Installation Instructions
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Introduction
Use this document to upgrade the fan inverter on a PowerFlex 700S or 700H
frame 9 drive.
ATTENTION: To avoid an electric shock hazard, ensure that all power to the drive
has been removed before performing the following.
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus
capacitors has discharged before performing any work on the drive. Measure the
DC bus voltage at the DC+ & DC- terminals. The voltage must be zero.
ATTENTION: HOT surfaces can cause severe burns. Do not touch the heatsink
surface during operation of the drive. After disconnecting power allow time for
cooling.
ATTENTION: Hazard of permanent eye damage exists when using optical
transmission equipment. This product emits intense light and invisible radiation.
Do not look into fiber-optic ports or fiber-optic cable connectors.
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 handbook.
What this Kit Contains
Verify that your kit contains the items listed in the following table. If your kit
does not contain the correct items, contact your Allen-Bradley sales
representative.
Part No.
FR09968
Quantity:
1
133256
1
Description
Connector Plate, EMI Protection Plate, Fan Assembly
and Fan Motor Capacitor
Disposable Static Discharge Wrist-strap
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
What You Need to Do
❐ Step 1: Remove power from the drive.
❐ Step 2: Remove the covers from the drive.
❐ Step 3: Remove the components from the Control Frame.
❐ Step 4: Remove the Control Frame and Conduit from the drive.
❐ Step 5: Remove the Cross Plate.
❐ Step 6: Remove the EMI-Protection Plate.
❐ Step 7: Remove the Main Fan.
❐ Step 8: Remove the Connector Plate.
❐ Step 9: Remove the AC components from the new Connector Plate
(on DC Input Drives).
❐ Step 10: Assemble the new Connector Plate.
❐ Step 11: Replace the fan capacitor.
❐ Step 12: Connect the new components.
❐ Step 13: Reassemble the drive.
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Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Step 1: Removing Power
from the Drive
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus
capacitors has discharged before performing any work on the drive. Measure the
DC bus voltage at the DC+ & DC- terminals of the Power Terminal Block. The
voltage must be zero.
ATTENTION: 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.
1. Turn off and lock out input power. Wait five minutes.
2. Verify that there is no voltage at the drive’s input power terminals.
3. Measure the DC bus voltage at the DC+ & DC- terminals on the Power
Terminal Block. The voltage must be zero.
L1
L2
L3
I
O
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PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Step 2: Removing Covers
from the Drive
Remove the M4x8 POZIDRIV ® screws, which secure the covers to the drive, and
then remove the covers. Proper tightening torque for reassembly is 3 N•m (27
lb•in).
(8 Screws)
(3 Screws)
L1
L2
L3
L1
L2
L3
U/T1 V/T2 W/T3 U/T1 V/T2 W/T3
(8 Screws)
POZIDRIV is a registered trademark of Phillips Screw Company
4
Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
DPI / HIM Assembly
Step 3: Removing the
Components from the
Control Frame
You must remove the DPI / HIM Assembly from the Control Frame, in order to
gain access to the fasteners that secure the Control Frame to the drive.
Task
Description
Remove the two M3x6 Phillips® screws, which secure the door on the front of the DPI / HIM Assembly.
Proper tightening torque for reassembly is 0.9 N•m (8 lb•in).
Open the door.
A
B
Unplug the DPI cable from the X2 connector.
Disconnect cables from communication adapter if present.
On 700S drives only, unplug the cable from the X4 connector.
Remove the four M3x6 Phillips screws, which secure the DPI / HIM Assembly to the Control Frame, and
remove the Assembly.
Proper tightening torque for reassembly is 0.9 N•m (8 lb•in).
C
D
IMPORTANT
Before removing connections and wires, mark the connections and wires to
avoid incorrect wiring during assembly.
B
A
C
C
A
D
D
D
D
=
Phillips is a registered trademark of Phillips Screw Company
Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
5
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
700S Control Assembly (on 700S drives only)
On 700S drives, you must also remove the Control Assembly, the Voltage
Feedback Circuit Board and the Power Interface Circuit Board.
Task
Description
On the 700S control assembly, unplug I/O and SynchLink cables from the Main Control Board, unplug
feedback wiring from feedback option card and unplug communication cables from Drivelogix controller.
