Rockwell Automation Allen-BradleyPowerFlex 700H Installation Instructions Manual
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Rockwell Automation Allen-BradleyPowerFlex 700H Installation Instructions Manual

Drive fan system
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Installation Instructions
PowerFlex 700H, 700S, and 700AFE Drive Fan Systems
Frames 9...14 Drives

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Summary of Contents for Rockwell Automation Allen-BradleyPowerFlex 700H

  • Page 1 Installation Instructions PowerFlex 700H, 700S, and 700AFE Drive Fan Systems Frames 9...14 Drives...
  • Page 2 If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
  • Page 3 Added the LCL Filter Fan DC Power Supply (SK-Y1-DCPS2-F13) Removal and Installation procedures for the new kit. Updated the Spare Part Kit Contents to include the new LCL filter fan DC power supply kits. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 4 Summary of Changes Notes: Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 5: Table Of Contents

    Installation ..........49 Chassis Stirring Fan (20-PP01068) Removal and Installation ..50 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 6 Removal and Installation ........101 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 7 -14 ) Retrofit ..........154 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 8 DC Fan System..........257 PowerFlex 700H and PowerFlex 700S Drives ....257 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 9 Spare Part Kit Contents ......... 277 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 10 Table of Contents Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 11: Preface

    420/500 420/500 1 Min Overload Amps 630/550 630/550 2 Sec Overload Amps 840/630 840/630 MFD. in 1989 on Nov 9 Frame #: 10 Serial Number: 2622381652 2622381652 MADE IN THE USA (FAC 1B) Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 12: What Is Not In This Manual

    DC fan system kits have been developed to support the repair of damaged units and to provide retrofit solutions. However, the ErP Directive does not require drives with existing AC fan systems to be retrofitted. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 13: Phase 2 - Starts January 1, 2013, And Ending December 31, 2014

    Kits are available to retrofit an AC to DC fan power supply. These kits include the DC fan assembly, DC fan power supply, fan inverter circuit board, all wire harnesses, and required hardware. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 14: Fan System Replacement Recommendations

    Figure 1 - DC Fan System Replacement Examples FAN = Main Fan INV = Fan Inverter (AC) FPS = Fan Power Supply (DC) = Defective AC Fan Component = Replacement DC Fan Kit Components = No Change Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 15: How To Use This Manual

    Drive Type Frame Size Chapter / Appendix Page Number PowerFlex 700H and 700S PowerFlex 700AFE PowerFlex 700H, 700S, and 700AFE 9…14 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 16: Fastener/Tool/Torque Information

    Hexagonal bolt Hexagonal nut or standoff Hexagonal screw Hexalobular head screw Phillips head screw POZIDRIV head screw Slotted Hexalobular head screw (1) Phillips® and POZIDRIV® are registered trademarks of the Phillips Screw Company. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 17: General Precautions

    Class 1 LED Product ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into module ports or fiber-optic cable connectors. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 18 Preface Notes: Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 19 Main AC Fan (20-PP01080) and Main DC Fan (SK-Y1-DCFAN1) Assembly Removal and Installation Main AC Fan Inverter Output Transformer (20-PP09055) Removal and Installation Chassis Stirring Fan (20-PP01068) Removal and Installation Cross-plate Stirring Fan (20-PP01068) Removal and Installation Internal Stirring Fan (20-PP01068) Removal and Installation Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 20: Frame 9 Fan System Spare Parts

    • 19 mm socket wrench • T20 hexalobular screwdriver with a shaft length of at least 9 cm (3.54 in.) • Cable ties • Electrical tape • Fuse puller • Multi-meter • Needle-nose pliers Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 21: Frame 9 Schematic Diagrams

    PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 Frame 9 Schematic Diagrams Figure 2 - Frame 9 AC Fan System Wiring Schematic Diagram Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 22: Frame 9 Fan System Replacement Procedures

    80 mm x 80 mm x 32 mm internal stirring fan assembly 20-PP01068 Cross-plate stirring fan (80 mm x 80 mm x 32 mm) 20-PP01068 Internal stirring fan (80 mm x 80 mm x 32 mm) Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 23: Remove Power From The Drive

    3. 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 24: Remove The Lower Protective Cover

    3. Remove the eight M4 x 8 mm POZIDRIV screws that secure the upper protective cover to the drive and remove the cover. (8 Screws) U/T1 V/T2 W/T3 U/T1 V/T2 W/T3 3.0 N m (27 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 25: Removing The Main Fan Inverter Capacitor Bracket

    1. Review the General Precautions on page 17. 2. Remove power from the drive. See Remove Power from the Drive on page 3. Remove the lower protective cover from the drive. See Remove the Lower Protective Cover on page 24. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 26 4. Remove the M4 x 8 mm POZIDRIV screw that secures the fan inverter cover to the drive frame and remove the cover. Series A Cover Shown 1.3 N m (11.5 lb • • Series B Cover Series A Cover Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 27 Note that the red wires connect to the left side terminal on the fuse IMPORTANT holder and the black wires connect to the right side terminal on the fuse holder. 7. Disconnect the stirring fan power wires. Black Black Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 28 9. Disconnect the fan capacitor wires from the connectors labeled ‘Blue’ and ‘Brown’ . Series A Assembly Shown 4.0 N m (35 lb • • Series A Assembly Series B Assembly (Note the Larger Capacitor) Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 29: Main Fan Fuses (20-Pp20202) And Fuse Holder (20-Pp20300) Removal And

    6. If, necessary, remove the two M4 x 8 mm POZIDRIV screws that secure the fuse block to the sheet metal. 3.0 N m (27 lb • • 7. Install the fuses and fuse block in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 30: Installation

    5. Note Direction of Air Flow Arrow on Fan. 3.0 N m (27 lb • • 6. Install the new cooling fan in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 31: Main Ac Fan Inverter Capacitor (Sk-H1-Fancap-F9) Removal And Installation

    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 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 32 12. Install the new capacitor and new bracket in the reverse order of removal. Note: Take care to protect the fan power wires from damage during installation. 13. Install the new fan inverter compartment (series B) cover. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 33: Main Ac Fan Inverter Circuit Board Assembly (20-Vb00299) Removal And Installation

    X4 and X5 on the fan inverter board. 6. Disconnect the wires from connector X8 on the fan inverter board. 7. Disconnect the wires from connector X2 on the fan inverter board. Retain these wires for reuse. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 34 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 3.0 N m (27 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 35 Verify that dip switch S1 on the new fan iverter board is properly configured, as IMPORTANT shown below. S1-1 S1-2 S1-3 S1-4 Switch Setting To Indicate the Following: 50 Hz Fan Motor Frequency 220 V AC Motor Voltage 230 V AC Motor Voltage Frame Size 9…14 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 36: Main Dc Fan Power Supply Circuit Board (Sk-H1-Dcfanbd1) Removal And Installation

