Fan Assembly The main fan assembly must be removed to gain access to the fan inverter circuit board. Follow these steps to remove the main fan 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.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 AC Fan Inverter Assembly (20-FI13301) Removal and Installation PowerFlex 700AFE frame 10 drives have a single fan in the inverter section. The fan inverter assembly includes the AC fan inverter circuit board, output transformer, and fan capacitor. See Isolating a Faulty Fan Inverter on page 265 for test procedures used to determine if the fan inverter assembly requires replacement. Follow these steps to remove and replace an AC fan inverter assembly.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures 7. Remove the four M5 x 10 mm POZIDRIV screws that secure the fan inverter to the power structure. Inverter Sections Wire harness is attached to frame with two cable ties. Fan Inverter 7 PZ2 3.5 N•m (31.0 lb•in) 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. Remove cable ties 9.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 Main AC Fan Inverter Circuit Board (20-VB00299) Removal and Installation Although not recommended, you may replace just the circuit board on the AC fan inverter assembly. Follow these steps to remove and replace the main AC fan inverter circuit board. 1. Review the General Precautions on page 17. 2. Remove power from the AFE. See Remove Power from the AFE on page 192. 3.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures 8. Remove two M4 x 8 mm POZIDRIV screws that secure the fan inverter board and its heatsink to the assembly carriage and carefully remove the fan inverter board and its heatsink from the assembly carriage. Note: AC fan system shown 8 PZ2 3.0 N•m (27.0 lb•in) 9. Install the main AC fan inverter circuit board in the reverse order of removal.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 6. Disconnect the wire cable harness from connectors X2, X3, X8, and X81 on the fan inverter circuit board. 7. Remove two M4 x 8 mm POZIDRIV screws that secure 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. DC fan inverter shown. 7 PZ2 3.0 N•m (26.5 lb•in) 6 8. Install the DC fan power supply circuit board in the reverse order of removal.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures Follow these steps to remove and replace an existing AC 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 AFE on page 192. 3. If applicable, move the control frame, and remove the screens, airflow plates, and protective covers. See Move the Control Frame, and Remove the Screens, Airflow Plate, and Protective Covers (IP21 - Rittal Enclosure) on page 193. 4.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 7. Secure the power supply cables to the inside of the main fan housings using the cable ties supplied with the kit. Inverter section shown 7 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.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures 9. Connect the fan power supply wires to the bottom of the fuse holders. Note that the red wire (+DC) is connected to the left side terminal and the black wire (-DC) is connected to the right side terminals. Inverter section shown 9 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.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 Main AC Fan Inverter Capacitor (SK-H1-FANCAPF1314) Removal and Installation 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 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).
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures 5. Remove the AC fan inverter assembly from 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.” AC fan inverter shown. 7 8. Unscrew and remove the existing fan capacitor from the inverter assembly. AC fan inverter shown.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 9. Secure the new fan capacitor to the bracket using the M12 hexagonal nut and lock washer provided. 12 mm 5.0 N•m (44.2 lb•in) 10. If necessary, secure the fan capacitor bracket (and capacitor) to the drive chassis using the M8 x 12 mm hexagonal socket screw and spring washer provided. Tightening torque is 20 N•m (178 lb•in).
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures 13. Complete the remaining installation in the reverse order of removal. AC fan inverter system shown. IMPORTANT: Verify that the fan capacitor does not touch the fan transformer. 10 11 12 Main AC Fan (20-FI13300) and Main DC Fan (SK-Y1-DCFAN1) Assembly Removal and Installation Follow these steps to measure the resistance between the main fan supply wires and remove and replace the main fan, if necessary.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 5. Using the appropriate table below, 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.
