20l tg001 - en P

Liquid-Cooled Adjustable Frequency AC Drive
Frames 3A and 3B
Hardware Service Manual
Important User Information
Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at http:// www.rockwellautomation.com/literature) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited. Throughout this manual, when necessary we use notes to make you aware of safety considerations. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.
Important: Identifies information that is critical for successful application and understanding of the product. ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid the hazard, and recognize the consequences. Shock Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present. Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures.
PowerFlex is a registered trademark of Rockwell Automation, Inc.
PowerFlex 700L Frames 3A and 3B Hardware Service Manual
Summary of Changes
This is the first release of the PowerFlex 700L Liquid-Cooled AC Drive Frames 3A and 3B Hardware Service Manual.
PowerFlex 700L Frames 3A and 3B Hardware Service Manual Publication 20L-TG001A-EN-P
soc-ii
Summary of Changes
Table of Contents
Preface
Overview
Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What is in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cross References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Support Available on Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Class 1 LED Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1 P-1 P-3 P-3 P-4 P-4 P-4 P-4 P-5 P-5
Chapter 1
Troubleshooting and Error Codes

Creating Fault Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Addressing Active Converter Hardware Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Addressing 700 Vector Control Hardware Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Addressing 700S Phase II Control Hardware Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Diagnostic Procedures by Symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Circuit Breaker Tripped Blown Input Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 No HIM Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Over-Temperature Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Chapter 2
Component Test Procedures

Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing the PowerFlex 700 Vector Control Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing the PowerFlex 700S Control Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Power From the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Periodic Inspections with No Power Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Hoses/Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal Bolts, Mounting Bolts, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply PCB, Addressable Power PCB, and Rating Plug PCB . . . . . . . . . . . . . Periodic Inspections with Power Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Power Module Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Input Filter Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Fan Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Input Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Input Filter Inductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward Biased Diode Tests for the Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Power Module Discharge Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Power Module Bay Door Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-2 2-2 2-3 2-3 2-4 2-5 2-5 2-5 2-5 2-5 2-5 2-6 2-6 2-6 2-7 2-7 2-8 2-8
ii
Table of Contents
Chapter 3
Access Procedures
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Understanding Torque Figures in Assembly Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Removing Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Input Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Removing the Input Filter Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Removing the Input Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Removing the Input Filter from the Complete Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Removing the Power Module Front Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Removing the HIM Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Removing the Communications Adapter Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Removing the Internal DPI Cable from the Power Module . . . . . . . . . . . . . . . . . . . . 3-11 Removing the Power Module Left Side Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Removing the 30-Pin Communications Interface Cable from the Power Module . . . 3-15 Removing the 40-Pin MCB Cable from the Power Module . . . . . . . . . . . . . . . . . . . . 3-16 Removing the Frame 3A 700S Control Synchronization Cable . . . . . . . . . . . . . . . . . 3-17 Removing the Frame 3B 700S Control Synchronization Cable . . . . . . . . . . . . . . . . . 3-18 Removing the Frame 3A 700 Vector Cable Synchronization Cable . . . . . . . . . . . . . . 3-19 Removing the Frame 3B 700 Vector Control Synchronization Cable. . . . . . . . . . . . . 3-20 Removing the Active Converter Control Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Removing the 700 Vector Control Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Removing the 700S Control Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Accessing the Control Panel of the Frame 3A Power Module . . . . . . . . . . . . . . . . . . 3-24 Accessing the Control Panel of the Frame 3B Power Module . . . . . . . . . . . . . . . . . . 3-26 Removing the 34-Pin Power Supply Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Removing the TB5/TB6 Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Removing the Frame 3A Current Feedback Devices and Current Harnesses . . . . . . . 3-31 Removing the Frame 3B Current Feedback Devices and Current Harness. . . . . . . . . 3-32 Removing the Frame 3A IGBT Interface Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Removing the Frame 3B IGBT Interface Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Removing the Frame 3A Temperature Sensor Harnesses . . . . . . . . . . . . . . . . . . . . . . 3-35 Removing the Frame 3B Temperature Sensor Harness . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Removing the Motor Voltage Feedback PCB (700S Control Only) . . . . . . . . . . . . . . 3-37 Removing the Rating Plug PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Removing the Addressable Power PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Removing the Power Supply PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Removing the Discharge Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Removing the Power Module Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Removing the Fan Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 Complete Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 Removing the Fan Filter Element for Power Module Bay Door Fan (Frames 3A and 3B) and the Power Module Bay Door Louver (Frame 3B Only) . . . . . . . . . . . 3-44 Removing the Power Module Bay Door Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Removing the Frame 3A Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Removing Frame 3B Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 Removing the Door-Mount HIM Bezel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 Removing the Power Module Bay Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 Removing the Frame 3A Power Module Bay Barrier . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 Removing the Frame 3B Power Module Bay Barriers . . . . . . . . . . . . . . . . . . . . . . . . 3-52 Removing the Power Module Jumper Bus Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Table of Contents
iii
Removing the Frame 3A and 3B Complete Drive Main Harness . . . . . . . . . . . . . . . . Removing the Frame 3A Power Module from the Power Module Bay . . . . . . . . . . . Removing the Frame 3B Power Module from the Power Module Bay . . . . . . . . . . . Frame 3A Power Module Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working with the Frame 3A Spare Power Module - Overview . . . . . . . . . . . . . . . . . Assembling the Frame 3A Spare Power Module as a Converter/Inverter (Catalog Number Digit 13 = E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling the Frame 3A Spare Power Module as a Dual Inverter (Catalog Number Digit 13 = L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Returning the Original Frame 3A Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame 3B Power Module Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working with the Frame 3B Spare Power Module - Overview . . . . . . . . . . . . . . . . . Assembling the Frame 3B Spare Power Module as an Active Converter (Catalog Number Digit 13 = G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling the Frame 3B Spare Power Module as an Active Converter Stand Alone Version (Catalog Number Digit 13 = P). . . . . . . . . . . . . . . . . . . . . . . Assembling the Frame 3B Spare Power Module as an Inverter (Catalog Number Digit 13 = J or K) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Returning the Original Frame 3B Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-55 3-57 3-61 3-66 3-66 3-66 3-69 3-73 3-73 3-73 3-74 3-77 3-78 3-82
Chapter 4
Start-Up After Repair

Performing the Power Circuit Diagnostic Test (only 700S Phase II Control) . . . . . . . . . 4-1 Testing With the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Appendix A
Service Tools and Equipment

Software Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Appendix B
Connector Descriptions
Power Supply Board Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Addressable Power Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Appendix C
Schematics
iv
Table of Contents
Preface
Overview
Who Should Use this Manual?
This manual is intended for qualified service personnel responsible for troubleshooting and repairing PowerFlex 700L Liquid-Cooled Frame 3A and 3B Drives. You should have previous experience with, and basic understanding of, electrical terminology, procedures, required troubleshooting equipment, equipment protection procedures and methods, and safety precautions.
What is in this Manual
This manual contains hardware service information for PowerFlex 700L Frame 3A and 3B drives only. Verify that you are working on a Frame 3A or 3B drive by checking the data nameplates on the inside of the bay doors and on the Power Modules. The frame number is printed just above the serial number. Figure P.1 shows the data nameplate locations.
P-2
Overview
Figure P.1 Complete Drive Data Nameplate Locations (Frame 3B shown)
NOTE: Input Filter data nameplate labels are duplicated on the interior circuit breaker mounting panel.
Input Filter Assembly (Label on inside front of door)
Cat No.
Complete Regenerative Drive (Label on inside front of door)

Cat No.
20LE800N0NNNCNW0WN
20LE800ACENNA6DELA
UL Open Type/IP00 Input Filter Assembly
Series: A
600V 870HP 518-633 800 518-633 N.A. 800 N.A. N.A.
Frame: 3B
NEMA Type 1/IP20 Complete Regenerative Drive

R
Series: A
600V 870HP 518-633 800 0-600 60 Hz 800 Treated Water 100 psig
Frame: 3B
TUV Rheinland Product Safety
Nominal Voltage Normal Duty Power
Original Firmware V. 2.005

N223
C
R
Input: 3 Phase, 47-63 Hz AC Voltage Range Amps Output: 3 Phase, 47-63 Hz AC Voltage Range
Base Hz (default)
C
US
Production inspected
Input: 3 Phase, 47-63 Hz AC Voltage Range Amps Output: 3 Phase, 0-400Hz AC Voltage Range
Base Hz (default)
US
Listed Ind. Cont. Eq. 966X
TUV
TUV Rheinland of North America
EN 50178
Continuous Amps Rated Coolant Nom. Coolant Pressure

MFD. in 2005 on MAR 05
Bauart gepruft
Functional
TUV Rheinland
Safety

TUV
EN 50178
Bauart gepruft
Functional
Type approved
TUV Rheinland
Safety
Type approved
Serial Number: MEAE2WJ0

Made in the U.S.A. (FAC1C) Made in the U.S.A. (FAC1C)

P/N 181255-A01
P/N 181255-A01
Input Filter Bay
Power Module Bay

Inverter Power Module
Cat No.
20LE800N0NNNJND0LA
UL Open Type/IP00 Inverter Power Module - Coupled With Converter
Series: A
Frame: 3B

R
Power Module Bay Door Cutaway
Input: DC DC Voltage Range Amps Output: 3 Phase, 0-400Hz AC Voltage Range

Base Hz (default)
C
US
TUV
EN 50178

Bauart gepruft
Functional
TUV Rheinland
Safety
Type approved

Made in the U.S.A. (FAC1C)
DANGER DANGER
P/N 181255-A01

FIELD INSTALLED OPTIONS
Power Module Front, Bottom Covers Removed
Firmware # : Firmware # : 20-HIM20-I/O20-COMM-
Converter Power Module

Cat No.
20B_-DB1-
Date: Date: HIM I/O COMM Module Internal Dynamic Brake
20LE800N0NNNGNW0WA
UL Open Type/IP00 Converter Power Module
Series: A
600V 870HP 518-633 800 730-900 N.A. 800 Treated Water 185 psig
Frame: 3B

R
Input: AC, 47-63 Hz DC Voltage Range Amps Output: DC DC Voltage Range

Base Hz (default)
C
US
TUV
EN 50178

Bauart gepruft
Functional
TUV Rheinland
Safety
Type approved

NOTE: Power Module data nameplate labels are duplicated on the exterior left side wall of the Power Modules. These labels may be viewed without removing the front, bottom covers of the Power Modules.
P/N 181255-A01
Overview
P-3
What is Not in this Manual
This manual does not contain in-depth fault information for troubleshooting. Depending on the control cassette installed in the drive, that information is available in the PowerFlex 700 Adjustable Frequency AC Drive User Manual (Publication 20B-UM002) or the PowerFlex 700S High Performance AC Drive - Phase II Control User Manual (Publication 20D-UM006). Additional information is also contained in the PowerFlex 700L Liquid-Cooled Adjustable Frequency AC Drive User Manual (Publication 20L-UM001) and the PowerFlex 700L Active Converter Power Module User Manual (Publication PFLEX-UM002).
Reference Materials
Allen-Bradley publications are available on the internet at http://www.rockwellautomation.com/literature. The following publications provide general drive information.
Title Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives Safety Guidelines for the Application, Installation and Maintenance of Solid State Control A Global Reference Guide for Reading Schematic Diagrams Guarding Against Electrostatic Damage Publication DRIVES-IN001 SGI-1.1 0100-2.10 8000-4.5.2
The following publications provide specific PowerFlex drive information.

Title PowerFlex 700L Liquid-Cooled Adjustable Frequency AC Drive User Manual PowerFlex 700L Active Converter Power Module User Manual PowerFlex 700 Adjustable Frequency AC Drive User Manual - Series B PowerFlex 700S High Performance AC Drive - Phase II Control User Manual Hi-Resolution Feedback Option Card Installation Instructions for PowerFlex 700S Drives Multi-Device Interface Option Card Installation Instructions for PowerFlex 700S Drives PowerFlex Adjustable Frequency Drive Reference Manual (Volume 1 - 70 & 700) PowerFlex Adjustable Frequency Drive Reference Manual (Volume 2 - 700S) Publication 20L-UM001 PFLEX-UM002 20B-UM002 20D-UM006 20D-IN001 20D-IN004 PFLEX-RM001 PFLEX-RM002
The following publications provide information that is necessary when applying the DriveLogix Controller.
Title User Manual - DriveLogix System Installation Instructions - DriveLogix Controller Installation Instructions - Memory Expansion for DriveLogix Controller ControlNet Daughtercard Installation Instructions ControlNet Daughtercard Installation Instructions Publication 20D-UM002... 20D-IN002... 20D-IN007... 1788-IN002... 1788-IN005...
P-4
Overview
Understanding Manual Conventions
Terms
The following words are used throughout the manual to describe an action:
Word Can Cannot May Must Shall Should Should Not Meaning Possible, able to do something Not possible, not able to do something Permitted, allowed Unavoidable, you must do this Required and necessary Recommended Not recommended
Cross References
Figure 2.1 on page 2-2 is a hyperlinked cross reference to Figure 2.1 on page 3 of Chapter 2. Table B.C on page B-2 is a hyperlinked cross reference to Table B.C on page 2 of Appendix B.
Additional Support Available on Internet
Additional troubleshooting information and software tools are available on the Allen-Bradley Drives Support Web site: www.ab.com/support/abdrives
Overview
P-5
General Precautions
Class 1 LED Product

ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into module ports or fiber-optic cable connectors. 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, refer to Allen-Bradley publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD protection handbook. ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring or application errors, such as undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system. ATTENTION: Only qualified personnel familiar with PowerFlex 700L Drives and associated machinery should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing. After removing power to the drive, wait 5 minutes for the bus capacitors to discharge. Measure the DC bus voltage at the DC+ and DC- TESTPOINT sockets on the lower front of the power module. The measured voltage must be zero (0). ATTENTION: Potentially fatal voltages may result from improper usage of an oscilloscope and other test equipment. The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded. If an oscilloscope is used to measure high voltage waveforms, use only a dual-channel oscilloscope in the differential mode with X 100 probes. It is recommended that the oscilloscope be used in the A minus B Quasi-differential mode with the oscilloscope chassis correctly grounded to an earth ground.
P-6
Overview
Notes:
Chapter
! !
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. After removing power to the drive, wait 5 minutes for the bus capacitors to discharge. Measure the DC bus voltage at the DC+ TESTPOINT and DC- TESTPOINT sockets on the front of the power module. The voltage must be zero. ATTENTION: HOT surfaces can cause severe burns. Do not touch the heatsink surface during operation of the drive. After disconnecting power allow time for cooling. ATTENTION: 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 Allen-Bradley publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD protection handbook.
! !
1-2
Creating Fault Reports
Clear and complete fault reports are critical for analysis and repair of modules returned to the factory. At a minimum, perform and record the following: Record the contents of the fault queue (faults and times of occurrence). Make record of any burn marks on the input inductor, filter capacitor assembly, precharge resistors, precharge contactors, printed circuit boards, bus bar, and cabling. Make record of any liquid or condensation marks on printed circuit boards, complete drive hose assemblies, and other mechanical parts. Make record of the amount of dust and other additional particles on drive and drive components. Make record of any mechanical damage to the drive and drive components. Record the size and type of main fuses. Record any other important marks and damages.
Addressing Active Converter Hardware Faults
The following table describes active converter hardware faults.

