Rockwell Automation Allen-BradleyPowerFlex 700H User manual

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

Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.
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.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
Allen-Bradley, PowerFlex, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 3
Summary of Changes
This manual contains new and updated information.
New and Updated
Information
This table contains the changes made to this revision.
Topic Page
Added information on parts availability to Phase 3 - Starts January 1, 2015 in the Energy-related
Products Fan Efficiency Directive section.
13
Add spare part information for the frame 9 drive fan bracket. 20
Updated the Frame 10 AFE Drive Configurations section to include a drawing and information on the
IP20 NEMA / UL Type 1 (MCC) Cabinet.
186
Updated the DC Fan Systems spare parts table to include the new LCL filter fan DC power supply kit. 188
Updated the Frame 10 AFE (LCL Filter Section) DC Fan System Wiring Schematic Diagram to reflect the
new LCL filter fan DC power supply kit.
191
Updated the LCL Filter Section table to include the new LCL filter fan DC power supply kit. 214
Added the LCL Filter DC Fan Power Supply Kit (SK-Y1-DCPS2-F10) Removal and Installation procedures
for the new kit.
219
Added the LCL Filter DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1) Removal and Installation
procedures for the new kit.
225
Updated the LCL Filter Main DC Fan (SK-Y1-DCFAN1) Assembly Removal and Installation to include new
steps.
230
Updated the DC Fan Systems spare parts table to include the new LCL filter fan DC power supply kit. 239
Updated the LCL Filter Fan DC Power Supply (SK-Y1-DCPS2-F13) Wiring Diagram - Newer Version to
reflect the new LCL filter fan DC power supply kit.
247
Updated the LCL Filter Section table to include the new LCL filter fan DC power supply kit. 243
Added the LCL Filter Fan DC Power Supply (SK-Y1-DCPS2-F13) Removal and Installation procedures for
the new kit.
247
Updated the Spare Part Kit Contents to include the new LCL filter fan DC power supply kits. 277

4Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Summary of Changes
Notes:

Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 5
Table of Contents
Preface Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Verify Your Drive Frame Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
What is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Energy-related Products Fan Efficiency Directive . . . . . . . . . . . . . . . . . . . 12
Phase 1 - Starts January 1, 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Phase 2 - Starts January 1, 2013, and Ending December 31, 2014 . 13
Phase 3 - Starts January 1, 2015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fan System Replacement FAQs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fan System Replacement Recommendations. . . . . . . . . . . . . . . . . . . . 14
How to Use this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fastener/Tool/Torque Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Product Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Class 1 LED Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 1
PowerFlex 700H and 700S Drives -
Frame 9 Procedures
Frame 9 Fan System Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
AC Fan Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DC Fan Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Tools Needed for Frame 9 Fan System Repairs. . . . . . . . . . . . . . . . . . . . . . 20
Frame 9 Schematic Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Frame 9 Fan System Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . 22
Remove Power from the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Remove the Lower Protective Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remove the Upper Protective Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removing the Main Fan Inverter Capacitor Bracket. . . . . . . . . . . . . 25
Main Fan Fuses (20-PP20202) and Fuse Holder (20-PP20300)
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Main Fan Inverter Cooling Fan (20-PP01049) Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Main AC Fan Inverter Capacitor (SK-H1-FANCAP-F9) Removal
and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Main AC Fan Inverter Circuit Board Assembly (20-VB00299)
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Main DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1)
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
AC to DC Fan System Retrofit Kit (SK-H1-DCFANRETROFIT-
F9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Main AC Fan (20-PP01080) and Main DC Fan (SK-Y1-DCFAN1)
Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Main AC Fan Inverter Output Transformer (20-PP09055) Removal
and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Chassis Stirring Fan (20-PP01068) Removal and Installation . . . . 50

6Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Table of Contents
Cross-plate Stirring Fan (20-PP01068) Removal and Installation . 51
Internal Stirring Fan (20-PP01068) Removal and Installation . . . . 52
Chapter 2
PowerFlex 700H and 700S Drives -
Frame 10 Procedures
Frame 10 Fan System Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
AC Fan Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
DC Fan Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Tools Needed for Frame 10 Fan System Repairs. . . . . . . . . . . . . . . . . . . . . 56
Frame 10 Schematic Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Frame 10 Fan System Replacement Procedures. . . . . . . . . . . . . . . . . . . . . . 59
Remove Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Move the Control Frame and Remove the Air Flow Plate and
Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Remove the Main AC or DC Fan Power Supply Assemblies . . . . . . 63
Main AC Fan Inverter Circuit Board (20-VB00299) and AC Fan
Output Transformer Assembly [20-FR10844 (Left) or 20-FR10845
(Right)] Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Main DC Fan Power Supply System (SK-H1-DCFANBD1) Removal
and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
AC to DC Fan System Retrofit Kit (SK-H1-DCFANRETROFIT-
F10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Main AC Fan Inverter Capacitor (SK-H1-FANCAP-F1012)
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Main AC Fan (20-PP01080) and Main DC Fan (SK-Y1-DCFAN1)
Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
ASIC Circuit Board Assembly Cooling Fan (20-PP01096) Removal
and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
AC or DC Fan System Fuses (20-PP20202) and Fuse Holder (20-
PP20300) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Chapter 3
PowerFlex 700H and 700S Drives -
Frame 11 Procedures
Frame 11 Fan System Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
AC Fan Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
DC Fan Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Tools Needed for Frame 11 Fan System Repairs. . . . . . . . . . . . . . . . . . . . . 88
Frame 11 Schematic Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Frame 11 Fan System Replacement Procedures. . . . . . . . . . . . . . . . . . . . . . 91
Remove Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Move the Control Frame and Remove the Air Flow Plate and
Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Removing the Main AC or DC Fan Power Supply Assemblies . . . . 95
Main AC Fan Inverter Circuit Board (20-VB00299) and AC Output
Transformer Assembly (20-FR10845) Removal and Installation. . 99
Main DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1)
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 7
Table of Contents
AC to DC Fan System Retrofit Kit (SK-H1-DCFANRETROFIT-
F11). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Main AC Fan Inverter Capacitor (SK-H1-FANCAP-F11) Removal
and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Main AC Fan (20-PP01080) and Main DC Fan (SK-Y1-DCFAN1)
Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
ASIC Circuit Board Assembly Cooling Fan (20-PP01096) Removal
and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
AC or DC Fan System Fuses (20-PP20202) and Fuse Holder (20-
PP20300) Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Chapter 4
PowerFlex 700H and 700S Drives -
Frame 12 Procedures
Frame 12 Fan System Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
AC Fan System Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
DC Fan System Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Frame 12 Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Chapter 5
PowerFlex 700H and 700S Drives -
Frame 13 Procedures
Frame 13 Drive Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Frame 13 Fan System Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
AC Fan Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
DC Fan Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Tools Needed for Frame 13 Fan System Repairs . . . . . . . . . . . . . . . . . . . 125
Frame 13 AFE Schematic Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Frame 13 Fan System Replacement Procedures . . . . . . . . . . . . . . . . . . . . 134
Remove Power from the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Move the Control Frame,and Remove the Screens, Airflow Plates, and
Protective Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Remove the Voltage Feedback Circuit Board Assembly (Inverter
Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
ASIC Circuit Board Assembly Cooling Fan (20-PP01096) Removal
and Installation (Inverter Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
AC or DC Fan System Fuses (20-PP20202) and Fuse Holder (20-
PP20300) Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Remove the Main Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Removing the Main AC or DC Fan Power Supply Assemblies
(Inverter Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Main AC Fan Inverter Circuit Board (20-VB00299) and DC Fan
Power Supply Circuit Board (SK-H1-DCFANBD1) Removal and
Installation (Converter Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Main AC Fan Inverter Circuit Board (20-VB00299) Removal and
Installation (Inverter Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Main DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1)
Removal and Installation (Inverter Only). . . . . . . . . . . . . . . . . . . . . . 153
AC to DC Main Fan System (SK-x1-DCFANRETROFIT-F13xand
-14x) Retrofit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

8Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Table of Contents
Main AC Fan Inverter Capacitor (SK-H1-FANCAP-F1314)
Removal and Installation (Converter Only). . . . . . . . . . . . . . . . . . . . 169
Main AC Fan Inverter Capacitor (SK-H1-FANCAP-F1314)
Removal and Installation (Inverter Only). . . . . . . . . . . . . . . . . . . . . . 170
Main AC Fan (20-FI13300) and Main DC Fan (SK-Y1-DCFAN1)
Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Chapter 6
PowerFlex 700H and 700S Drives -
Frame 14 Procedures
Frame 14 Drive Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Frame 14 Fan System Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
AC Fan Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
DC Fan Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Frame 14 System Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Chapter 7
PowerFlex 700AFE Drive - Frame 10
Procedures
Frame 10 AFE Drive Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Frame 10 AFE Fan System Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
AC Fan Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
DC Fan Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Tools Needed for Frame 10 AFE Fan System Repairs. . . . . . . . . . . . . . . 188
Frame 10 AFE Fan System Schematic Diagrams. . . . . . . . . . . . . . . . . . . . 189
Frame 10 AFE Fan System Replacement Procedures. . . . . . . . . . . . . . . . 192
Power Structure Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
LCL Filter Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Chapter 8
PowerFlex 700AFE Drive - Frame 13
Procedures
Frame 13 AFE Drive Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Frame 13 AFE Fan System Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
AC Fan Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
DC Fan Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Tools Needed for Frame 13 AFE Fan System Repairs. . . . . . . . . . . . . . . 239
Frame 13 AFE Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Frame 13 AFE Fan System Replacement Procedures. . . . . . . . . . . . . . . . 243
Power Structure Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
LCL Filter Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Appendix A
PowerFlex 700H and 700S Diagnostic
Procedures
Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Product Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Class 1 LED Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Fan Inverter System Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
AC Fan Inverter System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
DC Fan System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
PowerFlex 700H and PowerFlex 700S Drives . . . . . . . . . . . . . . . . . . 257

Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 9
Table of Contents
PowerFlex 700AFE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Checking the Fan Inverter Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Checking Fuse Integrity with no Power Applied . . . . . . . . . . . . . . . 263
Checking Fuse Integrity with Power Applied . . . . . . . . . . . . . . . . . . 263
Checking the Main Fan Supply Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Checking the AC Fan Inverter Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . 265
Isolating a Faulty Fan Inverter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Frame 9 PowerFlex 700H and 700S Drives . . . . . . . . . . . . . . . . . . . . 265
Frames 10 and 12 PowerFlex 700H and 700S Drives . . . . . . . . . . . 265
Frame 11 PowerFlex 700H and 700S Drives . . . . . . . . . . . . . . . . . . . 267
Frames 13 and 14 PowerFlex 700H and 700S Drives . . . . . . . . . . . 268
Frames 10 and 13 PowerFlex 700AFE. . . . . . . . . . . . . . . . . . . . . . . . . 268
Checking the Main AC Fan Inverter Circuit Board Diagnostic LEDs 268
AC Fan System LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
DC Fan System LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Fan System Wiring and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Testing the Main Fan Inverter Circuit Board Diagnostic LEDs . . . . . 274
AC Fan System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
DC Fan System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Appendix B
Available Fan System Kits
Spare Part Kit Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

10 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Table of Contents

Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 11
Preface
This manual contains fan system service information for frame 9…14 PowerFlex
700H and PowerFlex 700S AC drives, and the frame 10 and 13 PowerFlex
700AFE.
Who Should Use this Manual This manual is intended for qualified service personnel responsible for
troubleshooting and repairing frame 9…14 PowerFlex 700H and 700S and frame
10 and 13 PowerFlex 700AFE drives. You must have previous experience with,
and a basic understanding of, electrical terminology, procedures, required
troubleshooting equipment, equipment protection procedures and methods, and
safety precautions to make repairs on these drives and use this manual.
Verify Your Drive Frame Size You can verify your drive frame size by checking the data nameplate. This
information is printed just above the serial number.
Topic Page
Who Should Use this Manual 11
Verify Your Drive Frame Size 11
What is Not in this Manual 12
How to Use this Manual 15
Fastener/Tool/Torque Information 16
General Precautions 17
CatNo.
20D
J
300N 0 NNNBNNNN
ULOpenType/IP00
540V 650V
NormalDuty Power
160kW
132kW 250 kW 200kW
HeavyDuty Power
DCVoltage Range
462- 594
350 583- 713 350
Amps
Input:DC,
ACVoltageRange
0- 400
50Hz 0-460 60Hz
BaseHz (default)
Output:3 Phase, 0 - 320Hz
ContinuousAmps
300/245
330/368 300/245 330/368
1Min Overload Amps
2Sec Overload Amps
450/490 450/490
MFD.in1989 on Nov 9
SerialNumber: 2622381652
2622381652
MADEINTHE USA (FAC 1B)
Series:A
StandardI/O:NONE
OriginalFirmware No.2.04
UL
USC
Æ
LISTED
INDCONTEQ
Cat No. 20D J500 N 0 NNNBNNNN
UL Open Type/IP00 540V 650V
Normal Duty Power 250 kW
200 kW 450 kW 500 kW
Heavy Duty Power
DC Voltage Range 462 - 594
350 583 - 713 350
Amps
Input: DC,
AC Voltage Range 0 - 400
50 Hz 0 - 460 60 Hz
Base Hz (default)
Output: 3 Phase, 0 - 320Hz
Continuous Amps 420/500
630/550 420/500 630/550
1 Min Overload Amps
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)
Series: A
Standard I/O: NONE
Original Firmware No.2.04
UL
USC
Æ
LISTED
IND CONT EQ
9D42
Frame#:10
PowerFlex 700S Frame 10 drive shown