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. 7 8. Remove the two M4 x 5 mm flathead POZIDRIV screws and remove the sheet metal side.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 9. Cut the tie wraps that secure the fan cable to the sheet metal housing. 10. Remove 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. 11 12. Install the new main DC fan in reverse order.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures LCL Filter Section The LCL filter provides the filtering to minimize the harmonic content originating from the inverter section (PWM frequency) from interacting with the AC grid. Replacement procedures for these frame 10 AFE LCL filter fan system parts are included in this chapter. Cat. No.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 4. Remove the protective cover in the LCL Filter cabinet. IP21 (Rittal) cabinet shown with doors removed Protective Cover LCL Filter Fan and DC Power Supply (behind cover) LCL Filter DC Fan Fuses (20-PP20202) Removal and Installation See Figure 20 on page 186 for the location of the LCL filter DC fan fuses. 1. Review the General Precautions on page 17. 2. Remove power from the AFE. See Remove Power from the AFE on page 192. 3.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures Figure 25 - LCL Filter Fan DC Power Supply (SK-Y1-DCPS1-D460 or SK-Y1-DCPS1-F325) Wiring Diagram LCL Filter X1 KLIXON Fan X1 X4 Fan DC Power Supply PCB X3 X3 IMPORTANT X8 X52 (4-pin) Pin 1 = KLIXON Pin 4 = KLIXON Fuse X53 (3-pin) + Pin = DC+ (supply) - Pin = DC- (supply) X51 (4-pin) Pin 5 = +16.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 4. Remove the two M4 x 10 mm POZIDRIV screws that secure the cover to the chassis and remove the cover. Note: Image for SK-Y1-DCPS1-D460 or SK-Y1-DCPS1-F325 5. Disconnect the cables from connectors X1, X3, X4, and X8.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures 6. Remove the six fasteners that secure the DC power supply. Note: Images for SK-Y1-DCPS1-D460 or SK-Y1-DCPS1-F325 7. Install the LCL filter fan DC power supply in the reverse order of removal.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 LCL Filter DC Fan Power Supply Kit (SK-Y1-DCPS2-F10) Removal and Installation This kit contains the following components.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures Image for SK-Y1-DCPS2-F10 X51 X53 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.
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.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures 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. Image for SK-Y1-DCPS2-F10 X51 5 X53 6. Disconnect the X1 fan cable from the connector on the fan sheet metal housing.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 7. Remove the X1 cable from the sheet metal fan housing. Image for SK-Y1-DCPS2-F10 7 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.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures 10. Install 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. Image for SK-Y1-DCPS2-F10 X51 X53 12. Insert the X1 fan cable connector into the receptacle on the fan sheet metal housing.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 13. Reconnect the X1 connector from the fan to the connector on the sheet metal housing. Image for SK-Y1-DCPS2-F10 13 14. Install the fan housing the reverse order of removal. LCL Filter DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1) Removal and Installation If the LCL filter 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.
Chapter 7 PowerFlex 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. Image for SK-Y1-DCPS2-F10 4 5. Disconnect the cables from connectors X2, X3 and X8 at the top of the board.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 6. Disconnect the cable from connector X81 at the bottom of the board.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures 7. Remove 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. Image for SK-H1-DCFANBD1 8 8 8 8 7 9. Install the new DC fan power supply circuit board in the reverse order of removal.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 LCL Filter Fan Assembly Removal and Installation 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.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures 4. Remove the two M6 x 16 mm hexagonal bolts. Image for SK-Y1-DCPS2-F10 4 5. Lower the front fan sheet metal edge and slide it forward to remove the alignment studs from their respective holes in the fan frame sheet metal. 6. Slide the fan assembly out of the chassis. 7. If required. remove the LCL filter fan DC power supply.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 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 229. 4. Disconnect the X1 connector from the sheet metal housing. Image for SK-Y1-DCPS2-F10 4 5. Measure the resistance between the fan supply wires.
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. Image for SK-Y1-DCPS2-F10 6 7. Remove the grommets from the holes in the sheet metal.
PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 8. Remove the four M5 x10 mm hexalobular screws that secure the fan to the sheet metal housing and remove the fan. Retain the sheet metal housing for 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.
Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures Notes: 234 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Chapter 8 PowerFlex 700AFE Drive - Frame 13 Procedures This chapter contains spare part information and procedures for testing and replacing fan system components for frame 13 PowerFlex 700AFE drives. See Appendix A PowerFlex 700H and 700S Diagnostic Procedures on page 255 for additional component test procedures.