Fault HW Over Current HW Over Voltage HW Ground Fault HW Disabled HW Latch Error Precharge Open Precharge Closed DPI Mastr ComLos No. 1 2 3 4 5 6 7 8 Description Control board detected excessive phase current. Control board detected excessive DC Link voltage. Control board detected a ground fault. Enable signal is not present. Action Check cables and motor. Check input voltage.
Inverter Fault 9 PS1 Desat Phase R 10 PS1 Desat Phase S PS1 Desat Phase T PS1 Over Current PS1 Over Voltage PS1 Asym DC Link PS1 Power Supply 11 12 13 14 15 16
Check cables and motor. Verify hardware enable is present. Control board detected an unidentified Contact Technical Support. fault. The precharge contactor opened Verify operation of precharge when it was commanded closed. contactor. The precharge contactor closed when Verify operation of precharge it was commanded open. contactor. DPI communication with the inverter Verify DPI cable installation. was lost. Inverter detected a fault. Examine inverter fault code. Power structure 1 detected a desat Contact Technical Support. fault on phase R. Power structure 1 detected a desat Contact Technical Support. fault on phase S. Power structure 1 detected a desat Contact Technical Support. fault on phase T. Power structure 1 detected excessive Check motor, cables, and phase current. application for cause. Power structure 1 detected excessive Check input power and DC Link voltage. application for cause. Verify load balance resistors. Power structure 1 detected an asymmetrical DC Link voltage. Power structure 1 detected a power Replace power supply if supply out of tolerance. problem persists.
1-3
Fault PS1 HW Disable PS1 Latch Error PwrBd Incompat PB Ver Corrupted Default Corrupted Rating Corrupted New ControlBoard Elapsed Checksum Param Checksum Param Checksum B
No. 17 18 30 31 32 33 34 35 36 37
Param Checksum W 38 Param Checksum L Ac Line Lost Ac Phase Lost Ac Sync Low Vac AC Sync Low Freq AC Sync High Freq AC Sync Conflict PWM Sync Lost Ac Low Voltage 39 40 41 42 43 44 45 46 50
Ac High Voltage
51
Ac Low Frequency
52
Ac High Frequency
53
Ac High dFdT Ac I Imbalance
54 55
Ac V Imbalance
56
DcLink Low Volt
57
Description Power structure 1 hardware enable is not present. Power structure 1 detected an unidentified fault. Power board incompatible with control board. Power board version number is corrupted. Power board default data file is corrupted. Power board rating data file is corrupted. New converter control board was detected. Elapsed operation checksum is invalid at power up. Parameter data checksum is invalid at power up. Parameter data checksum error when writing a BYTE value. Parameter data checksum error when writing a WORD value. Parameter data checksum error when writing a LONG value. AC line synchronization was lost when power turned off. AC line synchronization was lost when when a phase was lost. AC line synchronization was lost because voltage was low. AC line synchronization was lost because frequency was low. AC line synchronization was lost because frequency was high. Conflict in AC line synchronization state machine. PWM Carrier synchronization was lost. AC line voltage was below the configured limit for the configured time. AC line voltage exceeded the configured limit for the configured time. AC line frequency was below the configured limit for the configured time. AC line frequency exceeded the configured limit for the configured time. Change in line frequecy exceeded the configured limit. AC current balance exceeded the configured limit for the configured time. AC voltage balance exceeded the configured limit for the configured time. DC link voltage was below the precharge open level.
Action Verify drive enable is present. Contact Technical Support. Load new file into power board. Load new file into power board. Load new file into power board. Load new file into power board. Reset to defaults is required. Reset to defaults is required. Reset to defaults is required. Reset to defaults is required. Reset to defaults is required. Reset to defaults is required. Verify proper input line voltage is present. Verify proper input line voltage is present. Verify proper input line voltage is present. Verify proper input line voltage is present. Verify proper input line voltage is present. Contact Technical Support. Verify wiring of carrier synchronization twisted pair. Verify proper input line voltage is present. Verify proper input line voltage is present. Verify proper input line voltage is present. Verify proper input line voltage is present. Verify proper input line voltage is present. Verify proper input line voltage is present. Verify proper input line voltage is present. Verify proper input line voltage is present.
1-4
Fault Ride Thru Expire Ride Thru Expire IT Over Load Ambnt Over Temp Base Over Temp Jnct Over Temp Ntc Range Low Ntc Range High PS1 Fan Loss PS1 Reactor Temp
No. 58 59 60 61 62 63 64 65 66 67
Description Power dip ride through expired with the precharge open. Power dip ride through expired with the precharge closed. Operating current levels exceeded the rated overload. Measured ambient temperature exceeded the maximum limit. IGBT base temperatures exceeded the maximum limit. IGBT junction temperature exceeded the maximum limit. NTC temperature below rated temperature range. NTC temperature above rated temperature range. Power structure 1 detected a circulating fan was lost. Power structure 1 detected the reactor thermal switch opened.
Action Verify proper input line voltage is present. Verify proper input line voltage is present. Verify application operates within limits. Take steps to lower ambient. Verify the required drive cooling is present. Verify drive cooling and excessive current levels. Check for open or shorted NTC device. Check for open or shorted NTC device. Verify internal circulating fans are turning. Verify reactor cooling fans are turning.
For additional information regarding the active converter, please refer to the PowerFlex 700 Active Converter Power Module User Manual (Publication PFLEX-UM002).
Addressing 700 Vector Control Hardware Faults
The following table describes two groups of 700 Vector Control faults. The first group contains faults common to both the 20B and 20L products. The second group contains faults existing only in the 20L product.
Fault Auxiliary Input Power Loss No. 2 3 Description Action Faults Common to 20B and 20L Products Auxiliary input interlock is open. Check remote wiring. DC bus voltage remained below 85% Monitor input voltage for low of nominal longer than [Power Loss voltage or line power interruptions. Time]. DC bus level fell below minimum Monitor input voltage for low value. voltage or line power interruptions. DC bus level exceeded maximum Monitor input voltage for high value. line or transient voltage. Internal electronic overload trip. Reduce load so drive output current does not exceed the current set by [Motor NP FLA]. Heatsink temperature exceeded Check water loop. 100% of [Drive Temp]. Check for excess load. Output transistors have exceeded Check water loop. their maximum operating limit. Check for excess load. The drive output current has Check programming. Check for exceeded the hardware current limit. excess load, improper DC boost or other causes of excess load. A current path to ground greater than Check motor and external 25% of drive rating exists. wiring to drive output terminals for a grounded condition. Drive output current is below [Load Verify the connections between Loss Level] for a time greater than motor and load. Verify level and [Load Loss Time]. time.
Under Voltage
Over Voltage Motor Overload
5 7
Heatsink OvrTemp Trnsistr OvrTemp HW OverCurrent
8 9 12
Ground Fault
13
Load Loss
15
1-5
Fault Motor Thermistor
Output Phase Loss
Phase U to Grnd Phase V to Grnd Phase W to Grnd Phase UV Short Phase VW Short Phase UW Short Drive Overload
Port 1-6 Adapter
Port 1-6 DPI Fault
700L Dsat U 700L Dsat V 700L Dsat W 700L OvrCurnt 700L OvrVolt 700L Asym Vdc 700L PwrSply 700L HW Disable1 700L Latch Err 700L Fan Loss Cnv NotLogin Cnv Not Start 700L NTC Open
Action Verify the thermistor is connected. Motor is overheated. Reduce load. 21 Current in one or more of the phases Check the drive and motor has been lost or is below a preset wiring. level. Check the wiring between the 38 A phase to ground short has been detected between the drive and the drive and the motor. Check 39 motor in this phase. motor for ground. Replace 40 power module. 41 Excessive current has been detected Check the motor and the drive between these two output terminals. output terminal wiring for a 42 shorted condition. Replace 43 power module. 64 Drive rating of 110% for 1 minute or Reduce load. 150% for 3 seconds has been exceeded. 71-76 Communications adapter on port Check communication cable reported a fault. and check adapter fault queue for information about the fault. 81-86 DPI communications to port was lost. If adapter was not intentionally disconnected, check wiring. Replace wiring, port expander, or Main Control Board as needed. Check HIM connection. Faults Existing Only in 20L Products 170 Phase U Desat fault on 700L power Contact Technical Support. structure. 171 Phase V Desat fault on 700L power Contact Technical Support. structure. 172 Phase W Desat fault on 700L power Contact Technical Support. structure. 173 Over current on 700L power structure. Check programming. Check for cause of excessive current. 174 Over voltage on 700L power structure. Check programming. Check for cause of excessive voltage. 175 Asymmetrical voltage on 700L power Verify load balance resistors. structure DC link. 176 Power supply failed on 700L power Replace power supply if structure. problem persists. 177 Hardware disable asserted on 700L Verify drive enable is present. power structure. 178 Fault reporting failure on 700L power Contact Technical Support. structure. 179 Fan failure on 700L power structure. Verify internal circulating fans are turning. 190 Active converter did not begin Check DPI connection. Check communication. for proper versions. 191 Active converter did not start when Check start inhibits. Check requested. parameter 214 - [Start Inhibit]. 192 Thermal sensor failed on 700L power Contact Technical Support. structure.
No. 16
Description Thermistor output is out of range.
For additional information regarding 700 Vector Control, please refer to the PowerFlex 700 Adjustable Frequency AC Drive User Manual Series B (Publication 20B-UM002).
1-6
Addressing 700S Phase II Control Hardware Faults
The following table describes two groups of 700S Phase II faults. The first group contains faults common to both the 20D and 20L products. The second group contains faults existing only in the 20L product.
Name Motor OLoad Trip Description Action Faults Common to 20D and 20L Products 11 Internal electronic overload trip. Reduce load so drive output current does not exceed the current set by [Motor NP FLA]. 15 P313 [Heatsink Temp] is above the Reduce the mechanical load. maximum limit. Check cooling loop. 17 The drives operating point has Reduce the mechanical load exceeded the intermittent current configured with P377 [Inv OL rating and a foldback to the Trip Cnfg]. continuous rating has occurred. 24 An over voltage has occurred on the Check programming. Check for DC bus. cause of excessive voltage. 26 A current to earth exceeds 35% of the Check the motor and external peak drive rating. wiring to the drive output terminal for a grounded condition. 42 Bus voltage has fallen below the level Monitor input voltage for low configured by P409 [Line Undervolts]. voltage. 49-54 The device at DPI Port 1-6 has Verify the DPI device is present stopped communicating. and functional at the port. 55-60 A communication fault has occurred Verify network connection. between the adapter at port 1-6. Verify status of network. Faults Existing Only in 20L Products 97 Phase U Desat fault on 700L power Contact Technical Support. structure 1. 98 Phase V Desat fault on 700L power Contact Technical Support. structure 1. 99 Phase W Desat fault on 700L power Contact Technical Support. structure 1. 100 Over current on 700L power structure Check programming. Check for 1. cause of excessive current. 101 Over voltage on 700L power structure Check programming. Check for 1. cause of excessive voltage. 102 Asymmetrical voltage on 700L power Verify load balance resistors. structure 1 DC link. 103 Power supply failed on 700L power Replace power supply if structure 1. problem persists. 104 Hardware disable asserted on 700L Verify drive enable is present. power structure 1. 105 Fault reporting failure on 700L power Contact Technical Support. structure 1. 106 Fan failure on 700L power structure 1. Verify internal circulating fans are turning. 110 Active converter has faulted. Check active converter fault log. 111 Active converter did not begin Check DPI connection. Check communication. for proper versions. 112 Active converter did not start when Check start inhibits. Check requested. parameter 214 [Start Inhibits]. No.
Inv OTemp Trip Inv OLoad Trip
DC Bus OverVolt Ground Fault
DC Bus Undervolt DPI Loss Port 1-6 Net Loss DPI 1-6
700L Dsat U1 700L Dsat V1 700L Dsat W1 700L OvrCurnt1 700L OvrVolt1 700L AsymDcLink1 700L PwrSply1 700L HW Disable1 700L Latch Err 1 700L Fan Fail 1 700L Cnv Faulted Cnv NotLogin Cnv Not Start
For additional information regarding 700S Phase II Control, please refer to the PowerFlex 700S High Performance AC Drive Phase II User Manual (Publication 20D-UM006).
1-7
Diagnostic Procedures by Symptom
The following charts list drive symptom, symptom descriptions, and recommended actions.
Circuit Breaker Tripped Blown Input Fuses

Use this procedure when a drive clears any of its circuit breaker or power fuses (branch circuit protection):
Disconnect Power Lock Out/ Tag Out Replace Damaged Components
Inspect for Visible Damage
Damage Visible?
Yes
No
Check MOV Block near Filter Caps
MOV Block Damaged?
Yes
Replace MOV Block
No Replace Fuses and Check Filter Capacitors for Shorts
Check Filter Capacitor Fuses
Input Filter Capacitor Fuses Blown?
Yes
No
No
Shorted Input Filter Capacitors?
Yes
Replace Filter Capacitor Bank
Check Control Transformer Primary No Check Control Transformer for Shorts/Visible Damage No
Control Transformer Fuses Blown?
Yes
Replace Transformer Fuses and Check/Repair Control Wiring
Is Transformer Damaged?
Yes
Replace Transformer
Check Precharge Resistor Fuses
Are Resistor Fuses Blown?
Yes
Replace Resistor Fuses
No Check Precharge Resistors for Damage/Shorts No Are Resistors Damaged? Replace Precharge Resistors
Temporarily Remove (1) Control Transformer Fuse
Yes
Continued on Next Page
1-8
Continued from Previous Page
Check for Line-toLine and Line-toGround Shorts at the Load Side of the Circuit Breaker No
Measures less than 100 ohms?
Yes
Temporarily Remove Precharge Resistor Fuses and Repeat Checks for Shorts
No
Yes
Disconnect Converter Module AC Terminals from the Input Filter
Short is Between the Breaker and Line Side of Precharge Contactors -Isolate and Repair
Replace the Precharge Resistor Fuses
Check for Line-toLine and Line-toGround Shorts at the Load Side of the Precharge Contactors No
Yes
Short is on the Load Side of the Contactors or Wiring to the Converter -Isolate and Repair
Perform Diode Tests on the Converter Module No
Did Converter Module Fail Test?
Yes
Replace the Converter Module
Perform Diode Tests on the Inverter Module No
Did Inverter Module Fail Test?
Yes
Replace the Inverter Module
Perform Start-Up Procedure No
Any Problems Found?
Yes
Contact Allen-Bradley Drives Technical Support
Power Up and Check the Fault Log
Drive Reports High Bus Fault?
Yes
This Fault May Indicate the Drive Intentionally Tripped on a Single Phase Condition and was Protected from Damage
1-9
No HIM Display
Use this procedure when the HIM does not function:
Check HIM Connection and Seating
Properly Connected?
No
Reseat or Reconnect HIM
Yes
Check Cable Connections: 34-Pin Power Supply Cable 40-Pin MCB Cable 30-Pin Comm. I/F Cable Comm. I/F PCB Internal DPI Cables External DPI Cables Yes
Properly Connected?
No
Reseat or Reconnect Cables
Replace HIM
Display?
No
Replace Power Supply PCB
1-10
Over-Temperature Faults
Use this procedure to troubleshoot drive over-temperature faults:
Check Surrounding Air Temperature No Check Motor Current and Load Levels No Current Exceeds Specification? Reduce Load or Procure a Drive with a Higher Rating Provide Additional Airflow or Air Conditioning
Temperature Exceeds Specification?
Yes
Yes
Check PWM Frequency
Frequency Too High for Lead Length and Surrounding Temp?
Yes
Lower PWM Frequency
No Check Fluid Flow Through the Drive Yes Check Fan and Air Flow Through the Drive Remedy Space at Inlet Fluid Meets Specification? Remedy Fluid Flow Rate and Temperature
No
Proper Space at Inlet?
No
Yes
Air Flow Blockages?
Yes
Remove Air Flow Blockages
No
Fan Running Properly?
Yes
No
Check Connection Between Power Module Fan and Power Supply PCB
Connection Good?
No
Repair Connection
Yes Check Fan Winding Resistance
Resistance = 7.3 Ohms 5%? No Contact Allen-Bradley Drives Technical Support
No
Replace Fan
Chapter
! !
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 Power Module DC bus capacitors has discharged completely before performing any work on the drive. 1. Turn off and lock out input power. Wait 5 minutes.
L1 L2 L3
2. Measure the DC bus voltage at the DC+ and DCTESTPOINT sockets on the lower front of the power module. The measured voltage must be zero (0).
! !
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: 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, refer to Allen-Bradley publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD protection handbook.
Drive Status
The condition or state of your 700L drive is constantly monitored. Any changes will be indicated through the HIM option (if present) and/or four sets of LEDs: Power Module status indicators (for both 700S and 700 vector control). SynchLink option LEDs (for 700S control only). DriveLogix communications option LEDs (for 700S control only). Communication option LEDs (if installed).
2-2
To access the LEDs, refer to the PowerFlex 700L Liquid-Cooled Adjustable Frequency AC Drive User Manual (Publication 20L-UM001), Chapter 4.
Figure 2.1 Power Module Drive Status Indicators
Frame 3A shown
Power STS

Port Mod NET A NET B
Viewing the PowerFlex 700 Vector Control Diagnostic LEDs
The PowerFlex 700L power module contains a Power LED, Status LEDs and, if installed, Communications Option LEDs (Figure 2.1). These LEDs are only operational when the drive is energized and only visible when the drive door is open. ATTENTION: The Status Indicators are only operational when the drive is energized. Servicing energized equipment can be hazardous. Severe injury or death can result from electrical shock, burn or unintended actuation of controlled equipment. Follow Safety related practices of NFPA 70E, ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES. DO NOT work alone on energized equipment!
Status Indicators
Item Name POWER STS (Status) Color Green Green State Steady Flashing Steady Yellow Flashing, Drive Stopped Flashing, Drive Running Steady, Drive Running Red Flashing Steady Refer to the Communications Adapter User Manual. Description Illuminates when power is applied to the drive. Drive ready, but not running and no faults are present. Drive running, no faults are present. A type 2 alarm condition exists, the drive cannot be started. Check parameter 211 [Drive Alarm 2]. An intermittent type 1 alarm condition is occurring. Check parameter 211 [Drive Alarm 1]. A continuous type 1 alarm condition exists. Check parameter 211 [Drive Alarm 1]. Fault has occurred. Check [Fault x Code] or Fault Queue. A non-resettable fault has occurred. Status of DPI port internal communications (if present). Status of communications module (when installed). Status of network (if connected). Status of secondary network (if connected).
PORT MOD NET A NET B
2-3
Viewing the PowerFlex 700S In addition to the PowerFlex 700L power module LEDs (Figure 2.1), the 700S control cassette contains a Run LED, controller LEDs, and SynchLink Control Diagnostic LEDs
LEDs. These LEDs are only operational when the drive is energized and only visible when the drive door is open. The status of these LEDs can also be viewed from the HIM or from an applications program (e.g. DriveExplorer) in parameter 554 (LED Status). This feature is only available with PowerFlex 700S Phase II control version 3.001 or later. ATTENTION: The Run LED and the controller LEDs are only operational when the drive is energized. Servicing energized equipment can be hazardous. Severe injury or death can result from electrical shock, burn or unintended actuation of controlled equipment. Follow Safety related practices of NFPA 70E, ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES. DO NOT work alone on energized equipment!
Status Indicators
Item Name PWR (Power) STS (Status) Color Green Green State Steady Flashing Steady Flashing Description Illuminates when power is applied to the drive.
Communications
Drive ready, but not running & no faults are present. Drive running, no faults are present. Yellow When running, a type 2 (non-configurable) alarm condition exists, drive continues to run. When stopped, a start inhibit exists and the drive cannot be started. Steady A type 1 (user configurable) alarm condition exists, but drive continues to run. Red Flashing A fault has occurred. Steady A non-resettable fault has occurred. Red / Flashing The drive is in flash recovery mode. The only operation Yellow Alternately permitted is flash upgrade. Status of DPI port internal communications (if present). Refer to the Communication Status of communications module (when installed). Adapter User Manual Status of network (if connected). Status of secondary network (if connected). Steady The module is configured as the time keeper. or The module is configured as a follower and synchronization is complete. The follower(s) are not synchronized with the time keeper. The module is configured as a time master on SynchLink and has received time information from another time master on SynchLink. The drives enable input is high. The drives enable input is low.
DRIVE
Control Assembly
Power Structure
(1)
SYNCHLINK Green
Control
Green Red
Flashing Flashing
ENABLE
(1)
Green Green
On Off
SynchLink LEDs are located on the SynchLink daughtercard on the main circuit board in the control cassette.
2-4
Removing Power From the Drive
1. Turn off and lock out input power. Wait five (5) minutes.
L1 L2 L3
2. Remove and save the upper and lower front cover from the power module (see Removing the Power Module Front Covers on page 3-9).
Inverter or Converter Module (Frame 3B Inverter Power Module shown)
(4 Screws)
3. Check for zero (0) volts between the DC+ and DC- testpoints. Using 4 mm (0.158 in.) socket probes, connect the voltmeter to DC+ and DCTESTPOINT sockets on the lower front of the power module. The measured voltage must be zero (0).
DC+ TESTPOINT
DC POSITIVE DC NEGATIVE
DC- TESTPOINT
2-5
Periodic Inspections with No Power Applied
Coolant Hoses/Connections
Visually inspect the inlet and outlet coolant hose assemblies; and power module coolant connections for leaks. Replace hoses if leaks cannot be stopped.
Terminal Bolts, Mounting Bolts, etc.

