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Home > Documents > PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module...

PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module...

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Publication PFLEX-IN023A-EN-P PowerFlex® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit Installation Instructions What This Kit Includes Rectifier module Rectifier DC+ bus bar (2) Bus bar insulator sheet Rectifier insulator sheet Do not begin the installation before reading Important Parts Information on page 2 . 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 completely before servicing. 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. 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 SynchLink fiber-optic ports or SynchLink 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. 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.
Transcript
Page 1: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

PowerFlexreg 700S and 700H Frames 10hellip12 Rectifier Module Replacement KitInstallation Instructions

What This Kit Includes bull Rectifier module

bull Rectifier DC+ bus bar (2)

bull Bus bar insulator sheet

bull Rectifier insulator sheet

Do not begin the installation before reading Important Parts Information on page 2

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 completely before servicing 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

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 SynchLink fiber-optic ports or SynchLink 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 8000-452 ldquoGuarding Against Electrostatic Damagerdquo or any other applicable ESD protection handbook

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

Publication PFLEX-IN023A-EN-P

2

Important Parts Information Important Due to a change in the SCR modules used in the rectifier module provided in this kit the rectifier module DC+ bus bars and insulator material provided in this kit must be used Therefore the existing rectifier module DC+ bus bar and insulator material must not be reused when installing this rectifier module kit See details below

Rectifier Modules

Rectifier Module DC+ Bus Bars

Rectifier module with round terminals Rectifier module with rectangular terminals provided in this kit

A

B

A gt B

A

B

A gt B

Frame 10 and 12 rectifier DC+ bus bar Frame 11 rectifier DC+ bus bar

Bus bar for round SCR terminals

Bus bar for rectangular SCR terminals provided in this kit

Bus bar for round SCR terminals

Bus bar for rectangular SCR terminals provided in this kit

Publication PFLEX-IN023A-EN-P

3

Bus Bar and Rectifier Module Insulator Material The insulator sheet that is placed between the main DC- and DC+ bus bars for rectifier modules with round SCR terminals is one piece The insulator material provided with this kit is two pieces one sheet for between the main DC- and DC+ bus bars and one to cover the rectifier module

Tools That You Need bull POZIDRIV screwdriver

bull Hexalobular screwdriver

bull Socket wrenches and extensions

bull Torque wrench

bull Wire cutter

bull PowerFlex 700H and 700S maintenance stand for Rittal TS8 enclosures only (catalog string 20-MAINSTD) (recommended)

bull Lifting equipment capable of securing holding and lifting the 210 kg (463 lb) frame 11 power structure

bull Multi-meter - Digital multi meter capable of ac and dc voltage continuity resistance capacitance measurements and forward diode bias tests

POZIDRIVreg is a registered trademark of Phillips Screw Company

Bus bar insulator material provided in this kit

Rectifier module insulator material provided in this kit

Publication PFLEX-IN023A-EN-P

4

Understanding Torque Figures in Illustrations

Icons and numbers in the assembly illustrations indicate how to tighten hardware after re-assembly

What You Need to Do Step 1 Remove power from the drive

Step 2 Remove the protective covers from the drive

Step 3 Remove the power structure from the enclosure

Step 4 Remove the existing rectifier module

Step 5 Install the new rectifier module

Step 6 Install the power structure in the enclosure

Step 7 Complete the circuit tests

Step 8 Install the protective covers

Step 9 Document the change

ATTENTION A hazard of personal injury andor equipment damage exists if the hardware securing power components in the drive is not installed in the same location from which it was removed according to size and the specified torque is not applied where indicated Take the appropriate steps to ensure that the location and size of hardware has been noted during disassembly and that proper torque is applied as indicated during re-assembly

PZ24 Nbullm(35 lbbullin)

Tool Type and SizePZ = POZIDRIV screwdriver bitT = Hexalobular (TORX) screwdriver bitxx mm = Socket wrenchHEX = Hexagonal screwdriverbit

Tightening Torque

Fastener Type

POZIDRIV Screw

Hexalobular (TORX) Screw

Hexagonal Screw

Hexagonal Bolt

Hexagonal Nut

Publication PFLEX-IN023A-EN-P

5

Step 1 Remove Power from the Drive

1 Turn off and lock out input power Wait five minutes

2 Verify that there is no voltage at the driversquos 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

ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing 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

bull sending an erroneous signal to your systemrsquos field devices causing unintended machine motion

bull 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

O

I

Publication PFLEX-IN023A-EN-P

6

Step 2 Remove the Protective Covers from the Drive

To remove the protective covers you must first move the control frame and then remove the air flow plate

1 Loosen the T8 hexalobular screws that hold the control frame to the drive enclosure (remove screws on early frame 10 drives)

2 Swing the control frame out and away from the power structure

Frame 10 drives from early production runs have holes instead of slots for these screws You must completely remove the screws from these drives in order to move the control frame

or

Screws

600 mm wide control frame shown

=

Publication PFLEX-IN023A-EN-P

7

3 Remove the four T8 hexalobular screws that secure the airflow plate to the drive and slide the airflow plate off the enclosure frame

Screws

Frame 10 enclosure shown

Airflow plate

Publication PFLEX-IN023A-EN-P

8

4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers

5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover

6 On frame 10 and 12 drives only remove the side protective covers

Frame 10 covers shown

PZ230 Nbullm(265 lbbullin)

4

4

4

4

5

5

5

5

6

6

5

Publication PFLEX-IN023A-EN-P

9

Step 3 Remove the Power Structure from the Enclosure

In order to remove the power structure from the enclosure you must first remove the power and ground wiring

For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives

1 Remove the insulator material from between the input terminals

2 Remove the input wiring from the following terminals

ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure

ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure

3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure

4 Remove the ground connection from the power structure

Figure 1 Frame 10 and 12 Drives

Motor Connection Terminals

AC Input Power Connection Terminals

Ground Connection

DC Input Power Connection Terminals

Frame 10 power structure shown

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

10

Figure 2 Frame 11 Drives

H LH LH L

Motor Connection Terminals

AC Input Power Connection Terminals

DC Input Power Connection Terminals

Ground Connection

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

11

5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)

6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand

Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures

7 Remove the power structure by sliding it onto the rails of the maintenance stand

Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure

Figure 3 Frame 10 and 12 Drives

Remove bolts

Frame 10 power structure shown

Remove bolts

Publication PFLEX-IN023A-EN-P

12

Figure 4 Frame 11 Drives

Step 4 Remove the Existing Rectifier Module(s)

The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22

H LH LH L

Remove bolts

Remove bolts

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13

Remove the Rectifier Module(s) from a Frame 10 or 12 Drive

The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

Rectifier module(s) located on right side of power structure(s)

Frame 10

Frame 12

Publication PFLEX-IN023A-EN-P

14

1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires

2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive

3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)

DC-

DC+ T2010 Nbullm(88 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Loosen but do not remove hex nuts

Rectifier board

Remove screws

Publication PFLEX-IN023A-EN-P

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

Publication PFLEX-IN023A-EN-P

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

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43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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 ESP 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 FRA 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 PTB 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 SUO ltFEFF004b00e40079007400e40020006e00e40069007400e4002000610073006500740075006b007300690061002c0020006b0075006e0020006c0075006f0074002000410064006f0062006500200050004400460020002d0064006f006b0075006d0065006e007400740065006a00610020006c0061006100640075006b006100730074006100200074007900f6007000f60079007400e400740075006c006f0073007400750073007400610020006a00610020007600650064006f007300740075007300740061002000760061007200740065006e002e00200020004c0075006f0064007500740020005000440046002d0064006f006b0075006d0065006e00740069007400200076006f0069006400610061006e0020006100760061007400610020004100630072006f0062006100740069006c006c00610020006a0061002000410064006f00620065002000520065006100640065007200200035002e0030003a006c006c00610020006a006100200075007500640065006d006d0069006c006c0061002egt SVE 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 ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
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(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
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LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
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QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
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WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
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Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 2: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

2

Important Parts Information Important Due to a change in the SCR modules used in the rectifier module provided in this kit the rectifier module DC+ bus bars and insulator material provided in this kit must be used Therefore the existing rectifier module DC+ bus bar and insulator material must not be reused when installing this rectifier module kit See details below

Rectifier Modules

Rectifier Module DC+ Bus Bars

Rectifier module with round terminals Rectifier module with rectangular terminals provided in this kit

A

B

A gt B

A

B

A gt B

Frame 10 and 12 rectifier DC+ bus bar Frame 11 rectifier DC+ bus bar

Bus bar for round SCR terminals

Bus bar for rectangular SCR terminals provided in this kit

Bus bar for round SCR terminals

Bus bar for rectangular SCR terminals provided in this kit

Publication PFLEX-IN023A-EN-P

3

Bus Bar and Rectifier Module Insulator Material The insulator sheet that is placed between the main DC- and DC+ bus bars for rectifier modules with round SCR terminals is one piece The insulator material provided with this kit is two pieces one sheet for between the main DC- and DC+ bus bars and one to cover the rectifier module

Tools That You Need bull POZIDRIV screwdriver

bull Hexalobular screwdriver

bull Socket wrenches and extensions

bull Torque wrench

bull Wire cutter

bull PowerFlex 700H and 700S maintenance stand for Rittal TS8 enclosures only (catalog string 20-MAINSTD) (recommended)

bull Lifting equipment capable of securing holding and lifting the 210 kg (463 lb) frame 11 power structure

bull Multi-meter - Digital multi meter capable of ac and dc voltage continuity resistance capacitance measurements and forward diode bias tests

POZIDRIVreg is a registered trademark of Phillips Screw Company

Bus bar insulator material provided in this kit

Rectifier module insulator material provided in this kit

Publication PFLEX-IN023A-EN-P

4

Understanding Torque Figures in Illustrations

Icons and numbers in the assembly illustrations indicate how to tighten hardware after re-assembly

What You Need to Do Step 1 Remove power from the drive

Step 2 Remove the protective covers from the drive

Step 3 Remove the power structure from the enclosure

Step 4 Remove the existing rectifier module

Step 5 Install the new rectifier module

Step 6 Install the power structure in the enclosure

Step 7 Complete the circuit tests

Step 8 Install the protective covers

Step 9 Document the change

ATTENTION A hazard of personal injury andor equipment damage exists if the hardware securing power components in the drive is not installed in the same location from which it was removed according to size and the specified torque is not applied where indicated Take the appropriate steps to ensure that the location and size of hardware has been noted during disassembly and that proper torque is applied as indicated during re-assembly

PZ24 Nbullm(35 lbbullin)

Tool Type and SizePZ = POZIDRIV screwdriver bitT = Hexalobular (TORX) screwdriver bitxx mm = Socket wrenchHEX = Hexagonal screwdriverbit

Tightening Torque

Fastener Type

POZIDRIV Screw

Hexalobular (TORX) Screw

Hexagonal Screw

Hexagonal Bolt

Hexagonal Nut

Publication PFLEX-IN023A-EN-P

5

Step 1 Remove Power from the Drive

1 Turn off and lock out input power Wait five minutes

2 Verify that there is no voltage at the driversquos 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

ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing 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

bull sending an erroneous signal to your systemrsquos field devices causing unintended machine motion

bull 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

O

I

Publication PFLEX-IN023A-EN-P

6

Step 2 Remove the Protective Covers from the Drive

To remove the protective covers you must first move the control frame and then remove the air flow plate

1 Loosen the T8 hexalobular screws that hold the control frame to the drive enclosure (remove screws on early frame 10 drives)

2 Swing the control frame out and away from the power structure

Frame 10 drives from early production runs have holes instead of slots for these screws You must completely remove the screws from these drives in order to move the control frame

or

Screws

600 mm wide control frame shown

=

Publication PFLEX-IN023A-EN-P

7

3 Remove the four T8 hexalobular screws that secure the airflow plate to the drive and slide the airflow plate off the enclosure frame