    4. Remove the M4 x 8 mm POZIDRIV screw that secures the fan power supply cover to the drive frame and remove the cover. Series A Cover Shown 1.3 N m (11.5 lb • • Series B Cover Series A Cover Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 37 10. Remove the two M5 x 10 mm Phillips head screws that secure the fuse holder / cooling fan bracket to the frame and left the bracket out of the drive. 4.0 N m (35 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 38 (20.4 lb • • 12. Install the main DC fan power supply system in the reverse order of removal. If you are servicing a 400V/480V Frame 9 drive, insert the jumper on connector IMPORTANT Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 39: F9)

    Removal and Installation on page 31. 6. Remove the main AC fan inverter circuit board assembly and discard the assembly. See Main AC Fan Inverter Circuit Board Assembly (20- VB00299) Removal and Installation on page 33. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 40 11. Secure the retrofit DC fan assembly to the drive chassis using the four M5 x 10 mm POZIDRIV screws. 12. Position the grommet into the hole and ensure the ware harness doesn't contact any sheetmetal surface. 3.2 N m (28.3 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 41 3.0 N m (27 lb • • 14. Install the four rubber bushings in the four holes in the drive chassis. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 42 18. Connect the fan supply wire from fan inverter connector X8. 19. Connect the DC fan power supply wire from connector X81 20. Connect the four fuse power wires (black and red pairs) from the top and bottom of the fuse holder. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 43: Assembly Removal And Installation

    • The main fan replacement kit only contains the fan motor and impeller assembly. Therefore, if the sheet metal mounting bracket is not available as a spare part for your fan system, it must be reused. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 44 5. Remove the four rubber bushings that cover the mounting screws for the main fan assembly. Retain these bushings for reuse. 6. Remove the rubber bushing from the hole that covers the main fan motor power connector at the bottom of the drive. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 45 PowerFlex 700H and 700S Drives - Frame 9 Procedures Chapter 1 7. Disconnect the main fan motor power connector from the output transformer. Note: DC fan system shown Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 46 ∞ Ω Red-Blue ∞ Ω Red-White ∞ Ω White-Yellow ∞ Ω Blue-White DC Fan Pinouts White (Tach Output) Pin 3 Blue (-) Pin 4 Red (+) Pin 1 Yellow (Control Output) Pin 2 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 47 Do not attempt to force the fan plate from the drive. This may bend the IMPORTANT fan and surrounding sheet metal. The sheet metal bracket must be reused. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 48 4.0 N m (35 lb • • 12. Install the main fan in the reverse order of removal. Verify that the fan turns easily on the bracket before installing it in the IMPORTANT drive. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 49: Main Ac Fan Inverter Output Transformer (20-Pp09055) Removal

    7. Remove the hexalobular screw, located at the back, left-hand corner of the fan inverter compartment, that secures the output transformer assembly to the drive frame. 4.0 N m (35 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 50: Chassis Stirring Fan (20-Pp01068) Removal And Installation

    3. Remove the upper protective cover from the drive. See Remove the Upper Protective Cover on page 24. 4. Disconnect the fan power cable from connector J18 on the power interface circuit board. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 51: Cross-Plate Stirring Fan (20-Pp01068) Removal And Installation

    2. Remove power from the drive. See Remove Power from the Drive on page 3. Remove the lower protective cover from the drive. See Remove the Lower Protective Cover on page 24. 4. Disconnect the stirring fan power wire connector. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 52: Internal Stirring Fan (20-Pp01068) Removal And Installation

    5. Remove the M8 nut and washer that secure the U/T1, V/T2, and W/T3 power wires to the terminals, to loosen the wires only. You do not need to remove the external wires from the terminals. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 53 9. Install the fan in the reverse order of removal. Refer to the motor terminal wire placement diagrams below during reassembly. 13 mm 20.0 N m (177 lb • • Power Wire Hex Nut Washer Bus Bar Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 54 Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures Notes: Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 55 Main AC Fan (20-PP01080) and Main DC Fan (SK-Y1-DCFAN1) Assembly Removal and Installation ASIC Circuit Board Assembly Cooling Fan (20-PP01096) Removal and Installation AC or DC Fan System Fuses (20-PP20202) and Fuse Holder (20-PP20300) Removal and Installation Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 56: Frame 10 Fan System Spare Parts

    • 19 mm socket wrench • T15, T20, T25, and T30 hexalobular screwdriver • Fuse puller • Nose pliers • Wire cutter • Optional: PowerFlex 700H and 700S maintenance stand (cat. No. 20- MAINSTND) Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 57: Frame 10 Schematic Diagrams

    PowerFlex 700H and 700S Drives - Frame 10 Procedures Chapter 2 Frame 10 Schematic Figure 4 - Frame 10 AC Fan System Wiring Schematic Diagram Diagrams Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 58 To ASIC Circuit Board X11 (Fan Control) Main DC Fan DC- DC+ Isolated 48 VDC Power Fan Module Supply Circuit Board Main DC Fan Fan Module Isolated 48 VDC Power Supply Circuit Board Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 59: Frame 10 Fan System Replacement Procedures

    3. 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 60: Protective Covers

    3. Loosen or remove the two hexalobular screws that secure the control frame to the drive enclosure. 4. Swing the control frame out and away from the power structure. 3.0 N m (27 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 61 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. 3.0 N m (27 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 62 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. 1.5 N m (13.3 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 63: Remove The Main Ac Or Dc Fan Power Supply Assemblies

    4. Remove the cable ties that secure the power cables with brown/orange insulation. Note: This will allow you to move the power cables while removing the fan inverter assemblies. Note: AC fan systems shown Left-side fan assembly Right-side fan assembly Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 64 AC fan system 2.3 N m (20.4 lb 2.3 N m (20.4 lb • • • • DC fan system 2.3 N m (20.4 lb 2.3 N m (20.4 lb • • • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 65 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: 2.3 N m (20.4 lb • • Note: Left- side AC fan power supply shown Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 66 Right-side AC fan power supply Note: Series A capacitor shown X3 (jumper installed) Right-side DC fan power supply 10. Carefully remove the fan power supply assemblies by pulling them out of the front of the drive. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 67: (Right)] Removal And Installation

    5. Disconnect the cables from connectors X4 and X5. Right-side AC fan inverter assembly shown X4 (Blue) X5 (Black) Series B capacitor in a left-side AC fan Series A capacitor in a left-side AC fan inverter assembly shown. inverter assembly shown Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 68 Note: AC fan system shown 50 Hz fan motor frequency 220 V AC motor voltage Install jumper on X3 for right- S1-1 S1-2 S1-3 S1-4 side fan inverter boards 230 V AC motor voltage Frame size 9…14 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 69: And Installation