Ensure all power conductor terminal bolts and mounting bolts are tight. Tighten loose bolts. Refer to Chapter 3 for torque specifications.
Power Supply PCB, Addressable Power PCB, and Rating Plug PCB
Visually inspect PCB's for any conductive dirt or oil mist. If present, clean with dry, clean air at approximately 50 psi pressure. Replace PCB's if they cannot be made clean.
Periodic Inspections with Power Applied
Checking the Power Module Fan

The power module cooling fan expected life span is approximately 60,000 hours. The actual life span is based on ambient temperature and drive usage. Based on control type, the actual hours of usage of the fan can be displayed with the following: Active converter control Parameter 026 - Life Run Time. 700 vector control Select Parameters 234/236, Testpoint No. 010; and View Parameters 235/237 - Life Run Time. 700S control Select Parameter 412, Option 010; and View Parameter 413 - Life Run Time. Fan failure may be imminent if vibration or increasing noise in fan bearings occur. Fan replacement is recommended at this time. Refer to Removing the Power Module Fans on page 3-42.
2-6
Checking the Input Filter Fans
The Frame 3A Input Filter has a pull out fan tray near the bottom of the cabinet with two or three 120 VAC fans depending on the voltage type. Frame 3A also has the same type fan mounted near the input circuit breaker. All Frame 3B Input Filters have four 120 VAC fans mounted in the bottom fan tray. ATTENTION: The Input Filter fans are only operational when the drive is energized and only visible with cabinet doors open. Servicing energized equipment can be hazardous. Severe injury or death can result from electrical shock, burn or unintended actuation of controlled equipment. Follow Safety related practices of NFPA 70E, ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES. DO NOT work alone on energized equipment!
Checking the Fan Motors

1. Remove power from the drive (see Removing Power From the Drive on page 2-4). 2. Open the Input Filter door and locate the fan tray. Refer to Removing the Input Filter Fans on page 3-6. 3. Measure the resistance of each fan at the wire connection points. If the resulting measurements are not similar to those in Table 2.A, replace the fan.
Table 2.A Correct Fan Measurements
Connection Wires Red - White Resistance to Ground Resistance 2.5 - 2.8 Ohms OL (zero load)
4. Repeat step 3 for the Frame 3A fan mounted near the circuit breaker.
Checking the Input Filter Capacitors
1. Remove power from the drive (see Removing Power From the Drive on page 2-4). 2. Open the cabinet door and inspect the clear protective covers in front of the Input Filter capacitors for discoloration, black marks or debris. 3. Remove the protective covers and visually inspect the capacitors and bus bars connecting the capacitor terminals for distortion. 4. If any discoloration or distortion of capacitors is present, remove and replace the entire capacitor bank. Refer to Removing the Input Filter Capacitors on page 3-7.
2-7
Checking the Input Filter Inductor
1. Remove power from the drive (see Removing Power From the Drive on page 2-4). 2. Visually checking the inductor without fully disassembling the Input Filter requires access to the back cabinet panel. If accessible, remove the cabinet back panel and inspect the inductor winding insulation for discoloration, black marks or debris. 3. Measuring resistance from inductor core and PE Ground to inductor input and output conductors should be OL (zero load).
Forward Biased Diode Tests for the Power Module
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions. To run the test, use a digital multi-meter with a diode check mode. To pass each test, the meter must display a voltage within the specification shown in the table. If the test finds a short, the meter will display .000. If the test finds an open circuit or reversed polarity, the meter will display .0L. 1. Remove power from the drive (see Removing Power From the Drive on page 2-4). 2. Disconnect power conductors from R/L1, S/L2, T/L3, U/T1, V/T2, and W/T3 terminals on the power module. For power module terminal names and locations, refer to the PowerFlex 700L User Manual, Figure 2.4 or Figure 2.5. 3. Perform forward biased diode tests on the points listed in Table 2.B. If the power module fails any of these tests, then replace the power module.
Table 2.B Forward Biased Diode Tests for the Power Module
Meter Leads + DC+ DCR/L1 DC+ S/L2 DC+ T/L3 DC+ DCR/L1 DCS/L2 DCT/L3 U/T1 DC+ V/T2 DC+ W/T3 DC+ DCU/T1 DCV/T2 DCW/T3 Nominal Meter Reading Value should gradually rise to 0.75V or greater.
0.20 - 0.40V
2-8
Checking the Power Module 1. Remove power from the drive (see Removing Power From the Drive on page 2-4). Discharge Resistors
2. Remove the resistor access cover (see Removing the Discharge Resistors on page 3-41). 3. Carefully remove the wire harness connector from each resistor by grasping only the wire connector. Important: Do not pull on wires. Otherwise, damage to the wire harnesses may result. 4. Measure the resistance of each of the resistors. If the resulting measurement for each resistor is not between 2340 and 2860 Ohms (2600 10%), then replace the resistors.
Checking the Power Module 1. Remove power from the drive (see Removing Power From the Drive on page 2-4). Bay Door Fan
2. Disconnect the complete drive main control harness wires L1, N, and PE from the fan. 3. Measure the resistance of the fan windings. If the resulting measurements are not similar to those in Table 2.C, replace the fan. Refer to Removing the Power Module Bay Door Fan on page 3-45.
Table 2.C Correct Power Module Bay Door Fan Measurements
Connection Wires L1 - N L1 - PE N - PE Resistance 5% 6.45 Ohms >20 Megohms >20 Megohms
4. Disconnect the capacitor from the fan. Measure the value of the start capacitor. If the resulting value is not 16 F, replace the fan. Refer to Removing the Power Module Bay Door Fan on page 3-45.
Chapter
Access Procedures
! !
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. Measure the DC bus voltage at the DC+ and DCTESTPOINT sockets on the lower front of the power module. The measured voltage must be zero (0). ATTENTION: The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage. Risk of electrical shock, injury, or death exists if someone comes into contact with the assembly. ATTENTION: HOT surfaces can cause severe burns. Do not touch the heatsink surface during operation of the drive. After disconnecting power allow time for cooling. ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into fiber-optic ports or fiber-optic cable connectors. ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference Allen-Bradley publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD protection handbook.
! ! !
Torque Specifications
The following table lists fastener torque specifications for the input filter bay of the complete drive equipment type:
Item Enclosure lifting angles Enclosure baying brackets Enclosure baying brackets Fastener M12 x 35 mm hexagonal bolt BZ5.5 x 13 mm Torx screw M8 x 16 mm hexagonal bolt Torque Final 32 N-m (280 lb.-in.) 5.1 N-m (45 lb.-in.) 11 N-m (100 lb.-in.)
3-2
Access Procedures
Item Enclosure door ground wire (frame end) Enclosure door ground wire (door end) Rittal door interlock brackets Rittal door interlock brackets Rittal door interlock cam Rittal door interlock shaft positioners Circuit breaker terminals L1, L2, and L3 Frame 3A Circuit breaker terminals L1, L2, and L3 Frame 3B Contactor terminals L1, L2, and L3 Ground terminal Line voltage fuse blocks terminals FU7, FU8, and FU9 Control terminal blocks TB1 and TB2
Fastener M8 x 30 mm hexagonal bolt M8 hex nut BZ5.5 x 13 mm Torx screw M8 x 16 mm hexagonal bolt M8 x 55 mm hexagonal bolt M5 x 8 mm hexagonal bolt 3/8 inch Allen hex set screw 3/8 inch Allen hex set screw M12 x 40 mm hexagonal bolt 3/8 inch Allen hex set screw #10 Phillips screw Captive slotted screw
Torque Final 11 N-m (100 lb.-in.) 11 N-m (100 lb.-in.) 5.1 N-m (45 lb.-in.) 11 N-m (100 lb.-in.) 11 N-m (100 lb.-in.) 2.8 N-m (25 lb.-in.) 42 N-m (375 lb.-in.) 62 N-m (550 lb.-in.) 62 N-m (550 lb.-in.) 34 N-m (300 lb.-in.) 4 N-m (35 lb.-in.) 1.5 N-m (13 lb.-in.)
Phillips is a registered trademark of the Phillips Screw Company.
The following table lists fastener torque specifications for non-electrical, mounting connections to the power module equipment type:
Top and bottom front covers Communications adapter Left side covers 700S cassette left side cover stand-off Left front cover bracket Cassette tray TB5/TB6 wire harness AC input/output bus bar support Left side plate Current feedback device Addressable power PCB Rating plug PCB Power supply PCB Resistor access cover 2.8 N-m (25 lb.-in.) M3 x 6 mm Phillips screw 0.6 N-m (5 lb.-in.) M5 x 12 mm POZIDRIVE 2.8 N-m screw (25 lb.-in.) M5 x 34 mm hex stand-off 2.8 N-m (25 lb.-in.) M5 x 12 mm POZIDRIVE 2.8 N-m screw (25 lb.-in.) M5 x 12 mm POZIDRIVE 2.8 N-m screw (25 lb.-in.) M4 x 16 mm POZIDRIVE 1.6 N-m screw (14 lb.-in.) M5 x 25 mm POZIDRIVE 2.8 N-m screw (25 lb.-in.) M5 x 10 mm POZIDRIVE 2.8 N-m screw (25 lb.-in.) M5 x 12 mm POZIDRIVE 2.8 N-m screw (25 lb.-in.) M3 x 8 mm POZIDRIVE screw 0.6 N-m (5 lb.-in.) M3 x 8 mm POZIDRIVE screw 0.6 N-m (5 lb.-in.) M3 x 8 mm POZIDRIVE screw 0.6 N-m (5 lb.-in.) M5 x 12 mm POZIDRIVE 2.8 N-m screw (25 lb.-in.) Captive slotted screw
Access Procedures
3-3
Discharge resistors Fan plate Fan
M5 x 10 mm POZIDRIVE screw M5 thumbscrew M4 x 60 mm slotted screw
2.8 N-m (25 lb.-in.) 2.8 N-m (25 lb.-in.) 1.6 N-m (14 lb.-in.)
POZIDRIVE is a registered trademark of the Phillips Screw Company.
The following table lists fastener torque specifications for electrical connections to the power module equipment type:
Power input terminals L1, L2, and L3 Motor output terminals U, V, and W Ground terminal Frame 3B DC+ and DC- bus bars between converter and inverter power modules SHLD (shield) terminal TB5/TB6 terminal block 700 vector control I/O terminal block TB1 700 vector control encoder terminal block J1 700S control I/O and standard encoder terminal blocks TB1 and TB2 Active converter control terminal blocks P1 and P2 M12 x 40 mm hexagonal bolt M12 x 40 mm hexagonal bolt M8 x 30 mm hexagonal bolt M12 x 40 mm hexagonal bolt M4 x 11 mm POZIDRIVE screw #6 Phillips screw Captive slotted screw Captive slotted screw Captive slotted screw Captive slotted screw 62 N-m (550 lb.-in.) 62 N-m (550 lb.-in.) 11 N-m (100 lb.-in.) 62 N-m (550 lb.-in.) 1.4 N-m (12 lb.-in.) 1.4 N-m (12 lb.-in.) 0.6 N-m (5 lb.-in.) 0.6 N-m (5 lb.-in.) 0.2 N-m (2 lb.-in.) 0.2 N-m (2 lb.-in.)
The following table lists fastener torque specifications for the power module bay of the complete drive equipment type:
Item Enclosure lifting angles Enclosure baying brackets Enclosure baying brackets Enclosure door ground wire (frame end) Enclosure door ground wire (door end) Power module mounting Power module top anti-sway bracket upper support bar Power module upper support bracket Power module upper support bracket Power module lower support bar Fastener M12 x 35 mm hexagonal bolt BZ5.5 x 13 mm Torx screw M8 x 16 mm hexagonal bolt M8 x 30 mm hexagonal bolt M8 hex nut M8 x 30 mm hexagonal bolt BZ5.5 x 13 mm Torx screw M6 hexagonal nut M6 x 16 mm hexagonal bolt BZ5.5 x 13 mm Torx screw Torque Final 32 N-m (280 lb.-in.) 5.1 N-m (45 lb.-in.) 11 N-m (100 lb.-in.) 11 N-m (100 lb.-in.) 11 N-m (100 lb.-in.) 11 N-m (100 lb.-in.) 5.1 N-m (45 lb.-in.) 5.1 N-m (45 lb.-in.) 5.1 N-m (45 lb.-in.) 5.1 N-m (45 lb.-in.)
3-4
Access Procedures
Item Power module angle bracket Power module lower support bar Frame 3A left shield Frame 3A left shield Frame 3B L1, L2, and L3 bus bar support Frame 3B L1, L2, and L3 bus bar support Frame 3B left shield Frame 3B left, middle, and top shields Enclosure door exhaust louver Door fan (mounting) Door fan (wire connection) Hose assembly connection to power module Hose assembly connection to L-bracket Hose L-bracket to hose C-bracket Hose C-bracket to enclosure Frame 3B hose clamp
Fastener M5 x 16 mm hexagonal bolt
Torque Final 2.8 N-m (25 lb.-in.) M6 x 16 mm Torx screw 5.1 N-m (45 lb.-in.) M5 x 16 mm POZIDRIVE 2.8 N-m screw (25 lb.-in.) M6 x 16 mm Phillips screw 5.1 N-m (45 lb.-in.) M8 x 13 mm slotted screw 0.8 N-m (plastic) (7 lb.-in.) M5 x 50 mm hexagonal screw 2.8 N-m (25 lb.-in.) M6 x 16 mm Phillips screw 5.1 N-m (45 lb.-in.) BZ5.5 x 13 mm Torx screw 5.1 N-m (45 lb.-in.) BZ5.5 x 13 mm Torx screw 5.1 N-m (45 lb.-in.) BZ5.5 x 13 mm Torx screw 5.1 N-m (45 lb.-in.) Captive slotted screw 0.8 N-m (7 lb.-in.) 3/4-inch fitting hexagonal 73 N-m swivel nut (650 lb.-in.) 1-inch fitting hexagonal lock 73 N-m nut (650 lb.-in.) M5 x 12 mm POZIDRIVE 2.8 N-m screw (25 lb.-in.) BZ5.5 x 13 mm Torx screw 5.1 N-m (45 lb.-in.) M5 x 12 mm POZIDRIVE 2.8 N-m screw (25 lb.-in.)
Access Procedures
3-5
Understanding Torque Figures in Assembly Diagrams

Icons and numbers in the assembly diagrams indicate how to tighten hardware:
Fastener Type POZIDRIVE Screw Phillips Screw Hexagonal Bolt or Standoff Hexagonal Screw Hexagonal Nut Torx Head Screw Captive Slotted Screw
Tool Type and Size PZ indicates POZIDRIVE screwdriver bit P indicates Phillips screwdriver bit
PZ2 2.8 N-m (25 lb.-in.)
Tightening Torque
Removing Power from the Drive
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the Power Module DC bus capacitors has discharged completely before performing any work on the drive. 1. Turn off and lock out input power. Wait 5 minutes.
L1 L2 L3
2. Measure the DC bus voltage at the DC+ and DCTESTPOINT sockets on the lower front of the power module. The measured voltage must be zero (0). Remove power before making or breaking cable connections. When you remove or insert a cable connector with power applied, an electrical arc may occur. An electrical arc can cause personal injury or property damage by: Sending an erroneous signal to your systems field devices, causing unintended machine motion. Causing an explosion in a hazardous environment. Electrical arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts may create electrical resistance.
3-6
Access Procedures
Input Filter
Removing the Input Filter Fans

Removal 1. Disconnect wires at TB4. 2. Remove two (2) M6 x 18 mm (0.7 in.) long screws. 3. Slide the fan tray assembly out from the cabinet. 4. Disconnect the fan harness connectors. 5. Remove #10-32 grounding screw. 6. Remove two (2) M4 x 60 mm (2.36 in.) long screws, two (2) lock washers, and two (2) flat washers per fan.
Screw, M4 x 60 mm Long with Flat and Lock Washers 2x per Each Fan
6.4 mm 1.6 N-m (14 lb.-in.) 6.4 mm 3.2 N-m (28 lb.-in.)
Air Flow to Inductor
Screw, #10-32 x 1/4 in. Long Ground Wire
Fan Harness Connectors
Doo
r Si
de
Wires to TB4
10 mm 5.1 N-m (45 lb.-in.)
M6 x 16 mm Long 2x Fan Mounting Tray
Installation Install the fans and wiring harness in reverse order of removal, while referring to torque specifications shown in the drawing.
Access Procedures
3-7
Removing the Input Filter Capacitors

Removal 1. Remove the capacitor lug screw. 2. Remove the MOV lug screw. 3. Disconnect the resistor connectors. 4. Remove the M6 x 16 mm long screws.
Capacitor Lug Screw M6 x 16 mm Long
10 mm 5.1 N-m (45 lb.-in.)
MOV Lug Screw M6 x 16 mm Long
Resistor
Resistor Lug Nuts 1/4-20 with Flat and Lock Washers

7/16 inch 5.1 N-m (45 lb.-in.)
Resistor Connector 3x - Frame 3A 6x - Frame 3B
Screw, M6 x 16 mm Long 6x - Frame 3A 8x - Frame 3B 10 mm 5.1 N-m (45 lb.-in.)
Installation Install the capacitors and connectors in reverse order of removal, while referring to torque specifications shown in the drawing.
3-8
Access Procedures
Removing the Input Filter from the Complete Drive

Removal 1. Disconnect power cables (Frame 3A) or bus bars (Frame 3B). 2. Disconnect control wiring at the fuse/terminal assembly. 3. Disconnect baying bracket hardware on the power module side. 4. Disconnect the interlock assembly. 5. Slide the power module bay away from the input filter bay.
Baying Bracket Screw, Torx BZ5.5 x 13 mm Long
Torx 25 5.1 N-m (45 lb.-in.)
Interlock Assembly
Fuse/Terminal Block Assembly 6.4 mm 1.6 N-m (14 lb.-in.)
INP
UT
FIL TE R
BA Y PO WE
Torx 25 5.1 N-m (45 lb.-in.)
Baying Bracket Screw, Torx BZ5.5 x 13 mm Long Screw, M8 x 16 mm Long 13 mm 5.1 N-m (100 lb.-in.)
RM
OD
UL
EB
AY
Installation Install the input filter bay in reverse order of removal, while referring to torque specifications shown in the drawing.
Access Procedures
3-9
Power Module
Removing the Power Module Front Covers

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Loosen the two (2) captive screws on the top front cover. 3. Lift the top cover to disengage its pins from the bracket slots, and set the cover aside. 4. Loosen the two (2) captive screws on the bottom front cover. 5. Lift the bottom front cover to disengage its pins from the bracket slots, and set the cover aside.
Top Front Cover
6.4 mm (0.25 in.) Tip Width 2.8 N-m (25 lb.-in.) Captive Screws 2X
PO WE R STS
PO RT MO D NE TA NE TB
Bottom Front Cover
Bracket Slots 2X Both Ends
Installation Install the covers in reverse order of removal, while referring to torque specifications shown in the drawing.
3-10
Access Procedures
Removing the HIM Option

Removal/Installation The HIM can be removed or installed while the drive is powered. Important: HIM removal is only permissible in Auto mode. If the HIM is removed while in Manual mode or the HIM is the only remaining control device, a fault will occur.
Step To remove the HIM: 1. Press ALT and then Enter (Remove). The Remove HIM confirmation screen appears. 2. Press Enter to confirm you want to remove HIM. 3. Remove the HIM from the drive. To install the HIM, insert into drive or connect cable. Key(s)
ALT +
Example Displays Remove Op Intrfc: Press Enter to Disconnect Op Intrfc? (Port 1 Control)
Removing the Communications Adapter Option

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Disconnect the communications adapter cable from the cable connector on the communications adapter. 3. Loosen the four (4) M3 x 6 mm (0.24 in.) long captive screws and remove the communications adapter.
HIM Bezel
Captive Screw M3 x 6mm Long 4X
P0 0.6 N-m (5 lb.-in.)
Cable Connector Communications Adapter Cable Communications Adapter
Access Procedures
3-11
Installation Install the communications adapter in reverse order of removal, while referring to the torque specification shown in the drawing.
Removing the Internal DPI Cable from the Power Module

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. 3. Remove external DPI cables from cable connectors on bracket. 4. Disconnect the internal DPI cable from the connectors on the front of the Power Module: A. For Frame 3A Converter/Inverter, disconnect from HIM bezel and active converter PCB. B. For Frame 3A Dual Inverter, disconnect from top and bottom HIM bezels. C. For Frame 3B Converter, disconnect from active converter PCB. D. For Frame 3B Active Converter (Stand Alone version) and Frame 3B Inverter, disconnect from HIM bezel. 5. Carefully cut the cable ties at locations shown in the figure. 6. Remove the rivets holding the internal DPI cable connectors at the bracket near the bottom of the Power Module. Using a 6.4 mm (0.25 in.) diameter drill and power drill, remove only the rivet heads. Important: Do not drill through the bracket.
3-12
Access Procedures
HIM Bezel Connector
Top HIM Bezel Connector
Cable Tie 6X Top Inverter
Active Converter PCB Connector J4
Cable Tie 6X
Bottom HIM Bezel Connector
Cable Tie 5X
Bottom Inverter
Internal DPI Cable Cable Connection to Bracket 2X
Internal DPI Cables Bottom Inverter Cable Connection to Bracket Top Inverter Cable Connection to Bracket
Frame 3A Converter/Inverter Power Module
Frame 3A Dual Inverter Power Module
Active Converter PCB Connector J4
HIM Bezel Connector
Cable Tie 7X
Cable Tie 6X
Cable Connection to Bracket 2X
Internal DPI Cable
Cable Connection to Bracket 2X
Internal DPI Cable
Frame 3B Active Converter Power Module
Frame 3B Active Converter (Stand Alone Version) and Frame 3B Inverter Power Module
Access Procedures
3-13
Key Feature 2X
3.2 mm (1/8") Rivet 2X
2.4 mm (3/32") Rivet 2X
Front Bracket
SECTION A-A
Installation 1. Assemble each internal DPI cable connector to the bracket with rivets. Using a pop-rivet tool, assemble one (1) 2.4 mm (3/32 in.) rivet and one (1) 3.2 mm (1/8 in.) rivet per connector at the locations shown in the figure. Important: Locate the connector keying feature towards the front of the Power Module. 2. Continue the installation of the internal DPI cable in reverse order of removal.
Removing the Power Module Left Side Covers