Chapter 8 PowerFlex 700AFE Drive - Frame 13 Procedures Frame 13 AFE Drive Configurations Frame 13 AFE drive consists of 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.
PowerFlex 700AFE Drive - Frame 13 Procedures Chapter 8 Figure 28 - Frame 13 AFE System - IP20 NEMA / UL Type 1 (MCC) Cabinet Inverter Fan Fuses LCL Filter DC Fan Fuses The PowerFlex 700AFE is available in several configurations: • The IP00 NEMA / UL Type Open drive is an open style frame that is available through the Rockwell Automation Systems and Solutions Business. This configuration is repackaged into a cabinet structure that is consistent with the system.
Chapter 8 PowerFlex 700AFE Drive - Frame 13 Procedures Frame 13 AFE Fan System Spare Parts AC Fan Systems See Available Fan System Kits starting on page 277 for an illustration of the spare part kit contents. Voltage Cat. No.
PowerFlex 700AFE Drive - Frame 13 Procedures Chapter 8 DC Fan Systems See Available Fan System Kits starting on page 277 for an illustration of the spare part kit contents. Voltage Cat. No.
DC+ DC- From DC Bus Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 F2 F1 (-) X2-1 DC/AC V1 U1 X8 (-) X2-1 DC/AC V1 U1 (-) X2-1 DC/AC V1 U1 X8 3 3 2 X5-1 X5-1 4 2.2uf 300VAC 2.2uf 300VAC 7uf 10Meg 10Meg BLK 1 BLK 1 3 BLK 5 BLK 4 BLK 6 BLK 3 BLK 5 BLK 4 BLK 6 BLK 2.2uf 300VAC 2.2uf 300VAC 2.2uf 300VAC 2.
PowerFlex 700AFE Drive - Frame 13 Procedures Chapter 8 Figure 30 - Frame 13 AFE Inverter DC Fan System To ASIC Circuit Board X11 (Fan Control) 3 4 DC- DC+ Main DC Fan X81 V Phase Fan Module X8 X3 Isolated 48 VDC Power X82 Supply Circuit Board X2 4 Main DC Fan X81 W Phase Fan Module X8 Isolated 48 VDC Power Supply Circuit Board X3 X82 X2 4 To X51 on the LCL Filter Fan Power Supply Circuit Board Main DC Fan X81 U Phase Fan Module X8 X3 Isolated 48 VDC Power X82 Supply Circuit Board X2 Roc
Chapter 8 PowerFlex 700AFE Drive - Frame 13 Procedures Figure 31 - Frame 13 AFE (LCL Filter Section) DC Fan System Wiring Schematic Diagram -L1 L1 L2 X52 1 L3 2 3 4 X53 + - M X51 1 3 5 U V W (Older version of X51 connections shown) PE LCL Filter DC Fan System Wiring -Older Version LCL Filter X1 KLIXON Fan X1 Fuse X53 (3-pin) + Pin = DC+ (supply) - Pin = DC- (supply) X4 Fan DC Power Supply PCB X3 X8 X3 X52 (4-pin) Pin 1 = KLIXON Pin 4 = KLIXON AFE Power Structure DC Bus X51 (4-pin)
PowerFlex 700AFE Drive - Frame 13 Procedures Frame 13 AFE Fan System Replacement Procedures Chapter 8 Replacement procedures for these frame 13 fan system parts are included in this chapter. Power Structure Section The frame 13 PowerFlex 700AFE power structure is essentially a PowerFlex 700H or PowerFlex 700S frame 13 DC input drive. The procedures for replacing PowerFlex 700AFE frame 13 fan system components are the same as those for frame 13 drives.
Chapter 8 PowerFlex 700AFE Drive - Frame 13 Procedures Removing the LCL Filter Protective Cover 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 four T25 Torx self-tapping 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.