Screws

Frame 10 enclosure shown

Airflow plate

Publication PFLEX-IN023A-EN-P

8

4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers

5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover

6 On frame 10 and 12 drives only remove the side protective covers

Frame 10 covers shown

PZ230 Nbullm(265 lbbullin)

4

4

4

4

5

5

5

5

6

6

5

Publication PFLEX-IN023A-EN-P

9

Step 3 Remove the Power Structure from the Enclosure

In order to remove the power structure from the enclosure you must first remove the power and ground wiring

For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives

1 Remove the insulator material from between the input terminals

2 Remove the input wiring from the following terminals

ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure

ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure

3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure

4 Remove the ground connection from the power structure

Figure 1 Frame 10 and 12 Drives

Motor Connection Terminals

AC Input Power Connection Terminals

Ground Connection

DC Input Power Connection Terminals

Frame 10 power structure shown

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

10

Figure 2 Frame 11 Drives

H LH LH L

Motor Connection Terminals

AC Input Power Connection Terminals

DC Input Power Connection Terminals

Ground Connection

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

11

5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)

6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand

Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures

7 Remove the power structure by sliding it onto the rails of the maintenance stand

Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure

Figure 3 Frame 10 and 12 Drives

Remove bolts

Frame 10 power structure shown

Remove bolts

Publication PFLEX-IN023A-EN-P

12

Figure 4 Frame 11 Drives

Step 4 Remove the Existing Rectifier Module(s)

The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22

H LH LH L

Remove bolts

Remove bolts

Publication PFLEX-IN023A-EN-P

13

Remove the Rectifier Module(s) from a Frame 10 or 12 Drive

The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

Rectifier module(s) located on right side of power structure(s)

Frame 10

Frame 12

Publication PFLEX-IN023A-EN-P

14

1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires

2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive

3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)

DC-

DC+ T2010 Nbullm(88 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Loosen but do not remove hex nuts

Rectifier board

Remove screws

Publication PFLEX-IN023A-EN-P

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

Publication PFLEX-IN023A-EN-P

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

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23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

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24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

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25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

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26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

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27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

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28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

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29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

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30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

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31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

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32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

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33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

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34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

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35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

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36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

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37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

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39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

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40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

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42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

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43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

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44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

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45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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 PTB 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 SUO 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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 3: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

3

Bus Bar and Rectifier Module Insulator Material The insulator sheet that is placed between the main DC- and DC+ bus bars for rectifier modules with round SCR terminals is one piece The insulator material provided with this kit is two pieces one sheet for between the main DC- and DC+ bus bars and one to cover the rectifier module

Tools That You Need bull POZIDRIV screwdriver

bull Hexalobular screwdriver

bull Socket wrenches and extensions

bull Torque wrench

bull Wire cutter

bull PowerFlex 700H and 700S maintenance stand for Rittal TS8 enclosures only (catalog string 20-MAINSTD) (recommended)

bull Lifting equipment capable of securing holding and lifting the 210 kg (463 lb) frame 11 power structure

bull Multi-meter - Digital multi meter capable of ac and dc voltage continuity resistance capacitance measurements and forward diode bias tests

POZIDRIVreg is a registered trademark of Phillips Screw Company

Bus bar insulator material provided in this kit

Rectifier module insulator material provided in this kit

Publication PFLEX-IN023A-EN-P

4

Understanding Torque Figures in Illustrations

Icons and numbers in the assembly illustrations indicate how to tighten hardware after re-assembly

What You Need to Do Step 1 Remove power from the drive

Step 2 Remove the protective covers from the drive

Step 3 Remove the power structure from the enclosure

Step 4 Remove the existing rectifier module

Step 5 Install the new rectifier module

Step 6 Install the power structure in the enclosure

Step 7 Complete the circuit tests

Step 8 Install the protective covers

Step 9 Document the change

ATTENTION A hazard of personal injury andor equipment damage exists if the hardware securing power components in the drive is not installed in the same location from which it was removed according to size and the specified torque is not applied where indicated Take the appropriate steps to ensure that the location and size of hardware has been noted during disassembly and that proper torque is applied as indicated during re-assembly

PZ24 Nbullm(35 lbbullin)

Tool Type and SizePZ = POZIDRIV screwdriver bitT = Hexalobular (TORX) screwdriver bitxx mm = Socket wrenchHEX = Hexagonal screwdriverbit

Tightening Torque

Fastener Type

POZIDRIV Screw

Hexalobular (TORX) Screw

Hexagonal Screw

Hexagonal Bolt

Hexagonal Nut

Publication PFLEX-IN023A-EN-P

5

Step 1 Remove Power from the Drive

1 Turn off and lock out input power Wait five minutes

2 Verify that there is no voltage at the driversquos 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

ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing 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

bull sending an erroneous signal to your systemrsquos field devices causing unintended machine motion

bull 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

O

I

Publication PFLEX-IN023A-EN-P

6

Step 2 Remove the Protective Covers from the Drive

To remove the protective covers you must first move the control frame and then remove the air flow plate

1 Loosen the T8 hexalobular screws that hold the control frame to the drive enclosure (remove screws on early frame 10 drives)

2 Swing the control frame out and away from the power structure

Frame 10 drives from early production runs have holes instead of slots for these screws You must completely remove the screws from these drives in order to move the control frame

or

Screws

600 mm wide control frame shown

=

Publication PFLEX-IN023A-EN-P

7

3 Remove the four T8 hexalobular screws that secure the airflow plate to the drive and slide the airflow plate off the enclosure frame

Screws

Frame 10 enclosure shown

Airflow plate

Publication PFLEX-IN023A-EN-P

8

4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers

5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover

6 On frame 10 and 12 drives only remove the side protective covers

Frame 10 covers shown

PZ230 Nbullm(265 lbbullin)

4

4

4

4

5

5

5

5

6

6

5

Publication PFLEX-IN023A-EN-P

9

Step 3 Remove the Power Structure from the Enclosure

In order to remove the power structure from the enclosure you must first remove the power and ground wiring

For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives

1 Remove the insulator material from between the input terminals

2 Remove the input wiring from the following terminals

ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure

ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure

3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure

4 Remove the ground connection from the power structure

Figure 1 Frame 10 and 12 Drives

Motor Connection Terminals

AC Input Power Connection Terminals

Ground Connection

DC Input Power Connection Terminals

Frame 10 power structure shown

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

10

Figure 2 Frame 11 Drives

H LH LH L

Motor Connection Terminals

AC Input Power Connection Terminals

DC Input Power Connection Terminals

Ground Connection

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

11

5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)

6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand

Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures

7 Remove the power structure by sliding it onto the rails of the maintenance stand

Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure

Figure 3 Frame 10 and 12 Drives

Remove bolts

Frame 10 power structure shown

Remove bolts

Publication PFLEX-IN023A-EN-P

12

Figure 4 Frame 11 Drives

Step 4 Remove the Existing Rectifier Module(s)

The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22

H LH LH L

Remove bolts

Remove bolts

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13

Remove the Rectifier Module(s) from a Frame 10 or 12 Drive

The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

Rectifier module(s) located on right side of power structure(s)

Frame 10

Frame 12

Publication PFLEX-IN023A-EN-P

14

1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires

2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive

3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)

DC-

DC+ T2010 Nbullm(88 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Loosen but do not remove hex nuts

Rectifier board

Remove screws

Publication PFLEX-IN023A-EN-P

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

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17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

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22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

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23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

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24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

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25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

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26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

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27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

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28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

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29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

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30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

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31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

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32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

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33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

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34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

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36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

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37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

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39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

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40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

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42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
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Selection Guide
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Selection Guide
Gray shading indicates Obsolete Print Catagories
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Page 4: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

4

Understanding Torque Figures in Illustrations

Icons and numbers in the assembly illustrations indicate how to tighten hardware after re-assembly

What You Need to Do Step 1 Remove power from the drive

Step 2 Remove the protective covers from the drive

Step 3 Remove the power structure from the enclosure

Step 4 Remove the existing rectifier module

Step 5 Install the new rectifier module

Step 6 Install the power structure in the enclosure

Step 7 Complete the circuit tests

Step 8 Install the protective covers

Step 9 Document the change

ATTENTION A hazard of personal injury andor equipment damage exists if the hardware securing power components in the drive is not installed in the same location from which it was removed according to size and the specified torque is not applied where indicated Take the appropriate steps to ensure that the location and size of hardware has been noted during disassembly and that proper torque is applied as indicated during re-assembly

PZ24 Nbullm(35 lbbullin)

Tool Type and SizePZ = POZIDRIV screwdriver bitT = Hexalobular (TORX) screwdriver bitxx mm = Socket wrenchHEX = Hexagonal screwdriverbit

Tightening Torque

Fastener Type

POZIDRIV Screw

Hexalobular (TORX) Screw

Hexagonal Screw

Hexagonal Bolt

Hexagonal Nut

Publication PFLEX-IN023A-EN-P

5

Step 1 Remove Power from the Drive

1 Turn off and lock out input power Wait five minutes

2 Verify that there is no voltage at the driversquos 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

ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing 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

bull sending an erroneous signal to your systemrsquos field devices causing unintended machine motion

bull 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

O

I

Publication PFLEX-IN023A-EN-P

6

Step 2 Remove the Protective Covers from the Drive

To remove the protective covers you must first move the control frame and then remove the air flow plate

1 Loosen the T8 hexalobular screws that hold the control frame to the drive enclosure (remove screws on early frame 10 drives)

2 Swing the control frame out and away from the power structure

Frame 10 drives from early production runs have holes instead of slots for these screws You must completely remove the screws from these drives in order to move the control frame

or

Screws

600 mm wide control frame shown

=

Publication PFLEX-IN023A-EN-P

7

3 Remove the four T8 hexalobular screws that secure the airflow plate to the drive and slide the airflow plate off the enclosure frame

Screws

Frame 10 enclosure shown

Airflow plate

Publication PFLEX-IN023A-EN-P

8

4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers

5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover

6 On frame 10 and 12 drives only remove the side protective covers

Frame 10 covers shown

PZ230 Nbullm(265 lbbullin)

4

4

4

4

5

5

5

5

6

6

5

Publication PFLEX-IN023A-EN-P

9

Step 3 Remove the Power Structure from the Enclosure

In order to remove the power structure from the enclosure you must first remove the power and ground wiring

For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives

1 Remove the insulator material from between the input terminals

2 Remove the input wiring from the following terminals

ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure

ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure

3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure

4 Remove the ground connection from the power structure

Figure 1 Frame 10 and 12 Drives

Motor Connection Terminals

AC Input Power Connection Terminals

Ground Connection

DC Input Power Connection Terminals

Frame 10 power structure shown

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

10

Figure 2 Frame 11 Drives

H LH LH L

Motor Connection Terminals

AC Input Power Connection Terminals

DC Input Power Connection Terminals

Ground Connection

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

11

5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)

6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand

Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures

7 Remove the power structure by sliding it onto the rails of the maintenance stand

Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure

Figure 3 Frame 10 and 12 Drives

Remove bolts

Frame 10 power structure shown

Remove bolts

Publication PFLEX-IN023A-EN-P

12

Figure 4 Frame 11 Drives

Step 4 Remove the Existing Rectifier Module(s)

The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22

H LH LH L

Remove bolts

Remove bolts

Publication PFLEX-IN023A-EN-P

13

Remove the Rectifier Module(s) from a Frame 10 or 12 Drive

The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

Rectifier module(s) located on right side of power structure(s)

