Allen-Bradley PowerFlex 700S Installation Instructions Manual

Brand: Allen-Bradley

Model: PowerFlex 700S

Type: Installation Instructions Manual

This manual is also suitable for

PowerFlex 700H

The Allen-Bradley PowerFlex 700S is a compact, high-performance AC drive designed to control a wide range of industrial applications, from simple fan and pump loads to complex multi-motor systems. It features an intuitive user interface, built-in intelligence, and a wide range of connectivity options, making it easy to integrate into your control system. With its robust construction and advanced control algorithms, the PowerFlex 700S provides reliable operation and precise control, even in the most demanding applications.

Installation Instructions

PFLEX-IN027A-EN-P

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan

Capacitor Replacement Kit

ATTENTION: The sheet metal cover and mounting screws on the ASIC

Board located on the power structure are energized at (-) DC bus potential

high voltage. Risk of electrical shock, injury, or death exists if someone

comes into contact with the assembly.

ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive

parts and assemblies. Static control precautions are required when

installing, testing, servicing or repairing this assembly. Component

damage may result if ESD control procedures are not followed. If you are

not familiar with static control procedures, reference A-B publication

8000-4.5.2, “Guarding Against Electrostatic Damage” or any other

applicable ESD protection guide.

ATTENTION: Only qualified personnel familiar with adjustable frequency

AC drives and associated machinery should perform maintenance/repair of

the system. Failure to comply may result in personal injury and/or

equipment damage.

ATTENTION: The following information is merely a guide for proper

installation. Rockwell Automation cannot assume responsibility for the

compliance or the noncompliance to any code, national, local or otherwise

for the proper installation of this drive or associated equipment. A hazard

of personal injury and/or equipment damage exists if codes are ignored

during installation.

2 Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

What This Kit Includes

Tools That You Need

• #2 POZIDRIV® screwdriver

• T20 hexalobular screwdriver

• Hexagonal head screwdriver/bit

• 19 mm wrench

• Wire cutter

• Nose pliers

POZIDRIV® is a registered trademark of the Phillips Screw Company

Photo ID# Part Description Quantity

1Fan 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

Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011 3

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

What You Need to Do

Complete the appropriate steps depending upon whether you are replacing a

main fan capacitor on a converter or inverter unit.

Step: 1 Remove Power

from the Drive

1. Turn off and lock out input power. Wait fifteen minutes.

2. Verify that there is no voltage at the drive’s input power terminals.

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.

Frame 13 Drive Frame 14 1500A Drive Frame 14 Drive Above 1500A

Converter

Unit

Inverter

Unit

Converter

Unit

Inverter

Unit

Inverter

Unit

Converter

Unit

Inverter

Unit

Inverter

Unit

Converter

Unit

ATTENTION: To avoid an electric shock hazard, verify that the voltage on

the bus capacitors has discharged before performing any work on the

drive. 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.

Remove power before making or breaking cable connections. When you

remove or insert a cable connector with power applied, an electrical arc

may occur. An electrical arc can cause personal injury or property damage

by:

• sending an erroneous signal to your system’s field devices, causing

unintended machine motion

• causing an explosion in a hazardous environment

Electrical arcing causes excessive wear to contacts on both the module

and its mating connector. Worn contacts may create electrical resistance.

L1 L2 L3

4 Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

Step: 2 Remove the

Protective Covers

1. If you are replacing the fan capacitor on an inverter unit for an AC input

drive, skip this step and continue with step 2 below. If you are replacing the

fan capacitor on a converter unit or an inverter unit for a DC input drive,

complete the following steps:

a. For DC input drives with a precharge interlock, disconnect the input

wiring to the X50 terminal block on the control frame.

b. Loosen the two hexalobular screws that secure the control frame to the

enclosure and swing the control frame away from the converter unit.

2. Remove the four hexalobular screws that secure the air flow plate to the

drive enclosure and slide the plate off the drive.