PowerFlex 700AFE Drive - Frame 13 Procedures Chapter 8 LCL Filter DC Fan Fuses (20-PP20202) Removal and Installation The LCL filter DC fan fuses are located behind the vented cover at the bottom of the LCL filter. See Figure 27 on page 236 or Figure 28 on page 237 for details. 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.
Chapter 8 PowerFlex 700AFE Drive - Frame 13 Procedures 3. Remove the LCL filter protective covers. See Removing the LCL Filter Protective Cover in page 244. 4. Remove the LCL filter DC fan assembly from the AFE. See LCL Filter Fan 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.
PowerFlex 700AFE Drive - Frame 13 Procedures Chapter 8 LCL Filter Fan DC Power Supply (SK-Y1-DCPS2-F13) Removal and Installation This kit contains the following components.
Chapter 8 PowerFlex 700AFE Drive - Frame 13 Procedures IMPORTANT Before doing any work, disconnect the AFE power structure from the AC supply, and wait until the fan stops and the indicators on the keypad turn off. (If a keypad is not attached, see the indicator through the keypad base.) Wait 5 more minutes before doing any work on the DC-to-DC power supply. Do not even open the cover until after this time has expired. 1. Review the General Precautions on page 17. 2. Remove power from the AFE.
PowerFlex 700AFE Drive - Frame 13 Procedures Chapter 8 8. 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. 9. Install the new LCL filter fan power supply using the screws provided. 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.
Chapter 8 PowerFlex 700AFE Drive - Frame 13 Procedures Note: The DC fan replacement kit only contains the fan motor and impeller assembly. Therefore, the sheet metal housing for the fan must be reused. 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 bracket. The DC fan uses four M5 x 10 mm screws that are spaced 65 mm apart on the bracket.
PowerFlex 700AFE Drive - Frame 13 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. Image for SK-H1-DCFANBD1 8 8 8 8 7 9. Install the new DC fan power supply circuit board in the reverse order of removal.
Chapter 8 PowerFlex 700AFE Drive - Frame 13 Procedures LCL Filter Fan Assembly Removal and Installation 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. Disconnect terminal blocks X51 and X53. 5. Remove the three M4 x 8 mm hexalobular screws that secure the fan housing to the chassis.
PowerFlex 700AFE Drive - Frame 13 Procedures Chapter 8 LCL Filter Main DC Fan (SK-Y1-DCFAN1) Assembly Removal and Installation 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 must be reused. 1. Review the General Precautions on page 17. 2. Remove power from the AFE.
Chapter 8 PowerFlex 700AFE Drive - Frame 13 Procedures 6. 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 DC Fan Pinouts White (Tach Output) Pin 3 Blue (-) Pin 4 Red (+) Pin 1 Yellow (Control Output) Pin 2 7. Remove the M5 x 16 mm hexalobular screw that secures the fan power cable to the fan housing. 8.
Appendix A PowerFlex 700H and 700S Diagnostic Procedures The following diagnostic procedures can be used to determine whether specific fan system components require replacement.
Appendix A PowerFlex 700H and 700S Diagnostic Procedures Qualified Personnel ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. Personal Safety ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before servicing the drive.
PowerFlex 700H and 700S Diagnostic Procedures Appendix A AC Fan Inverter System Fan Inverter System Block Diagrams The AC fan inverter system is summarized in the following block diagram. ASIC Circuit Board +/- DC Bus X11 Fuse X8 X2 Fan Inverter Circuit Board X4 Power Conditioning AC Fan X5 X3 Fan Capacitor DC Fan System The DC fan system is summarized in the following block diagram.
Appendix A PowerFlex 700H and 700S Diagnostic Procedures • Frame 13 drives - three fan systems for common DC bus drives, five or six fan systems 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.
PowerFlex 700H and 700S Diagnostic Procedures Appendix A The fan system topology differs between the ac and dc versions, however, they contain the similar functions. Function AC Fan System DC Fan System Dc bus fuses (qty 2) Early version Bussmann 6 A or present factory installed Ferraz ATQ8 fuses are in the +/- DC bus voltage input at all voltage classes. Ferraz ATQ8 fuses are in the +/- DC bus voltage input at all voltage classes.