A
Unplug the J2 and J7 ribbon cables from the Main Control Board.
B
Loosen the captive screw.
C
Swing the Control Assembly towards the front of the drive.
D
Lift the Control Assembly up and off of the hinge.
E
ATTENTION: Hazard of permanent eye damage exists when using optical
transmission equipment. This product emits intense light and invisible
radiation. Do not look into fiber-optic ports or fiber-optic cable connectors.
IMPORTANT
Minimum inside bend radius for fiber-optic cable is 25.4 mm (1 in.). Any
bends with a shorter inside radius can permanently damage the fiber-optic
cable. Signal attenuation increases with decreased inside bend radii.
IMPORTANT
Before removing connections and wires, mark the connections and wires to
avoid incorrect wiring during assembly.
B
B
=
E
D
C
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Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
700S Voltage Feedback Circuit Board (on 700S drives only)
Task
Description
Carefully disconnect fiber-optic cables from sockets J4 and J5 of the Voltage Feedback Circuit Board, and carefully set
them aside.
A
Disconnect cables from sockets J1, J2 and J8.
B
C
Remove the four M3x6 Phillips screws, which secure the clear plastic shield to the standoffs, and remove the shield.
Proper tightening torque for reassembly is 0.9 N•m (8 lb•in).
D
Remove the five 3 mm hex standoffs, which support the clear plastic shield, and secure the Voltage Feedback Circuit
Board to its mounting plate. Proper tightening torque for reassembly is 0.9 N•m (8 lb•in).
Remove the Voltage Feedback Circuit Board from its mounting plate.
E
ATTENTION: Hazard of permanent eye damage exists when using optical
transmission equipment. This product emits intense light and invisible
radiation. Do not look into fiber-optic ports or fiber-optic cable connectors.
IMPORTANT
Minimum inside bend radius for fiber-optic cable is 25.4 mm (1 in.). Any
bends with a shorter inside radius can permanently damage the fiber-optic
cable. Signal attenuation increases with decreased inside bend radii.
IMPORTANT
Before removing connections and wires, mark the connections and wires to
avoid incorrect wiring during assembly.
B
=
D
B
D
C
D
A
C
D
B
D
C
C
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PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
700S Power Interface Circuit Board (on 700S drives only)
Task
A
Description
Disconnect the ribbon cables from the sockets at the top of the Power Interface Circuit Board, and
carefully set them aside.
B
Carefully disconnect fiber-optic cables from sockets along the right-hand side of the Power Interface
Circuit Board, and carefully set them aside.
C
Disconnect the other cables from the sockets on the Power Interface Circuit Board, and carefully set them
aside.
D
Remove the five M3x6 Phillips screws, which secure the Power Interface Circuit Board to the Control
Frame, and remove the circuit board.
Proper tightening torque for reassembly is 0.9 N•m (8 lb•in).
Remove the Power Interface Circuit Board from the Control Frame.
E
ATTENTION: Hazard of permanent eye damage exists when using optical
transmission equipment. This product emits intense light and invisible
radiation. Do not look into fiber-optic ports or fiber-optic cable connectors.
IMPORTANT
Minimum inside bend radius for fiber-optic cable is 25.4 mm (1 in.). Any
bends with a shorter inside radius can permanently damage the fiber-optic
cable. Signal attenuation increases with decreased inside bend radii.
IMPORTANT
Before removing connections and wires, mark the connections and wires to
avoid incorrect wiring during assembly.
A
D
D
B
D
D
D
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Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
=
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
700H I/O Boards and Control Assembly (on 700H drives only)
On 700H drives, you must also remove the Control Assembly and I/O
boards.
Task
Description
Open the enclosure that contains the Control and I/O Boards and carefully unplug the DPI cable and any
I/O cables.
A
Remove the three M4 Pozidrive screws, which secure the Control Assembly to the drive.
Proper tightening torque for reassembly is 0.9 N•m (8 lb•in).
Remove the Control Assembly.
B
C
IMPORTANT
Before removing connections and wires, mark the connections and wires to
avoid incorrect wiring during assembly.
=
B
Do not remove enclosure cover or I/O
boards. Enclosure is illustrated without
the cover and boards for clarity.