    See Move the Control Frame and Remove the Air Flow Plate and Protective Covers on page 60. 4. Remove the appropriate main fan assembly. See Remove the Main AC or DC Fan Power Supply Assemblies on page 63. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 70: F10)

    The frame 10 main AC to DC fan system retrofit kit contains the following parts: Item Number Description Quantity Main DC fan assembly DC fan power supply assembly M6 x 20 mm POZIDRIV screw M5 x 10 mm POZIDRIV screw Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 71 See Move the Control Frame and Remove the Air Flow Plate and Protective Covers on page 60. 4. Remove the main AC fan power supply assemblies. See Remove the Main AC or DC Fan Power Supply Assemblies on page 63. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 72 3.0 N m (26.5 lb • • 6. Install the new DC main fan assemblies in the reverse order of removal as instructed in step 5. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 73 8. Remove the backing from the drive modification label and attach the label, in a clearly visible location, to the front of the drive. 9. Write “DC fan retrofit” and the installation date on the label. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 74: Removal And Installation

    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 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 75 If the value of the capacitor is less than 7 μF, continue with the next step. 8. Unscrew and remove the fan capacitor from the AC fan inverter assembly. Note: AC fan system shown Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 76 • Use this hole (2) when installing the adapter bracket on the left-side AC fan inverter assembly. Use this hole (1) when installing the adapter bracket on the right-side AC fan inverter assembly. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 77 M5 x 10 mm POZIDRIV screws provided in the kit. Note: AC Fan System Shown m (35 lb • • 12. Install the AC fan inverter assembly in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 78: Assembly Removal And Installation

    Control Frame and Remove the Air Flow Plate and Protective Covers on page 60. 4. Disconnect the fan power supply cable from the bottom of the fan assembly for each main fan (see the illustration on the following page for connection location). Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 79 ∞ Ω Red-Blue ∞ Ω Red-White ∞ Ω White-Yellow ∞ Ω Blue-White DC Fan Pinouts White (Tach Output) Pin 3 Blue (-) Pin 4 Red (+) Pin 1 Yellow (Control Output) Pin 2 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 80 3.0 N m (26.5 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 81 65 mm apart on the housing. Based on the manufacturing date, the sheet metal housing was fabricated for either an AC fan, a DC fan, or both. 1.9 N m (16.8 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 82: And Installation

    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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 83 After removing the fan assembly from the ASIC board assembly, the IMPORTANT fan power cable will still be connected to the ASIC circuit board. 3.0 N m (27 lb 1.65 N m (14.6 lb • • • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 84 6. For newer drives only, remove the M4 x 15 mm hexalobular screw that secures the fan to the bracket. 3.0 N m (27 lb • • 7. Install the ASIC cooling fan and assembly in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 85: Ac Or Dc Fan System Fuses (20-Pp20202) And Fuse Holder (20- Pp20300) Removal And Installation

    5. Check the fuses. See Checking the Fan Inverter Fuses on page 263. 6. Disconnect the four fuse power wires (black and red pairs) connected to the top and bottom of the fuse holder. Black 3.0 N m (27 lb • • Black Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 86 7. Remove the M4 x 8 mm POZIDRIV screw that secures the fuse holder to the drive frame and remove the fuse holder. 3.0 N m (27 lb • • 8. Install the new fan system fuses and fuse holder in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 87 Main AC Fan (20-PP01080) and Main DC Fan (SK-Y1-DCFAN1) Assembly Removal and Installation ASIC Circuit Board Assembly Cooling Fan (20-PP01096) Removal and Installation AC or DC Fan System Fuses (20-PP20202) and Fuse Holder (20-PP20300) Removal and Installation Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 88: Ac To Dc Fan System Retrofit Kit

    • T20 and T30 hexalobular screwdriver • Multi meter • Fuse puller • Needle-nose pliers • Wire cutter • Cable ties • Electrical tape • Optional: PowerFlex 700H and 700S maintenance stand (cat. No. 20- MAINSTND) Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 89: Frame 11 Schematic Diagrams

    PowerFlex 700H and 700S Drives - Frame 11 Procedures Chapter 3 Frame 11 Schematic Figure 6 - Frame 11 AC Fan System Wiring Schematic Diagram Diagrams Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 90 Isolated 48 VDC Power Supply Circuit Board Main DC Fan V Phase Fan Module Isolated 48 VDC Power Supply Circuit Board Main DC Fan U Phase Fan Module Isolated 48 VDC Power Supply Circuit Board Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 91: Frame 11 Fan System Replacement Procedures

    3. 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 92: Protective Covers

    X50. 4. Loosen the two hexalobular screws that secure the control frame to the enclosure and swing the control frame away from the drive. 3.0 N m (27 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 93 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. 3.0 N m (27 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 94 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. 2.6 N m (23.0 lb • • 1.9 N m (16.8 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 95: Removing The Main Ac Or Dc Fan Power Supply Assemblies

    2. Remove power from the drive. See Remove Power from the Drive on page 3. Move the control frame and remove the air flow plate and protective covers. See Move the Control Frame and Remove the Air Flow Plate and Protective Covers on page 92. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 96 Note: AC Fan System Shown 17 mm 40 N m (354 lb • • 6. Disconnect the four wires from the top and bottom of the fuse block (located on the center drive inverter assembly). Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 97 9. Remove the four M5 x 10 mm POZIDRIV screws that secure the bottom of the fan power supply assembly to the drive frame. All Screws: 2.3 N m (20.4 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 98 Right-side AC Fan Inverter System Note: Series A Fan Capacitor Shown X3 (Jumper Installed) Right-side DC Fan Power Supply 12. Carefully remove the fan power supply assemblies by pulling them out of the front of the drive. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 99: Main Ac Fan Inverter Circuit Board (20-Vb00299) And Ac Output Transformer Assembly (20-Fr10845) Removal And Installation

    4. Remove the appropriate main fan inverter assembly. See on page Removing the Main AC or DC Fan Power Supply Assemblies. 5. Disconnect the cables from connectors X4 and X5. AC Fan System Shown Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 100 • If you are replacing the AC output transformer assembly, install the existing AC fan inverter circuit board on the new AC output transformer assembly in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 101: Removal And Installation

    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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 102 5. Install the new DC fan power supply in the reverse order of removal, using the existing sheet metal housing. If you are replacing a left-side AC fan inverter circuit board, install the jumper IMPORTANT on connector X3. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 103: F11)

    Note: The back of the fan housing contains two holes in the sheet metal that fit onto positioning pins located on the drive frame. To remove the main fan assemblies, lower the front end of the assembly downward in Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 104 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. 8 mm 12 N m (106 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 105: And Installation