12 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Preface
What is Not in this Manual This manual does not contain information about parts and functions of the drive
that are not related to fan system service within the drive. For more information
and service procedures for your particular drive, see the applicable publication in
this table.
You can view or download publications at
http://www.rockwellautomation.com/literature/. To order paper copies of
technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.
Energy-related Products Fan
Efficiency Directive
The Energy-related Products (ErP) Directive (2012/27/EU on Energy
Efficiency, 25, October 2012) is the European Commission Directive required
for products sold and exported to the European Union (EU). This directive aims
to protect the environment by increasing energy efficiency in the EU. This
directive, among other things, defines the minimum efficiency for fans in the
range of 0.125…500 kW.
For PowerFlex 700H and 700S drive fan systems, this directive will be
implemented in multiple phases.
Phase 1 - Starts January 1, 2013
New products delivered within the EU (with a power structure manufacture date
of January 1, 2013 and later) will have a DC fan system installed. Phase I includes
PowerFlex 700H and 700S frame 9 and larger drives and PowerFlex 700AFE
systems.
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.
Drive Type Frame Size Publication Title Publication Number
PowerFlex 700H and
700S
9 PowerFlex 700H/S Drives, Frame 9
Hardware Service Manual
PFLEX-TG001
10 PowerFlex 700H/S Drives, Frame 10
Hardware Service Manual
PFLEX-TG002
11 PowerFlex 700H/S Drives, Frame 11
Hardware Service Manual
PFLEX-TG003
12 PowerFlex 700H/S Drives, Frame 12
Hardware Service Manual
PFLEX-TG004
13 PowerFlex 700H/S Drives, Frame 13
Hardware Service Manual
PFLEX-TG005
14 PowerFlex 700H/S Drives, Frame 14
Hardware Service Manual
PFLEX-TG006
PowerFlex 700AFE 10 PowerFlex 700AFE Frame 10 Hardware
Service Manual
20Y-TG001
13 PowerFlex 700AFE Frame 13 Hardware
Service Manual
20Y-TG002

Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 13
Preface
Phase 2 - Starts January 1, 2013, and Ending December 31, 2014
According to the ErP Directive, delivering the existing AC fan systems as spare
parts for PowerFlex 700H and 700S, frame 9 and larger, drives and PowerFlex
700AFE systems is allowed until the December 31, 2014 deadline within the EU.
DC fan systems are available as spare parts.
Phase 3 - Starts January 1, 2015
Use DC fan systems as spare part kits for PowerFlex 700H and 700S, frame 9 and
larger, drives, and PowerFlex 700AFE systems. DC fan system retrofit kits are
available for drives that were originally manufactured with AC fan systems.
AC fan system kits that were manufactured before January 1, 2015 can still be
used as a replacement spare part kit.
Fan System Replacement FAQs
Typical questions and solutions to fan system replacements can include:
Question Solution
Do all AC fans in a drive need to be replaced with a new DC
fan if only one has failed?
It is recommended that a power structure always
contains the same type of fan system, either all AC or
all DC.
If only one AC fan inverter circuit board fails, can I replace
only the damaged board with a new one?
Yes, if the other components of the AC fan unit are
functioning properly, you can replace the circuit board
only.
What does a DC fan kit include? This kit includes the DC fan assembly.
What does a DC fan circuit board kit include? This kit includes the DC fan power supply circuit board.
Are retrofit kits available? 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.