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Remove and save the five (5) M5 x 12 mm (0.47 in.) long screws for each left side cover, and set the cover aside. Note: The 700S control cover has one (1) additional M5 x 34 mm (1.34 in.) threaded standoff fastener. 3. Repeat step 2 until all left side covers are removed.
3-14
Access Procedures
Frame 3B chassis shown
3A and 3B Vector Control; and 3B Active Converter Control
Air Slots Typical
Screw M5 x 12 mm Long 5X per cover

PZ2 2.8 N-m (25 lb.-in.)
3B All Types 3A and 3B 700S Control 3A Active Converter Control 3A and 3B All Types
Stand-Off M5 x 34 mm Long (700S Control only)

8 mm 2.8 N-m (25 lb.-in.)
No Air Slots Note: Dual inverter cassette covers not shown.
Installation Install the covers in reverse order of removal, while referring to torque specification shown in the drawing. Important: Ensure left side covers with air slots are installed where control cassettes are installed.
Access Procedures
3-15
Removing the 30-Pin Communications Interface Cable from the Power Module
Removal Important: This cable is used only with the inverter control cassette. This cable is not used with the active converter control cassette. 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. 3. Disconnect the cable from the connector on the communications interface PCB near the HIM bezel on the front of the Power Module. 4. Disconnect the cable from the connector on the control PCB in the control cassette.
Control PCB Connector Communications Interface PCB Connector
30-Pin Communications Interface Cable
Installation Install the cable in reverse order of removal.
3-16
Access Procedures
Removing the 40-Pin MCB Cable from the Power Module

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. 3. Disconnect the cable from the connector on the control PCB in the control cassette. 4. Remove the components required to access the addressable power PCB (see Accessing the Control Panel of the Frame 3A Power Module on page 3-24 or Accessing the Control Panel of the Frame 3B Power Module on page 3-26). 5. Disconnect the cable from the connector J8 on the addressable power PCB.
Control PCB Connector Cutaway to Addressable Power PCB Connector
40-Pin MCB Cable
Installation Install the cable in reverse order of removal.
Access Procedures
3-17
Removing the Frame 3A 700S Control Synchronization Cable

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. 3. Disconnect cable connector P6 from the 700S main control PCB. Important: This step requires partial removal of the 700S control cassette. Refer to Removing the 700S Control Cassette on page 3-23. 4. Peel away the tape from the cable and cassette cover, and save the tape for later reinstallation. 5. Disconnect cable connector J9 from the active converter control PCB. 6. Carefully cut cable ties holding the cable to the Power Module, and remove the cable.
P6 Header on 700S Phase II Control Cassette
Control Synchronization Cable (Factory-Installed) J9 Header on Active Converter Control Cassette
DC POSITIVE
DC NEGATIVE
1 120 VAC 2 PRECHARGE COIL 24 VDC 4 CHARGE FEEDBACK GATE ENABLE 6 INDUCTOR OVERTEMP WIRE RANGE: 24-10 AWG (0.2-4 MM) STRIP LENGTH: 0.31 IN (8 MM) TORQUE: 8 IN-LB (0.9 N-M)
Installation Install the cable in reverse order of removal. Important: This step requires bending the cable and reattaching the tape to the right side of the cassette.
3-18
Access Procedures
Removing the Frame 3B 700S Control Synchronization Cable

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. 3. Disconnect cable connector P6 from the 700S main control PCB in the inverter Power Module. Important: This step requires partial removal of the 700S control cassette. Refer to Removing the 700S Control Cassette on page 3-23. 4. Peel away tape from the cable and cassette cover, and save the tape for later reinstallation. 5. Disconnect cable connector J9 from the active converter control PCB in the converter Power Module. 6. Carefully cut cable ties holding the cable to both the Power Module and the Power Module support brackets. Route the cable through the grommets at the bottom front of each Power Module, and remove cable.
P6 Header for Control Synchronization Cable Connection
Active Converter Control Cassette
700S Phase II Control Cassette
J9 Header for Control Synchronization Cable Connection

DC POSITIVE DC POSITIVE DC NEGATIVE DC NEGATIVE 1 120 VAC 2 PRECHARGE COIL 24 VDC 4 CHARGE FEEDBACK GATE ENABLE 6 INDUCTOR OVERTEMP WIRE RANGE: 24-10 AWG (0.2-4 MM) STRIP LENGTH: 0.31 IN (8 MM) TORQUE: 8 IN-LB (0.9 N-M) 4 1 120 VAC 2 PRECHARGE COIL 24 VDC CHARGE FEEDBACK GATE ENABLE 6 INDUCTOR OVERTEMP WIRE RANGE: 24-10 AWG (0.2-4 MM) STRIP LENGTH: 0.31 IN (8 MM) TORQUE: 8 IN-LB (0.9 N-M)
Control Synchronization Cable (Factory-Provided) Active Converter Power Module Inverter Power Module
Access Procedures
3-19
Installation Install cable in reverse order of removal. Important: This step requires bending the cable and reattaching the tape to the right side of the cassette.
Removing the Frame 3A 700 Vector Cable Synchronization Cable

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. 3. Disconnect cable connector TB2 from the 700 vector main control PCB. 4. Disconnect cable wires from terminal block P1-7 and P1-8 on the active converter control PCB. 5. Carefully cut cable ties holding the cable to the Power Module, and remove the cable.
TB2-2
TB2 Header on 700 Vector Control Cassette
TB2-1
Control Synchronization Cable (Factory-Installed)

SHLD
P1 Terminal Block on Active Converter Control Cassette
P1-7
4
DC POSITIVE
DC NEGATIVE
1 120 VAC 2 PRECHARGE COIL 24 VDC CHARGE FEEDBACK GATE ENABLE 6 INDUCTOR OVERTEMP WIRE RANGE: 24-10 AWG (0.2-4 MM) STRIP LENGTH: 0.31 IN (8 MM) TORQUE: 8 IN-LB (0.9 N-M)
15
P1-8
3.2 mm (0.13 in.) 0.8 N-m (7 lb.-in.)
SHLD
3-20
Access Procedures
Installation Install the cable in reverse order of removal, while referring to the torque specification in the drawing.
Removing the Frame 3B 700 Vector Control Synchronization Cable

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. 3. Disconnect cable connector TB2 from the 700 vector main control PCB in the inverter Power Module. 4. Disconnect cable wires from terminal block P1-7 and P1-8 on the active converter control PCB in the converter Power Module. 5. Carefully cut cable ties holding the cable to both the Power Module and the Power Module support brackets. Route the cable through the grommets at the bottom front of each Power Module, and remove the cable.
3.2 mm (0.13 in.) 0.8 N-m (7 lb.-in.)
Active Converter Control Cassette
700 Vector Control Cassette TB2-2
P1 Terminal Block for Control Synchronization Cable Connection
P1-7
TB2 Header for Control Synchronization Cable Connection

DC POSITIVE DC NEGATIVE 1 120 VAC 2 PRECHARGE COIL 24 VDC 4 CHARGE FEEDBACK GATE ENABLE 6 INDUCTOR OVERTEMP WIRE RANGE: 24-10 AWG (0.2-4 MM) STRIP LENGTH: 0.31 IN (8 MM) TORQUE: 8 IN-LB (0.9 N-M)
TB2-1
DC POSITIVE
15
P1-8
DC NEGATIVE
1 120 VAC 2 PRECHARGE COIL 24 VDC 4 CHARGE FEEDBACK GATE ENABLE 6 INDUCTOR OVERTEMP WIRE RANGE: 24-10 AWG (0.2-4 MM) STRIP LENGTH: 0.31 IN (8 MM) TORQUE: 8 IN-LB (0.9 N-M)
Control Synchronization Cable (Factory-Provided) Active Converter Power Module Inverter Power Module
Access Procedures
3-21
Installation Install the cable in reverse order of removal, while referring to the torque specification in the drawing.
Removing the Active Converter Control Cassette

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. 3. Disconnect the internal DPI cable from connector J4. 4. Disconnect the 700S control synchronization cable (if installed) from connector J9. 5. Disconnect the 40-Pin MCB cable from connector J1. Leave the cable's other end connected to the addressable power PCB. 6. Disconnect the I/O terminal block P1. Important: Do not disconnect the 700 vector control synchronization cable (if installed) from P1-7 and P1-8. 7. Disconnect the voltage feedback resistor PCB terminal block P2. 8. Loosen the (2) two screw latches on the front of the cassette and slide the cassette out from the cassette mounting bracket.
Figure 3.1 Removing the Frame 3A Active Converter Cassette
Pin 1 Synchronization Cable (For use with 700S Phase II Control only) Internal DPI Cable P1 Synchronization Cable (For use with 700 Vector Control only) P2 40-Pin Ribbon Cable
Detail
SH
LD
SH
LD
Communications Adapter Option
3-22
Access Procedures
Figure 3.2 Removing the Frame 3B Active Converter Cassette

Synchronization Cable (For use with coupled Inverter Power Modules with 700S Phase II Control only) Internal DPI Cable Synchronization Cable (For use with coupled Inverter Power Modules with 700 Vector Control only) 40-Pin Ribbon Cable Pin 1 P1
P2
Detail
Installation Install the cassette in reverse order of removal. Hand tighten the two (2) cassette screw latches to the cassette mounting bracket.
Removing the 700 Vector Control Cassette

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. 3. Disconnect the 700 vector control synchronization cable terminal block TB2 [installed for Frame 3A (all) and Frame 3B (coupled)]. 4. Disconnect the 40-Pin MCB cable from connector J2. Leave the cable's other end connected to the addressable power PCB. 5. Disconnect the 30-Pin communications interface cable from connector J3. Leave the cable's other end connected to the communications interface PCB. 6. Disconnect the I/O terminal block TB1. 7. Disconnect the encoder terminal block J1 (if installed). 8. Loosen the two (2) screw latches on the front of the cassette and slide the cassette out from the cassette mounting bracket.
Access Procedures
3-23
Frame 3B Inverter Power Module shown
Pin 1
Detail
Removing the 700S Control Cassette

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. 3. Disconnect the 40-Pin MCB cable from connector P1. Leave the cable's other end connected to the addressable power PCB. 4. Disconnect the 30-Pin communications interface cable from connector P2. Leave the cable's other end connected to the communications interface PCB. 5. Disconnect four (4) I/O terminal blocks TB1 and TB2. 6. Loosen the two (2) screw latches on the front of the cassette and slide the cassette out from the cassette mounting bracket. Important: While the cassette is being removed, ensure the 700S synchronization cable [for Frame 3A (all) and Frame 3B (coupled)] does not snag on the cassette mounting bracket.
3-24
Access Procedures
7. Disconnect the 700S synchronization cable connector P6 [for Frame 3A (all) and Frame 3B (coupled)]. Remove and save the tape holding the cable to the cassette.
Frame 3B Inverter Power Module shown
Detail
TB1 Terminals TB2 Terminals
Accessing the Control Panel of the Frame 3A Power Module

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. 3. Remove three (3) left side covers from the Power Module (see Removing the Power Module Left Side Covers on page 3-13). 4. Remove the active converter control cassette (see Removing the Active Converter Control Cassette on page 3-21). 5. Remove the main inverter control cassette (see Removing the 700 Vector Control Cassette on page 3-22 or Removing the 700S Control Cassette on page 3-23).
Access Procedures
3-25
Left Front Cover Bracket Cassette Mounting Bracket Top Cassette Tray
Cassette Mounting Bracket Support 2X Bottom Cassette Tray

PZ2 2.8 N-m (25 lb.-in.)
Screw M5 X 12 mm Long Typ.
6. Remove two (2) M5 x 12 mm (0.47 in.) long screws and the left front cover bracket, and set all aside. 7. Remove three (3) M5 x 12 mm (0.47 in.) long screws and the top cassette tray with cassette mounting bracket, and set all aside. Note: The center screw mounts a tie wrap base. 8. Remove three (3) M5 x 12 mm (0.47 in.) long screws and the bottom cassette tray with cassette mounting bracket, and set all aside. Note: The center screw mounts a tie wrap base. 9. Remove four (4) M5 x 12 mm (0.47 in.) long screws and (2) two supports, and set all aside. Installation Install the above components in reverse order of removal, while referring to the torque specification shown in the drawing.
3-26
Access Procedures
Accessing the Control Panel of the Frame 3B Power Module

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. 3. Remove three (3) left side covers from the Power Module (see Removing the Power Module Left Side Covers on page 3-13). 4. Remove the active converter control cassette, if installed (see Removing the Active Converter Control Cassette on page 3-21). 5. Remove the main inverter control cassette, if installed (see Removing the 700 Vector Control Cassette on page 3-22 or Removing the 700S Control Cassette on page 3-23).
Left Front Cover Bracket Cassette Mounting Bracket Top Cassette Tray
Cable Tie Anchor
Shield
Top Support Bottom Support
Screw M5 X 12 mm Long Typ.
PZ2 2.8 N-m (25 lb.-in.)
Access Procedures
3-27
6. Remove two (2) M5 x 12 mm (0.47 in.) long screws and the left front cover bracket, and set all aside. 7. Remove three (3) M5 x 12 mm (0.47 in.) long screws and the top cassette tray with cassette mounting bracket, and set all aside. Note: The center screw mounts a tie wrap base. 8. Remove two (2) M5 x 12 mm (0.47 in.) long screws and shield, and set all aside. 9. Remove three (3) M5 x 12 mm (0.47 in.) long screws holding the bottom cassette tray, and set all aside. 10.Remove four (4) M5 x 12 mm (0.47 in.) long screws and two (2) supports, and set all aside. Installation Install the above components in reverse order of removal, while referring to the torque specification shown in the drawing.
Removing the 34-Pin Power Supply Cable

Removal 1. Remove components necessary to access the cable (see Accessing the Control Panel of the Frame 3A Power Module on page 3-24 or Accessing the Control Panel of the Frame 3B Power Module on page 3-26). 2. Follow standard ESD procedures. 3. For Frame 3A, release retaining wings on both top and bottom addressable power PCB connectors J9 and release retaining wings on power supply PCB connector J1. Grip the cable connectors and pull them away from the board connectors. Important: DO NOT use the ribbon portion of the cable to separate the cable from the board connectors.
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Figure 3.3 Frame 3A Harness Connections

Temperature Sensor Harness Connector 4X Temperature Sensor Harness Connector Jumper Location (Used when DriveLogix Motor Voltage Feedback PCB is not installed.) Top Addressable Power PCB
J1 J2 J1 J4 J4 J8 J3
Left Side Plate
Current Harness Connector 6X
CT1
Phase L1
#4 Top IGBT Module

J2
40-Pin MCB Cable Connector 2X IGBT Interface Harness Connector 6X
CT2 #3 Upper Middle IGBT Module CT3
J5 J3 J1 J2 J4 J6 J7 J1 J2 J4 J4 J3 J9 J8 J11 Phase L2
Rating Plug PCB Connector 2X Current Harness Connector 2X 34-Pin Power Supply Cable Bottom Addressable Power PCB Power Supply PCB
Phase L3
#2 Lower Middle IGBT Module CT4 CT5 #1 Bottom IGBT Module
J3 J1 J2 J3 J1 J2 J4
Phase U
J5
Phase V
J6 J7 J2 J3 J9 J1
J11
Phase W
CT6
Chillplate NTC Connector 400/480V DC Bus Harness Connector
J3
NTC
J4 J6 J7
TB5/TB6 Wire Harness Connector Terminal Block TB5
600/690V DC Bus Harness Connector Current Harness Push Mount Cable Ties 8X Current Harness 2X
PZ2 2.8 N-m (25 lb.-in.)
Fan 1 Harness Connector Fan 1 Fan 2 Fan 2 Harness Connector
Screw, M5 Current Feedback Typ.
For Frame 3B, open the ribbon cable clamp on the control panel, located between the top addressable power PCB and the power supply PCB. Release retaining wings on addressable power PCB connector J9 and release retaining wings on power supply PCB connector J1. Grip the cable connectors and pull them away from the board connectors.
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Figure 3.4 Frame 3B Harness Connections

Temperature Sensor Harness Connector 4X
Left Side Plate Current Harness 1X Current Harness Connector 3X
Temperature Sensor Harness Connector
Jumper Location (Used when DriveLogix Motor Voltage Feedback PCB is not installed.) Addressable Power PCB
J1
J8 J2 J3
#4 Top IGBT Module

Phase L1/U
40-Pin MCB Cable Connector IGBT Interface Harness Connector 3X
J1 J2
J4
J4
CT1 #3 Upper Middle IGBT Module
J5 J3 J1 J2 J4 J6 J7 J9 J11
Rating Plug PCB Connector Current Harness Connector
Phase L2/V
CT2
#2 Lower Middle IGBT Module
J3 J1 J2 J4
34-Pin Power Supply Cable Ribbon Cable Clamp

J4
Phase L3/W
CT3
#1 Bottom IGBT Module Chillplate NTC Connector 400/480V DC Bus Harness Connector 600/690V DC Bus Harness Connector
J3 J1 J2 J3 J2 J3 J1 J4 J6 J7
Power Supply PCB TB5/TB6 Wire Harness Connector
NTC
Terminal Block TB5 & TB6 Fan 1 Harness Connector Fan 2 Harness Connector
Current Harness Push Mount Cable Ties 5X
Note: CT3 Flange Orientation is Rotated 180 Degrees from CT1 & CT2
PZ2 2.8 N-m (25 lb.-in.)
Fan 1
Fan 2
Screw, M5 Current Feedback Typ.
Installation Install the cable in reverse order of removal, while referring to Figure 3.3 or Figure 3.4.
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Removing the TB5/TB6 Wire Harness

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Remove components necessary to access the power supply PCB (see Accessing the Control Panel of the Frame 3A Power Module on page 3-24 or Accessing the Control Panel of the Frame 3B Power Module on page 3-26). 3. Follow standard ESD procedures. 4. Remove and save jumper wire (if installed), Input Filter wiring, and/or other control wiring from the terminal block. Ensure wires are labeled for correct installation. 5. Disconnect harness connector J4 from power supply PCB. 6. Remove the two (2) M4 x 16 mm (0.63 in.) long screws holding the harness to the front of the Power Module chassis. 7. Pull the harness away from the chassis while carefully routing the harness connector end through the slot in the chassis.
Terminal #1 Red Wire (Towards Top)
Screw M4 x 16 mm 2X
PZ1 1.6 N-m (14 lb.-in.)
Installation Install the harness in reverse order of removal, while referring to the installation orientation and torque specification shown in the drawing, and Figure 3.3 on page 3-28 or Figure 3.4 on page 3-29.
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Removing the Frame 3A Current Feedback Devices and Current Harnesses