Frame 10

Frame 12

Publication PFLEX-IN023A-EN-P

14

1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires

2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive

3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)

DC-

DC+ T2010 Nbullm(88 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Loosen but do not remove hex nuts

Rectifier board

Remove screws

Publication PFLEX-IN023A-EN-P

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

Publication PFLEX-IN023A-EN-P

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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 ESP 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 FRA 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 SUO 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 SVE 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 ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
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(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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(press releases should not be checked into DocMan or printed)
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77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
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1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
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2 color text
Selection Guide
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Selection Guide
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Post Sale Technical Communication
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B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
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Catalogs
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D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
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D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 5: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

5

Step 1 Remove Power from the Drive

1 Turn off and lock out input power Wait five minutes

2 Verify that there is no voltage at the driversquos 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

ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing 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

bull sending an erroneous signal to your systemrsquos field devices causing unintended machine motion

bull 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

O

I

Publication PFLEX-IN023A-EN-P

6

Step 2 Remove the Protective Covers from the Drive

To remove the protective covers you must first move the control frame and then remove the air flow plate

1 Loosen the T8 hexalobular screws that hold the control frame to the drive enclosure (remove screws on early frame 10 drives)

2 Swing the control frame out and away from the power structure

Frame 10 drives from early production runs have holes instead of slots for these screws You must completely remove the screws from these drives in order to move the control frame

or

Screws

600 mm wide control frame shown

=

Publication PFLEX-IN023A-EN-P

7

3 Remove the four T8 hexalobular screws that secure the airflow plate to the drive and slide the airflow plate off the enclosure frame

Screws

Frame 10 enclosure shown

Airflow plate

Publication PFLEX-IN023A-EN-P

8

4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers

5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover

6 On frame 10 and 12 drives only remove the side protective covers

Frame 10 covers shown

PZ230 Nbullm(265 lbbullin)

4

4

4

4

5

5

5

5

6

6

5

Publication PFLEX-IN023A-EN-P

9

Step 3 Remove the Power Structure from the Enclosure

In order to remove the power structure from the enclosure you must first remove the power and ground wiring

For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives

1 Remove the insulator material from between the input terminals

2 Remove the input wiring from the following terminals

ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure

ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure

3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure

4 Remove the ground connection from the power structure

Figure 1 Frame 10 and 12 Drives

Motor Connection Terminals

AC Input Power Connection Terminals

Ground Connection

DC Input Power Connection Terminals

Frame 10 power structure shown

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

10

Figure 2 Frame 11 Drives

H LH LH L

Motor Connection Terminals

AC Input Power Connection Terminals

DC Input Power Connection Terminals

Ground Connection

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

11

5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)

6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand

Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures

7 Remove the power structure by sliding it onto the rails of the maintenance stand

Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure

Figure 3 Frame 10 and 12 Drives

Remove bolts

Frame 10 power structure shown

Remove bolts

Publication PFLEX-IN023A-EN-P

12

Figure 4 Frame 11 Drives

Step 4 Remove the Existing Rectifier Module(s)

The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22

H LH LH L

Remove bolts

Remove bolts

Publication PFLEX-IN023A-EN-P

13

Remove the Rectifier Module(s) from a Frame 10 or 12 Drive

The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

Rectifier module(s) located on right side of power structure(s)

Frame 10

Frame 12

Publication PFLEX-IN023A-EN-P

14

1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires

2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive

3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)

DC-

DC+ T2010 Nbullm(88 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Loosen but do not remove hex nuts

Rectifier board

Remove screws

Publication PFLEX-IN023A-EN-P

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

Publication PFLEX-IN023A-EN-P

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

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29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

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30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

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31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

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32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

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33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

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34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

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37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

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39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

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40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

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41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

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42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

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43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

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44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

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45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT ltFEFF4f7f752890194e9b8a2d7f6e5efa7acb7684002000410064006f006200650020005000440046002065874ef653ef5728684c9762537088686a5f548c002000700072006f006f00660065007200204e0a73725f979ad854c18cea7684521753706548679c300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c4f86958b555f5df25efa7acb76840020005000440046002065874ef63002gt DAN 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 DEU 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 ESP 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 FRA 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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
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IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
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WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
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Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
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A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 6: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

6

Step 2 Remove the Protective Covers from the Drive

To remove the protective covers you must first move the control frame and then remove the air flow plate

1 Loosen the T8 hexalobular screws that hold the control frame to the drive enclosure (remove screws on early frame 10 drives)

2 Swing the control frame out and away from the power structure

Frame 10 drives from early production runs have holes instead of slots for these screws You must completely remove the screws from these drives in order to move the control frame

or

Screws

600 mm wide control frame shown

=

Publication PFLEX-IN023A-EN-P

7

3 Remove the four T8 hexalobular screws that secure the airflow plate to the drive and slide the airflow plate off the enclosure frame

Screws

Frame 10 enclosure shown

Airflow plate

Publication PFLEX-IN023A-EN-P

8

4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers

5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover

6 On frame 10 and 12 drives only remove the side protective covers

Frame 10 covers shown

PZ230 Nbullm(265 lbbullin)

4

4

4

4

5

5

5

5

6

6

5

Publication PFLEX-IN023A-EN-P

9

Step 3 Remove the Power Structure from the Enclosure

In order to remove the power structure from the enclosure you must first remove the power and ground wiring

For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives

1 Remove the insulator material from between the input terminals

2 Remove the input wiring from the following terminals

ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure

ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure

3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure

4 Remove the ground connection from the power structure

Figure 1 Frame 10 and 12 Drives

Motor Connection Terminals

AC Input Power Connection Terminals

Ground Connection

DC Input Power Connection Terminals

Frame 10 power structure shown

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

10

Figure 2 Frame 11 Drives

H LH LH L

Motor Connection Terminals

AC Input Power Connection Terminals

DC Input Power Connection Terminals

Ground Connection

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

11

5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)

6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand

Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures

7 Remove the power structure by sliding it onto the rails of the maintenance stand

Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure

Figure 3 Frame 10 and 12 Drives

Remove bolts

Frame 10 power structure shown

Remove bolts

Publication PFLEX-IN023A-EN-P

12

Figure 4 Frame 11 Drives

Step 4 Remove the Existing Rectifier Module(s)

The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22

H LH LH L

Remove bolts

Remove bolts

Publication PFLEX-IN023A-EN-P

13

Remove the Rectifier Module(s) from a Frame 10 or 12 Drive

The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

Rectifier module(s) located on right side of power structure(s)

Frame 10

Frame 12

Publication PFLEX-IN023A-EN-P

14

1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires

2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive

3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)

DC-

DC+ T2010 Nbullm(88 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Loosen but do not remove hex nuts

Rectifier board

Remove screws

Publication PFLEX-IN023A-EN-P

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

Publication PFLEX-IN023A-EN-P

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

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27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

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42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

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44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 7: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

7

3 Remove the four T8 hexalobular screws that secure the airflow plate to the drive and slide the airflow plate off the enclosure frame

Screws

Frame 10 enclosure shown

Airflow plate

Publication PFLEX-IN023A-EN-P

8

4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers

5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover

6 On frame 10 and 12 drives only remove the side protective covers

Frame 10 covers shown

PZ230 Nbullm(265 lbbullin)

4

4

4

4

5

5

5

5

6

6

5

Publication PFLEX-IN023A-EN-P

9

Step 3 Remove the Power Structure from the Enclosure

In order to remove the power structure from the enclosure you must first remove the power and ground wiring

For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives

1 Remove the insulator material from between the input terminals

2 Remove the input wiring from the following terminals

ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure

ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure

3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure

4 Remove the ground connection from the power structure

Figure 1 Frame 10 and 12 Drives

Motor Connection Terminals

AC Input Power Connection Terminals

Ground Connection

DC Input Power Connection Terminals

Frame 10 power structure shown

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

10

Figure 2 Frame 11 Drives

H LH LH L

Motor Connection Terminals

AC Input Power Connection Terminals

DC Input Power Connection Terminals

Ground Connection

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

11

5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)

6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand

Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures

7 Remove the power structure by sliding it onto the rails of the maintenance stand

Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure

Figure 3 Frame 10 and 12 Drives

Remove bolts

Frame 10 power structure shown

Remove bolts

Publication PFLEX-IN023A-EN-P

12

Figure 4 Frame 11 Drives

Step 4 Remove the Existing Rectifier Module(s)

The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22

H LH LH L

Remove bolts

Remove bolts

Publication PFLEX-IN023A-EN-P

13

Remove the Rectifier Module(s) from a Frame 10 or 12 Drive

The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

Rectifier module(s) located on right side of power structure(s)

Frame 10

Frame 12

Publication PFLEX-IN023A-EN-P

14

1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires

2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive

3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)

DC-

DC+ T2010 Nbullm(88 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Loosen but do not remove hex nuts

Rectifier board

Remove screws

Publication PFLEX-IN023A-EN-P

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

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17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

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22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

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23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

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24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

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25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

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26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

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27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

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28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

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29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

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30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

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31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

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33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

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34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

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36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

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37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

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39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

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40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

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42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

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43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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PreserveOverprintSettings true StartPage 1 SubsetFonts false TransferFunctionInfo Apply UCRandBGInfo Remove UsePrologue false ColorSettingsFile () AlwaysEmbed [ true ] NeverEmbed [ true ] AntiAliasColorImages false CropColorImages true ColorImageMinResolution 300 ColorImageMinResolutionPolicy OK DownsampleColorImages true ColorImageDownsampleType Average ColorImageResolution 300 ColorImageDepth 8 ColorImageMinDownsampleDepth 1 ColorImageDownsampleThreshold 200000 EncodeColorImages true ColorImageFilter FlateEncode AutoFilterColorImages false ColorImageAutoFilterStrategy JPEG ColorACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt ColorImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000ColorACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000ColorImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 300 GrayImageMinResolutionPolicy OK 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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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 SVE 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 ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
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C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
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D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
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Page 8: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

8

4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers

5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover

6 On frame 10 and 12 drives only remove the side protective covers

Frame 10 covers shown

PZ230 Nbullm(265 lbbullin)

4

4

4

4

5

5

5

5

6

6

5

Publication PFLEX-IN023A-EN-P

9

Step 3 Remove the Power Structure from the Enclosure

In order to remove the power structure from the enclosure you must first remove the power and ground wiring

For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives

1 Remove the insulator material from between the input terminals

2 Remove the input wiring from the following terminals

ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure

ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure

3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure

4 Remove the ground connection from the power structure

Figure 1 Frame 10 and 12 Drives

Motor Connection Terminals

AC Input Power Connection Terminals

Ground Connection

DC Input Power Connection Terminals

Frame 10 power structure shown

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

10

Figure 2 Frame 11 Drives

H LH LH L

Motor Connection Terminals

AC Input Power Connection Terminals

DC Input Power Connection Terminals

Ground Connection

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

11

5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)

6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand

Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures

7 Remove the power structure by sliding it onto the rails of the maintenance stand

Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure

Figure 3 Frame 10 and 12 Drives

Remove bolts

Frame 10 power structure shown

Remove bolts

Publication PFLEX-IN023A-EN-P

12

Figure 4 Frame 11 Drives

Step 4 Remove the Existing Rectifier Module(s)

The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22

H LH LH L

Remove bolts

Remove bolts

Publication PFLEX-IN023A-EN-P

13

Remove the Rectifier Module(s) from a Frame 10 or 12 Drive

The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

Rectifier module(s) located on right side of power structure(s)

Frame 10

Frame 12

Publication PFLEX-IN023A-EN-P

14

1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires

2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive

3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)

DC-

DC+ T2010 Nbullm(88 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Loosen but do not remove hex nuts