Appendix A PowerFlex 700H and 700S Diagnostic Procedures Figure 36 - Frame 10 AFE Fan System Topology (New Style) ASIC Circuit Board X11 +/- DC Bus Fuse Fuse 260 DC Fan Power X8 Supply Circuit X2 Board X81 (power Structure Section) X3 DC Fan Power Supply Circuit Board (LCL Filter Section) Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 DC Fan DC Fan
PowerFlex 700H and 700S Diagnostic Procedures Appendix A Figure 37 - Frame 13 AFE Fan System Topology (Older Style) ASIC Circuit Board +/- DC Bus X11 Fuse AC Fan Inverter X8 Circuit Board X4 X2 (Power Structure X5 Section) X3 Power Conditioning AC Fan Fan Capacitor AC Fan Inverter X8 Circuit Board X4 X2 (Power Structure X5 Section) X3 Power Conditioning AC Fan Fan Capacitor AC Fan Inverter X8 Circuit Board X4 X2 (Power Structure X5 Section) X3 Power Conditioning AC Fan Fan Capacitor Fuse D
Appendix A PowerFlex 700H and 700S Diagnostic Procedures Figure 38 - Frame 13 AFE Fan System Topology (New Style) ASIC Circuit Board X11 +/- DC Bus Fuse Fuse DC Fan Power X8 Supply Circuit X2 Board (Power X81 Structure Section) X3 DC Fan DC Fan Power X8 Supply Circuit X2 Board (Power X81 Structure Section) X3 DC Fan DC Fan Power X8 Supply Circuit X2 Board (Power X81 Structure Section) X3 DC Fan DC Fan Power Supply Circuit Board (LCL Filter Section DC Fan The PowerFlex 700AFE frame 10 and 13 co
PowerFlex 700H and 700S Diagnostic Procedures Checking the Fan Inverter Fuses Appendix A Two fuses are included in the circuit that provides DC bus power to the fan inverter circuit boards. See the diagrams on pages 258 and 259 for details. See the chapter in this manual that applies to your drive frame size for the fuse locations. Using an ohmmeter or a voltmeter to check the fan inverter fuses.
Appendix A PowerFlex 700H and 700S Diagnostic Procedures Checking the Main Fan Supply Wires Verify that power has been removed from the drive. To disconnect the fan power wire connection, refer to the chapter in this manual that apply to your drive frame size. • Disconnect the fan power supply connector from the drive and 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.
PowerFlex 700H and 700S Diagnostic Procedures Checking the AC Fan Inverter Capacitor Appendix A To measure the main AC fan inverter capacitor, you must remove the fan inverter assembly from the drive. Follow these steps to check the AC fan inverter capacitor. 1. Remove the main AC fan inverter assembly from the drive. See Main AC Fan Inverter Capacitor Removal and Installation in the corresponding chapter for your drive frame size. 2.
Appendix A PowerFlex 700H and 700S Diagnostic Procedures 4. Remove the main fan inverter assemblies. See Remove the Main AC or DC Fan Power Supply Assemblies on page 63. Isolate the Left-side Fan Inverter 5. Disconnect the cable from connector X3 of the left-side fan inverter. 6. Remove the jumper from connector X3 of the right-hand inverter, and install it on connector X3 of the left-hand inverter. Right-side AC fan inverter shown X3 (jumper installed) X8 X2 7. Energize the drive.
PowerFlex 700H and 700S Diagnostic Procedures Appendix A Frame 11 PowerFlex 700H and 700S Drives The ASIC board controls all three fan inverters. • X11 on the ASIC board to X8 on the W phase inverter • X3 on the W phase inverter to X8 on the V phase inverter • X3 on the V phase inverter to X8 on the U phase inverter • X3 on the U phase inverter is terminated by a jumper Refer to the wiring schematics on page 89. Use the following procedure to isolate a faulty inverter if the main fans are not running.