Removal 1. Remove components necessary to access the addressable power PCB (see Accessing the Control Panel of the Frame 3A Power Module on page 3-24). 2. Follow standard ESD procedures. 3. Disconnect the inverter current harness from the connector marked J7 on the inverter addressable power PCB by gripping the connector on its sides and pulling away from the PCB. 4. Disconnect the converter current harness from the connector marked J7 on the converter addressable power PCB by gripping the connector on its sides and pulling away from the PCB. 5. Remove and save two (2) M5 x 25 mm (0.98 in.) long screws and two (2) M6 flat washers holding each of six (6) bus bar support angles to the bus bar labeled L1, L2, L3, U, V, and W.
Screw M5 x 25 mm Long 2X
PZ2 2.8 N-m (25 lb.-in.)
M6 Flat Washer 2X
6. Remove and save eleven (11) M5 x 10 mm (0.40 in.) long screws holding the left side plate to the Power Module chassis. 7. After carefully routing both current harness connectors through the openings in the control panel, lift the left side plate away from the Power Module chassis. Important: The left side plate with six (6) current feedback devices attached weighs approximately 6 kg (13 lbs.) Use hoists or other means to lift the left side plate. DO NOT use the bus bars to support this weight, since this may damage the IGBT power devices. 8. Place the left side plate on a horizontal surface away from the Power Module with the current feedback devices facing upward. If necessary, use two (2) 75 mm (3 in.) thick blocks beneath the left side plate (if the bus bar support angles are not removed.) 9. Disconnect the inverter current harness from the connector on each of the three (3) current feedback devices labeled U, V, and W. To completely
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remove the harness, disengage the four (4) push mount cable ties from the left side plate. 10.Disconnect the converter current harness from the connector on each of the three (3) current feedback devices labeled L1, L2, and L3. To completely remove the harness, disengage the four (4) push mount cable ties from the left side plate. 11.Remove and save four (4) M5 x 12 mm (0.47 in.) long screws holding each of six (6) current feedback devices onto the left side plate. Installation Install the current feedback devices and current harnesses in reverse order of removal, while referring to the torque specification, component locations, component orientation, and harness connections in Figure 3.3 on page 3-28. Important: Orient the six (6) current feedback devices as shown in the drawing. Important: Use blocking, hoisting, or other means to prevent harness pinching or damage during left side plate installation and to aid harness connector pass-through the control panel opening.
Removing the Frame 3B Current Feedback Devices and Current Harness

Removal 1. Remove components necessary to access the addressable power PCB (see Accessing the Control Panel of the Frame 3B Power Module on page 3-26). 2. Follow standard ESD procedures. 3. Disconnect the current harness from the connector marked J7 on the addressable power PCB by gripping the connector on its sides and pulling away from the PCB. 4. Remove and save two (2) M5 x 25 mm (0.98 in.) long screws and two (2) M6 flat washers holding each of three (3) bus bar support angles to the bus bar labeled L1, L2, and L3 (if converter Power Module); or U, V, and W (if inverter Power Module.)
Screw M5 x 25 mm Long 2X PZ2 2.8 N-m (25 lb.-in.)
M6 Flat Washer 2X
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5. Remove and save eleven (11) M5 x 10 mm (0.40 in.) long screws holding the left side plate to the Power Module chassis. 6. After carefully routing the current harness connector through the opening in the control panel, lift the left side plate away from the Power Module chassis. Important: The left side plate with three (3) current feedback devices attached weighs approximately 7 kg (15 lbs.) Use hoists or other means to lift the left side plate. DO NOT use the bus bars to support this weight, since this may damage the IGBT power devices. 7. Place the left side plate on a horizontal surface away from the Power Module with the current feedback devices facing upward. If necessary, use two (2) 75 mm (3 in.) thick blocks beneath the left side plate (if the bus bar support angles are not removed.) 8. Disconnect the current harness from the connector on each of the three (3) current feedback devices labeled L1, L2, and L3 (if converter Power Module); or U, V, and W (if inverter Power Module). To completely remove the harness, disengage the four (4) push mount cable ties from the left side plate. 9. Remove and save four (4) M5 x 12 mm (0.47 in.) long screws holding each of three (3) current feedback devices onto the left side plate. Installation Install the current feedback devices and current harnesses in reverse order of removal, while referring to the torque specification, component locations, component orientation, and harness connections in Figure 3.4 on page 3-29. Important: Orient the three (3) current feedback devices as shown in the drawing. Important: Use blocking, hoisting, or other means to prevent harness pinching or damage during left side plate installation and to aid harness connector pass-through the control panel opening.
Removing the Frame 3A IGBT Interface Harnesses

Removal 1. Remove components necessary to access the addressable power PCB (see Accessing the Control Panel of the Frame 3A Power Module on page 3-24). 2. Remove the left side plate with the current feedback devices and the current harnesses (see Removing the Frame 3A Current Feedback Devices and Current Harnesses on page 3-31). 3. Follow standard ESD procedures.
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4. Untwist the three (3) twist-lock retaining clips near the top addressable power PCB holding the harness to the control panel. 5. Disengage the lever on the harness connector at the top addressable power PCB connector J4, and pull the harness connector away from the addressable power PCB connector. Important: Do not pull on the wires. Grasp the harness connector by its sides. 6. Repeat step 5 for the harness connectors at the top addressable power PCB connectors J5 and J6. 7. Disconnect six (12) harness connectors from the IGBT connectors labeled J1, J2, and J3. Important: Do not pull on the wires. Grasp the harness connectors by their sides. Note: With the retaining clips loosened in step 4, the harness has three (3) sections. Each section connects one (1) addressable power PCB connector to two (2) IGBT's. 8. Route the addressable power PCB end of the three (3) sections of harness through the slot in the control panel, and remove the harness. 9. Repeat steps 4 through 8 for the second harness connected to the bottom addressable power PCB in the Frame 3A Power Module. Installation Install the two (2) Frame 3A harnesses in reverse order of removal, while referring to Figure 3.3 on page 3-28. Note: When replacing the Frame 3A harnesses with new spare part kit harnesses, cut off the three (3) twist-lock retaining clips prior to each harness installation.
Removing the Frame 3B IGBT Interface Harness

Removal 1. Remove components necessary to access the addressable power PCB (see Accessing the Control Panel of the Frame 3B Power Module on page 3-26). 2. Remove the left side plate with the current feedback devices and the current harness (see Removing the Frame 3B Current Feedback Devices and Current Harness on page 3-32). 3. Follow standard ESD procedures. 4. Untwist the three (3) twist-lock retaining clips near the addressable power PCB holding the harness to the control panel.
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5. Disengage the lever on the harness connector at the addressable power PCB connector J4, and pull the harness connector away from the addressable power PCB connector. Important: Do not pull on the wires. Grasp the harness connectors by their sides. 6. Repeat step 5 for the harness connectors at addressable power PCB connectors J5 and J6. 7. Disconnect twelve (12) harness connectors from the IGBT connectors labeled J1, J2, and J3. Important: Do not pull on the wires. Grasp the harness connectors by their sides. Note: With the retaining clips loosened in step 4, the harness has three (3) sections. Each section connects one (1) addressable power PCB connector to four (4) IGBT's. 8. Route the addressable power PCB end of the three (3) sections of harness through the slot in the control panel, and remove the harness. Installation Install the Frame 3B harness in reverse order of removal, while referring to Figure 3.4 on page 3-29. Note: When replacing the Frame 3B harness with a new spare part kit harness, cut off three (3) twist-lock retaining clips prior to harness installation.
Removing the Frame 3A Temperature Sensor Harnesses

Removal 1. Remove components necessary to access the addressable power PCB (see Accessing the Control Panel of the Frame 3A Power Module on page 3-24). 2. Remove the left side plate with the current feedback devices and the current harnesses (see Removing the Frame 3A Current Feedback Devices and Current Harnesses on page 3-31). 3. Follow standard ESD procedures. 4. Disengage the lever on the harness connector at the top addressable power PCB connector J1, and pull the harness connector away from the addressable power PCB connector. Important: Do not pull on the wires. Grasp the harness connector by its sides.
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5. Disengage the lever on the harness connector at the two (2) IGBT connectors J4 on #4 top IGBT and #3 upper middle IGBT, and pull the harness connector away from the IGBT connectors. Important: Do not pull on the wires. Grasp the harness connectors by their sides. Note: The harness for the top addressable power PCB is not connected to the chillplate NTC connector. 6. Release the two (2) push mount cable ties on the harness from the control panel, and remove the first of two harnesses. 7. Disengage the lever on the harness connector at the bottom addressable power PCB connector J1, and pull the harness connector away from the addressable power PCB connector. Important: Do not pull on the wires. Grasp the harness connectors by its sides. 8. Disengage the lever on the harness connector at the two (2) IGBT connectors J4 on #2 lower middle IGBT and #1 bottom IGBT, and pull the harness connector away from the IGBT connectors. Important: Do not pull on the wires. Grasp the harness connectors by their sides. 9. Disconnect the harness from the chillplate NTC connector. 10.Release two (2) push mount cable ties on the harness from the control panel, and remove the second of two harnesses. Installation Install the two (2) Frame 3A harnesses in reverse order of removal, while referring to Figure 3.3 on page 3-28.
Removing the Frame 3B Temperature Sensor Harness

Removal 1. Remove components necessary to access the addressable power PCB (see Accessing the Control Panel of the Frame 3B Power Module on page 3-26). 2. Remove the left side plate with the current feedback devices and the current harness (see Removing the Frame 3B Current Feedback Devices and Current Harness on page 3-32). 3. Follow standard ESD procedures.
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4. Disengage the lever on the harness connector at the addressable power PCB connector J1, and pull the harness connector away from the addressable power PCB connector. Important: Do not pull on the wires. Grasp the harness connector by its sides. 5. Disengage the lever on the harness connector at the four (4) IGBT connectors J4, and pull the harness connectors away from the IGBT connectors. Important: Do not pull on the wires. Grasp the harness connectors by their sides. 6. Disconnect the harness from the chillplate NTC connector. 7. Release the four (4) push mount cable ties on the harness from the control panel, and remove the harness. Installation Install the Frame 3B harness in reverse order of removal, while referring to Figure 3.4 on page 3-29.
Removing the Motor Voltage Feedback PCB (700S Control Only)

Removal 1. Remove components necessary to access the motor voltage feedback PCB located on the inverter addressable power PCB (see Accessing the Control Panel of the Frame 3A Power Module on page 3-24 or Accessing the Control Panel of the Frame 3B Power Module on page 3-26). 2. Follow standard ESD procedures. 3. Using a pair of insulated needle-nose pliers, carefully pinch the three (3) plastic stand-offs to release the PCB. 4. Remove the PCB by firmly gripping its edges and slowly pulling away from the addressable power PCB connectors J2 and J3. 5. Remove the insulation sheet. 6. Remove the three (3) plastic stand-offs.
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Addressable Power PCB J2 Plastic Stand-Off 3X J3
Motor Voltage Feedback PCB Insulation Sheet
Installation Install three (3) plastic standoffs, insulation sheet, and motor voltage feedback PCB in reverse order of removal.
Removing the Rating Plug PCB

Removal 1. Remove components necessary to access the rating plug PCB located on the addressable power PCB (see Accessing the Control Panel of the Frame 3A Power Module on page 3-24 or Accessing the Control Panel of the Frame 3B Power Module on page 3-26). 2. Follow standard ESD procedures. 3. Remove and save one (1) M3 x 8 mm (0.32 in.) long screw attaching the rating plug PCB to the addressable power PCB (Figure 3.5). 4. Remove the rating plug PCB by firmly gripping its edges and slowly pulling away from the addressable power PCB connector J11. Installation Install the rating plug PCB and screw in reverse order of removal while referring to torque specifications in Figure 3.5 on page 3-39.
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Figure 3.5 Addressable Power and Rating Plug PCBs
Addressable Power PCB
Screw M3 X 8 mm Long 6X
PZ1 0.6 N-m (5 lb.-in.)
Screw M3 X 8 mm Long 1X Rating Plug PCB
Removing the Addressable Power PCB

Removal 1. Remove components necessary to access the addressable power PCB (see Accessing the Control Panel of the Frame 3A Power Module on page 3-24 or Accessing the Control Panel of the Frame 3B Power Module on page 3-26). 2. Follow standard ESD procedures. 3. Remove and save the motor voltage feedback PCB (if present). See Removing the Motor Voltage Feedback PCB (700S Control Only) on page 3-37. 4. Remove and save the rating plug PCB (see Removing the Rating Plug PCB on page 3-38). 5. Disconnect the 34-Pin power supply cable from connector J9. 6. Disconnect the 40-pin MCB cable from connector J8. 7. Disconnect the temperature sensor harness from connector J1. 8. Disconnect the IGBT interface harness from connectors J4, J5, and J6. 9. Disconnect the current harness from connector J7.
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10.Remove and save six (6) M3 x 8 mm (0.32 in.) long screws that mount the PCB to the control panel. 11.Gently slide the PCB toward the top of the Power Module to disengage the five (5) key-hole stand-offs, and lift the PCB away from the control panel. Installation 1. Install the addressable power PCB in reverse order of removal while referring to torque specification in Figure 3.5. 2. Make harness connections while referring to Figure 3.3 on page 3-28 or Figure 3.4 on page 3-29.
Removing the Power Supply PCB

Removal 1. Remove components necessary to access the power supply PCB (see Accessing the Control Panel of the Frame 3A Power Module on page 3-24 or Accessing the Control Panel of the Frame 3B Power Module on page 3-26). 2. Follow standard ESD procedures. 3. Disconnect the 34-Pin power supply cable from connector J1. 4. Disconnect the TB5/TB6 wire harness from connector J4. 5. Disconnect the DC bus harness from either connector marked J2 (for 400/480V Power Modules) or J3 (for 600/690V Power Modules.) 6. Disconnect the fan 1 fan harness from connector J6. 7. Disconnect the fan 2 fan harness from connector J7. 8. Remove and save three (3) M3 x 8 mm (0.32 in.) long screws that mount the PCB to the control panel. 9. Gently slide the PCB toward the top of the Power Module to disengage the six (6) keyhole stand-offs, and lift the PCB away from the control panel.
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Keyhole Stand-Offs 6X
Power Supply PCB
Screw M3 x 8 mm Long 3X PZ1 0.6 N-m (5 lb.-in.)
Installation 1. Install the power supply PCB in reverse order of removal while referring to torque specification in the drawing. 2. Make harness connections while referring to Figure 3.3 on page 3-28 or Figure 3.4 on page 3-29.
Removing the Discharge Resistors

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. 3. Remove three (3) M5 x 12 mm (0.47 in.) long screws and resistor access cover, and set all aside. 4. Disconnect the resistor harness from the resistor terminals. Important: Resistor R3 is installed only on 600/690V equipment. 5. Remove and save two (2) M5 x 10 mm (0.40 in.) long screws per resistor. Remove resistors, while exercising care due to the presence of thermal grease on the mounting surface of the resistors.
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Power Module Access Openings
R3 (600/690V) R3-2 R3-1 R2 (400/690V) R2-2 R2-1 R1-2 R1 (400/690V) R1-1
Resistor Access Cover
Danger Label Screw M5 x 10 mm Long 2X Typ.

PZ2 2.8 N-m (25 lb.-in.)
Screw M5 x 12 mm Long 3X
Installation 1. Apply a thin, uniform layer of thermal grease to the mounting surface of new resistors. 2. Align hole and slot on the resistor with holes on the mounting surface. 3. Install two (2) M5 x 10 mm (0.40 in.) long screws per resistor, while referring to torque specification shown in the drawing. 4. Connect resistor harness to resistor terminals. Important: Match wire harness terminal labels with those shown in the drawing. 5. Install the resistor access cover using three (3) M5 x 12 mm (0.47 in.) long screws, while referring to the torque specification shown in the drawing. Important: Danger label must be legible.
Removing the Power Module Fans

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures.
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3. Remove and save five (5) M5 thumb screws with flat and lock washers from fan plate, and lower the fan plate. 4. Disconnect the fan harness from the fan 1 and fan 2 connectors. 5. Disengage two (2) push mount cable ties on the fan harness from the fan plate. 6. Set the fan plate on a horizontal surface away from the Power Module with the fans facing upward. 7. Remove and save two (2) M4 x 60 mm (2.36 in.) long screws, two (2) lock washers, and two (2) flat washers per each of two (2) fans.
Screw M4 x 60 mm Long with Flat and Lock Washers 2X per each fan
6.4 mm (0.25 in.) Tip Width 1.6 N-m (14 lb.-in.)
Power Module Front
Airflow into Power Module
Fan Harness Connectors
Fan 1 Fan 2
Fan Plate
M5 Thumbscrew with Flat and Lock Washers 5X
Push Mount Cable Ties
Installation Install the fans and fan harness in reverse order of removal while referring to torque specification shown in the drawing. Important: Fan airflow direction is into the Power Module.
Removing the Fan Harness

Removal 1. Remove components necessary to access the power supply PCB (see Accessing the Control Panel of the Frame 3A Power Module on page 3-24 or Accessing the Control Panel of the Frame 3B Power Module on page 3-26).
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2. Disconnect the fan harness from two (2) fans and the fan plate (see Removing the Power Module Fans on page 3-42). 3. Follow standard ESD procedures. 4. Disconnect the fan harness from the power supply PCB connectors J6 and J7. 5. Disengage one (1) push mount cable tie on the fan harness in contact with the control panel. 6. Push the PCB end of the fan harness and harness grommet through the slot in the control panel. Installation Install the fan harness in reverse order of removal (see Figure 3.3 on page 3-28 or Figure 3.4 on page 3-29).
Complete Drive
Removing the Fan Filter Element for Power Module Bay Door Fan (Frames 3A and 3B) and the Power Module Bay Door Louver (Frame 3B Only)
Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Remove and save the exterior plastic grille by prying at its corners with a flat head screwdriver. 3. Remove existing fan filter mat and discard.
Airflow Enclosure Exterior Filter Element (White Side)
Filter Element (Color Side) Plastic Grille
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Installation Install fan filter mat in reverse order of removal. Important: The white side of the fan filter mat faces towards the exterior of the enclosure.
Removing the Power Module Bay Door Fan

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Disconnect three (3) fan wires from the fan by loosening screws with a flat head screwdriver. 3. Remove exterior plastic grille by prying at its corners with a flat head screwdriver, and set it aside. 4. Remove the fan filter mat and discard. 5. Remove and save four (4) BZ5.5 x 13 mm (0.51 in.) long screws attaching the door fan to the exterior of the door. 6. Release eight (8) plastic retention tabs on the interior side of the door fan housing, and remove the door fan.
Airflow
Enclosure Exterior
Filter Element (Color Side) Filter Element (White Side)
Fan PE L1 N
317 GRN
300 318 RED BLK
Screw BZ5.5 x 13 mm Long 4x T20 5.1 N-m (45 lb.-in.) Plastic Grille
3.2 mm (0.15 in.) Tip Width 0.8 N-m (7 lb.-in.)
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Installation Install the door fan, fan filter mat, and plastic grille in reverse order of removal, while referring to torque specifications shown in the drawing. Important: The white side of the fan filter mat faces towards the exterior of the enclosure.
Removing the Frame 3A Hose Assemblies