Loosen two

screws and

swing control

frame out

If present, remove

wiring from X50

terminal block

Remove four screws and air flow plate

Converter unit

Inverter unit

Note: AC input drive shown

Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011 5

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

3. Remove the four POZIDRIV screws that secure the protective cover to

the unit being repaired and remove the cover. Tightening torque for re-

assembly is 1.5 N

•m (13.3 lb•in).

4. If necessary, remove the side protective cover.

DC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE. REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER

Remove four screws

and covers

Top two screws are

5 x 10 mm

Bottom two screws

are 5 x 16 mm

Remove side cover,

if necessary.

Inverter unit shown

6 Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

Step: 3 Remove the

Existing Fan Capacitor

The procedures vary depending on whether you are replacing a main fan

capacitor on a converter or inverter unit.

• If you are replacing a capacitor for a fan on the converter unit, continue

with Replacing the Fan Capacitor on the Converter Unit

below.

• If you are replacing a capacitor for a fan on the inverter unit, continue with

Replacing the Fan Capacitor on the Inverter Unit

on page 11.

Replacing the Fan Capacitor on the Converter Unit

1. Remove the two fuses from the fuse holder.

2. Disconnect the +DC and -DC wires from the fan fuse holder.

3. Remove the M4 x 8 mm POZIDRIV screw that secures the fuse holder

assembly to the drive chassis and remove the fuse holder assembly.

Tightening torque for re-assembly is 3 N

•m (26.5 lb•in).

Remove fuses, +DC and -DC

wires, screw and fuse holder

Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011 7

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

4. Remove the four Phillips® head screws that secure the fan inverter

protection cover to the drive, and remove the cover. Tightening torque for

re-assembly is 0.9 N

•m (8 lb•in).

Remove screws

Remove cover

8 Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

5. Disconnect the connector X3 from the fan inverter circuit board.

6. Cut the cable ties that secure the fan capacitor wires to the wire bundle.

7. Disconnect the fan capacitor wires from the connectors marked “Brown”

and “Blue.”

8. Unscrew and remove the existing fan capacitor from the inverter assembly.

Disconnect X3

Cut cable ties

Disconnect “Brown”

and “Blue” wires

Unscrew and

remove capacitor

Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011 9

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

9. Secure the fan capacitor bracket to the drive chassis using the M8 x 12 mm

hexagonal socket screw and spring washer provided as shown below.

Tightening torque is 20 N

•m (178 lb•in).

Fan capacitor bracket

Fan inverter

circuit board

Washer and screw

Side view of fan

capacitor bracket

Front of drive

Front view of drive and

fan capacitor bracket

10 Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

10. Secure the new fan capacitor to the bracket using the M12 hexagonal nut

and lock washer provided. Tightening torque is 5 N

•m (44.2 lb•in).

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.

13. Complete the remaining installation in the reverse order of removal as

detailed in the previous steps for the Converter Unit.

IMPORTANT

Verify that no wire shields are touching the sheet metal

on the drive chassis.

Fan capacitor

Lock washer

Hexagonal nut

Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011 11

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

Replacing the Fan Capacitor on the Inverter Unit

1. If you are replacing a fan capacitor on a PowerFlex 700H drive inverter

unit, continue with step 2 on page 12

. For PowerFlex 700S drives, if you

are replacing the fan capacitor on the V phase of the inverter unit,

complete steps a.…c.

a. Disconnect the bus connection cable from connector J2 and the motor

feedback connection cable from connector J1 on the voltage feedback

board.

b. Disconnect the fiber-optic cables from connectors J4 and J5 on the

voltage feedback board.

c. Remove the four POZIDRIV screws that secure the voltage feedback

board assembly to the fan housing and remove the assembly. Tightening

torque for re-assembly is 1.35 N

•m (12 lb•in).

IMPORTANT

Minimum inside bend radius for fiber-optic cable is 50 mm

(2 in.). Any bends with a shorter inside radius can

permanently damage the fiber-optic cable. Signal

attenuation increases with decreased inside bend radii.