Appendix A PowerFlex 700H and 700S Diagnostic Procedures 2. Energize the drive. 3. If all three fan inverter circuit boards fault, then replace the U phase fan inverter circuit board. For AC fan systems, see Main AC Fan Inverter Circuit Board (20-VB00299) and AC Output Transformer Assembly (20FR10845) 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.
PowerFlex 700H and 700S Diagnostic Procedures Appendix A • For frame 11 drives, Main AC Fan Inverter Circuit Board (20-VB00299) and AC Output Transformer Assembly (20-FR10845) Removal and Installation on page 99 or Main DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1) Removal and Installation on page 101 • For frame 13 and 14 drives, Main AC Fan Inverter Circuit Board (20VB00299) Removal and Installation (Inverter Only) on page 151 or Main DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1) Removal and I
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.
X8 of Next Fan ASIC Circuit Board (X11) Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 OPTO OPTO OPTO SMPS Σ -DC µP -18V +5V NTC DCFDBK Fault Detect ISENSE I2t Gate Driver Board VL UL VH UH DC- DC+ AC Fan Inverter Circuit Board * 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.
DC+ Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 4 - Next Fan Alarm* 3 - Next Fan Control 2 - Iso +18V* 1 - Next Fan PWM X3 +18V DC- OPTO OPTO OPTO Temp Rotate Vfdbk Fault Detect Isolation Control DC Fan Power Supply Circuit Board Ifdbk OPTO PWM Contoller Driver dc/dc Converter + X81 White 48V DC Fan X81 Yellow _ X81 Blue 7 - Fan Alarm Fr10 6 - Fan Alarm Fr8 5 - DC- Ref 4 - Fan Alarm Fr9 3 - Fan Control 2 - Iso +18V 1 - Fan PWM X8 3 - DC- 1 - DC+ X
PowerFlex 700H and 700S Diagnostic Procedures Appendix A Logic Power: DC bus voltage is connected to X2 on the AC or DC fan inverter board, which is routed to the SMPS that develops the logic power on the circuit board and DC bus to the “H” bridge. Fault Detection: The AC or DC fan inverter board contains the fault detection scheme which includes current, temperature, and DC bus voltage feedback systems.
Appendix A PowerFlex 700H and 700S Diagnostic Procedures Testing the Main Fan Inverter Circuit Board Diagnostic LEDs ATTENTION: Potentially fatal voltages may result from improper usage of a multimeter and other test equipment. The 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.
PowerFlex 700H and 700S Diagnostic Procedures Appendix A AC Fan System Test Complete the following steps to test the AC fan system. 1. Connect an external 500V DC source, through two fuses, similar to those on the drive power structure (Ferraz ATQ8), to connector X2 (+DC to pin 3 and –DC to pin 1) on the fan inverter circuit board. 2. Connect X3 and X8 to a test fixture that incorporates 2 switches and appropriate interconnection wires. SW1 between X3, pins 2 - 4 and SW2 between X8, pins 3 - 5. 3.
Appendix A PowerFlex 700H and 700S Diagnostic Procedures DC Fan System Test Complete the following steps to test the DC fan system. 1. Connect an external 500V DC source, through two fuses, similar to those on the drive power structure (Ferraz ATQ8), to connector X2 (+DC to pin 3 and –DC to pin 1) on the fan inverter circuit board. 2. Connect X3 and X8 to a test fixture that incorporates 2 switches and appropriate interconnection wires. SW1 between X3, pins 2 - 4 and SW2 between X8, pins 3 - 5. 3.
Appendix B Available Fan System Kits As stated in the Energy-related Products Fan Efficiency Directive section on page 12, new products delivered within the EU (with a power structure manufacturing date of January 1, 2013 and later) will have a DC fan system installed. This includes PowerFlex 700H and 700S frame 9 and larger drives and PowerFlex 700AFE systems. Spare Part Kit Contents The following table describes and shows the contents of each available fan system spare part kit.
80 mm x 80 mm x 32 mm internal stirring fan assembly 60 mm internal fan for ASIC board 20-PP01096 50 mm Cooling fan for fan inverter 20-PP01049 20-PP01068 Description in Spare Parts Catalog Kit Cat. No.