B
B
Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
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PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Step 4: Removing the Control
Frame and Conduit
Task
A
B
C
Description
If removing a Control Frame from a DC input drive with precharge interlock, disconnect the wiring from
terminal strip X50.
Remove the eight M4x8 Pozidrive screws, which secure the Control Frame to the drive.
Proper tightening torque for reassembly is 3 N•m (27 lb•in).
Remove the six M4x8 Pozidrive screws, which secure the Conduit to the drive.
Proper tightening torque for reassembly is 3 N•m (27 lb•in).
Remove the Conduit from the drive.
D
E
Remove the Control Frame from the drive while carefully routing the cables and wires through the access
hole of the Control Frame.
IMPORTANT
Before removing connections and wires, mark the connections and wires to
avoid incorrect wiring during assembly.
Control Frame
Conduit
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Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Step 5: Removing the Cross
Plate
Task
Description
Disconnect the MOV if present.
A
Disconnect the Cross Plate fan if present.
B
C
D
Disconnect the grounding wires.
Proper tightening torque for reassembly is 4 N•m (35 lb•in).
Remove the three M4x8 Pozidrive screws, which secure the Cross Plate to the drive.
Proper tightening torque for reassembly is 3 N•m (27 lb•in).
Remove the Cross Plate from the drive.
E
Note the sequence of
hardware.
Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
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PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Step 6: Removing the Old
EMI-Protection Plate
Task
A
B
C
D
B
E
B
Description
Disconnect the external cables, which connect the drive to incoming AC power and
the motor, from the power terminal block.
Disconnect the internal cables from the power terminal block and place them at the
top of the drive, in order to gain access to the EMI-Protection Plate.
Proper tightening torque for reassembly is 20 N•m (177 lb•in).
Remove four M4x8 Pozidrive screws, which secure the EMI-Protection Plate to the
drive.
Proper tightening torque for reassembly is 3 N•m (27 lb•in).
Remove the two screws, which secure the common mode inductors. Then remove
the inductors.
Proper tightening torque for reassembly is 3 N•m (27 lb•in).
Disconnect the fan which is mounted on the EMI-Protection Plate. You may need to
remove the fan on the new EMI Plate to rotate it. If you do, the proper tightening
torque for reassembly is 3 N•m (27 lb•in).
Remove the EMI-Protection Plate from the drive.
F
C
C
EMI
Protection
Plate
D
C
D
C
E
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Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Step 7: Removing the Old
Main Fan
Task
A
B
Description
Remove the M4x8 Pozidrive screw, which secures the fan inverter cover. Then lift and
pull the plate away from the drive.
Proper tightening torque for reassembly is 3 N•m (27 lb•in).
Disconnect the motor lead wires including the ground wire. Refer to Figure 1 on
page 20, when reconnecting the motor.
X2
X8
S1
NO
4
3
2
1
If a common mode choke is present on
the cover, disconnect and remove it.
X7
X5
X1
X4
X6
Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
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PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Step 7: Removing the Old
Main Fan (continued)
Task
C
Description
Check that the upper mounting bolts securely hold drive on the wall of the system enclosure. Remove
lower mounting bolts from the bottom of the frame.
Remove the four rubber bushings, which cover the screws that mount the fan assembly.
D
E
F
Loosen, but do NOT remove, four M4X8 Pozidrive front screws (which are accessible through the holes
vacated by the rubber bushings) so that the fan assembly can easily slide off. To loosen, but not remove
these front screws, turn them 12 times.
Proper tightening torque for reassembly is 3 N•m (27 lb•in).
Remove four M4X8 Pozidrive screws from bottom of the frame. The fan plate should now easily slide
down. If it does not, loosen the front screws another turn and attempt again. Continue loosening the
screws until the fan plate slides easily from the drive.
Proper tightening torque for reassembly is 3 N•m (27 lb•in).
D E
D E
D E
D E
F
C
C
F
F
F
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Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
F
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Step 8: Removing the
Connector Plate
Task
A
Description
Remove the M5 Pozidrive screws, which secure the Connector Plate.
Proper tightening torque for reassembly is 4 N•m (35 lb•in).
Then lift and pull the plate away from the drive.
B
C
Remove all connectors and bus bars from the old Connector Plate.