Remove four screws

and assembly

12 Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

2. If you are replacing the fan capacitor on the V phase power structure of the

inverter unit, cut the cable tie that secures the ASIC board fiber-optic

cable bundle to the fan housing (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.

3. Disconnect the fan inverter power supply wires from the bottom of the

fuse holder.

PowerFlex 700S drive shown

Cut cable tie

and remove

wire bundle and

grommet from

bracket

V phase power structure

Disconnect

wires from

bottom of

fuse holder

Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011 13

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

4. Disconnect the fan inverter connector from the connector on the support

bracket and pull the connector out of the sheet metal support bracket

using a pliers.

5. Remove the M8 x 20 mm hexagonal socket screw from the chassis in front

of the fan housing in order to allow room for the fan housing to be

removed from the unit. Tightening torque for re-assembly is 20 N

•m (177

•in).

6. Remove the four POZIDRIV screws that secure the main fan housing to

the inverter assembly and remove the fan housing. Tightening torque for

re-assembly is 3.5 N

•m (31 lb•in).

Disconnect fan

cable

Remove screws

and fan housing

Using a pliers,

remove connector

from bracket

Remove screw from

chassis in front of

fan housing.

14 Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

7. Carefully push the rubber grommet with the fan wire and connectors

through the hole in the drive chassis.

Remove grommet

and fan wires

from drive chassis

Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011 15

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

8. On the inside of the housing for the fan, cut the cable ties that secure the

fan inverter cable to the housing.

9. Remove the four M5 x 10 mm POZIDRIV screws that secure the fan

inverter assembly to the fan housing and, using the handle provided at the

base of the assembly, slide the fan inverter assembly out of the housing.

Tightening torque for re-assembly is 3.5 N

•m (31 lb•in).

Remove four screws

Cut cable ties

Use handle to remove fan

inverter assembly

16 Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

10. Cut the cable ties that secure the fan capacitor wires to the wire bundle.

11. Disconnect the fan capacitor wires from the connectors marked “Brown”

and “Blue.”

12. Unscrew and remove the existing fan capacitor from the inverter assembly.

13. Secure the new fan capacitor to the bracket using the M12 hexagonal nut

and lock washer provided. Tightening torque is 5 N

•m (44.2 lb•in).

Disconnect “Brown”

and “Blue” wires

Unscrew and

remove capacitor

Remove cable tieRemove cable tie

Fan capacitor

Lock washer

Hex nut

Rockwell Automation Publication PFLEX-IN027A-EN-P - July 2011 17

PowerFlex 700H and 700S AC Drives Frames 13 and 14 Main Fan Capacitor Replacement Kit

14. Secure the fan capacitor bracket (and fan capacitor) to the fan inverter

assembly using the M8 x 12 mm hexagonal socket screw and spring washer

provided as shown below. Secure the capacitor in a position that allows the

maximum amount of clearance possible between the transformer and

capacitor, ensuring that they DO

NOT touch. Tightening torque is

20 N

•m (178 lb•in).

15. Connect the new fan capacitor wires to the connectors marked “Brown”

and “Blue.”

16. Secure the fan capacitor wires to the fan wire bundle using cable ties.

17. Complete the remaining installation in the reverse order of removal as

detailed in the previous steps for the Inverter Unit.

IMPORTANT

Verify that no wire shields are touching the sheet metal on the

fan inverter assembly.

IMPORTANT:

Verify that the fan

capacitor does not

touch the fan

transformer.

Secure fan bracket

(and capacitor) to

fan inverter

assembly using

hexagonal socket

screw and washer in

orientation shown

at left

Secure fan capacitor

wires to wire bundle

using cable ties

Connect fan capacitor

wires to “Brown” and

“Blue” connectors

Publication PFLEX-IN027A-EN-P – July 2011

U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, E-mail: suppor[email protected].com, Online: www.ab.com/support/abdrives

www.rockwellautomation.com

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cas:

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Street,

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