14 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Preface
Fan System Replacement Recommendations
This table provides recommendations for replacing a failed fan system on
PowerFlex 700H and 700S frame 9 and larger drives and PowerFlex 700AFE
systems. See Figure 1 on page 14 for more information.
Figure 1 - DC Fan System Replacement Examples
Frame Size Number of Fan Systems
in the Drive
Recommendation for Replacement
9 1 Always replace the failed AC fan system with a new DC fan system.
10 2 If one AC fan system fails, replace both existing AC fan systems with
new DC fan systems.
11 3 If one AC fan system fails, replace all three existing AC fan systems
with new DC fan systems.
12 4 If one AC fan system fails, replace the existing two AC fan systems
contained in the power structure that contains the failed AC fan
system with new DC fan systems.
13 5 or 6 If one AC fan system fails, replace all existing AC fan systems with new
DC fan systems.
14 9…12 If one AC fan system fails, replace all existing AC fan systems
contained in the power structure that contains the failed AC fan
system with new DC fan systems.
10 AFE 1 (LCL) Replace the existing DC fan systems, as necessary.
2 (Drive) Always replace the failed AC fan system with a new DC fan system.
13 AFE 1 (LCL) Replace the existing DC fan systems, as necessary.
3 (Drive) If one AC fan system fails, replace all three existing AC fan systems
with new DC fan systems.
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 15
Preface
How to Use this Manual This manual contains a chapter for each drive type and frame size. Use this table
to locate a list of available spare parts and the procedures for replacing fan system
components for a specific drive and frame size.
Drive Type Frame Size Chapter / Appendix Page Number
PowerFlex 700H and 700S 9 1 19
10 2 55
11 3 87
12 4 117
13 5 121
14 6 179
PowerFlex 700AFE 10 7 185
13 8 235
PowerFlex 700H, 700S, and 700AFE 9…14 A 255
B277

16 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Preface
Fastener/Tool/Torque
Information
The disassembly illustrations contained in this manual identify the type of
fastener, tool, and tightening torque used for disassembly/assembly of
components in the drive.
(1) Phillips® and POZIDRIV® are registered trademarks of the Phillips Screw Company.
Tool Type and Size:
FFlatnosescrewdriver
Px Phillips screw driver/bit and size
PZx POZIDRIV screw driver/bit and size
Txx Hexalobular screw driver/bit and size
xx mm Hexagonal socket wrench
Tightening Torque
Fastener Type:
Flat head screw
Hexagonal bolt
Hexagonal nut or standoff
Hexagonal screw
Hexalobular head screw
Phillips head screw (1)
POZIDRIV head screw (1)
Slotted Hexalobular head screw
Fastener/Tool/Torque Information:
PZ2
3.0 N•m (27 lb•in)

Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 17
Preface
General Precautions Read the following precautions before you begin testing components, performing
maintenance, or repairing the drive.
Qualified Personnel
Personal Safety
Product Safety
Class 1 LED Product
ATTENTION: Only qualified personnel familiar with adjustable frequency AC
drives and associated machinery should plan or implement the installation,
start-up and subsequent maintenance of the system. Failure to comply may
result in personal injury and/or equipment damage.
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the
bus capacitors has discharged before servicing the drive. Check the DC bus
voltage at the Power Terminal Block by measuring between the +DC & -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.
ATTENTION: Potentially fatal voltages may result from improper usage of an
oscilloscope and other test equipment. The oscilloscope chassis may be at a
potentially fatal voltage if not properly grounded. If an oscilloscope is used to
measure high voltage waveforms, use appropriately rated differential voltage
probes. Be sure that they are set to the highest voltage scaling in order to
achieve safe measurement resolution. Verify that the oscilloscope chassis is
correctly grounded to an earth ground.
ATTENTION: The sheet metal cover and mounting screws on the ASIC board
located on the inverters of 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 Guarding Against Electrostatic Damage, publication
8000-4.5.2 or any other applicable ESD protection handbook.
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.