    (1) If a series B AC fan inverter assembly is currently installed in the drive, the sheet metal frame has been modified to accommodate the series B (larger) capacitor. Therefore, in this case, the fan capacitor bracket, adapter bracket and adapter fastening hardware is not needed. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 106 See Move the Control Frame and Remove the Air Flow Plate and Protective Covers on page 92. 4. Remove the appropriate main AC fan inverter assembly. See Removing the Main AC or DC Fan Power Supply Assemblies on page 95. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 107 8. Unscrew and remove the fan capacitor from the AC fan inverter assembly. Note: AC Fan System Shown Series A Capacitor Shown Series B Capacitor in a Right-side Series A Capacitor in a Right-side AC Fan Inverter Assembly Shown. AC Fan Inverter Assembly Shown Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 108 10. For the V phase AC fan inverter assembly, the fuse holder and bracket to which it is secured must be installed on top of the new adapter bracket. Note: AC Fan System Shown Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 109 M5 x 10 mm POZIDRIV screws provided in the kit. Note: AC Fan System Shown m (35 lb • • 13. Install the AC fan inverter assembly in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 110: Assembly Removal And Installation

    Resistance ±5% 62 Ω Black-Brown 36 Ω Brown-Blue 27 Ω Blue-Black 0 Ω Green-chassis AC Fan Pinouts Blue (Motor) Pin 4 Brown (Motor) Pin 3 Green/Yellow (Ground) Pin 1 Black (Motor) Pin 2 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 111 4.5 N m (39.8 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 112 65 mm apart on the housing. Based on the manufacturing date, the sheet metal housing was fabricated for either an AC fan, a DC fan, or both. 2.6 N m (23 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 113: And Installation

    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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 114 6. Remove the M4 x 15 mm screw(s) that secure the cooling fan to the ASIC assembly cover and remove the fan. 7. Install the ASIC cooling fan in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 115: Ac Or Dc Fan System Fuses (20-Pp20202) And Fuse Holder (20- Pp20300) Removal And Installation

    7. Remove the M5 x 10 mm POZIDRIV screw that secures the fuse holder to the drive frame and remove the fuse holder. 8. Install the new fan system fuse holder in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 116 Chapter 3 PowerFlex 700H and 700S Drives - Frame 11 Procedures Notes: Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 117: Frame 12 Fan System Spare Parts

    PowerFlex 700H and 700S Drives - Frame 10 Procedures on page for detailed replacement procedures. See Frame 12 AC Fan System Wiring Schematic Diagram on page and Frame 12 DC Fan System Wiring Schematic Diagram on page for more information. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 118: Ac Fan System Spare Parts

    Number SK-Y1-DCFAN1 Main DC fan assembly – SK-H1-DCFANBD1 Main DC fan power supply circuit board – SK-H1-DCFANRETROFIT-F10 AC to DC fan system retrofit kit – (1) Circuit board only, no sheet metal bracket. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 119: Frame 12 Schematic Diagrams

    50 Hz 10Meg Setup Switch Fan Frequency Converter YLW/GRN Jumper Switch Setting To indicate the following: 50 Hz fan motor frequency 220 V AC motor voltage 230 V AC motor voltage Frame size 9…14 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 120 (Fan Control) Drive Bay 2 Main DC Fan DC- DC+ Left-side Fan Module Isolated 48 VDC Power Supply Circuit Board Main DC Fan Right-side Fan Module Isolated 48 VDC Power Supply Circuit Board Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 121 Main AC Fan Inverter Capacitor (SK-H1-FANCAP-F1314) Removal and Installation (Converter Only) Main AC Fan Inverter Capacitor (SK-H1-FANCAP-F1314) Removal and Installation (Inverter Only) Main AC Fan (20-FI13300) and Main DC Fan (SK-Y1-DCFAN1) Assembly Removal and Installation Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 122: Frame 13 Drive Configurations

    The converter converts ac (fixed 50 / 60 Hz) to dc voltage. The inverter section inverts dc to variable ac frequency. Converter Inverter Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 123: Frame 13 Fan System Spare Parts

    (2) The factory default fuses are Ferraz Shawmut ATQ8, 8 A fuses. Older drives may contain Bussman 6 A fuses. (3) The part may not contain wires, connectors, or mounting hardware when bought directly from vendor. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 124: Dc Fan Systems

    (3) The factory default fuses are Ferraz Shawmut ATQ8, 8 A fuses. Older drives may contain Bussman 6 A fuses. (4) The part may not contain wires, connectors, or mounting hardware when bought directly from vendor. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 125: Tools Needed For Frame 13 Fan System Repairs

    Converter Figure 11 on page Figure 12 on page Inverter Figure 13 on page Figure 14 on page System Figure 15 on page Converter Inverter Figure 16 on page Figure 17 on page Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 126 Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures Figure 10 - Frame 13 AC Input Drive Converter and Inverter Sections Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 127 PowerFlex 700H and 700S Drives - Frame 13 Procedures Chapter 5 Figure 11 - Frame 13 AC Input Drive Converter AC Fan System Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 128 Figure 12 - Frame 13 AC Input Drive Converter DC Fan System Rectifier X201 Circuit Main DC Fan To Next Board Fan Module Fan Module Isolated 48 VDC Power Supply Circuit Board DC + DC - Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 129 Figure 13 - Frame 13 AC Input Drive Inverter AC Fan System Switch Setting To indicate the following: 50 Hz fan motor frequency 220 V AC motor voltage 230 V AC motor voltage Frame size 9…14 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 130 Isolated 48 VDC Power Supply Circuit Board Main Dc Fan U Phase Fan Module Isolated 48 VDC Power X2 / ASIC Supply Circuit Board Ending Terminal in FI13 X1 / NFE In Frame 13 Only Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 131 Measure L/R Gate Driver Bd. U / T1 Phase V / T2 Module W / T3 Measure L/R Gate Driver Bd. Phase Module Measure L/R Gate Driver Bd. Charge Relay +24V 0EVA ASIC Board Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 132 Figure 16 - Frame 13 DC Input Drive Inverter AC Fan System Switch Setting To indicate the following: 50 Hz fan motor frequency 220 V AC motor voltage 230 V AC motor voltage Frame size 9…14 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 133 Isolated 48 VDC Power Supply Circuit Board Main DC Fan U Phase Fan Module Isolated 48 VDC Power X2 / ASIC Supply Circuit Board Ending Terminal in FI13 X1 / NFE In Frame 13 Only Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 134: Frame 13 Fan System Replacement Procedures

    3. 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 135: Protective Covers

    X50. 4. Loosen the two hexalobular screws that secure the control frame to the enclosure and swing the control frame away from the drive. 3.0 N m (27 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 136 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 137 IN G A IT IG H IN U LT A C IT V IC IN G 8. Replace the control frame, screens, airflow plates, and protective covers in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 138: Remove The Voltage Feedback Circuit Board Assembly