Rectifier board

Remove screws

Publication PFLEX-IN023A-EN-P

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

Publication PFLEX-IN023A-EN-P

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

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30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

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33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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PreserveOverprintSettings true StartPage 1 SubsetFonts false TransferFunctionInfo Apply UCRandBGInfo Remove UsePrologue false ColorSettingsFile () AlwaysEmbed [ true ] NeverEmbed [ true ] AntiAliasColorImages false CropColorImages true ColorImageMinResolution 300 ColorImageMinResolutionPolicy OK DownsampleColorImages true ColorImageDownsampleType Average ColorImageResolution 300 ColorImageDepth 8 ColorImageMinDownsampleDepth 1 ColorImageDownsampleThreshold 200000 EncodeColorImages true ColorImageFilter FlateEncode AutoFilterColorImages false ColorImageAutoFilterStrategy JPEG ColorACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt ColorImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000ColorACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000ColorImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 300 GrayImageMinResolutionPolicy OK 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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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ltFEFF0041006e007600e4006e00640020006400650020006800e4007200200069006e0073007400e4006c006c006e0069006e006700610072006e00610020006f006d002000640075002000760069006c006c00200073006b006100700061002000410064006f006200650020005000440046002d0064006f006b0075006d0065006e00740020006600f600720020006b00760061006c00690074006500740073007500740073006b0072006900660074006500720020007000e5002000760061006e006c00690067006100200073006b0072006900760061007200650020006f006300680020006600f600720020006b006f007200720065006b007400750072002e002000200053006b006100700061006400650020005000440046002d0064006f006b0075006d0065006e00740020006b0061006e002000f600700070006e00610073002000690020004100630072006f0062006100740020006f00630068002000410064006f00620065002000520065006100640065007200200035002e00300020006f00630068002000730065006e006100720065002egt ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
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Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
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Page 9: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

9

Step 3 Remove the Power Structure from the Enclosure

In order to remove the power structure from the enclosure you must first remove the power and ground wiring

For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives

1 Remove the insulator material from between the input terminals

2 Remove the input wiring from the following terminals

ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure

ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure

3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure

4 Remove the ground connection from the power structure

Figure 1 Frame 10 and 12 Drives

Motor Connection Terminals

AC Input Power Connection Terminals

Ground Connection

DC Input Power Connection Terminals

Frame 10 power structure shown

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

10

Figure 2 Frame 11 Drives

H LH LH L

Motor Connection Terminals

AC Input Power Connection Terminals

DC Input Power Connection Terminals

Ground Connection

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

11

5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)

6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand

Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures

7 Remove the power structure by sliding it onto the rails of the maintenance stand

Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure

Figure 3 Frame 10 and 12 Drives

Remove bolts

Frame 10 power structure shown

Remove bolts

Publication PFLEX-IN023A-EN-P

12

Figure 4 Frame 11 Drives

Step 4 Remove the Existing Rectifier Module(s)

The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22

H LH LH L

Remove bolts

Remove bolts

Publication PFLEX-IN023A-EN-P

13

Remove the Rectifier Module(s) from a Frame 10 or 12 Drive

The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

Rectifier module(s) located on right side of power structure(s)

Frame 10

Frame 12

Publication PFLEX-IN023A-EN-P

14

1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires

2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive

3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)

DC-

DC+ T2010 Nbullm(88 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Loosen but do not remove hex nuts

Rectifier board

Remove screws

Publication PFLEX-IN023A-EN-P

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

Publication PFLEX-IN023A-EN-P

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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DownsampleGrayImages true GrayImageDownsampleType Average GrayImageResolution 300 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 200000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 1200 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Average MonoImageResolution 1200 MonoImageDepth -1 MonoImageDownsampleThreshold 150000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects false CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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ESP 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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
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AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
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77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
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A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
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Catalogs
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C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
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2 color text 32-33 Coated Sheet
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D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 10: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

10

Figure 2 Frame 11 Drives

H LH LH L

Motor Connection Terminals

AC Input Power Connection Terminals

DC Input Power Connection Terminals

Ground Connection

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

19 mm40 Nbullm(354 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Remove Insulator Material from between Terminals

Publication PFLEX-IN023A-EN-P

11

5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)

6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand

Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures

7 Remove the power structure by sliding it onto the rails of the maintenance stand

Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure

Figure 3 Frame 10 and 12 Drives

Remove bolts

Frame 10 power structure shown

Remove bolts

Publication PFLEX-IN023A-EN-P

12

Figure 4 Frame 11 Drives

Step 4 Remove the Existing Rectifier Module(s)

The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22

H LH LH L

Remove bolts

Remove bolts

Publication PFLEX-IN023A-EN-P

13

Remove the Rectifier Module(s) from a Frame 10 or 12 Drive

The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

Rectifier module(s) located on right side of power structure(s)

Frame 10

Frame 12

Publication PFLEX-IN023A-EN-P

14

1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires

2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive

3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)

DC-

DC+ T2010 Nbullm(88 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Loosen but do not remove hex nuts

Rectifier board

Remove screws

Publication PFLEX-IN023A-EN-P

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

Publication PFLEX-IN023A-EN-P

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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 ESP 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 FRA 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 KOR 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 SUO 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 SVE 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 ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
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(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
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(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
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(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
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(press releases should not be checked into DocMan or printed)
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PM B2 D6 Programming Manual 1 5 Post External
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QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
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SG B2 D5 D6 Selection Guide BW 5 50 Presale External
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77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
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2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
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B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
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Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
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D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 11: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

11

5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)

6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand

Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures

7 Remove the power structure by sliding it onto the rails of the maintenance stand

Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure

Figure 3 Frame 10 and 12 Drives

Remove bolts

Frame 10 power structure shown

Remove bolts

Publication PFLEX-IN023A-EN-P

12

Figure 4 Frame 11 Drives

Step 4 Remove the Existing Rectifier Module(s)

The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22

H LH LH L

Remove bolts

Remove bolts

Publication PFLEX-IN023A-EN-P

13

Remove the Rectifier Module(s) from a Frame 10 or 12 Drive

The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

Rectifier module(s) located on right side of power structure(s)

Frame 10

Frame 12

Publication PFLEX-IN023A-EN-P

14

1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires

2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive

3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)

DC-

DC+ T2010 Nbullm(88 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Loosen but do not remove hex nuts

Rectifier board

Remove screws

Publication PFLEX-IN023A-EN-P

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

Publication PFLEX-IN023A-EN-P

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT ltFEFF4f7f752890194e9b8a2d7f6e5efa7acb7684002000410064006f006200650020005000440046002065874ef653ef5728684c9762537088686a5f548c002000700072006f006f00660065007200204e0a73725f979ad854c18cea7684521753706548679c300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c4f86958b555f5df25efa7acb76840020005000440046002065874ef63002gt DAN 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 DEU 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 ESP ltFEFF005500740069006c0069006300650020006500730074006100200063006f006e0066006900670075007200610063006900f3006e0020007000610072006100200063007200650061007200200064006f00630075006d0065006e0074006f0073002000640065002000410064006f0062006500200050004400460020007000610072006100200063006f006e00730065006700750069007200200069006d0070007200650073006900f3006e002000640065002000630061006c006900640061006400200065006e00200069006d0070007200650073006f0072006100730020006400650020006500730063007200690074006f00720069006f00200079002000680065007200720061006d00690065006e00740061007300200064006500200063006f00720072006500630063006900f3006e002e002000530065002000700075006500640065006e00200061006200720069007200200064006f00630075006d0065006e0074006f00730020005000440046002000630072006500610064006f007300200063006f006e0020004100630072006f006200610074002c002000410064006f00620065002000520065006100640065007200200035002e003000200079002000760065007200730069006f006e0065007300200070006f00730074006500720069006f007200650073002egt FRA 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 ITA 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 JPN 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 KOR 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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
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AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
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(press releases should not be checked into DocMan or printed)
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LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
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QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
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SG B2 D5 D6 Selection Guide BW 5 50 Presale External
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WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
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Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
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A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 12: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

12

Figure 4 Frame 11 Drives

Step 4 Remove the Existing Rectifier Module(s)

The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22

H LH LH L

Remove bolts

Remove bolts

Publication PFLEX-IN023A-EN-P

13

Remove the Rectifier Module(s) from a Frame 10 or 12 Drive

The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

Rectifier module(s) located on right side of power structure(s)

Frame 10

Frame 12

Publication PFLEX-IN023A-EN-P

14

1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires

2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive

3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)

DC-

DC+ T2010 Nbullm(88 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Loosen but do not remove hex nuts

Rectifier board

Remove screws

Publication PFLEX-IN023A-EN-P

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

Publication PFLEX-IN023A-EN-P

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

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31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

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32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

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33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

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34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

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37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

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39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

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40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

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41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

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42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

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43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

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44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

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45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

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49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT ltFEFF4f7f752890194e9b8a2d7f6e5efa7acb7684002000410064006f006200650020005000440046002065874ef653ef5728684c9762537088686a5f548c002000700072006f006f00660065007200204e0a73725f979ad854c18cea7684521753706548679c300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c4f86958b555f5df25efa7acb76840020005000440046002065874ef63002gt DAN ltFEFF004200720075006700200069006e0064007300740069006c006c0069006e006700650072006e0065002000740069006c0020006100740020006f007000720065007400740065002000410064006f006200650020005000440046002d0064006f006b0075006d0065006e007400650072002000740069006c0020006b00760061006c00690074006500740073007500640073006b007200690076006e0069006e006700200065006c006c006500720020006b006f007200720065006b007400750072006c00e60073006e0069006e0067002e0020004400650020006f007000720065007400740065006400650020005000440046002d0064006f006b0075006d0065006e0074006500720020006b0061006e002000e50062006e00650073002000690020004100630072006f00620061007400200065006c006c006500720020004100630072006f006200610074002000520065006100640065007200200035002e00300020006f00670020006e0079006500720065002egt DEU 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 ESP ltFEFF005500740069006c0069006300650020006500730074006100200063006f006e0066006900670075007200610063006900f3006e0020007000610072006100200063007200650061007200200064006f00630075006d0065006e0074006f0073002000640065002000410064006f0062006500200050004400460020007000610072006100200063006f006e00730065006700750069007200200069006d0070007200650073006900f3006e002000640065002000630061006c006900640061006400200065006e00200069006d0070007200650073006f0072006100730020006400650020006500730063007200690074006f00720069006f00200079002000680065007200720061006d00690065006e00740061007300200064006500200063006f00720072006500630063006900f3006e002e002000530065002000700075006500640065006e00200061006200720069007200200064006f00630075006d0065006e0074006f00730020005000440046002000630072006500610064006f007300200063006f006e0020004100630072006f006200610074002c002000410064006f00620065002000520065006100640065007200200035002e003000200079002000760065007200730069006f006e0065007300200070006f00730074006500720069006f007200650073002egt FRA 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 ITA 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 JPN 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 ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
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DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 13: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

13

Remove the Rectifier Module(s) from a Frame 10 or 12 Drive

The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

Rectifier module(s) located on right side of power structure(s)

Frame 10

Frame 12

Publication PFLEX-IN023A-EN-P

14

1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires

2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive

3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)

DC-

DC+ T2010 Nbullm(88 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Loosen but do not remove hex nuts

Rectifier board

Remove screws

Publication PFLEX-IN023A-EN-P

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

Publication PFLEX-IN023A-EN-P

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

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27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

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29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

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30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

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31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

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32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

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33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

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34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

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37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

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39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

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40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

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42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

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43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