18 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Preface
Notes:

Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014 19
Chapter 1
PowerFlex 700H and 700S Drives - Frame 9
Procedures
This chapter contains spare part information and procedures for testing and
replacing fan system components for frame 9 PowerFlex 700H and 700S drives.
See Appendix A PowerFlex 700H and 700S Diagnostic Procedures on page 255
for additional component test procedures.
Topic Page
Frame 9 Fan System Spare Parts 20
Tools Needed for Frame 9 Fan System Repairs 20
Frame 9 Schematic Diagrams 21
Frame 9 Fan System Replacement Procedures 22
Remove Power from the Drive 23
Remove the Lower Protective Cover 24
Remove the Upper Protective Cover 24
Removing the Main Fan Inverter Capacitor Bracket 25
Main Fan Fuses (20-PP20202) and Fuse Holder (20-PP20300) Removal and
Installation
29
Main Fan Inverter Cooling Fan (20-PP01049) Removal and Installation 30
Main AC Fan Inverter Capacitor (SK-H1-FANCAP-F9) Removal and Installation 31
Main AC Fan Inverter Circuit Board Assembly (20-VB00299) Removal and Installation 33
Main DC Fan Power Supply Circuit Board (SK-H1-DCFANBD1) Removal and Installation 36
AC to DC Fan System Retrofit Kit (SK-H1-DCFANRETROFIT-F9) 39
Main AC Fan (20-PP01080) and Main DC Fan (SK-Y1-DCFAN1) Assembly Removal and
Installation
43
Main AC Fan Inverter Output Transformer (20-PP09055) Removal and Installation 49
Chassis Stirring Fan (20-PP01068) Removal and Installation 50
Cross-plate Stirring Fan (20-PP01068) Removal and Installation 51
Internal Stirring Fan (20-PP01068) Removal and Installation 52

20 Rockwell Automation Publication PFLEX-IN029B-EN-P - August 2014
Chapter 1 PowerFlex 700H and 700S Drives - Frame 9 Procedures
Frame 9 Fan System Spare
Parts
AC Fan Systems
See Available Fan System Kits starting on page 277 for an illustration of the spare
part kit contents.
DC Fan Systems
See Available Fan System Kits starting on page 277 for an illustration of the spare
part kit contents.
Tools Needed for Frame 9 Fan
System Repairs
•#2 Phillips head screwdriver
•#2 POZIDRIV screwdriver
•Flat blade screwdriver
•13 mm socket wrench
•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
Cat. No. Part Description Quantity
per Drive
Original Vendor and
Model Number (3)
(3) This part may not contain wires, connectors, or mounting hardware when bought directly from the vendor.
20-PP01049 50 mm cooling fan for fan inverter 1 Sinwan
SD5012PT-24H
20-PP01068 80 mm x 80 mm x 32 mm internal stirring fan
assembly
2 or 3 (2)
(2) 2 for PowerFlex 700H drives and 3 for PowerFlex 700S drives.
Japan Servo Co., LTD
PUDC24H4C-049
20-PP01080 230 W Main AC fan assembly 1 –
20-PP09055 Output transformer for main fan inverter 1 –
20-PP20202 Fuse for fan system 2 Ferraz Shawmut
ATQ8 (4)
(4) The factory default fuses are Ferraz Shawmut ATQ8, 8 A fuses. Older drives may contain Bussman 6 A fuses.
20-PP20300 Fuse holder for main fan system fuses 1 Ferraz Shamut 30322
20-VB00299 Main fan inverter circuit board (1)
(1) The same part and catalog number is used for both 400/480V AC and 600/690V AC input drives.
1–
SK-H1-FANCAP-F9 Capacitor (7 μF) for main fan inverter 1 –
SK-H1-FR9BRKT AC fan bracket 1 –
Cat. No. Part Description Quantity
per Drive
Original Vendor and
Model Number
SK-Y1-DCFAN1 Main DC fan assembly 1 –
SK-H1-DCFANBD1 Main DC fan power supply circuit board (1)
(1) Circuit Board only, no sheet metal bracket.
1–
SK-H1-DCFANRETROFIT-F9 AC to DC fan system retrofit kit 1 –