    7. Remove the four M4 x 8 mm Phillips head screws that secure the voltage feedback circuit board assembly to the fan housing on the drive and carefully remove the assembly. 1.0 N m (8.8 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 139: And Installation (Inverter Only)

    (if present) and remove the fiber-optic bundle and rubber grommet from the support bracket in order to allow room for the fan housing to be removed from the unit. V phase power structure PowerFlex 700S drive shown Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 140 ASIC circuit board. 3.0 N m (26.5 lb • • 6. Disconnect the cable from connector X1 on the ASIC board and remove the fan assembly from the drive. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 141: Ac Or Dc Fan System Fuses (20-Pp20202) And Fuse Holder (20- Pp20300) Removal And Installation

    See Move the Control Frame, and Remove the Screens, Airflow Plates, and Protective Covers on page 135. 4. Remove the fuses from the fuse holder. 5. Check the fuses. See Checking the Fan Inverter Fuses on page 263. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 142 Note: Converter section shown Insulator 3.0 N m (26.5 lb • • Fuse holder 8. Install the AC or DC fan inverter fuses and fuse holder in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 143: Remove The Main Fan Assembly

    Remove the Screens, Airflow Plates, and Protective Covers on page 135. 4. If necessary, remove the voltage feedback circuit board assembly. See Remove the Voltage Feedback Circuit Board Assembly (Inverter Only) on page 138. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 144 5.5 mm or HOP6 bit 20 N m (177 lb 3.5 N m (31.0 lb • • • • 8. Install the main fan assembly in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 145: Removing The Main Ac Or Dc Fan Power Supply Assemblies

    5. Disconnect the fan power supply wires from the bottom of the fuse holder. 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 146 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 147 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. 3.5 N m (31.0 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 148: Installation (Converter Only)

    Press the rubber grommet through the hole in the cover and remove the cover. Be sure to not damage the precharge resistors wires on the series B IMPORTANT converter. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 149 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 150 Converter section with DC fan system 3.0 N m (26.5 lb • • 8. Install the fan circuit board in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 151: Installation (Inverter Only)

    5. Remove the AC fan inverter assembly from the drive. See Removing the Main AC or DC Fan Power Supply Assemblies (Inverter Only) on page 145. 6. Disconnect the cables from connectors X2 and X8. AC fan system shown. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 152 AC fan inverter assembly shown. 3.0 N m (26.5 lb • • 11. Install the fan inverter circuit board in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 153: Removal And Installation (Inverter Only)

    Then carefully remove the circuit board from the assembly. 3.0 N m (26.5 lb • • 8. Install the DC fan power supply circuit board in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 154: Retrofit

    DC fan power supply wire harness 2 DC chaining wire harness M4 x 8 mm POZIDRIV screws M5 x 10 mm hexagonal socket screws Wire ties Wire tie mounting clamps Wire harness for 2 NFE Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 155 DC fan power supply wire harness 2 DC chaining wire harness M4 x 8 mm POZIDRIV screws M5 x 10 mm hexagonal socket screws Wire ties Wire tie mounting clamps Wire harness for 3 NFE Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 156 • Inverter Units on page • Converter Units on page • Fan Wire Harness Installation on page Follow these steps to remove and replace an existing AC fan system with a new DC fan system. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 157 Note: DC input drives do not have an converter section, so there is no converter to inverter interconnect wire harness. Converter Section Inverter Section Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 158 M5 x10 mm POZIDRIV screws supplied in the kit. See Removing the Main AC or DC Fan Power Supply Assemblies (Inverter Only) on page for details. Inverter section shown 3.5 N m (31.0 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 159 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. Inverter section shown Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 160 12. Install the M8 x 20 mm hexagonal socket screws supplied with the kit in the front of the main fans. Final torque is 20 N•m (177 lb•in). 13. Connect the fan power supply cables to the connectors on the support brackets on the main chassis. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 161 15. Remove the backing from the drive modification label and attach the label to the front of a main fan housing. 16. Write “DC fan retrofit” and the installation date on the label. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 162 4. Remove the main fan assemblies. See Remove the Main Fan Assembly on page 143. 5. Disconnect the converter X1 wire harness (#1) from the connector and fan extension wire (#2) on the sheetmetal cover. Series B converter shown Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 163 5.5 mm or HOP6 bit AC Fan System 10 N m (88.5 lb 1.0 N m (8.8 lb • • • • Converter Section Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 164 (31.0 lb • • 5.5 mm or HOP6 bit 20 N m (177 lb • • 16. Connect the fan power supply cables to the connectors on the support brackets on the drive chassis. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 165 Connect the 300 mm DC– wire between connectors X1, pin 15 and connector X8, pin 5. b. Connect the loose end of the 210 mm DC– wire to connector X1, pin 1. X201 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 166 Use two of the cable ties supplied in the retrofit kit to tie together the wire harness and fan power supply wire. DC Fan System Converter Section 19. Reinstall the converter sheet metal cover. 20. Complete steps 5, 6, and of this procedure in the reverse order. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 167 Connect the wire harness DC- wire on the fuse base. c. Use two of the cable ties supplied in the retrofit kit to tie together the wire harness and DC wires. Note: Converter section shown Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 168 25. Remove the backing from the drive modification label and attach the label to the front of a main fan housing. 26. Write “DC fan retrofit” and the installation date on the label. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 169 3. Move the control frame, and remove the screens, airflow plates, and protective covers from the drive. See Move the Control Frame, and Remove the Screens, Airflow Plates, and Protective Covers on page 135. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 170 (50 mm dia. x 62 mm tall) is larger than the series A capacitor (35 mm dia. x 57 mm tall). If a series A capacitor is currently installed, always replace it with the new series B capacitor. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 171 5. Remove the AC fan inverter assemblies from the drive. See Removing the Main AC or DC Fan Power Supply Assemblies (Inverter Only) on page 145. 6. Cut the cable ties that secure the fan capacitor wires to the wire bundle. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 172 7. Disconnect the fan capacitor wires from the connectors marked “Brown” and “Blue.” AC fan inverter shown. 8. Unscrew and remove the existing fan capacitor from the inverter assembly. AC fan inverter shown. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 173 Verify that no wires are touching the sheet metal on the IMPORTANT drive chassis. 11. Connect the new fan capacitor wires to the connectors marked “Brown” and “Blue.” 12. Secure the fan capacitor wires to the fan wire bundle using cable ties. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 174 Remove the Screens, Airflow Plates, and Protective Covers on page 135. 4. Remove the main fan assemblies from the drive. See Remove the Main Fan Assembly on page 143. 5. Using the appropriate table below, measure the resistance between the fan supply wires. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 175 Red (+) Pin 1 Yellow (Control Output) Pin 2 6. For AC fan systems, install the new fan assembly in the reverse order of removal. For DC fan systems, complete the remaining steps. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 176 7. Remove the three M4 x 8 mm POZIDRIV screws from the front of the fan housing. 8. Remove the two M4 x 5 mm flathead POZIDRIV screws and remove the sheet metal side. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 177 12. Install the new main DC fan in reverse order. Verify that the fan turns easily and does not make contact with the sheet metal housing or fan cable before installing the fan assembly in the drive. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 178 Chapter 5 PowerFlex 700H and 700S Drives - Frame 13 Procedures Notes: Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 179: Frame 14 Drive Configurations