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44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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ltFEFF4f7f752890194e9b8a2d7f6e5efa7acb7684002000410064006f006200650020005000440046002065874ef653ef5728684c9762537088686a5f548c002000700072006f006f00660065007200204e0a73725f979ad854c18cea7684521753706548679c300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c4f86958b555f5df25efa7acb76840020005000440046002065874ef63002gt DAN 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 DEU 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 ESP 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 FRA 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ltFEFF9ad854c18cea51fa529b7528002000410064006f0062006500200050004400460020658766f8306e4f5c6210306b4f7f75283057307e30593002537052376642306e753b8cea3092670059279650306b4fdd306430533068304c3067304d307e3059300230c730b930af30c830c330d730d730ea30f330bf3067306e53705237307e305f306f30d730eb30fc30d57528306b9069305730663044307e305930023053306e8a2d5b9a30674f5c62103055308c305f0020005000440046002030d530a130a430eb306f3001004100630072006f0062006100740020304a30883073002000410064006f00620065002000520065006100640065007200200035002e003000204ee5964d3067958b304f30533068304c3067304d307e30593002gt KOR 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 PTB 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 SUO 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ltFEFF0041006e007600e4006e00640020006400650020006800e4007200200069006e0073007400e4006c006c006e0069006e006700610072006e00610020006f006d002000640075002000760069006c006c00200073006b006100700061002000410064006f006200650020005000440046002d0064006f006b0075006d0065006e00740020006600f600720020006b00760061006c00690074006500740073007500740073006b0072006900660074006500720020007000e5002000760061006e006c00690067006100200073006b0072006900760061007200650020006f006300680020006600f600720020006b006f007200720065006b007400750072002e002000200053006b006100700061006400650020005000440046002d0064006f006b0075006d0065006e00740020006b0061006e002000f600700070006e00610073002000690020004100630072006f0062006100740020006f00630068002000410064006f00620065002000520065006100640065007200200035002e00300020006f00630068002000730065006e006100720065002egt ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 14: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

14

1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires

2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive

3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)

DC-

DC+ T2010 Nbullm(88 lbbullin)

17 mm40 Nbullm(354 lbbullin)

Loosen but do not remove hex nuts

Rectifier board

Remove screws

Publication PFLEX-IN023A-EN-P

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

Publication PFLEX-IN023A-EN-P

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

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25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

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27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

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28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

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29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

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30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

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31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

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32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

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34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

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39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

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40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

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42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

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43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

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44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 15: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

15

Figure 5 Series A Rectifier Circuit Board

Figure 6 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

Publication PFLEX-IN023A-EN-P

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

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27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

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44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 16: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

16

4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

Remove bolts

17 mm14 Nbullm(124 lbbullin)

AC input cables

Terminal bus bars

Publication PFLEX-IN023A-EN-P

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

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27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

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44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 17: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

17

7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts

17 mm14 Nbullm(124 lbbullin)

Remove bolts

Do Not reuse existing DC+ bus bar

Top of Power Structure

Power cable

Publication PFLEX-IN023A-EN-P

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

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25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

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27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

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29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

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32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

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34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

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37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

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39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

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40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

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42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

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44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 18: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

18

8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

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25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

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27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

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30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

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42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

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43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

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44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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ltFEFF4f7f752890194e9b8a2d7f6e5efa7acb7684002000410064006f006200650020005000440046002065874ef653ef5728684c9762537088686a5f548c002000700072006f006f00660065007200204e0a73725f979ad854c18cea7684521753706548679c300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c4f86958b555f5df25efa7acb76840020005000440046002065874ef63002gt DAN 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 DEU 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 19: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

19

10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar T3040 Nbullm(354 lbbullin)

DC- Bus Bar T3050 Nbullm(442 lbbullin)

DC+ Bus Bar T3050 Nbullm(442 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

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30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

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31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

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39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

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42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

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43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

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44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT ltFEFF4f7f752890194e9b8a2d7f6e5efa7acb7684002000410064006f006200650020005000440046002065874ef653ef5728684c9762537088686a5f548c002000700072006f006f00660065007200204e0a73725f979ad854c18cea7684521753706548679c300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c4f86958b555f5df25efa7acb76840020005000440046002065874ef63002gt DAN ltFEFF004200720075006700200069006e0064007300740069006c006c0069006e006700650072006e0065002000740069006c0020006100740020006f007000720065007400740065002000410064006f006200650020005000440046002d0064006f006b0075006d0065006e007400650072002000740069006c0020006b00760061006c00690074006500740073007500640073006b007200690076006e0069006e006700200065006c006c006500720020006b006f007200720065006b007400750072006c00e60073006e0069006e0067002e0020004400650020006f007000720065007400740065006400650020005000440046002d0064006f006b0075006d0065006e0074006500720020006b0061006e002000e50062006e00650073002000690020004100630072006f00620061007400200065006c006c006500720020004100630072006f006200610074002000520065006100640065007200200035002e00300020006f00670020006e0079006500720065002egt DEU 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 ESP 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 FRA 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ltFEFF0041006e007600e4006e00640020006400650020006800e4007200200069006e0073007400e4006c006c006e0069006e006700610072006e00610020006f006d002000640075002000760069006c006c00200073006b006100700061002000410064006f006200650020005000440046002d0064006f006b0075006d0065006e00740020006600f600720020006b00760061006c00690074006500740073007500740073006b0072006900660074006500720020007000e5002000760061006e006c00690067006100200073006b0072006900760061007200650020006f006300680020006600f600720020006b006f007200720065006b007400750072002e002000200053006b006100700061006400650020005000440046002d0064006f006b0075006d0065006e00740020006b0061006e002000f600700070006e00610073002000690020004100630072006f0062006100740020006f00630068002000410064006f00620065002000520065006100640065007200200035002e00300020006f00630068002000730065006e006100720065002egt ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
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CP E-only E-only D5 Competitive Information 5 50 NA Confidential
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DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 20: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

20

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Do Not reuse this insulator sheet Replace with new insulator sheet

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

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43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT ltFEFF4f7f752890194e9b8a2d7f6e5efa7acb7684002000410064006f006200650020005000440046002065874ef653ef5728684c9762537088686a5f548c002000700072006f006f00660065007200204e0a73725f979ad854c18cea7684521753706548679c300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c4f86958b555f5df25efa7acb76840020005000440046002065874ef63002gt DAN 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 DEU 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 ESP ltFEFF005500740069006c0069006300650020006500730074006100200063006f006e0066006900670075007200610063006900f3006e0020007000610072006100200063007200650061007200200064006f00630075006d0065006e0074006f0073002000640065002000410064006f0062006500200050004400460020007000610072006100200063006f006e00730065006700750069007200200069006d0070007200650073006900f3006e002000640065002000630061006c006900640061006400200065006e00200069006d0070007200650073006f0072006100730020006400650020006500730063007200690074006f00720069006f00200079002000680065007200720061006d00690065006e00740061007300200064006500200063006f00720072006500630063006900f3006e002e002000530065002000700075006500640065006e00200061006200720069007200200064006f00630075006d0065006e0074006f00730020005000440046002000630072006500610064006f007300200063006f006e0020004100630072006f006200610074002c002000410064006f00620065002000520065006100640065007200200035002e003000200079002000760065007200730069006f006e0065007300200070006f00730074006500720069006f007200650073002egt FRA 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 ITA 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 JPN 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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
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CP E-only E-only D5 Competitive Information 5 50 NA Confidential
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DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
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SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
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TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 21: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

21

11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

12 Continue with Step 5 Install the New Rectifier Module on page 43

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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 ESP 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FRA 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 PTB 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 SVE 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 ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
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(press releases should not be checked into DocMan or printed)
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RM B2 D5 D6 Reference Manual 1 5 Post External
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77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
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A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
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A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
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2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
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Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
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JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
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D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 22: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

22

Remove the Rectifier Module from a Frame 11 Drive

The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure

Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal

Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly

H LH LH L

Rectifier modules located on sides of power structures

U Phase

V Phase

W Phase

Publication PFLEX-IN023A-EN-P

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
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DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
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IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
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QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
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WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
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A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
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B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
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D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
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D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 23: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

23

1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover

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

Remove screws

Upper-left corner of drive

PZ215 Nbullm(133 lbbullin)

ASIC assembly

Publication PFLEX-IN023A-EN-P

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 24: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

24

2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside

4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly

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

H11 H12 H13H8 H9 H10

X9 X15

X3 X4 X5

X2

H4 H5 H6H1 H2 H3 H7

X11

X1

X6

X10

Fiber Optics

Fiber Optics

PZ230 Nbullm(265 lbbullin)

Publication PFLEX-IN023A-EN-P

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 25: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

25

5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards

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

X6

H16H15

+ -

Fiber Optics

Gate driver board locations

Remove wires from terminals + ndash

Publication PFLEX-IN023A-EN-P

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

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37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

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40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

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42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

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43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

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44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

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45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT ltFEFF4f7f752890194e9b8a2d7f6e5efa7acb7684002000410064006f006200650020005000440046002065874ef653ef5728684c9762537088686a5f548c002000700072006f006f00660065007200204e0a73725f979ad854c18cea7684521753706548679c300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c4f86958b555f5df25efa7acb76840020005000440046002065874ef63002gt DAN ltFEFF004200720075006700200069006e0064007300740069006c006c0069006e006700650072006e0065002000740069006c0020006100740020006f007000720065007400740065002000410064006f006200650020005000440046002d0064006f006b0075006d0065006e007400650072002000740069006c0020006b00760061006c00690074006500740073007500640073006b007200690076006e0069006e006700200065006c006c006500720020006b006f007200720065006b007400750072006c00e60073006e0069006e0067002e0020004400650020006f007000720065007400740065006400650020005000440046002d0064006f006b0075006d0065006e0074006500720020006b0061006e002000e50062006e00650073002000690020004100630072006f00620061007400200065006c006c006500720020004100630072006f006200610074002000520065006100640065007200200035002e00300020006f00670020006e0079006500720065002egt DEU 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 ESP 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 FRA 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 KOR 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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 26: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

26

7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module

8 Remove the air flow sheet from below the gate driver boards

DC-

DC+

Rectifier signal connectors

Fan signal connectors

Fan power connections on fuse holder

ASIC board power connections

Fan signal connector

Remove air flow sheet

Remove screws

PZ250 Nbullm(442 lbbullin)

Publication PFLEX-IN023A-EN-P

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
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Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
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(press releases should not be checked into DocMan or printed)
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77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
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1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
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2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
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B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
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C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
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D5 1 color 80gsm bond 20 bond self cover
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D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 27: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

27

9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside

Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii

10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board

11 Disconnect the cable from connector J8 on the voltage feedback board

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

J4 J5

J8

J2 J3

Voltage feedback board location

Publication PFLEX-IN023A-EN-P

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 28: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

28

12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure

a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees

b Lift the power structure off of the maintenance stand and place it rear side down on the work surface

Maximum angle 45 degrees

210 kg (463 lb)

Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure

Publication PFLEX-IN023A-EN-P

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

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30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

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31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

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32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

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33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

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34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

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37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

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39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

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40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

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41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

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42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

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43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

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44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

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45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

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48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT ltFEFF4f7f752890194e9b8a2d7f6e5efa7acb7684002000410064006f006200650020005000440046002065874ef653ef5728684c9762537088686a5f548c002000700072006f006f00660065007200204e0a73725f979ad854c18cea7684521753706548679c300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c4f86958b555f5df25efa7acb76840020005000440046002065874ef63002gt DAN ltFEFF004200720075006700200069006e0064007300740069006c006c0069006e006700650072006e0065002000740069006c0020006100740020006f007000720065007400740065002000410064006f006200650020005000440046002d0064006f006b0075006d0065006e007400650072002000740069006c0020006b00760061006c00690074006500740073007500640073006b007200690076006e0069006e006700200065006c006c006500720020006b006f007200720065006b007400750072006c00e60073006e0069006e0067002e0020004400650020006f007000720065007400740065006400650020005000440046002d0064006f006b0075006d0065006e0074006500720020006b0061006e002000e50062006e00650073002000690020004100630072006f00620061007400200065006c006c006500720020004100630072006f006200610074002000520065006100640065007200200035002e00300020006f00670020006e0079006500720065002egt DEU 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 ESP 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 FRA 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 PTB 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 SUO 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 ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
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DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 29: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