Removal 1. Remove power from drive (see Removing Power from the Drive on page 3-5). 2. Drain water from drive-side water cooling equipment in accordance with the equipment manufacturer's instructions. ATTENTION: Risk of injury, death or equipment damage exists. Coolant, if sprayed, spilled or leaked, can cause a slippery condition or an electrical shock hazard when making contact with an electrical conductor. To avoid coolant spraying, spills, and leakage inside the drive cabinet, drain the cooling system by loosening fittings exterior to the drive cabinet before loosening hose fittings inside the drive cabinet.
3. Remove water cooling equipment hose fittings from the drive inlet and outlet hose assemblies. Important: Use a backup wrench for 41.3 mm (1.63 in.) wrench flats on the hose assembly bulkhead fitting. Do not use a backup wrench on bulkhead fitting locknut. 4. Remove and save two (2) bulkhead fitting locknuts. Important: Use a backup wrench for 41.3 mm (1.63 in.) wrench flats on the hose assembly bulkhead fitting. 5. Remove two (2) M5 x 12 mm (0.47 in.) long screws holding each of two (2) L-brackets to C-brackets, and remove the L-brackets. Set aside the L-brackets and screws for later installation. 6. Loosen one (1) inlet hose assembly fitting at the Power Module inlet and remove the inlet hose assembly from the enclosure. Important: Use a backup wrench for 31.8 mm (1.25 in.) wrench flats on the Power Module inlet fitting. 7. Loosen one (1) outlet hose assembly fitting at the Power Module outlet and remove the outlet hose assembly from the enclosure. Important: Use a backup wrench for 31.8 mm (1.25 in.) wrench flats on the Power Module outlet fitting.
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Power Module Fitting 2X Use Backup Wrench Here Inlet Hose Assembly Screw M5 x 12 mm 4X PZ2 2.8 N-m (25 lb.-in.)
Outlet Hose Assembly
Bulkhead Fitting Locknut
L-Bracket 2X C-Bracket
Hose Assembly Bulkhead Fitting Use Backup Wrench Here
Installation Install inlet and outlet hose assemblies in reverse order of removal. To ensure alignment and fit, start all screws and locknuts, but do not tighten. Then tighten as follows: 1. For the M5 screw torque, refer to the torque specifications shown in the drawing. 2. For the hose assembly connections to the Power Module: A. Tighten the hose assembly fittings to wrench resistance or approximately 3.4 N-m (30 lb.-in.). B. Further tighten the hose assembly fittings by one (1) additional hex flat. Important: Use a backup wrench for 31.8 mm (1.25 in.) wrench flats on Power Module fittings. C. For reference, the tightening torque is approximately 73 N-m (650 lb.-in.). 3. For the bulkhead fitting locknuts to the L-brackets and hose assemblies: A. Tighten the bulkhead fitting locknuts to wrench resistance or approximately 3.4 N-m (30 lb.-in.). B. Further tighten the bulkhead fitting locknuts by one (1) additional hex flat. Important: Use a backup wrench for 41.3 mm (1.63 in.) wrench flats on the hose assembly bulkhead fitting.
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C. For reference, the tightening torque is approximately 73 N-m (650 lb.-in.). 4. Connect drive-side water cooling equipment to the drive inlet and outlet hose assemblies in accordance with the equipment manufacturer's instructions.
Removing Frame 3B Hose Assemblies

Removal 1. Remove power from drive (see Removing Power from the Drive on page 3-5). 2. Drain water from drive-side water cooling equipment in accordance with the equipment manufacturer's instructions. ATTENTION: Risk of injury, death or equipment damage exists. Coolant, if sprayed, spilled or leaked, can cause a slippery condition or an electrical shock hazard when making contact with an electrical conductor. To avoid coolant spraying, spills, and leakage inside the drive cabinet, drain the cooling system by loosening fittings exterior to the drive cabinet before loosening hose fittings inside the drive cabinet.
3. Remove water cooling equipment hose fittings from the drive inlet and outlet hose assemblies. Important: Use a backup wrench for 41.3 mm (1.63 in.) wrench flats on the hose assembly bulkhead fitting. Do not use a backup wrench on the bulkhead fitting locknut. 4. Remove and save two (2) bulkhead fitting locknuts. Important: Use a backup wrench for 41.3 mm (1.63 in.) wrench flats on the hose assembly bulkhead fitting. 5. Remove one (1) M5 x 12 mm (0.47 in.) long screw holding each of two (2) hose clamps to the L-hose brackets, and remove the hose clamps. Set aside the hose clamps and screws for later installation. 6. Remove two (2) M5 x 12 mm (0.47 in.) long screws holding each of four (4) L-brackets to the C-brackets. Set aside the L-brackets and screws for later installation. 7. Loosen two (2) inlet hose assembly fittings at the Power Module inlets and remove the inlet hose assembly from the enclosure. Important: Use a backup wrench for 31.8 mm (1.25 in.) wrench flats on the Power Module inlet fittings.
Access Procedures
3-49
8. Loosen two (2) outlet hose assembly fittings at the Power Module outlets and remove the outlet hose assembly from the enclosure. Important: Use a backup wrench for 31.8 mm (1.25 in.) wrench flats on the Power Module outlet fittings.
Screw M5 x 12 mm 2X
PZ2 2.8 N-m (25 lb.-in.)
Hose Clamp 2X Inlet Hose Assembly Outlet Hose Assembly
Power Module Fitting 4X Use Backup Wrench Here Bulkhead Fitting Locknut
Screw M5 x 12 mm 8X PZ2 2.8 N-m (25 lb.-in.)
Hose Assembly Bulkhead Fitting Use Backup Wrench Here C-Bracket 2X L-Bracket 4X
Installation Install inlet and outlet hose assemblies in reverse order of removal. To ensure alignment and fit, start all screws and locknuts, but do not tighten. Then tighten as follows: 1. For the M5 screw torque, refer to the torque specifications shown in the drawing. 2. For the hose assembly connections to the Power Module: A. Tighten the hose assembly fittings to wrench resistance or approximately 3.4 N-m (30 lb.-in.). B. Further tighten the hose assembly fittings by one (1) additional hex flat. Important: Use a backup wrench for 31.8 mm (1.25 in.) wrench flats on the Power Module fittings.
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Access Procedures
C. For reference, the tightening torque is approximately 73 N-m (650 lb.-in.). 3. For the bulkhead fitting locknuts to the L-brackets and hose assemblies: A. Tighten the bulkhead fitting locknuts to wrench resistance or approximately 3.4 N-m (30 lb.-in.). B. Further tighten the bulkhead fitting locknuts by one (1) additional hex flat. Important: Use a backup wrench for 41.3 mm (1.63 in.) wrench flats on the hose assembly bulkhead fitting. C. For reference, the tightening torque is approximately 73 N-m (650 lb.-in.). 4. Connect drive-side water cooling equipment to the drive inlet and outlet hose assemblies in accordance with the equipment manufacturer's instructions.
Removing the Door-Mount HIM Bezel

Instructions for the door-mount HIM bezel (available at http:// www.rockwellautomation.com/literature) include:
Title PowerFlex 7-Class HIM Bezel (DPI) Installation Instructions Using the 20-HIM-B1 Bezel Kit Publication 20HIM-IN002 20HIM-IN004
Removing the Power Module Bay Door

Removal 1. Remove power from drive (see Removing Power from the Drive on page 3-5). 2. Remove and save one (1) M8 nut, M8 contact washer, and Power Module ground wire lug from the door ground stud at the upper right, inside corner of the door. 3. If the door-mount HIM and bezel are installed, then disconnect the HIM cable from the power module. Cut cable ties to disconnect the HIM cable from the enclosure. 4. Disconnect three (3) wires #300, #317, and #318 from the power module bay door fan. Cut the cable tie to disconnect the three (3) wires from the enclosure door. 5. Remove and save three (3) hinge pins, and remove the door.
Access Procedures
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Power Module Bay Ground Wire
M8 Nut and Contact Washer

13 mm 11 N-m (100 lb.-in.)
Door-Mount HIM Cable and Cable Tie Mounts
Door Fan Wires #300, #317, and #318, and Cable Tie Mount
Installation Install the door, door fan wires and cable ties, door-mount HIM bezel cable and cable ties, and ground cable in reverse order of removal, while referring to the torque specification shown in the drawing. To reconnect the fan wires to the fan, refer to Removing the Power Module Bay Door Fan on page 3-45. Important: When the door is being replaced due to damage, the replacement door kit does not contain a new fan and a new door-mount HIM bezel with cable. These kits must be ordered separately, if required. For additional installation information, refer to Removing the Door-Mount HIM Bezel on page 3-50 and Removing the Power Module Bay Door Fan on page 3-45.
Removing the Frame 3A Power Module Bay Barrier

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5).
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Access Procedures
2. Remove and save two (2) M6 x 16 mm (0.63 in.) long screws along the left side of the barrier. 3. Remove and save four (4) M5 x 16 mm (0.63 in.) long screws at the top and bottom of the barrier, and remove the barrier.
Screw M5 x 16 mm Long
PZ2 2.8 N-m (25 lb.-in.)
Barrier
DANGER
DANGER
P2 5.1 N-m (45 lb.-in.)
Screw M5 x 16 mm Long PZ2 2.8 N-m (25 lb.-in.)
Installation Install the barrier in reverse order of removal, while referring to the torque specifications shown in the drawing.
Removing the Frame 3B Power Module Bay Barriers

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. For the left barrier: A. Remove and save three (3) M6 x 16 mm (0.63 in.) long screws along the left side of the barrier.
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B. Remove and save four (4) BZ5.5 x 13 mm (0.51 in.) long screws at the top and bottom of the barrier, and remove the barrier. 3. For the center barrier, remove and save four (4) BZ5.5 x 13 mm (0.51 in.) long screws at the top and bottom of the barrier, and remove the barrier. 4. For the top barrier, remove and save five (5) BZ5.5 x 13 mm (0.51 in.) long screws, and remove the barrier.
Screw BZ5.5 x 13 mm Long 5X Top Barrier Middle Barrier
T25 5.1 N-m (45 lb.-in.)
Screw BZ5.5 x 13 mm Long

T25 5.1 N-m (45 lb.-in.)
Left Barrier Screw M6 x 16 mm Long

P2 5.1 N-m (45 lb.-in.)
DANGER
DANGER
Screw BZ5.5 x 13 mm Long

T25 5.1 N-m (45 lb.-in.)
Installation Install the three barriers in reverse order of removal, while referring to the torque specifications shown in the drawing.
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Access Procedures
Removing the Power Module Jumper Bus Bars

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Remove user-installed power cables. 3. Remove barriers as required, while referring to Removing the Frame 3A Power Module Bay Barrier on page 3-51 or Removing the Frame 3B Power Module Bay Barriers on page 3-52. 4. Remove and save two (2) M12 nuts, four (4) M12 flat washers, and two (2) M12 x 40 mm (1.59 in.) long hex head screws, and remove each jumper bus bar as required.
M12 Nut with Conical Washer (2x) and M12 Flat Washer (4x) Jumper Bus Bar (Typ.)
Power Module Bus Bar (Typ.)
19 mm 61 N-m (45 lb.-in.)
Screw M12 x 40 mm Long 2x
Installation Install the jumper bus bar(s), barriers, and power cables in reverse order of removal, while referring to the torque specifications shown in the drawing. Important: The Frame 3A complete drive has only two (2) jumper bus bars installed. The U phase towards the top of the power module does not have a factory-installed jumper.
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Removing the Frame 3A and 3B Complete Drive Main Harness

Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. Important: The PowerFlex 700L User Manual contains detailed information regarding the complete drive main harness. Refer to the section titled Installing Control Wiring from the Input Filter Bay to the Power Module Bay and the drive schematics in Appendix B. Note: The main harness consists of four separate sections. Three of the sections are individually cable tied. The fourth section is the power module bay ground wire between the power module bay enclosure and its door. 3. For the three individually cable tied sections, disconnect both ends of all wires from the equipment terminals. Cut only the cable ties holding the harness sections to the power module, power module support brackets, power module bay enclosure, and input filter bay enclosure. Remove the three harness sections from the drive. 4. For the power module bay ground wire: A. On the enclosure side, remove and save one (1) M8 x 30 mm (1.19 in.) long screw, and one (1) M8 contact washer. B. On the door side, remove and save one (1) M8 nut, and one (1) M8 contact washer. Remove the ground wire.
Figure 3.6 Harness Input Filter Side
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Access Procedures
Figure 3.7 Harness Power Module Side
Figure 3.8 Harness Door Fan
Installation 1. Install the three individually cable tied sections while referring to: A. Specifications shown in the PowerFlex 700L User Manual in the section titled Installing Control Wiring from the Input Filter Bay to the Power Module Bay.
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B. Drive schematics shown in the PowerFlex 700L User Manual, Appendix B. C. Wire routings shown in Figure 3.6, Figure 3.7, and Figure 3.8. ATTENTION: Do not route signal and control wiring with power wiring in the same conduit. This can cause interference with drive operation. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
Note: For the 400/480V Input Filter, wires connected to FU7, FU8, and FU9 require #10 spade tongue terminals. Spare parts kits for the complete drive main harness contain three (3) #10 spade tongue terminals. 2. Install the power module bay ground wire and its M8 hex hardware using a 13 mm socket. Torque to 11 N-m (100 lb.-in.).
Removing the Frame 3A Power Module from the Power Module Bay
Removal 1. Remove power from the drive (see Removing Power from the Drive on page 3-5). 2. Follow standard ESD procedures. 3. Remove the Frame 3A hose assemblies (see Removing the Frame 3A Hose Assemblies on page 3-46). 4. Remove the Frame 3A barrier (see Removing the Frame 3A Power Module Bay Barrier on page 3-51). 5. To disconnect the motor lead cables from the U/T1, V/T2, and W/T3 power module terminals: A. Remove and save user-provided hardware. Typically, this hardware may be one (1) M12 screw, two (2) M12 flat washers, and one (1) M12 hex nut per each of two (2) holes in each of the three (3) terminals. B. Carefully cut cable ties holding the cables to the cable support rail. The cable support rail will be removed in step 11. Secure the cables so as not to hinder power module removal. 6. Remove and save two (2) motor lead bus bars (see Removing the Power Module Jumper Bus Bars on page 3-54). 7. To disconnect the input power cables from the R/L1, S/L2, and T/L3 power module terminals: A. Remove and save one (1) M12 x 40 mm (1.57 in.) long screw, two (2) M12 flat washers, and one (1) M12 hex nut per each of two (2) holes in each of the three (3) terminals.
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B. Secure cables so as not to hinder power module removal. If necessary, carefully cut cable ties holding the conductors to the D-ring supports on the left-side wall of the power module bay.
M12 Hex Nut 2x Input Power Cable 2x M12 Flat Washer 4x
19 mm 62 N-m (550 lb.-in.)
Screw M12 x 40 mm Long 2x
8. Remove and save one (1) M8 x 30 mm (1.18 in.) long screw, two (2) M10 flat washers, and one (1) M8 hex nut, and disconnect the ground cable from the power module GND terminal. Secure the cable so as not to hinder power module removal.
M8 Hex Nut Ground Cable M10 Flat Washer 2x
13 mm 11 N-m (100 lb.-in.)
9. Disconnect the Complete Drive main harness from both the power module and lower support bar (see Removing the Frame 3A and 3B Complete Drive Main Harness on page 3-55). Secure the main harness so as not to hinder power module removal.
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10.If installed, disconnect the door mount HIM cable or other external DPI cable from DPI Port 2 on the bottom-front bracket on the Frame 3A power module. Refer to the Frame 3A DPI Connection Points figure in the PowerFlex 700L User Manual. Carefully cut cable ties connecting the door mount HIM cable or other external DPI cable to the lower support bar. Secure the cable so as not to hinder power module removal. 11.To remove the upper support bar, upper support bracket, cable support rail, and angle bracket: A. Remove and save one (1) M6 x 16 mm (0.63 in.) long screw near the top-right, front-side of the power module that secures the power module to the upper support bracket. B. Remove and save two (2) M6 hex nuts connecting the upper support bracket to the upper support bar. Remove and save the upper support bracket. C. Remove and save two (2) M6 x 16 mm (0.63 in.) long screws securing the cable support rail and angle bracket to the cabinet. Remove and save the cable support rail with angle bracket attached. D. Remove and save four (4) BZ5.5 x 13 mm (0.51) long screws two (2) per each end of the upper support bar. Remove and save the upper support bar.
Upper Support Bar Mounting Location Cable Support Rail Mounting Location
T20 5.1 N-m (45 lb.-in.) P2 2.8 N-m (25 lb.-in.)
Screw BZ5.5 x 13 mm Long 2x, 2 Places
See Detail A
DETAIL A Typical
DETAIL B See Detail B
Screw M5 x 16 mm Long Cable Support Rail
10 mm 5.1 N-m (45 lb.-in.)
M6 Hex Nut 2x
POWER STS
Upper Support Bar Upper Support Bracket

P2 2.8 N-m (25 lb.-in.)
Screw M5 x 16 mm Long and Flat Washer
Angle Bracket
10 mm 5.1 N-m (45 lb.-in.)
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Access Procedures
12.To remove the lower support bar: A. Remove and save four (4) M6 x 16 mm (0.63 in.) long screws two (2) per each of two (2) power module chassis legs. B. Remove and save six (6) BZ5.5 x 13 mm (0.51 in.) long screws three (3) per each end of the lower support bar. Remove and save the lower support bar.
Cable Tie Anchors 13x (Do Not Remove)
Lower Support Bar
T30 5.1 N-m (45 lb.-in.)
Screw M6 x 16 mm Long 2x, 2 Places
Screw BZ5.5 x 13 mm Long 3x, 2 Places
T20 5.1 N-m (45 lb.-in.)
13.To hoist the power module: ATTENTION: Each power module weighs approximately 112 kg (247 lbs.). Size hoisting equipment accordingly. Refer to the Equipment Lifting section in Chapter 2 of the PowerFlex 700L User Manual. ATTENTION: Risk of equipment damage exists. Do not use input, output, ground, and DC bus bars for lifting or handling.
! !
A. Attach hoist to the power module lifting eyes. B. Loosen, but do not remove, two (2) M8 x 30 mm (1.18 in.) long screws at the top of the power module that secure it to the cabinet frame. C. Remove and save two (2) M8 x 30 mm (1.18 in.) long screws and two (2) M8 flat washers at the bottom of the power module that secure it to the cabinet frame. D. Lift the power module so that the power module chassis top keyhole slots pass over the loosened M8 hardware from the prior step, and remove the power module from cabinet. E. The power module may be place upright on its four (4) feet or laid on its right side in its shipping container. Installation Install the power module and power module bay components in reverse order of removal.
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Removing the Frame 3B Power Module from the Power Module Bay
Removal 1. Remove power from the drive (see Removing Power From the Drive on page 2-4). 2. Follow standard ESD procedures. 3. Remove the Frame 3B hose assemblies (see Removing Frame 3B Hose Assemblies on page 3-48). 4. Remove the Frame 3B barriers (see Removing the Frame 3B Power Module Bay Barriers on page 3-52). 5. To disconnect the motor lead cables from the U/T1, V/T2, and W/T3 power module terminals: A. Remove and save user-provided hardware. Typically, this hardware may be one (1) M12 screw, two (2) M12 flat washers, and one (1) M12 hex nut per each of two (2) holes in each of the three (3) terminals. B. Secure the cables so as not to hinder power module removal. 6. Remove and save three (3) motor lead bus bars (see Removing the Power Module Jumper Bus Bars on page 3-54.) 7. To disconnect the Phase R/L1 input power Flexibus conductor: Important: Steps 7 and 8 are required only if removing the Frame 3B converter power module. A. Loosen, but do not remove, two (2) M8 plastic set screws and two (2) M5 clamp mounting screws on the Flexibus support clamps. Slide the support clamps apart to permit conductor removal. B. Remove and save one (1) M12 x 40 mm (1.57 in.) long screw, two (2) M12 flat washers, and one (1) M12 hex nut per each of two (2) holes in each of the two (2) ends of the conductor. Remove and save the conductor.
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Access Procedures
M8 Set Screw 2X, 3 Places

