Rockwell Automation 20D-700H, 20D-700S User Manual

Installation Instructions

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.

PFLEX-IN027A-EN-P

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

What This Kit Includes

Tools That You Need

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

• #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

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

What You Need to Do

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

Converter

Unit

Inverter

Unit

Converter

Step: 1 Remove Power
from the Drive

Complete the appropriate steps depending upon whether you are replacing a
main fan capacitor on a converter or inverter unit.

Unit

Inverter

Unit

Inverter

Unit

Converter

Unit

Inverter

Unit

Inverter

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.

Converter

Unit

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.

L1 L2 L3

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

I

O

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.

Loosen two
screws and
swing control
frame out

If present, remove
wiring from X50
terminal block

2. Remove the four hexalobular screws that secure the air flow plate to the
drive enclosure and slide the plate off the drive.

Note: AC input drive shown

Converter unit

Inverter unit

Remove four screws and air flow plate

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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 re­assembly is 1.5 N

Top two screws are
5 x 10 mm

Remove four screws
and covers

Bottom two screws
are 5 x 16 mm

•m (13.3 lb•in).

DC BUS CONDUCTORS AND CAPACITORS

!

OPERATE AT HIGH VOLTAGE. REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING

DANGER

4. If necessary, remove the side protective cover.

Inverter unit shown

Remove side cover,
if necessary.

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

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

• 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.

below.

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

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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

Remove screws

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

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.

Cut cable ties

Disconnect X3

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 “Brown”

and “Blue” wires

Unscrew and

remove capacitor

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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

Front view of drive and

fan capacitor bracket

Fan capacitor bracket

•m (178 lb•in).

Washer and screw

Fan inverter

circuit board

Side view of fan

capacitor bracket

Front of drive

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

10. Secure the new fan capacitor to the bracket using the M12 hexagonal nut
and lock washer provided. Tightening torque is 5 N

Fan capacitor

•m (44.2 lb•in).

Lock washer

Hexagonal nut

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.

IMPORTANT

Verify that no wire shields are touching the sheet metal
on the drive chassis.

13. Complete the remaining installation in the reverse order of removal as
detailed in the previous steps for the Converter Unit.

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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
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.

. For PowerFlex 700S drives, if you

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.

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

J2

J1

•m (12 lb•in).

Remove four screws
and assembly

J4
J5

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

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.

PowerFlex 700S drive shown

Cut cable tie
and remove
wire bundle and
grommet from
bracket

V phase power structure

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

Disconnect
wires from
bottom of
fuse holder

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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

•in).

lb

•m (177

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).

Using a pliers,
remove connector
from bracket

Disconnect fan
cable

Remove screw from
chassis in front of
fan housing.

Remove screws
and fan housing

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

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

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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

Cut cable ties

•m (31 lb•in).

Remove four screws

Use handle to remove fan

inverter assembly

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

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.

Disconnect “Brown”
and “Blue” wires

Remove cable tieRemove cable tie

Unscrew and
remove capacitor

13. Secure the new fan capacitor to the bracket using the M12 hexagonal nut
and lock washer provided. Tightening torque is 5 N

Fan capacitor

Lock washer

•m (44.2 lb•in).

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

Hex nut

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
20 N

•m (178 lb•in).

NOT touch. Tightening torque is

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.

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

17. Complete the remaining installation in the reverse order of removal as
detailed in the previous steps for the Inverter Unit.

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

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*PN-117698*

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Publication PFLEX-IN027A-EN-P – July 2011

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. Printed in USA.