29

13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars

17 mm40 Nbullm(354 lbbullin)

Remove nuts

17 mm40 Nbullm(354 lbbullin)

Remove nuts

DC- DC+

Remove bus bars

Note Power cables not shown for clarity only

Publication PFLEX-IN023A-EN-P

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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(press releases should not be checked into DocMan or printed)
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33 to 76 pages 25
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2 color text
Selection Guide
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Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
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B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
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Gray shading indicates Obsolete Print Catagories
Page 30: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

30

14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals

15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables

Remove nuts from bus bars

17 mm20 Nbullm(177 lbbullin)

Remove bolts from output terminals

17 mm20 Nbullm(177 lbbullin)

Power cables

Publication PFLEX-IN023A-EN-P

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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DownsampleGrayImages true GrayImageDownsampleType Average GrayImageResolution 300 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 200000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 1200 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Average MonoImageResolution 1200 MonoImageDepth -1 MonoImageDownsampleThreshold 150000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects false CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 31: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

31

16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them

Important The insulator material must be installed between the bus bars during installation

Remove nuts

17 mm20 Nbullm(177 lbbullin)

DC- and DC+ bus bars

Publication PFLEX-IN023A-EN-P

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

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38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

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39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

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42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

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43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

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44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

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45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

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47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT ltFEFF4f7f752890194e9b8a2d7f6e5efa7acb7684002000410064006f006200650020005000440046002065874ef653ef5728684c9762537088686a5f548c002000700072006f006f00660065007200204e0a73725f979ad854c18cea7684521753706548679c300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c4f86958b555f5df25efa7acb76840020005000440046002065874ef63002gt DAN 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 DEU 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 ESP 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 FRA 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 ITA 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 JPN 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 KOR ltFEFFc7740020c124c815c7440020c0acc6a9d558c5ec0020b370c2a4d06cd0d10020d504b9b0d1300020bc0f0020ad50c815ae30c5d0c11c0020ace0d488c9c8b85c0020c778c1c4d560002000410064006f0062006500200050004400460020bb38c11cb97c0020c791c131d569b2c8b2e4002e0020c774b807ac8c0020c791c131b41c00200050004400460020bb38c11cb2940020004100630072006f0062006100740020bc0f002000410064006f00620065002000520065006100640065007200200035002e00300020c774c0c1c5d0c11c0020c5f40020c2180020c788c2b5b2c8b2e4002egt NLD (Gebruik deze instellingen om Adobe PDF-documenten te maken voor kwaliteitsafdrukken op desktopprinters en proofers De gemaakte PDF-documenten kunnen worden geopend met Acrobat en Adobe Reader 50 en hoger) NOR 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 PTB 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 SUO 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 SVE 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 ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
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DU B3 D5 Document Update 1 5 Post External
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IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
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QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
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SG B2 D5 D6 Selection Guide BW 5 50 Presale External
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WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
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Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 32: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

32

17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables

Remove nuts

17 mm40 Nbullm(354 lbbullin)

AC supply cables

Publication PFLEX-IN023A-EN-P

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
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(press releases should not be checked into DocMan or printed)
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Minimum order quantities on all JIT items are based on the publication length
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77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
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A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
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A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
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Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
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4 color text 45 Coated Sheet
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JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
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D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
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D5 1 color 80gsm bond 20 bond self cover
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D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 33: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

33

18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly

Remove screws

Remove screwsRemove screws

PZ240 Nbullm(354 lbbullin)

Terminal assembly

Publication PFLEX-IN023A-EN-P

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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ESP 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 FRA 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 KOR 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 PTB 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 SUO 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 ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 34: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

34

19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame

Remove screws

Remove screwsHEX820 Nbullm(177 lbbullin)

HEX820 Nbullm(177 lbbullin)

Rectifier circuit board(on side of phase module)

Publication PFLEX-IN023A-EN-P

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

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43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

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46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT ltFEFF4f7f752890194e9b8a2d7f6e5efa7acb7684002000410064006f006200650020005000440046002065874ef653ef5728684c9762537088686a5f548c002000700072006f006f00660065007200204e0a73725f979ad854c18cea7684521753706548679c300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c4f86958b555f5df25efa7acb76840020005000440046002065874ef63002gt DAN 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 ESP 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 FRA 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 PTB 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 SUO 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 SVE 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 ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
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Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
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Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
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AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
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(press releases should not be checked into DocMan or printed)
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33 to 76 pages 25
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1 or 2 pages 100
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Selection Guide
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Selection Guide
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Post Sale Technical Communication
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2 color text 50 matte sheet text
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4 color text 45 Coated Sheet
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D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
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D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 35: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

35

20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate

21 Carefully remove the phase module from the top of the drive frame

22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)

Remove M5 screws

Remove M5 screws

Remove M6 screws

Remove M6 screws

PZ250 Nbullm(443 lbbullin)

PZ350 Nbullm(443 lbbullin)

Publication PFLEX-IN023A-EN-P

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 36: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

36

Figure 7 Series A Rectifier Circuit Board

Figure 8 Series B Rectifier Circuit Board

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8X101X50

J3J7

J11T2015 Nbullm(133 lbbullin)

X13X6X10X11X12X9 X100

X3 X2 X1

X4

X41

X8

X101X50X33 X23 X32 X22 X31 X21

T2015 Nbullm(133 lbbullin)

Publication PFLEX-IN023A-EN-P

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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ltFEFF00560065007200770065006e00640065006e0020005300690065002000640069006500730065002000450069006e007300740065006c006c0075006e00670065006e0020007a0075006d002000450072007300740065006c006c0065006e00200076006f006e002000410064006f006200650020005000440046002d0044006f006b0075006d0065006e00740065006e002c00200076006f006e002000640065006e0065006e002000530069006500200068006f00630068007700650072007400690067006500200044007200750063006b006500200061007500660020004400650073006b0074006f0070002d0044007200750063006b00650072006e00200075006e0064002000500072006f006f0066002d00470065007200e400740065006e002000650072007a0065007500670065006e0020006d00f60063006800740065006e002e002000450072007300740065006c006c007400650020005000440046002d0044006f006b0075006d0065006e007400650020006b00f6006e006e0065006e0020006d006900740020004100630072006f00620061007400200075006e0064002000410064006f00620065002000520065006100640065007200200035002e00300020006f0064006500720020006800f600680065007200200067006500f600660066006e00650074002000770065007200640065006e002egt ESP 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FRA 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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
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(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
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(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
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(press releases should not be checked into DocMan or printed)
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PC B3 D5 Packaging Contents
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RM B2 D5 D6 Reference Manual 1 5 Post External
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Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 37: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

37

23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board

Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed

24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8

25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors

Rectifier circuit board

Do not remove screw at X41 on rectifier circuit board

Remove screw

T2015 Nbullm(133 lbbullin)

Top of Power Structure

Common mode jumper

T2015 Nbullm(133 lbbullin)

Remove nuts

8 mm15 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 38: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

38

26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module

27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars

Important Do Not reuse the existing DC+ rectifier bus bar

Remove bolts 17 mm12 Nbullm(106 lbbullin)

AC supply cables

Terminal bus bars

Remove bolts

17 mm12 Nbullm(106 lbbullin)

Do Not reuse existing DC+ bus bar

Publication PFLEX-IN023A-EN-P

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

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 ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
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AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
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(press releases should not be checked into DocMan or printed)
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Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
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A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
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A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
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2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
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B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
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B5 2 color 100gsm bond 50 matte sheet text self cover
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C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
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2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 39: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

39

28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars

Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly

29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars

Remove M4x8 screws

Remove M4x8 screw

600690V AC Input Drives

Remove M6x20 screw

Balancing resistors

Balancing resistors

T2015 Nbullm(133 lbbullin)

T3040 Nbullm(354 lbbullin)

400480V AC Input Drives

T2015 Nbullm(133 lbbullin)

Remove M4x8 screws

T2015 Nbullm(133 lbbullin)

Remove screws

T3050 Nbullm(442 lbbullin)

Snubber capacitor assembly

Publication PFLEX-IN023A-EN-P

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 40: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

40

30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41

Remove the Bus Bars from a 400480V AC Input Drive

ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

Outer Bus Bar PZ350 Nbullm(442 lbbullin)

DC- Bus Bar PZ350 Nbullm(442 lbbullin)

DC+ Bus Bar PZ350 Nbullm(442 lbbullin)

Bus bar insulator sheetsCapacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

Publication PFLEX-IN023A-EN-P

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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FRA 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 ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
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(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
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(press releases should not be checked into DocMan or printed)
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PM B2 D6 Programming Manual 1 5 Post External
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RM B2 D5 D6 Reference Manual 1 5 Post External
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WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
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77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
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A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
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A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
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B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 41: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

41

Remove the Bus Bars from a 600690V AC Input Drive

ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet

ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet

T3040 Nbullm(354 lbbullin)

Bus bar insulator sheets

Capacitor insulator sheet

Do Not reuse this insulator sheet Replace with new insulator sheet

T3040 Nbullm(354 lbbullin)

Outer Bus Bar

DC- Bus Bar

DC+ Bus Bar

Publication PFLEX-IN023A-EN-P

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 42: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

42

31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module

32 Continue with Step 5 Install the New Rectifier Module below

PZ215 Nbullm(133 lbbullin)

Remove screws

Publication PFLEX-IN023A-EN-P

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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(press releases should not be checked into DocMan or printed)
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77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
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A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
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A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
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2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
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B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
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D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
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D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
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D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 43: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

43

Step 5 Install the New Rectifier Module

Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12

Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below

Important You must only install the new insulator sheet provided with the kit over the rectifier module

ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only

Bus bar may touch SCR terminal if installed

Bus bar provided in this kit does not touch SCR terminal

DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)

DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)

Align holes in new insulator sheet over rectifier AC input terminal tabs

New insulator sheet

Publication PFLEX-IN023A-EN-P

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
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(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
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(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
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(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
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Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
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Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
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(press releases should not be checked into DocMan or printed)
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77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
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A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
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Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
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2 color text 50 matte sheet text
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D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
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D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 44: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

44

Step 6 Install the Power Structure in the Enclosure

Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9

Step 7 Complete the Circuit Tests

Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)

A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)

There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below

1 Verify that no power is applied to the drive

2 Disconnect all motor leads from the drive

3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47

~0L

+

-

~05V

+

-Forward biased test on PN-junction

Reverse biased test on PN-junction

Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B

400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462

Publication PFLEX-IN023A-EN-P

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

ltlt ASCII85EncodePages false AllowTransparency false AutoPositionEPSFiles true AutoRotatePages All Binding Left CalGrayProfile (Dot Gain 20) CalRGBProfile (sRGB IEC61966-21) CalCMYKProfile (US Web Coated 050SWOP051 v2) sRGBProfile (sRGB IEC61966-21) CannotEmbedFontPolicy Error CompatibilityLevel 14 CompressObjects Tags CompressPages true ConvertImagesToIndexed true PassThroughJPEGImages true CreateJDFFile false CreateJobTicket false DefaultRenderingIntent Default DetectBlends true DetectCurves 00000 ColorConversionStrategy LeaveColorUnchanged DoThumbnails false EmbedAllFonts true EmbedOpenType false ParseICCProfilesInComments true EmbedJobOptions true DSCReportingLevel 0 EmitDSCWarnings false EndPage -1 ImageMemory 1048576 LockDistillerParams true MaxSubsetPct 1 Optimize true OPM 1 ParseDSCComments false ParseDSCCommentsForDocInfo true PreserveCopyPage true PreserveDICMYKValues true PreserveEPSInfo true PreserveFlatness true PreserveHalftoneInfo false PreserveOPIComments false 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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 45: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