4 mm 2.8 N-m (25 lb.-in.)
M5 Clamp Mounting Screw 2X, 3 Places
5 mm 0.8 N-m (7 lb.-in.)
R/L1
Screw M12 x 40 mm Long M12 Flat Washer 2x M12 Hex Nut with Conical Washer 2X, 3 Places
13 mm 62 N-m (550 lb.-in.)
S/L2
Flexibus Support Clamp 2X, 3 Places
T/L3
Screw M12 x 40 mm Long M12 Flat Washer 2x M12 Hex Nut with Conical Washer 2X, 3 Places
13 mm 62 N-m (550 lb.-in.)
8. Repeat step 7 for both the Phase S/L2 and Phase T/L3 input power Flexibus conductors. 9. Remove and save four (4) M12 x 40 mm (1.57 in.) long screws, eight (8) M12 flat washers, and four (4) M12 hex nuts per each of two (2) ends of the DC negative bus bar. Remove the DC negative bus bar. Refer to Figure 3.9.
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Figure 3.9 Removing the DC Bus Bars and Ground Cable

Screw M8 x 30 mm Long M10 Flat Washer 2x M8 Hex Nut with Conical Washer 3x 13 mm 11 N-m (100 lb.-in.) Screw M12 x 40 mm Long M12 Flat Washer 2x M12 Hex Nut with Conical Washer 4x, 4 Places 19 mm 61 N-m (540 lb.-in.) DC Positive Bus Bar Terminal 2x DC Negative Bus Bar Terminal 2x
Power Module to Power Module Ground Cable Input Filter to Power Module Ground Cable Cable Ties 2x, 2 Places
Upper Support Bar Screw BZ5.5 x 13 mm Long 2x, 2 Places T20 5.1 N-m (45 lb.-in.)
Hex Nut M6 with Conical Washer 2x, 2 Places 10 mm 5.1 N-m (45 lb.-in.)
Upper Support Bracket 2x Screw M6 x 16 mm Long 2x 10 mm 5.1 N-m (45 lb.-in.)
10.Repeat step 9 for the DC positive bus bar. Refer to Figure 3.9. 11.To disconnect the ground cable from the input filter and the converter power module: Important: Step 11 is required only if removing the Frame 3B converter power module. A. Remove and save one (1) M8 x 30 mm (1.18 in.) long screw, two (2) M10 flat washers, and one (1) M8 hex nut, and disconnect the ground cable from the GND terminal on the converter power module. Refer to Figure 3.9. B. Secure the cable so as not to hinder converter power module removal.
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Access Procedures
12.Remove and save one (1) M8 x 30 mm (1.18 in.) long screw, two (2) M10 flat washers, and one (1) M8 hex nut on each of two (2) ends of the power module ground cable. Refer to Figure 3.9. Secure the cable so as not to hinder either converter or inverter power module removal. 13.Disconnect the Complete Drive main harness from the converter power module and lower support bar (see Removing the Frame 3A and 3B Complete Drive Main Harness on page 3-55). Secure the main harness so as not to hinder either converter or inverter power module removal. 14.If installed, disconnect the door mount HIM cable or other external DPI cable from DPI Port 2 on the bottom-front bracket on the Frame 3B inverter power module. Refer to the Frame 3B DPI Connection Points figure in the PowerFlex 700L User Manual. Carefully cut cable ties connecting the door mount HIM cable or other external DPI cable to the lower support bar. Secure the cable so as not to hinder power module removal. 15.If installed, remove and save the Frame 3B synchronization cable: A. Carefully cut cable ties connecting the cable to the converter power module, lower support bar, and inverter power module. B. Disconnect the cable from the control cassettes while referring to the Synchronization Connections for Frame 3B section in Chapter 2 of the PowerFlex 700L User Manual. 16.If installed, remove and save the Frame 3B inverter-to-converter DPI cable: A. Carefully cut cable ties connecting the cable to the converter power module, lower support bar, and inverter power module. B. Disconnect the cable from DPI Port 2 on both the converter and inverter power modules. Refer to Frame 3B DPI Connection Points figure in the PowerFlex 700L User Manual. 17.To remove the upper support bar and upper support bracket: A. Refer to Figure 3.9. B. Remove and save one (1) M6 x 16 mm (0.63 in.) long screw near the top-right, front-side of each of two (2) power modules that secure the power modules to the upper support bar. C. Remove and save two (2) M6 hex nuts connecting each of two (2) upper support brackets to the upper support bar. Remove and save two (2) upper support brackets. D. Remove and save four (4) BZ5.5 x 13 mm (0.51) long screws two (2) per each of the upper support bar. Remove and save the upper support bar.
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18.To remove the lower support bar: A. Remove and save eight (8) M6 x 16 mm (0.63 in.) long taptite screws four (4) per each of two (2) power module chassis. B. Remove and save six (6) BZ5.5 x 13 mm (0.51 in.) long screws three (3) per each end of the lower support bar. Remove and save lower support bar.
Screw M6 x 16 mm Long Taptite 2x, 4 Places
T30 5.1 N-m (45 lb.-in.)
Screw BZ5.5 x 13 mm Long 3x, 2 Places T20 5.1 N-m (45 lb.-in.)
Cable Tie Anchors (for use with main harness) 13x Lower Support Bar
19.To hoist the power module: ATTENTION: Each power module weighs approximately 132 kg (290 lbs.). Size hoisting equipment accordingly. Refer to the Equipment Lifting section in Chapter 2 of the PowerFlex 700L User Manual. ATTENTION: Risk of equipment damage exists. Do not use input, output, ground, and DC bus bars for lifting or handling.
! !
A. Attach hoist to the power module lifting eyes. B. Loosen, but do not remove, two (2) M8 x 30 mm (1.18 in.) long screws at the top of the power module that secure it to the cabinet frame.
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C. Remove and save two (2) M8 x 30 mm (1.18 in.) long screws and two (2) M8 flat washers at the bottom of the power module that secure it to the cabinet frame. D. Lift the power module so that the power module chassis top keyhole slots pass over the loosened M8 hardware from the prior step, and remove the power module from cabinet. E. The power module may be placed upright on its four (4) bottom legs or laid on its right side in its shipping container. Installation Install the power module and power module bay components in reverse order of removal.
Frame 3A Power Module Spares
Working with the Frame 3A Spare Power Module - Overview

The Frame 3A spare power module is not a complete version of the original factory-built power module. Certain parts, such as control cassettes, covers, etc., have not been provided in order to supply a generic spare power module that may be field-assembled into either a converter/inverter or dual inverter power module. Original power module parts must be removed, saved, and re-installed on the spare power module. See Removing Parts from the Original Converter/Inverter Power Module on page 3-67 for each equipment type as described later. Important: The UL Recognized mark on the spare power module data nameplate label is applicable up to 600V AC. Contents of the Frame 3A spare power module kit are: Frame 3A spare power module Motor voltage feedback PCB kit: Note: Install only if the original catalog number digit 17 = K or L. Motor voltage feedback PCB Insulation sheet Plastic stand-off (quantity 3) Jumper (spare for addressable power PCB J3-9, 10; not used with motor voltage feedback PCB)
Assembling the Frame 3A Spare Power Module as a Converter/Inverter (Catalog Number Digit 13 = E)
Important: This procedure applies to spare power module catalog numbers 20LD650N0ENNXNW0WA and 20LF380N0ENNXNW0WA
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for use as a replacement to a converter/inverter power module with catalog number digit 13 = E. Removing Parts from the Original Converter/Inverter Power Module Important: This section requires removal of parts from the original power module that the spare is replacing. Prior to using this section, remove the original power module from the cabinet (Removing the Frame 3A Power Module from the Power Module Bay on page 3-57). Remove and save the following original converter/inverter power module parts: Power module front covers - top and bottom. Power module top left-side cover, and five (5) mounting screws (700 vector and 700S control); plus one (1) standoff (700S control only.) 700 vector control cassette option (with 700 vector control encoder option), and 700 vector control synchronization cable - if installed. 700S control cassette option (with 700S control feedback options), and 700S control synchronization cable - if installed. Power module middle left-side cover, and five (5) mounting screws. Active converter control cassette option (with voltage feedback resistor PCB). Important: Refer to the table of contents for procedures for removing and installing these parts. Installing Parts on the Spare Frame 3A Converter/Inverter Power Module 1. Install the original bottom cassette parts: A. See Removing the Active Converter Control Cassette on page 3-21 for: Original active converter control cassette Loose end of 40-pin MCB cable B. Power module middle left-side cover. For reference, see Removing the Power Module Left Side Covers on page 3-13. 2. Install the original top cassette parts: A. See Removing the 700 Vector Control Cassette on page 3-22 or Removing the 700S Control Cassette on page 3-23 for: Inverter end of synchronization cable Original inverter control cassette Loose end of 40-pin MCB cable
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30-pin communication interface cable (inverter control PCB to communications interface PCB) Converter end of synchronization cable Internal DPI cable to HIM bezel connector B. Power module top left-side cover. For reference, see Removing the Power Module Left Side Covers on page 3-13. 3. Mark the field installed options label on the front of the power module, if necessary.
Figure 3.10 Frame 3A Terminal Labels and Data Nameplates
Terminal Block Label
DC+ TESTPOINT =>
GND
DC- TESTPOINT =>
U/T1 V/T2
1 120 VAC LINE 2 PRECHARGE COIL 3 120 VAC NEUTRAL 4 24 VDC
Data Nameplate
Cat No.
W/T3
5 PRECHARGE FEEDBACK
20LD650N0ENNXNW0WA
L1
Series: A
R
6 GATE ENABLE 7 INDUCTOR OVERTEMP
UL Open Type/IP00 Spare Power Module Used as a replacement for catalog numbers starting with 20LC650 and 20LD650 only.
L2
US
Nominal Voltage Normal Duty Power Input: 3 Phase, 47-63 Hz AC Voltage Range Amps Output: 3 Phase, 0-400Hz AC Voltage Range Base Hz (default) Continuous Amps Rated Coolant Nom. Coolant Pressure MFD. in 2005 on MAR 05
480V 600HP 432-528 650 0-480 60 Hz 650
C
L3
DANGER
TUV
EN 50178
TB5 GND
WIRE RANGE: 24-10 AWG (0.2-4 MM2) STRIP LENGTH: .31 IN (8 MM) TORQUE: 8 IN-LB (0.9 N-M)
Functional Safety
TUV
TUV Rheinland Group
Frame: 3A
Type Approved

P/N 181255-A01
Field-Installed Options Label Frame 3A Converter/Inverter Power Module Terminal Block Label
DC+ TESTPOINT =>
GND U/T1 V/T2 W/T3

DC- TESTPOINT =>
1 120 VAC LINE 2 PRECHARGE COIL 3 120 VAC NEUTRAL 4 24 VDC
Data Nameplate
U/T1
Cat No.
20LD650N0ENNXNW0WA
5 PRECHARGE FEEDBACK 6 GATE ENABLE
UL Open Type/IP00 Spare Power Module Used as a replacement for catalog numbers starting with 20LC650 and 20LD650 only.
Series: A
R
V/T2
7 INDUCTOR OVERTEMP
Nominal Voltage Normal Duty Power Input: 3 Phase, 47-63 Hz AC Voltage Range Amps Output: 3 Phase, 0-400Hz AC Voltage Range Base Hz (default) Continuous Amps Rated Coolant Nom. Coolant Pressure MFD. in 2005 on MAR 05
480V 600HP 432-528 650 0-480 60 Hz 650
C
US
W/T3
DANGER
TUV
EN 50178
Functional Safety
TB5 GND
WIRE RANGE: 24-10 AWG (0.2-4 MM2) STRIP LENGTH: .31 IN (8 MM) TORQUE: 8 IN-LB (0.9 N-M)
TUV
TUV Rheinland Group
Frame: 3A
Type Approved

P/N 181255-A01
Field-Installed Options Label Frame 3A Dual Inverter Power Module
PZ2 2.8 N-m (25 lb.-in.)
Screw M5 x 12 mm Long Bracket
All labels shown for Frame 3A spare power modules are factory-installed.
Access Procedures
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Installing the Spare Frame 3A Converter/Inverter Power Module in the Power Module Bay of the Complete Drive 1. Install the spare power module and re-install the original power module bay parts (power module support parts, conductors, harness, cables, etc.) in reverse order of removal. For reference, see Removing the Frame 3A Power Module from the Power Module Bay on page 3-57. 2. Install the original power module front covers. For reference, see Removing the Power Module Front Covers on page 3-9.
Assembling the Frame 3A Spare Power Module as a Dual Inverter (Catalog Number Digit 13 = L)
Important: This procedure applies to spare power module catalog numbers 20LD650N0ENNXNW0WA and 20LF380N0ENNXNW0WA for use as a replacement to a dual inverter power module with catalog number digit 13 = L. The procedure for replacing the original dual inverter is similar to the spare converter/inverter power module procedure. However, the procedure differs based on several part differences: The dual inverter has DC+ and DC- bus bar terminals at the top of the power module. The converter/inverter does not. The dual inverter has no synchronization cable. The converter/inverter does. The dual inverter has a bottom inverter control cassette. The converter/ inverter has a bottom converter control cassette. The dual inverter has a bottom HIM bezel and communications interface PCB allowing the installation of the HIM option and the communications adapter option. The converter/inverter does not. The dual inverter has two internal DPI cables one connected to the top HIM bezel and the other connected to the bottom HIM bezel. The converter/inverter has one internal DPI cable connected to the top HIM bezel. To replace an original dual inverter with a spare power module, the following kits are required: Frame 3A spare power module, which includes quantity one (1) of the motor voltage feedback PCB kit. DC bus bar conversion kit SK-L1-DCBS1-F3, quantity one (1). For 400/480V applications: Inverter rating plug kit SK-L1-RPICB1-D650, quantity two (2). Motor voltage feedback PCB kit SK-L1-MVF1-C, quantity one (1).
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Access Procedures
For 600/690V applications: Inverter rating plug kit SK-L1-RPICB1-F380, qty. two (2). Motor voltage feedback PCB kit SK-L1-MVF1-E, qty. one (1). Note: Both motor voltage feedback kits are installed only if the original catalog number digit 17 = K or L. Removing Parts from the Original Dual Inverter Power Module Important: This section requires removal of parts from the original dual inverter power module for which the spare is replacing. Prior to using this section, remove the original power module from its cabinet (see Removing the Frame 3A Power Module from the Power Module Bay on page 3-57). Remove and save the following original converter/inverter power module parts: Power module front covers - top and bottom. Power module top left-side cover, and five (5) mounting screws (700 vector and 700S control); plus one (1) standoff (700S control only.) Top inverter control cassette option (700 vector or 700S.) Power module middle left-side cover, and five (5) mounting screws (700 vector and 700S control); plus one (1) standoff (700S control only.) Bottom inverter control cassette option (700 vector or 700S.) Top and bottom communications adapter option. For reference, see Removing the Communications Adapter Option on page 3-10. Top and bottom HIM option. For reference, see Removing the HIM Option on page 3-10. Original two (2) internal DPI cable assemblies. Carefully cut six (6) cable ties and disconnect the top inverter cable from the top HIM bezel connector. Carefully cut four (4) cable ties and disconnect the bottom inverter cable from the bottom HIM bezel connector. Remove and save two (2) M5 x 12 mm (0.47 in.) long screws from the mounting bracket at the bottom, front of the power module. Remove and save the cable with bracket. Do not disconnect the cable from the bracket. See Removing the Internal DPI Cable from the Power Module on page 3-11 and Figure 3.10. Remove and discard the following spare converter/inverter power module parts: Spare internal DPI cable assembly. Carefully cut six (6) cable ties and disconnect the cable from the top HIM bezel connector. Remove and save two (2) M5 x 12 mm (0.47 in.) long screws from the mounting bracket at the bottom, front of the power module. Remove and set aside the cable with bracket. Do not disconnect the cable from the bracket. See
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Removing the Internal DPI Cable from the Power Module on page 3-11 and Figure 3.10. Important: Refer to the table of contents for procedures for removing and installing these parts. Installing Parts on the Spare Frame 3A Dual Inverter Power Module 1. Remove and save the following parts from the spare power module (see Accessing the Control Panel of the Frame 3A Power Module on page 3-24) prior to installing the new rating plug PCB: Top cassette tray, cassette mounting bracket, cable tie anchor, and three screws. Left front cover bracket and two screws. Bottom cassette tray, cassette mounting bracket, cable tie anchor, and three screws. Top support and two screws. Bottom support and two screws. 2. Install rating plug PCB's to both top and bottom addressable power PCB's. 3. If original inverter power module catalog number digit 17 = K or L, then perform the following steps related to the motor voltage feedback PCB: A. Remove and set aside the jumper J3-9, -10 on the top inverter and bottom inverter addressable power PCB's.
Jumper J3-9, -10
B. Install one (1) voltage feedback board kit to each of two (2) addressable power PCB's. Each kit contains three (3) plastic stand-offs, one (1) insulation sheet, and one (1) motor voltage feedback PCB. See Removing the Motor Voltage Feedback PCB (700S Control Only) on page 3-37. 4. Install parts removed from the spare power module in step 1. Use caution to prevent damage to loose end of the 40-pin MCB cable. 5. Install the original top inverter cassette parts: A. See Removing the 700 Vector Control Cassette on page 3-22 or Removing the 700S Control Cassette on page 3-23 for:
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Access Procedures
Original top inverter control cassette Loose end of 40-pin MCB cable 30-pin communication interface cable (inverter control PCB to communications interface PCB) B. Original power module left side cover - top only, and five (5) mounting screws (700 vector and 700S control); plus one (1) standoff (700S control only). For reference, see Removing the Power Module Left Side Covers on page 3-13. 6. Install the original bottom inverter cassette parts: A. See Removing the 700 Vector Control Cassette on page 3-22 or Removing the 700S Control Cassette on page 3-23 for: Original bottom inverter control cassette Loose end of 40-pin MCB cable 30-pin communication interface cable (inverter control PCB to communications interface PCB) B. Original power module left side cover - middle only, and five (5) mounting screws (700 vector and 700S control); plus one (1) standoff (700S control only). For reference, see Removing the Power Module Left Side Covers on page 3-13. 7. Install the original two (2) internal DPI cable assemblies. Install mounting bracket using two (2) M5 x 12 mm (0.47 in.) long screws and tighten to 2.8 N-m (25 in.-lb.). Connect top inverter cable to the top HIM bezel connector and secure the cable to the power module using six (6) cable ties. Connect bottom inverter cable to the bottom HIM bezel connector, loop the cable twice, and secure the cable to the power module using five (5) cable ties. See Figure 3.10. 8. Install the original top and bottom HIM options, if necessary. 9. Install the original top and bottom communications adapter options, if necessary. 10.Mark the field installed options label on the front of the power module, if necessary. See Figure 3.10. Installing the Spare Frame 3A Inverter Power Module in the Power Module Bay of the Complete Drive 1. Install the spare power module and re-install the original power module bay parts (power module support parts, conductors, harness, cables, etc.) in reverse order of removal. For reference, see Removing the Frame 3A Power Module from the Power Module Bay on page 3-57. 2. Install the original power module front covers. For reference, see Removing the Power Module Front Covers on page 3-9.
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Returning the Original Frame 3A Power Module