    14 fan system components are also the same as those for frame 13 drives. See Frame 13 Fan System Replacement Procedures on page for detailed replacement procedures. See Frame 14 System Diagrams on page for more information. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 180: Ac Fan Systems

    (3) The factory default fuses are Ferraz Shawmut ATQ8, 8 A fuses. Older drives may contain Bussman 6 A fuses. (4) The part may not contain wires, connectors, or mounting hardware when bought directly from vendor. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 181: Dc Fan Systems

    (4) The factory default fuses are Ferraz Shawmut ATQ8, 8 A fuses. Older drives may contain Bussman 6 A fuses. (5) The part may not contain wires, connectors, or mounting hardware when bought directly from vendor. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 182: Frame 14 System Diagrams

    Drive Hardware Section AC Fan Systems DC Fan Systems System Figure 18 on page Converter Inverter System Figure 19 on page Converter Inverter Please see Frame 13 AFE Schematic Diagrams on page for more information. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 183 Power Structure 1 (typical left side) V/T2 W/T3 X11 on PM1 ASIC Board NFE 2 FI13 PM2 NFE 3 Power Structure 2 U/T1 (typical right side) V/T2 W/T3 X11 on PM2 ASIC Board NFE 4 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 184 Inverter Section FI13 PM1 U/T1 Power Structure 1 (typical left side) V/T2 W/T3 X11 on PM1 ASIC Board FI13 PM2 Power Structure 2 U/T1 (typical right side) V/T2 W/T3 X11 on PM2 ASIC Board Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 185 LCL Filter DC Fan Power Supply Kit (SK-Y1-DCPS2-F10) Removal and Installation LCL Filter DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1) Removal and Installation LCL Filter Fan Assembly Removal and Installation LCL Filter Main DC Fan (SK-Y1-DCFAN1) Assembly Removal and Installation Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 186: Frame 10 Afe Drive Configurations

    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.

  • Page 187: Frame 10 Afe Fan System Spare Parts

    (1) The part may not contain wires, connectors, or mounting hardware when bought directly from vendor. (2) The factory default fuses are Ferraz Shawmut ATQ8, 8 A fuses. Older drives may contain Bussman 6 A fuses. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 188: Dc Fan Systems

    • 10 mm and 19 mm socket wrench • T20 and T25 hexalobular screwdriver • Fuse puller • Nose pliers • Wire cutter • Optional: PowerFlex 700H and 700S maintenance stand (cat. No. 20- MAINSTND) Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 189: Frame 10 Afe Fan System Schematic Diagrams

    PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 Frame 10 AFE Fan System Figure 21 - Frame 10 AFE (Power Module Section) AC Fan System Wiring Schematic Diagram Schematic Diagrams Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 190 To ASIC Circuit Board X11 (Fan Control) To X51 on the LCL Filter Power Supply Circuit Main DC Fan Board Fan Module Isolated 48 VDC Power Supply Circuit Board DC + DC - Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 191 X3 on AFE Power Structure Pin 4 = +16.5V Pin 1 Pin 3 = (fan control) Pin 2 Pin 2 = –DC Pin 3 Pin 1 = (fan alarm) Flying Lead to –DC Bus Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 192: Frame 10 Afe Fan System Replacement Procedures

    3. 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 193 4. If applicable, loosen the two hexalobular screws that secure the control frame to the AFE enclosure, lift up on the control frame, and swing it out and away from the power structure. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 194 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 195 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. 1.65 N m (14.6 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 196 6. Disconnect the fan supply wire from connector X1 on the ASIC circuit board and remove the fan. Note: Inverter section shown 7. Install the ASIC cooling fan and assembly in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 197 7. Remove the M4 x 8 mm POZIDRIV screw that secures the fuse holder and insulator to the assembly. 8. Install the AC or DC fan inverter fuses and fuse holder in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 198 5.5 mm or HOP6 bit 20 N m (177 lb 3.5 N m (31.0 lb • • • • 7. Install the main cooling fan assembly in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 199 5. Disconnect the fan inverter cables from the connections on the front of the power structure. 6. Push the fan inverter cables and connectors, largest first, through the rubber grommet into the frame, where the main cooling fan was located. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 200 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. Install the AC fan inverter assembly in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 201 Note: These wires connect the fan capacitor to the fan inverter circuit board. 7. Disconnect the wires from connectors X8 and X2 on the fan inverter circuit board. Note: AC fan system shown Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 202 4. Remove the main fan assembly from the AFE. See Remove the Main Fan Assembly on page 198. 5. Remove the AC fan inverter assembly from the AFE. See AC Fan Inverter Assembly (20-FI13301) Removal and Installation on page 199. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 203 AC to DC Main Fan System (SK-Y1-DCFANRETROFIT-F10) Retrofit There are three different AC to DC fan retrofit kits available. The correct kit is identified in Figure Figure 24 - SK-Y1-DCFANRETROFIT-F10 Qty 2 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 204 M5 x10 mm POZIDRIV screws supplied in the kit. See Main DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1) Removal and Installation on page for details. Inverter section shown 3.5 N m (31.0 lb • • Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 205 Inverter section shown 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. Inverter section shown Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 206 11. Remove the backing from the drive modification label and attach the label to the front of a main fan housing. 12. Write “DC fan retrofit” and the installation date on the label. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 207 Remove the Screens, Airflow Plate, and Protective Covers (IP21 - Rittal Enclosure) on page 193. 4. Remove the main fan assembly from the AFE. See Remove the Main Fan Assembly on page 198. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 208 7. Disconnect the fan capacitor wires from the connectors marked “Brown” and “Blue.” AC fan inverter shown. 8. Unscrew and remove the existing fan capacitor from the inverter assembly. AC fan inverter shown. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 209 Verify that no wires are touching the sheet metal on the IMPORTANT drive chassis. 11. Connect the new fan capacitor wires to the connectors marked “Brown” and “Blue.” 12. Secure the fan capacitor wires to the fan wire bundle using cable ties. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 210 Remove the Screens, Airflow Plate, and Protective Covers (IP21 - Rittal Enclosure) on page 193. 4. Remove the main fan assembly from the AFE. See Remove the Main Fan Assembly on page 198. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 211 Red (+) Pin 1 Yellow (Control Output) Pin 2 6. For AC fan systems, install the new fan assembly in the reverse order of removal. For DC fan systems, complete the remaining steps. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 212 7. Remove the three M4 x 8 mm POZIDRIV screws from the front of the fan housing. 8. Remove the two M4 x 5 mm flathead POZIDRIV screws and remove the sheet metal side. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 213 12. Install the new main DC fan in reverse order. Verify that the fan turns easily and does not make contact with the sheet metal housing or fan cable before installing the fan assembly in the drive. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 214: Lcl Filter Section