45

Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives

Series A Rectifier Circuit Board - Rectifier Module Tests

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS

OPERATE AT HIGH VOLTAGE REMOVE POWER

AND WAIT 5 MINUTES BEFORE SERVICING

Cat No

1234567890-

FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS

DC- DC+ DC- DC+

1L11L2

1L3

2L12L2

2L3

1UT1

1VT2

1WT3 2UT1

2VT2

2WT3

Power Structure 1 Power Structure 2

Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-

Publication PFLEX-IN023A-EN-P

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
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Selection Guide
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Page 46: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

46

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading- +DC+ 1L1

Meter should beep once and value should gradually rise to about 10 V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

DC+ 1L2DC+ 1L31L1 DC-

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules

1L2 DC-1L3 DC-

Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -1L1 DC-

Meter should display ldquo0Lrdquo (zero load)

1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3

Publication PFLEX-IN023A-EN-P

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

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JIT Printing Specifications RA-QR005F-EN-P - 8072009
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(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
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BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
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IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
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QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
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TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
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WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
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77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
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A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
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B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
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B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
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D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 47: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

47

Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives

Figure 9 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifier Circuit Board - Rectifier Module Tests

Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 05V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1DC- L2DC- L3

2L12L2

2L31L11L2

1L3

UT1 VT2 WT3

DC-DC+

Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module

Publication PFLEX-IN023A-EN-P

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
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(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
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BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
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Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
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Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
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Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
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(press releases should not be checked into DocMan or printed)
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PM B2 D6 Programming Manual 1 5 Post External
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Minimum order quantities on all JIT items are based on the publication length
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77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
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A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
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2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
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B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
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Catalogs
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C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
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D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 48: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

48

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Series B Rectifier Circuit Board - Rectifier Module Tests

Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module

Step 8 Install the Protective Covers

Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6

Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC+

The value should gradually rise to about 10V(1)

(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

L2 DC+L3 DC+DC- L1

The value should gradually rise to about 035V(2)

(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules

DC- L2DC- L3

Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads

Nominal meter reading+ -L1 DC-

The meter should display ldquo0Lrdquo (zero load)

L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3

Publication PFLEX-IN023A-EN-P

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 49: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

49

Step 9 Documenting the Change

Record the rectifier module installation on the Field Installed Option label

Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature

For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives

PowerFlex 700H Programming Manual 20C-PM001

Programming and troubleshooting information on PowerFlex 700S Phase II drives

PowerFlex 700S with Phase II Control User Manual 20D-UM006

Information on installing Frame 9-14 PowerFlex 700H and 700S drives

Installation Instructions - PowerFlex 700H and 700S Frame 9-14 Drives PFLEX-IN006

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 10 drives

PowerFlex 700H and 700S Frame 10 Hardware Service Manual PFLEX-TG002

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 11 drives

PowerFlex 700H and 700S Frame 11 Hardware Service Manual PFLEX-TG003

Information on troubleshooting and repairing PowerFlex 700H and 700S frame 12 drives

PowerFlex 700H and 700S Frame 12 Hardware Service Manual PFLEX-TG004

Publication PFLEX-IN023A-EN-P

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

ltlt ASCII85EncodePages false AllowTransparency false AutoPositionEPSFiles true AutoRotatePages All Binding Left CalGrayProfile (Dot Gain 20) CalRGBProfile (sRGB IEC61966-21) CalCMYKProfile (US Web Coated 050SWOP051 v2) sRGBProfile (sRGB IEC61966-21) CannotEmbedFontPolicy Error CompatibilityLevel 14 CompressObjects Tags CompressPages true ConvertImagesToIndexed true PassThroughJPEGImages true CreateJDFFile false CreateJobTicket false DefaultRenderingIntent Default DetectBlends true DetectCurves 00000 ColorConversionStrategy LeaveColorUnchanged DoThumbnails false EmbedAllFonts true EmbedOpenType false ParseICCProfilesInComments true EmbedJobOptions true DSCReportingLevel 0 EmitDSCWarnings false EndPage -1 ImageMemory 1048576 LockDistillerParams true MaxSubsetPct 1 Optimize true OPM 1 ParseDSCComments false ParseDSCCommentsForDocInfo true PreserveCopyPage true PreserveDICMYKValues true PreserveEPSInfo true PreserveFlatness true PreserveHalftoneInfo false PreserveOPIComments false PreserveOverprintSettings true StartPage 1 SubsetFonts false TransferFunctionInfo Apply UCRandBGInfo Remove UsePrologue false ColorSettingsFile () AlwaysEmbed [ true ] NeverEmbed [ true ] AntiAliasColorImages false CropColorImages true ColorImageMinResolution 300 ColorImageMinResolutionPolicy OK DownsampleColorImages true ColorImageDownsampleType Average ColorImageResolution 300 ColorImageDepth 8 ColorImageMinDownsampleDepth 1 ColorImageDownsampleThreshold 200000 EncodeColorImages true ColorImageFilter FlateEncode AutoFilterColorImages false ColorImageAutoFilterStrategy JPEG ColorACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt ColorImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000ColorACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000ColorImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 300 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Average GrayImageResolution 300 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 200000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 1200 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Average MonoImageResolution 1200 MonoImageDepth -1 MonoImageDownsampleThreshold 150000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects false CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly 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JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 50: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

wwwrockwellautomationcom

Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444

EuropeMiddle EastAfrica Rockwell Automation VorstlaanBoulevard du Souverain 36 1170 Brussels Belgium Tel (32) 2 663 0600 Fax (32) 2 663 0640

Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel (852) 2887 4788 Fax (852) 2508 1846

Power Control and Information Solutions Headquarters

Publication PFLEX-IN023A-EN-P ndash March 2010Copyright copy 2010 Rockwell Automation Inc All rights reserved Printed in USA

US Allen-Bradley Drives Technical Support - Tel (1) 2625128176 Fax (1) 2625122222 Email supportdrivesrarockwellcom Online wwwabcomsupportabdrives

Introduction_Catagory Types

Print Spec Sheet

ltlt ASCII85EncodePages false AllowTransparency false AutoPositionEPSFiles true AutoRotatePages All Binding Left CalGrayProfile (Dot Gain 20) CalRGBProfile (sRGB IEC61966-21) CalCMYKProfile (US Web Coated 050SWOP051 v2) sRGBProfile (sRGB IEC61966-21) CannotEmbedFontPolicy Error CompatibilityLevel 14 CompressObjects Tags CompressPages true ConvertImagesToIndexed true PassThroughJPEGImages true CreateJDFFile false CreateJobTicket false DefaultRenderingIntent Default DetectBlends true DetectCurves 00000 ColorConversionStrategy LeaveColorUnchanged DoThumbnails false EmbedAllFonts true EmbedOpenType false ParseICCProfilesInComments true EmbedJobOptions true DSCReportingLevel 0 EmitDSCWarnings false EndPage -1 ImageMemory 1048576 LockDistillerParams true MaxSubsetPct 1 Optimize true OPM 1 ParseDSCComments false ParseDSCCommentsForDocInfo true PreserveCopyPage true PreserveDICMYKValues true PreserveEPSInfo true PreserveFlatness true PreserveHalftoneInfo false PreserveOPIComments false PreserveOverprintSettings true StartPage 1 SubsetFonts false TransferFunctionInfo Apply UCRandBGInfo Remove UsePrologue false ColorSettingsFile () AlwaysEmbed [ true ] NeverEmbed [ true ] AntiAliasColorImages false CropColorImages true ColorImageMinResolution 300 ColorImageMinResolutionPolicy OK DownsampleColorImages true ColorImageDownsampleType Average ColorImageResolution 300 ColorImageDepth 8 ColorImageMinDownsampleDepth 1 ColorImageDownsampleThreshold 200000 EncodeColorImages true ColorImageFilter FlateEncode AutoFilterColorImages false ColorImageAutoFilterStrategy JPEG ColorACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt ColorImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000ColorACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000ColorImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 300 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Average GrayImageResolution 300 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 200000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 1200 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Average MonoImageResolution 1200 MonoImageDepth -1 MonoImageDownsampleThreshold 150000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects false CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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ESP 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FRA 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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 51: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