Fuse holder for main fan system fuses 20-PP20300 AC fan inverter, frames 9…12 Fuse for fan system 20-PP20202 20-VB00299 Description in Spare Parts Catalog Kit Cat. No.
Output transformer for AC fan inverter Main DC fan power supply circuit board SK-H1-DCFANBD1 230 W main AC fan assembly 20-PP01080 20-PP09055 Description in Spare Parts Catalog Kit Cat. No.
Description in Spare Parts Catalog Output transformer assembly for AC fan inverter, left Output transformer assembly for AC fan inverter, right Main DC fan assembly Kit Cat. No.
AC fan inverter (fan inverter includes circuit board, capacitor, isolation transformer, and mounting hardware) 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) SK-Y1-DCPS1-E1K0 AC and DC input main fan assembly 20-FI13300 20-FI13301 Description in Spare Parts Catalog Kit Cat. No.
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) DC fan power supply assembly for a 400/480V PowerFlex 700AFE (older version) Replaced by kit cat. no. SK-Y1-DCPS2-F13 (see page 286) SK-Y1-DCPS1-D1K3 SK-Y1-DCPS1-D460 Description in Spare Parts Catalog Kit Cat. No.
Fan power supply wire kit for a PowerFlex 700AFE LCL filter (older version) DC fan 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) SK-Y1-DCPS1-F325 SK-Y1-HF1-DF Description in Spare Parts Catalog Kit Cat. No.
Description in Spare Parts Catalog DC fan power supply circuit board upgrade kit for a PowerFlex 700AFE LCL filter (newer version) Kit Cat. No.
Fan power supply fuse for a PowerFlex 700AFE LCL filter Fan power supply circuit board upgrade kit for a PowerFlex 700AFE LCL filter (newer version) SK-Y1-DCPS2-F13 SK-Y1-F11-F10 (same as 20-PP20202 on page 279) Description in Spare Parts Catalog Kit Cat. No.
AC fan capacitor kit, 7 µF, PF700H/S 10, 12 9 AC fan capacitor kit, 7 µF, PF700H/S SK-H1-FANCAP-F9 SK-H1-FANCAP-F1012 Drive Frame Size Description in Spare Parts Catalog Kit Cat. No.
AC fan capacitor kit, 7 µF, PF700H/S Main fan support bracket (short) SK-H1-FR9BRKT 9 13, 14 10 AFE (Power Strctr) 13 AFE (Power Strctr) 11 AC fan capacitor kit, 7 µF, PF700H/S SK-H1-FANCAP-F11 SK-H1-FANCAP-F1314 Drive Frame Size Description in Spare Parts Catalog Kit Cat. No.
AC to DC fan system retrofit kit AC to DC fan system retrofit kit SK-H1DCFANRETROFIT-F9 SK-H1DCFANRETROFIT-F10 Description in Spare Parts Catalog Kit Cat. No.
AC to DC fan system retrofit kit SK-H1DCFANRETROFIT-F11 SK-Y1-DCFANRETROFIT- AC to DC fan system retrofit kit F10 Description in Spare Parts Catalog Kit Cat. No.
Description in Spare Parts Catalog SK-H1DCFANRETROFIT-F13A AC to DC fan system retrofit kit for AC input, 1150 A drives SK-Y1-DCFANRETROFIT- AC to DC fan system retrofit kit for DC input drives F13 Kit Cat. No.
AC to DC fan system retrofit kit for 2700 A, AC input converter AC to DC fan system retrofit kit for AC input, 1500 A drives SK-H1DCFANRETROFIT-F14A AC to DC fan system retrofit kit for AC input, 1300/1450 A drives SK-H1DCFANRETROFIT-F13B SK-H1DCFANRETROFIT-CONV Description in Spare Parts Catalog Kit Cat. No.
Description in Spare Parts Catalog AC to DC fan system retrofit kit for AC input, 1770/2150 A drives Kit Cat. No.
Appendix B Available Fan System Kits Notes: 294 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
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