    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 sixteen T25 Torx self-tapping cover screws. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 215 DC power supply circuit board. The LCL filter fan DC power supply wiring diagram is shown in Figure 25. The diagram shows the connections to the AFE power structure and DC bus. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 216 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 217 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. Note: Image for SK-Y1-DCPS1-D460 or SK-Y1-DCPS1-F325 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 218 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 219 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 220 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 221 PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 4. Remove the two M4 x 8 mm POZIDRIV screws that secure the cover to the chassis and remove the cover. Image for SK-Y1-DCPS2-F10 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 222 Then shift the assembly sufficient to remove the X51 and X53 connectors. Image for SK-Y1-DCPS2-F10 6. Disconnect the X1 fan cable from the connector on the fan sheet metal housing. Image for SK-Y1-DCPS2-F10 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 223 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 224 11. Connect the X51 and X53 connectors to the fan power supply circuit board. Image for SK-Y1-DCPS2-F10 12. Insert the X1 fan cable connector into the receptacle on the fan sheet metal housing. Image for SK-Y1-DCPS2-F10 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 225 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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 226 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 5. Disconnect the cables from connectors X2, X3 and X8 at the top of the board. Image for SK-H1-DCFANBD1 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 227 PowerFlex 700AFE Drive - Frame 10 Procedures Chapter 7 6. Disconnect the cable from connector X81 at the bottom of the board. Image for SK-H1-DCFANBD1 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 228 8. Remove the four fasteners that secure the DC power supply board to the chassis and remove the board. Image for SK-H1-DCFANBD1 9. Install the new DC fan power supply circuit board in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 229 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. Note: Image for SK-Y1-DCPS1-D460 or SK-Y1-DCPS1-F325 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 230 The DC fan uses four M5 x 10 mm screws that are spaced 65 mm apart on the bracket. Based on the manufacturing date, the sheet metal mounting bracket was fabricated for either an AC fan, a DC fan, or both. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 231 ∞ Ω Red-Blue ∞ Ω Red-White ∞ Ω White-Yellow ∞ Ω Blue-White DC Fan Pinouts White (Tach Output) Pin 3 Blue (-) Pin 4 Red (+) Pin 1 Yellow (Control Output) Pin 2 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 232 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 7. Remove the grommets from the holes in the sheet metal. Image for SK-Y1-DCPS2-F10 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 233 9. Install the new main DC fan in reverse order. Verify that the fan turns easily and does not make contact with the sheet metal housing or fan cable before installing the fan assembly in the AFE. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 234 Chapter 7 PowerFlex 700AFE Drive - Frame 10 Procedures Notes: Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 235 LCL Filter Fan DC Power Supply (SK-Y1-DCPS2-F13) Removal and Installation LCL Filter Fan DC Power Supply Circuit Board (SK-H1-DCFANBD1) Removal and Installation LCL Filter Fan Assembly Removal and Installation LCL Filter Main DC Fan (SK-Y1-DCFAN1) Assembly Removal and Installation Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 236: Frame 13 Afe Drive Configurations

    Figure 27 - Frame 13 AFE System - IP21 NEMA / UL Type 1 (Rittal) Cabinet Inverter Fan Fuses LCL Filter DC Fan Fuses Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 237 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.

  • Page 238: Frame 13 Afe Fan System Spare Parts

    (1) The part may not contain wires, connectors, or mounting hardware when bought directly from vendor. (2) The factory default fuses are Ferraz Shawmut ATQ8, 8 A fuses. Older drives may contain Bussman 6 A fuses. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 239: Dc Fan Systems

    AFE Fan System Repairs • 19 mm socket wrench • T20 and T25 hexalobular screwdriver • Fuse puller • Nose pliers • Wire cutter • Optional: PowerFlex 700H and 700S maintenance stand (cat. No. 20- MAINSTND) Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 240: Frame 13 Afe Schematic Diagrams

    Figure 29 - Frame 13 AFE Power Structure AC Fan Connections Diagrams Switch Setting To indicate the following: 50 Hz fan motor frequency 220 V AC motor voltage 230 V AC motor voltage Frame size 9…14 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 241 W Phase Fan Module Isolated 48 VDC Power Supply Circuit Board To X51 on the LCL Main DC Fan Filter Fan Power Supply Circuit Board U Phase Fan Module Isolated 48 VDC Power Supply Circuit Board Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 242 X3 on AFE Power Structure Pin 4 = +16.5V Pin 1 Pin 3 = (fan control) Pin 2 Pin 2 = –DC Pin 3 Pin 1 = (fan alarm) Flying Lead to –DC Bus Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 243: Frame 13 Afe Fan System Replacement Procedures

    (1) Only use this circuit board if you are replacing a newer version circuit board (same catalog number). Note: Additional procedures will be added to future revisions of this publication as they become available. Enter ‘PFLEX-IN029’ in the Search field on the Rockwell Automation Literature Library at: http:/www.rockwellautomation.com/literature/ Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 244 • LCL Filter DC Fan Fuses • LCL Filter Fan • DC Power Supply (all behind vented cover) Front Bracket 5. Install the protective covers in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 245 1. Review the General Precautions on page 17. 2. Remove power from the AFE. See Remove Power from the AFE on page 192. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 246 DC power supply to the fan housing and remove the DC power supply. Note: Image for SK-Y1-DCPS1-D1K3 or SK-Y1-DCPS1-E1K0 8. Install the LCL filter fan DC power supply in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 247 X3 on AFE Power Structure Pin 4 = +16.5V Pin 1 Pin 3 = (fan control) Pin 2 Pin 2 = –DC Pin 3 Pin 1 = (fan alarm) Flying Lead to –DC Bus Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 248 6. Remove the three M5 x 16 mm hexalobular screws that secure the assembly to the fan housing. 7. Disconnect the cable from X51 on the LCL filter fan power supply and X3 on the AFE power unit and discard the cable. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 249 If the LCL filter already has a new fan power supply kit (SK-Y1-DCPS2-F13) installed, the DC fan power supply board (SK-H1-DCFANBD1) can be installed as a replacement part in the newer version DC power supply system. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 250 5. Disconnect the cables from connectors X2, X3 and X8 at the top of the board. 6. Disconnect the cable from connector X81 at the bottom of the board. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 251 8. Remove the four fasteners that secure the DC power supply. Image for SK-H1-DCFANBD1 9. Install the new DC fan power supply circuit board in the reverse order of removal. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 252 7. Install the LCL filter fan assembly in reverse order of removal. Be sure that the alignment tabs are seated in the slots on the back wall as you slide the fan assembly back into place. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 253 Protective Cover in page 244. 4. Remove the LCL filter fan assembly from the AFE. See LCL Filter Fan Assembly Removal and Installation on page 252. 5. Disconnect the X1 connector from the sheet metal housing. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 254 10. Install the new main DC fan in reverse order. Verify that the fan turns easily and does not make contact with the sheet metal housing or fan cable before installing the fan assembly in the AFE. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 255 Checking the Main Fan Supply Wires Checking the AC Fan Inverter Capacitor Isolating a Faulty Fan Inverter Checking the Main AC Fan Inverter Circuit Board Diagnostic LEDs Testing the Main Fan Inverter Circuit Board Diagnostic LEDs Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 256: Qualified Personnel