Introduction_Catagory Types

Print Spec Sheet

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DownsampleGrayImages true GrayImageDownsampleType Average GrayImageResolution 300 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 200000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 1200 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Average MonoImageResolution 1200 MonoImageDepth -1 MonoImageDownsampleThreshold 150000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects false CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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ESP 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FRA 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ITA 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 JPN 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 KOR ltFEFFc7740020c124c815c7440020c0acc6a9d558c5ec0020b370c2a4d06cd0d10020d504b9b0d1300020bc0f0020ad50c815ae30c5d0c11c0020ace0d488c9c8b85c0020c778c1c4d560002000410064006f0062006500200050004400460020bb38c11cb97c0020c791c131d569b2c8b2e4002e0020c774b807ac8c0020c791c131b41c00200050004400460020bb38c11cb2940020004100630072006f0062006100740020bc0f002000410064006f00620065002000520065006100640065007200200035002e00300020c774c0c1c5d0c11c0020c5f40020c2180020c788c2b5b2c8b2e4002egt NLD (Gebruik deze instellingen om Adobe PDF-documenten te maken voor kwaliteitsafdrukken op desktopprinters en proofers De gemaakte PDF-documenten kunnen worden geopend met Acrobat en Adobe Reader 50 en hoger) NOR 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 SUO 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 SVE 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 ENU (Use these settings to create Adobe PDF documents for quality printing on desktop printers and proofers Created PDF documents can be opened with Acrobat and Adobe Reader 50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type Off Set Print Category Spec (See table below) JIT Spec (See table below) Description Order Min Order Max Life Cycle Usage Release Option
AD NA - Puttman NA Advertisement Reprint Colour NA NA Presale Internal
AP A3 D2 Application Solution or Customer Success Story 5 100 Presale External
AR NA NA ArticleEditorialByline NA NA Presale Internal
(press releases should not be checked into DocMan or printed)
AT B3 B4 D5 Application techniques 5 100 Presale External
BR A2 Primary A1 NA Brochures 5 100 Presale External
CA C2 Primary C1 NA Catalogue 1 50 Presale External
CG NA NA Catalogue Guide 1 50 Presale External
CL NA NA Collection 5 50 Presale External
CO A5 A6 A9 D5 Company Confidential Information NA NA NA Confidential
CP E-only E-only D5 Competitive Information 5 50 NA Confidential
DC E-only E-only Discount Schedules NA NA Presale Internal
DI A1 A3 NA Direct Mail 5 100 Presale Internal
DM NA NA Product Demo 5 50 Presale Internal
DS B3 D5 Dimensions Sheet 1 5 Post External
DU B3 D5 Document Update 1 5 Post External
GR B2 D6 Getting Results 1 5 Post External
IN B3 Primary B2 D5 D6 Installation instructions 1 5 Post External
LM NA NA Launch Materials 5 50 Presale Internal
PC B3 D5 Packaging Contents
PL E-only primary B3 E-only Price List 5 50 Presale Internal
PM B2 D6 Programming Manual 1 5 Post External
PP A3 D1 Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type 5 100 Presale External
QR B2 primary B3 B5 D5 D6 Quick Reference 1 5 Post External
QS B2 primary B3 B5 D5 D6 Quick Start 1 5 Post External
RM B2 D5 D6 Reference Manual 1 5 Post External
RN B3 D5 Release Notes 1 5 Post External
SG B1 Primary B4 D5 D6 Selection Guide Colour 5 50 Presale External
SG B2 D5 D6 Selection Guide BW 5 50 Presale External
SP A1 A2 A3 A4 NA Sales Promotion NOTE Service profiles are to be assigned the PP pub type 5 100 Presale Internal
SR B2 B3 D5 D6 Specification Rating Sheet 5 100 Presale External
TD B2 Primary B3 B4 B5 D5 D6 Technical Data 5 50 Presale External
TG B2 B3 D6 Troubleshooting Guide 1 5 Post External
UM B2 Primary B4 D6 User Manual BW 1 5 Post External
WD B3 D5 Wiring Diagrams Dwgs 1 5 Post Internal
WP B3 Primary B5 D5 White Paper 5 50 Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length Minimum Order Quantity
77 or more pages 1 (no shrink wrap required)
33 to 76 pages 25
3 to 32 pages 50
1 or 2 pages 100
Pre-sale Marketing All paper in this category is White Brightness 90 or better Opacity 90 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
A1 4 color 170 gsm 2pp 100 gloss cover 100 gloss text
A2 4 color 170 gsm folded 4pp 100 gloss cover 80 gloss text
A3 4 color Cover 170 gsm with Body 120 gsm gt 4pp 80 gloss cover 80 gloss text
A4 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 gloss text
A5 2 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A6 1 color 170gsm Silk ndash 120gsm Silk 80 gloss cover 80 matt sheet text
A7 4 color cover2 color textSelection Guide Category being deleted 10 Point Cover C2S50 matte sheet text
A8 4 color cover Category being deleted 50 matte sheet text self cover
2 color text
Selection Guide
A9 2 color 100gsm bond 50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
B1 4 color cover 270gsm Gloss 100gsm bond 10 Point Cover C2S
2 color text 50 matte sheet text
B2 1 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B3 1 color 100gsm bond 50 matte sheet text self cover
B4 2 color 160gsm Colortech amp 100gsm Bond 90 Cover50 matte sheet text
B5 2 color 100gsm bond 50 matte sheet text self cover
Catalogs
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
C1 4 color cover 270gsm Gloss 90gsm silk 10 Point Cover C2S
4 color text 45 Coated Sheet
C2 4 color cover 270gsm Gloss 80gsm silk 10 Point Cover C2S
2 color text 32-33 Coated Sheet
JIT POD All paper in this category is White Brightness 82 or better Opacity 88 or better
Category Color Options AP EMEA Paper Requirements Canada LA US Paper Requirements
D1 4 color 170gsm white silk 80 gloss cover coated 2 sides
D2 4 color 120gsm white silk 80 gloss text coated 2 sides self cover
D3 4 color Cover 170gsm with Body 120gsm 80 gloss cover 80 gloss text coated 2 sides
D4 1 color 160gsm tab 90 index
D5 1 color 80gsm bond 20 bond self cover
D6 1 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D7 2 color 160gsm tab 90 index
D8 2 color 80gsm bond 20 bond self cover
D9 2 color Cover 160gsm tab with Body 80gsm bond 90 index 20 bond
D10 Combination 4 color cover with 2 color body Cover 160gsm with Body 80gsm 90 index 20 bond
Gray shading indicates Obsolete Print Catagories
Page 52: PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module.

Print Spec Sheet

ltlt ASCII85EncodePages false AllowTransparency false AutoPositionEPSFiles true AutoRotatePages All Binding Left CalGrayProfile (Dot Gain 20) CalRGBProfile (sRGB IEC61966-21) CalCMYKProfile (US Web Coated 050SWOP051 v2) sRGBProfile (sRGB IEC61966-21) CannotEmbedFontPolicy Error CompatibilityLevel 14 CompressObjects Tags CompressPages true ConvertImagesToIndexed true PassThroughJPEGImages true CreateJDFFile false CreateJobTicket false DefaultRenderingIntent Default DetectBlends true DetectCurves 00000 ColorConversionStrategy LeaveColorUnchanged DoThumbnails false EmbedAllFonts true EmbedOpenType false ParseICCProfilesInComments true EmbedJobOptions true DSCReportingLevel 0 EmitDSCWarnings false EndPage -1 ImageMemory 1048576 LockDistillerParams true MaxSubsetPct 1 Optimize true OPM 1 ParseDSCComments false ParseDSCCommentsForDocInfo true PreserveCopyPage true PreserveDICMYKValues true PreserveEPSInfo true PreserveFlatness true PreserveHalftoneInfo false PreserveOPIComments false PreserveOverprintSettings true StartPage 1 SubsetFonts false TransferFunctionInfo Apply UCRandBGInfo Remove UsePrologue false ColorSettingsFile () AlwaysEmbed [ true ] NeverEmbed [ true ] AntiAliasColorImages false CropColorImages true ColorImageMinResolution 300 ColorImageMinResolutionPolicy OK DownsampleColorImages true ColorImageDownsampleType Average ColorImageResolution 300 ColorImageDepth 8 ColorImageMinDownsampleDepth 1 ColorImageDownsampleThreshold 200000 EncodeColorImages true ColorImageFilter FlateEncode AutoFilterColorImages false ColorImageAutoFilterStrategy JPEG ColorACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt ColorImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000ColorACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000ColorImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasGrayImages false CropGrayImages true GrayImageMinResolution 300 GrayImageMinResolutionPolicy OK DownsampleGrayImages true GrayImageDownsampleType Average GrayImageResolution 300 GrayImageDepth 8 GrayImageMinDownsampleDepth 2 GrayImageDownsampleThreshold 200000 EncodeGrayImages true GrayImageFilter FlateEncode AutoFilterGrayImages false GrayImageAutoFilterStrategy JPEG GrayACSImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt GrayImageDict ltlt QFactor 015 HSamples [1 1 1 1] VSamples [1 1 1 1] gtgt JPEG2000GrayACSImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt JPEG2000GrayImageDict ltlt TileWidth 256 TileHeight 256 Quality 30 gtgt AntiAliasMonoImages false CropMonoImages true MonoImageMinResolution 1200 MonoImageMinResolutionPolicy OK DownsampleMonoImages true MonoImageDownsampleType Average MonoImageResolution 1200 MonoImageDepth -1 MonoImageDownsampleThreshold 150000 EncodeMonoImages true MonoImageFilter CCITTFaxEncode MonoImageDict ltlt K -1 gtgt AllowPSXObjects false CheckCompliance [ None ] PDFX1aCheck false PDFX3Check false PDFXCompliantPDFOnly false PDFXNoTrimBoxError true PDFXTrimBoxToMediaBoxOffset [ 000000 000000 000000 000000 ] PDFXSetBleedBoxToMediaBox true PDFXBleedBoxToTrimBoxOffset [ 000000 000000 000000 000000 ] PDFXOutputIntentProfile (None) PDFXOutputConditionIdentifier () PDFXOutputCondition () PDFXRegistryName () PDFXTrapped False Description ltlt CHS ltFEFF4f7f75288fd94e9b8bbe5b9a521b5efa7684002000500044004600206587686353ef901a8fc7684c976262535370673a548c002000700072006f006f00660065007200208fdb884c9ad88d2891cf62535370300260a853ef4ee54f7f75280020004100630072006f0062006100740020548c002000410064006f00620065002000520065006100640065007200200035002e003000204ee553ca66f49ad87248672c676562535f00521b5efa768400200050004400460020658768633002gt CHT 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ESP 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 FRA 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ITA 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 JPN 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 KOR 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 PTB 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50 and later) gtgt Namespace [ (Adobe) (Common) (10) ] OtherNamespaces [ ltlt AsReaderSpreads false CropImagesToFrames true ErrorControl WarnAndContinue FlattenerIgnoreSpreadOverrides false IncludeGuidesGrids false IncludeNonPrinting false IncludeSlug false Namespace [ (Adobe) (InDesign) (40) ] OmitPlacedBitmaps false OmitPlacedEPS false OmitPlacedPDF false SimulateOverprint Legacy gtgt ltlt AddBleedMarks false AddColorBars false AddCropMarks false AddPageInfo false AddRegMarks false ConvertColors NoConversion DestinationProfileName () DestinationProfileSelector NA Downsample16BitImages true FlattenerPreset ltlt PresetSelector MediumResolution gtgt FormElements false GenerateStructure true IncludeBookmarks false IncludeHyperlinks false IncludeInteractive false IncludeLayers false IncludeProfiles true MultimediaHandling UseObjectSettings Namespace [ (Adobe) (CreativeSuite) (20) ] PDFXOutputIntentProfileSelector NA PreserveEditing true UntaggedCMYKHandling LeaveUntagged UntaggedRGBHandling LeaveUntagged UseDocumentBleed false gtgt ]gtgt setdistillerparamsltlt HWResolution [2400 2400] PageSize [612000 792000]gtgt setpagedevice

JIT Printing Specifications RA-QR005F-EN-P - 8072009
Printing Specification YOUR DATA HERE Instructions NO
(required) Category D5 Select Print Category ABC or D from category list on Introduction_Catagory Types tab 11rdquo x 17rdquo LOOSE -Loose Leaf YES Pre-sale Marketing TOP
(required) Finished Trim Size Width 85rdquo x 11rdquo 85rdquo x 11rdquo PERFECT - Perfect Bound A1 LEFT
(required) Publication Number PFLEX-IN023A-EN-P Sample 2030-SP001B-EN-P 3rdquo x 5rdquo SADDLE - Saddle Stitch A2 RIGHT CORNER
Use Legacy Number NO YES or NO 18rdquo x 24rdquo Poster PLASTCOIL - Plastic Coil (Coil Bound) A4 BOTTOM SIDE
Legacy Number if applicable Sample Legacy Number 0160-533 24rdquo x 36rdquo Poster STAPLED1 -1 position A3
Publication Title PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit Sample ElectroGuard Selling Brief 36rdquo x 24rdquo Poster STAPLED1B - bottom 1 position A5
(required) Business Group Marketing Commercial As entered in DocMan 4rdquo x 6rdquo STAPLED2 - 2 positions A6
(required) Cost Center 19010 As entered in DocMan - enter number only no description Example - 19021 CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105 475rdquo x 7rdquo (slightly smaller half-size) THERMAL - Thermal bound (Tape bound) A7
BindingStitching STAPLED2 - 2 positions Review key on right Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise) 475rdquo x 775rdquo THERMALO - Thermal Bound (Tape bound - offline) A8
(required) Page Count of Publication 50 Total page count including cover 55rdquo x 85rdquo (half-size) Wire O - Double Wire Bound (offline) A9
Paper Stock Color White is assumed For color options contact your vendor 6rdquo x 4rdquo Post Sale Technical Communication
Number of Tabs Needed 5 tab in stock at RR Donnelley 7385rdquo x 9rdquo (RSI Std) B1
Stitching Location SIDE Blank Corner or Side 825rdquo x 10875rdquo B2
Drill Hole YESNO NO All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border 825rdquo x 11rdquo (RA product profile std) B3 None
Glue Location on Pad Glue location on pads 8375rdquo x 10875 B4 Half
Number of Pages per Pad Average sheets of paper 25 50 75100 Max 9rdquo x 12rdquo (Folder) B5 C
Ink Color One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm) Catalogs DbleParll
Used in Manufacturing NO A5 (583rdquo x 826rdquo) (148 x 210 mm) C1 Offset Z
Fold None Sample
Comments C2 Short
Part Number JIT POD V
D1 Z
D2 Microfold
D3
D4
D5
D6
D7
D8
D9

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