Proper tightening torque for reassembly is 4 N•m (35 lb•in).
A B
C
Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
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PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Step 9: Removing AC
Components from the New
Connector Plate
(on DC Input Drives Only)
IMPORTANT
Task
A
B
Do not perform this step on drives with AC input. It removes noise mitigation
circuitry, which is important to drives with AC input.
Description
Remove the 6 M4 Pozidrive screws on the front of the connector plate, which secure the cover for the
circuit board containing AC conditioning circuitry.
Proper tightening torque for reassembly is 3 N•m (27 lb•in).
Remove the M4 Pozidrive screw on the back of the connector plate, which secures the cover for the
circuit board containing AC conditioning circuitry.
Proper tightening torque for reassembly is 3 N•m (27 lb•in).
Remove the plate.
C
Remove the circuit board.
D
Replace the plate and screws.
E
A
A
A
A
A
A
=
B
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Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Step 10: Assembling New
Connector Plate
a
Task
A
Description
Mount the connectors and bus bars on the new connector plate.
Proper tightening torque for reassembly is 3 N•m (27 lb•in).
Connect the AC conditioning circuit to the terminals for incoming three-phase power.
B
A
=
B
Components from AC
input drive shown.
Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
17
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Step 11: Replacing the Motor
Capacitor
a
Task
Description
Disconnect the wires from the old motor capacitor.
A
Remove the nut, which secures the capacitor to its bracket.
B
Remove the old capacitor and install the new one.
C
Install the new capacitor in reverse order of above steps.
D
IMPORTANT
Before removing connections and wires, mark the connections and wires to
avoid incorrect wiring during assembly.
B
A
C
The mounting bracket for the capacitor will vary with revision
of drive. The most recent revision is shown.
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Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Step 12: Connecting the New
Components
Task
Description
Pre-install the new connector plate by laying it near its final position.
A
Connect the components as shown in Figure 1 on page 20.
B
Components from AC input drive shown.
Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
19
20
Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
X2
-
Fan Frequency
Converter
F1, 6A
X8
4
From Power
Board X7
Area Under Fan Power Supply Plate
Off Off On Off
S1 - Setup Switch
S1-1 S1-2 S1-3 S1-4
+
F2, 6A
From Power
Board X10
X5
X4
Black 1
Black 2
Black 3
Black 4
Black 5
Black 6
2.2 mf
2.2 mf
Area Under Connector Plate
PCB
To Three-Phase
AC Input
7 mf
10 MW
10 MW
Fan Area
Black
Yellow/Green
Blue
M1
Main Fan
Brown
M
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Figure 1 - Schematic of Upgraded Fan Inverter Scheme
PowerFlex 700S and 700H Fan Inverter Upgrade Kit (Frame 9)
Step 13: Reassemble the
Drive
Assemble the drive in reverse order of disassembly.
When reconnecting internal cables to the power terminal block, remember to
route incoming AC cables through the common mode inductors on the new
EMI Protection Plate.
If the cable for the fan on the new EMI Protection Plate does not reach the
connection point, rotate the fan 180 degrees.
Rockwell Automation Publication PFLEX-IN015A-EN-P - March 2005
21
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TechConnectSM support programs. For more information, contact your local distributor or Rockwell Automation
representative, or visit http://www.rockwellautomation.com/support/.
Installation Assistance
If you experience a problem within the first 24 hours of installation, review the information that is contained in this
manual. You can contact Customer Support for initial help in getting your product up and running.
United States or Canada
1.440.646.3434
Outside United States or Canada
Use the Worldwide Locator at http://www.rockwellautomation.com/rockwellautomation/support/overview.page, or contact your
local Rockwell Automation representative.
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.
United States
Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your
distributor to complete the return process.
Outside United States
Please contact your local Rockwell Automation representative for the return procedure.
Documentation Feedback
Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this
document, complete this form, publication RA-DU002, available at http://www.rockwellautomation.com/literature/.
U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, E-mail: [email protected]
Online: www.ab.com/support/abdrives
Allen-Bradley, Rockwell Software, Rockwell Automation, PowerFlex, RSLinx, DriveExplorer, DriveExecutive, ControlFLASH, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Publication PFLEX-IN015A-EN-P - March 2005
366144-P01
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
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