    Class 1 LED Product ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into module ports or fiber-optic cable connectors. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 257: Fan Inverter System Block Diagrams

    • Frame 9 drives - one fan system • Frame 10 drives - two fan systems • Frame 11 drives - three fan systems • Frame 12 drives - four fan systems, where the topology is parallel frame 10 drives Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 258 AC input drives This drive topology and fan system distribution is shown here. ASIC Circuit Board +/- DC Bus Fuse Fan Inverter Circuit Board Fan Inverter Circuit Board Fan Inverter Circuit Board Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 259: Powerflex 700Afe

    Figure 35 - Frame 10 AFE Fan System Topology (Older Style) ASIC Circuit Board +/- DC Bus Fuse AC Fan Inverter Power Circuit Board AC Fan Conditioning (Power Structure Section) Fuse DC Fan Power Supply DC Fan Circuit Board (LCL Filter Section) Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 260 Figure 36 - Frame 10 AFE Fan System Topology (New Style) ASIC Circuit Board +/- DC Bus Fuse DC Fan Power Supply Circuit DC Fan Board (power Structure Section) DC Fan Power Fuse Supply Circuit Board DC Fan (LCL Filter Section) Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 261 AC Fan Conditioning Structure Section) Fan Capacitor AC Fan Inverter Circuit Board Power (Power AC Fan Conditioning Structure Section) Fan Capacitor Fuse DC Fan Power Supply Circuit Board DC Fan (LCL Filter Section) Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 262 Section The PowerFlex 700AFE frame 10 and 13 contain the same fan topology as the PowerFlex 700H/700S drives. In addition, there is a DC fan system in the LCL filter of each frame. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 263: Checking The Fan Inverter Fuses

    OR measure across the body of each fuse to have no voltage drop. If a voltage drop exists across the fuse body, replace both fuses. DC Bus Vout No Volt Drop No Volt Drop DC Bus Vout Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 264: Checking The Main Fan Supply Wires

    ∞ Ω Red-Blue ∞ Ω Red-White ∞ Ω White-Yellow ∞ Ω Blue-White DC Fan Pinouts White (Tach Output) Pin 3 Blue (-) Pin 4 Red (+) Pin 1 Yellow (Control Output) Pin 2 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 265: Checking The Ac Fan Inverter Capacitor

    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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 266 Inverter Circuit Board (20-VB00299) and AC Fan Output Transformer Assembly [20-FR10844 (Left) or 20-FR10845 (Right)] Removal and Installation on page 67. For DC fan systems, see Main DC Fan Power Supply System (SK-H1-DCFANBD1) Removal and Installation on page Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 267: Frame 11 Powerflex 700H And 700S Drives

    Main DC Fan Power Supply Circuit Board (SK-H1- DCFANBD1) Removal and Installation on page 101. 6. Restore original wiring configuration. Checking the U Phase Fan Inverter 1. Verify the original wiring configuration. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 268: Frames 13 And 14 Powerflex 700H And 700S Drives

    • For frame 10 and 12 drives, Main AC Fan Inverter Circuit Board (20- VB00299) and AC Fan Output Transformer Assembly [20-FR10844 (Left) or 20-FR10845 (Right)] Removal and Installation on page Main DC Fan Power Supply System (SK-H1-DCFANBD1) Removal and Installation on page Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 269: Ac Fan System Leds

    Component LED Color Description Green Power On Yellow Fan control enabled Minimum fan rotation speed has not been reached Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 270: Fan System Wiring And Operation

    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. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 271 PowerFlex 700H and 700S Diagnostic Procedures Appendix A Figure 39 - AC Fan System Block Diagram Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 272 Appendix A PowerFlex 700H and 700S Diagnostic Procedures Figure 40 - DC Fan System Block Diagram X81 Red X81 Blue Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 273 The third phase is sourced through the 7 μF capacitor which provides the phase shift to start rotation and help to control the fan speed. The DC fan system uses a 48V DC output that energizes the DC fan motor. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 274: Testing The Main Fan Inverter Circuit Board Diagnostic Leds

    Failure to do so can result in equipment damage or personal injury. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 275: Ac Fan System Test

    6. Remove the 500V DC source power. 7. Wait a few minutes and verify power is not present with a DVM at the fuse input. 8. Remove the AC fan inverter circuit board from the test fixture. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 276: Dc Fan System Test

    6. Remove the 500V DC source power. 7. Wait a few minutes and verify power is not present with a DVM at the fuse input. 8. Remove the DC fan inverter circuit board from the test fixture. Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...

  • Page 277: Available Fan System Kits

    • Frame 13 Fan System Spare Parts on page • Frame 14 Fan System Spare Parts on page • Frame 10 AFE Fan System Spare Parts on page • Frame 13 AFE Fan System Spare Parts on page Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 278 Appendix B Available Fan System Kits Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 279 Available Fan System Kits Appendix B Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 280 Appendix B Available Fan System Kits Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 281 Available Fan System Kits Appendix B Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 282 Appendix B Available Fan System Kits Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 283 Available Fan System Kits Appendix B Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 284 Appendix B Available Fan System Kits Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 285 Available Fan System Kits Appendix B Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 286 Appendix B Available Fan System Kits Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 287 Available Fan System Kits Appendix B Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 288 Appendix B Available Fan System Kits Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 289 Available Fan System Kits Appendix B Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 290 Appendix B Available Fan System Kits Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 291 Available Fan System Kits Appendix B Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 292 Appendix B Available Fan System Kits Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 293 Available Fan System Kits Appendix B Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 294 Appendix B Available Fan System Kits Notes: Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014...
  • Page 296 New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.

This manual is also suitable for:

Allen-bradleypowerflex 700sAllen-bradleypowerflex 700afe

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