Package the original power module on the skid provided with the spare power module. Return in accordance with established return procedures.
Frame 3B Power Module Spares
Working with the Frame 3B Spare Power Module - Overview

The Frame 3B spare power module is not a complete version of the original factory-built converter and inverter power modules. Certain parts, such as control cassettes, cables, covers, etc., have not been provided in order to supply a generic spare power module that may be field- assembled into either a converter or an inverter power module. Original power module parts must be removed, saved, and re-installed on the spare power module. See Removing Parts from the Original Active Converter Power Module on page 3-74 for each equipment type as described later. Important: The UL Recognized mark on the spare power module data nameplate label is applicable up to 600V AC. Contents of the Frame 3B spare power module kit are: Frame 3B spare power module Motor voltage feedback PCB kit: Note: Install only if original catalog number digit 17 = K or L. Motor voltage feedback PCB Insulation sheet Plastic stand-off (quantity 3) Jumper (spare for addressable power PCB J3-9, -10; not used with motor voltage feedback PCB) Converter field installed parts: Note: Install only if original catalog number digit 13 = G or P. Auxiliary converter data nameplate label Converter input/output label Converter terminal block label Converter rating plug PCB Converter internal DPI cable assembly (with mounting bracket) Inverter field installed parts: Note: Install only if original catalog number digit 13 = J or K. Auxiliary inverter data nameplate label
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Access Procedures
Inverter input/output label Inverter terminal block label Inverter rating plug PCB Inverter internal DPI cable assembly (with mounting bracket) 40-pin MCB cable 30-pin communications interface cable
Assembling the Frame 3B Spare Power Module as an Active Converter (Catalog Number Digit 13 = G)
Important: This procedure applies to spare power module catalog numbers 20LD1K2N0ENNXNW0WA and 20LF705N0ENNXNW0WA for use as a replacement to an active converter power module with catalog number digit 13 = G. Removing Parts from the Original Active Converter Power Module Important: This section requires removal of parts from the original power module that the spare is replacing. Prior to using this section, remove the original power module from the cabinet (see Removing the Frame 3B Power Module from the Power Module Bay on page 3-61). Remove and save the following original converter power module parts: Power module front covers - top and bottom. Power module left side cover - top only, and five (5) mounting screws. Active converter control cassette option (with voltage feedback resistor PCB). Important: Refer to the table of contents for procedures for removing and installing these parts. Installing Parts on the Spare Frame 3B Active Converter Power Module Important: To build the spare power module as a converter, use the box labeled Converter Field Installed Parts. Set aside both the box labeled Inverter Field Installed Parts and the motor voltage feedback PCB kit. 1. Remove and save the following parts from the original power module (see Accessing the Control Panel of the Frame 3B Power Module on page 3-26) prior to installing the new rating plug PCB: A. Top cassette tray, cassette mounting bracket, cable tie anchor, and three screws. B. Left front cover bracket and two screws.
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C. Top support and two screws. 2. Install the new converter rating plug PCB to the converter addressable power PCB connector J-11. Install one (1) M3 x 8 mm (0.31 in.) long screw and tighten to 0.6 N-m (5 in.-lb.). For reference, see Removing the Rating Plug PCB on page 3-38, Figure 3.5, and Figure 3.11.
Figure 3.11 Removing the Rating Plug PCB
Addressable Power PCB 40-Pin MCB Cable
Screw M3 x 8 mm Long PZ1 0.6 N-m (5 lb.-in.)
Rating Plug PCB
3. Install one end only of the new 40-pin MCB cable to the converter addressable power PCB connector J8. Leave the other end loose. See Figure 3.11. 4. Install parts removed from the original power module in step 1. Use caution to prevent damage to the loose end of the 40-pin MCB cable. 5. Install the original top cassette parts: A. See Removing the Active Converter Control Cassette on page 3-21 for: Original active converter control cassette Loose end of 40-pin MCB cable B. Power module left side cover - top only. For reference, see Removing the Power Module Left Side Covers on page 3-13. 6. Install the new converter internal DPI cable assembly with bracket (see Figure 3.12): A. Install the assembly bracket to the bottom, front of the power module. Install two (2) M5 x 12 mm (0.47 in.) long screws and tighten to 2.8 N-m (25 in.-lb.).
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Access Procedures
B. Route the cable to the active converter PCB connector J4. C. Secure the cable to the front of the power module with seven (7) cable ties.
Figure 3.12 Frame 3B Terminal Labels and Data Nameplates
Factory-Installed Data Nameplate
Cat No.
Terminal Block Label

DC+ TESTPOINT =>
20LD1K2N0ENNXNW0WA
UL Open Type/IP00 Spare Power Module Used as a replacement for catalog numbers starting with 20LC1K2 and 20LD1K2 only.
Series: A
R
GND
DC- TESTPOINT =>
Nominal Voltage Normal Duty Power Rated Coolant Nom. Coolant Pressure
400V 480V 960HP 1150HP Treated Water 185 psig
C
US
1 120 VAC LINE
L1
TUV
2 PRECHARGE COIL 3 120 VAC NEUTRAL
EN 50178
Functional Safety
TUV
TUV Rheinland Group
Frame: 3B
Type Approved
4 24 VDC

L2
5 PRECHARGE FEEDBACK 6 GATE ENABLE 7 INDUCTOR OVERTEMP
P/N 181255-A01
Auxiliary Data Nameplate

Cat. No.
Converter Power Module
L3
DANGER
20LD1K2NOENNXNWOWA
400V 360-440 1250 510-625 1250 480V 432-528 1250
Input: 3 Phase, 47-63 Hz AC Voltage Range Amps Output: DC DC Voltage Range Continuous Amps
P/N 181744-A01
TB5
WIRE RANGE: 24-10 AWG (0.2-4 MM 2) STRIP LENGTH: .31 IN (8 MM) TORQUE: 8 IN-LB (0.9 N-M)
GND
610-750 1250
Field-Installed Options Label Frame 3B Active Converter and Active Converter - Stand Alone Version Power Module Terminal Block Label
DC+ TESTPOINT =>
Factory-Installed Data Nameplate

Cat No.
20LD1K2N0ENNXNW0WA
UL Open Type/IP00 Spare Power Module Used as a replacement for catalog numbers starting with 20LC1K2 and 20LD1K2 only.
Series: A
R
GND
DC- TESTPOINT =>
Nominal Voltage Normal Duty Power Rated Coolant Nom. Coolant Pressure
400V 480V 960HP 1150HP Treated Water 185 psig
C
US
1Production inspected
U/T1
23-
TUV
EN 50178
Functional Safety
TUV
TUV Rheinland Group
4 24 VDC
Type Approved
Frame: 3B

U/T1
56 GATE ENABLE 7-
P/N 181255-A01
Auxiliary Data Nameplate

Cat. No.
U/T1
DANGER
20LD1K2NOENNXNWOWA
Input: DC DC Voltage Range Amps Output: DC AC Voltage Range Base Hz (default) Continuous Amps
P/N 181744-A01
TB6
510-625 1250 0-400 60 Hz 1250 610-750 1250 0-480 60 Hz 1250
WIRE RANGE: 24-10 AWG (0.2-4 MM 2) STRIP LENGTH: .31 IN (8 MM) TORQUE: 8 IN-LB (0.9 N-M)
GND
Field-Installed Options Label Frame 3B Inverter Power Module
PZ2 2.8 N-m (25 lb.-in.)
Screw M5 x 12 mm Long Bracket
All labels shown for Frame 3B spare power modules are field-installed. Exception: Factory-installed data nameplate.
7. Install two (2) new auxiliary converter data nameplate labels one on the front and two on the left side of the power module. For locations, see Figure 3.12. 8. Install the new TB5 label, five (5) new terminal labels, and the new converter terminal block label on the front of the power module. For locations, see Figure 3.12.
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9. Mark the field-installed options label on the front of the power module, if necessary. Installing the Spare Frame 3B Active Converter Power Module in the Power Module Bay of the Complete Drive 1. Install the spare power module and re-install the original power module bay parts (power module support parts, conductors, harness, cables, etc.) in reverse order of removal. For reference, see Removing the Frame 3B Power Module from the Power Module Bay on page 3-61. 2. Install the original power module front covers. For reference, see Removing the Power Module Front Covers on page 3-9.
Assembling the Frame 3B Spare Power Module as an Active Converter Stand Alone Version (Catalog Number Digit 13 = P)
Important: This procedure applies to spare power module catalog numbers 20LD1K2N0ENNXNW0WA and 20LF705N0ENNXNW0WA for use as a replacement to an active converter power module stand alone version - with catalog number digit 13 = P. Removing Parts from the Original Active Converter Power Module - Stand Alone Version Important: This section requires removal of parts from the original converter power module for which the spare is replacing. Prior to using this section, remove the original power module from the cabinet (see Removing the Frame 3B Power Module from the Power Module Bay on page 3-61). Remove and save the same parts as described previously for the active converter power module, with the addition of the following parts installed only on the stand alone version: Communications adapter option. For reference, see Removing the Communications Adapter Option on page 3-10. HIM option. For reference, see Removing the HIM Option on page 3-10. Converter original internal DPI cable assembly. Carefully cut seven (7) cable ties. Disconnect the cable from the HIM bezel connector. Remove and save two (2) M5 x 12 mm (0.47 in.) long screws from the mounting bracket at the bottom, front of the power module. Remove and save the cable with bracket. Do not disconnect the cable from the bracket. See Removing the Internal DPI Cable from the Power Module on page 3-11 and Figure 3.12.
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Installing Parts on the Spare Frame 3B Active Converter Power Module - Stand Alone Version Important: To build the spare power module as a converter, use the box labeled Converter Field Installed Parts. Set aside both the box labeled Inverter Field Installed Parts and the motor voltage feedback PCB kit. 1. Follow the same procedures previously described or the spare active converter power module. 2. Install the original converter internal DPI cable assembly. Install the mounting bracket using two (2) M5 x 12 mm (0.47 in.) long screws and tighten to 2.8 N-m (25 in.-lb.). Connect the cable to the HIM bezel connector. Secure the cable to the power module using seven (7) cable ties. See Figure 3.12. Important: Do not install the internal DPI cable assembly provided with the Converter Field Installed Parts. 3. Install the original HIM option, if necessary. 4. Install the original communications adapter option, if necessary. Installing the Spare Frame 3B Active Converter Power Module - Stand Alone Version - in the Power Module Bay of the Complete Drive Follow the same procedures previously described for the spare active converter power module.
Assembling the Frame 3B Spare Power Module as an Inverter (Catalog Number Digit 13 = J or K)
Important: This procedure applies to spare power module catalog numbers 20LD1K2N0ENNXNW0WA and 20LF705N0ENNXNW0WA for use as a replacement to inverter power modules with catalog number digit 13 = J or K. Removing Parts from the Original Inverter Power Module Important: This section requires removal of parts from the original power module that the spare is replacing. Prior to using this section, remove the original power module from the cabinet (see Removing the Frame 3B Power Module from the Power Module Bay on page 3-61). Remove and save the following original inverter power module parts: Power module front covers - top and bottom. Communications adapter option. HIM option.
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Power module left side cover - top only, and five (5) mounting screws (700 vector and 700S control); plus one (1) standoff (700S control only). 700 vector control cassette option (with 700 vector control encoder option.) 700 vector control coupling cables (synchronization and DPI), if installed. 700S control cassette option (with 700S control feedback options). 700S control coupling cables (synchronization and DPI), if installed. Important: Refer to the table of contents for procedures for removing and installing these parts. Installing Parts on the Spare Frame 3B Inverter Power Module Important: To build the spare power module as an inverter, use the box labeled Inverter Field Installed Parts and the motor voltage feedback PCB kit. Set aside the box labeled Converter Field Installed Parts. 1. Remove and save the following parts from the original power module (see Accessing the Control Panel of the Frame 3B Power Module on page 3-26) prior to installing the new rating plug PCB: A. Top cassette tray, cassette mounting bracket, cable tie anchor, and three screws. B. Left front cover bracket and two screws. C. Top support and two screws. 2. Install the new inverter rating plug PCB to the inverter addressable power PCB connector J-11. Install one (1) M3 x 8 mm (0.31 in.) long screw and tighten to 0.6 N-m (5 in.-lb.). For reference, see Removing the Rating Plug PCB on page 3-38, Figure 3.5, and Figure 3.13.
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Access Procedures
Figure 3.13 Removing the Rating Plug PCB

Addressable Power PCB J2
J3
40-Pin MCB Cable
Plastic Stand-Off 3x
Motor Voltage Feedback PCB

PZ1 0.6 N-m (5 lb.-in.)
Insulation Sheet Screw M3 x 8 mm Long
Rating Plug PCB
3. Install one end only of the new 40-pin MCB cable to the inverter addressable power PCB connector J8. Leave the other end loose. See Figure 3.13. 4. If original inverter power module catalog number digit 17 = K or L, then perform the following steps related to the motor voltage feedback PCB: A. Remove and set aside the jumper J3-9, -10 on the inverter addressable power PCB.
Jumper J3-9, -10
B. Install the voltage feedback board kit. Each kit contains three (3) plastic stand-offs, one (1) insulation sheet, and one (1) motor voltage feedback PCB. See Removing the Motor Voltage Feedback PCB (700S Control Only) on page 3-37. 5. Install parts removed from the original power module in step 1. Use caution to prevent damage to the loose end of the 40-pin MCB cable.
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6. Install the original top cassette parts: A. See Removing the 700 Vector Control Cassette on page 3-22 or Removing the 700S Control Cassette on page 3-23 for: Inverter end of synchronization cable, if required. Original inverter control cassette. Loose end of 40-pin MCB cable. 30-pin communication interface cable (inverter control PCB to communications interface PCB). B. Original inverter control cassette and inverter-end of synchronization cable (if power module left side cover - top only, and five (5) mounting screws (700 vector and 700S control); plus one (1) standoff (700S control only). For reference, see Removing the Power Module Left Side Covers on page 3-13. 7. Install the new inverter internal DPI cable assembly with bracket (see Figure 3.12): A. Install the assembly bracket to the bottom, front of power module. Install two (2) M5 x 12 mm (0.47 in.) long screws and tighten to 2.8 N-m (25 in.-lb.). B. Route the cable to the HIM bezel connector. C. Secure the cable to the front of power module with six (6) cable ties. 8. Install the original HIM option, if necessary. For reference, see Removing the HIM Option on page 3-10. 9. Install the original communications adapter option, if necessary. For reference, see Removing the Communications Adapter Option on page 3-10. 10.Install two (2) new auxiliary inverter data nameplate labels one on the front and two on the left side of the power module. For locations, see Figure 3.12. 11.Install the new TB6 label, five (5) new terminal labels, and the new inverter terminal block label on the front of the power module. For locations, see Figure 3.12. 12.Mark the field installed options label on the front of the power module, if necessary.
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Installing the Spare Frame 3B Inverter Power Module in the Power Module Bay of the Complete Drive 1. Install the spare power module and re-install the original power module bay parts (power module support parts, conductors, harness, cables, etc.) in reverse order of removal. For reference, see Removing the Frame 3B Power Module from the Power Module Bay on page 3-61. 2. Install the original power module front covers. For reference, see Removing the Power Module Front Covers on page 3-9.
Returning the Original Frame 3B Power Module

Package the original power module on the skid provided with the spare power module. Return in accordance with established return procedures.
Chapter
ATTENTION: Power must be applied to the drive to perform the following start-up procedure. Some of the voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, only qualified service personnel should perform the following procedure. Thoroughly read and understand the procedure before beginning. If an event does not occur while performing this procedure, Do Not Proceed. Remove Power including user supplied control voltages. User supplied voltages may exist even when main AC power is not applied to then drive. Correct the malfunction before continuing.
Phone
United States/ Canada Outside United States/Canada
1.262.512.8176 (7 AM - 6 PM CST) 1.440.646.5800 (24 hour support) You can access the phone number for your country via the Internet: Go to http://www.ab.com Click on Support (http://support.rockwellautomation.com/) Under Contact Customer Support, click on Phone Support Go to http://www.ab.com/support/abdrives/ support@drives.ra.rockwell.com
Internet E-mail
Be prepared to provide the following information when you contact support: Product Catalog Number Product Serial Number Firmware Revision Level
The Power Circuit Diagnostic Test, for the PowerFlex 700L with 700S Performing the Power Circuit Diagnostic Test (only Phase II Control, allows you to diagnose problems in the drives power structure without applying large amounts of power. 700S Phase II Control) 1. Verify that input power wiring and grounding is connected. 2. Verify that the motor cables are connected. 3. Energize the drive.
4-2
4. From the Monitor menu on the HIM press navigate to the Main menu.
Esc
(the escape button) to
5. Use (the down button) to move the cursor to the Start-Up selection, and to select Start-Up. Then press again to verify your intention to continue with the Start-Up menu. 6. Use (the down button) to move the cursor to Power Circuit Diagnostics (Pwr Circuit Diag), and to select Power Circuit Diagnostics. 7. Press to begin the Power Circuit Diagnostic routine. Follow indications and instructions on the HIM.
Testing With the Motor
This test allows you to measure several operating parameters and diagnose problems without connecting the motor to its mechanical load. 1. Verify that input power wiring and grounding is connected. 2. Verify that the motor cables are connected. 3. Verify that the motor load is disconnected. 4. Energize the drive. 5. Start the drive and increase the speed from zero to base speed. 6. Measure drive output current on all three phases, and verify that the value is reflected in: parameter 003 [Output Current] (700 Vector Control) parameter 308 [Output Current] (700S Phase II Control) 7. Stop the drive.
Appendix
Software Tools
DriveTools SP, DriveExecutive, DriveExplorer, and DriveObserver are software tools for uploading, downloading, and monitoring system parameters.
Service Tools
Service of the PowerFlex frequency converter requires certain kinds of tools, devices, and test equipment. Basic tools, devices, and test equipment have to meet requirements of professional services. The tools have to be in good condition and have to fit how and where they are going to be used. This list of basic service tools covers the needs of tools for repair and maintenance measurements.
Item 1 2 3 4 5 6 Description Oscilloscope Current clamp Soldering station Adjustable power supply Adjustable power supply Multi-meter Details Portable, digitizing, dual channel scope, with isolation 1000A (ac, rms), signal output Soldering / de-soldering 01300Vdc, 1A, adjustable current limit. Efore LPS 750-HV or equivalent. 0690Vac (+10%), 10A, three phase, galvanic isolation Digital multi-meter, capable of ac and dc voltage, continuity, resistance, capacitance measurements, and forward diode bias tests. Fluke model 87 III or equivalent. 1000Vdc 112 Nm 650 Nm 0140 Nm 7 mm, 8 mm, 10 mm, 13 mm, 17 mm, 19 mm, 22 mm 7/16 in., 9/16 in., 3/4 in. (input filter only) 230 mm 7 mm, 8 mm, 10 mm, 13 mm, 17 mm, 19 mm, 22 mm 45 mm (1.75 in.) jaw capacity
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Insulation tester Torque wrench Torque wrench Torque wrench Box wrench Box wrench Socket extension Wrench Adjustable wrench Wire cutter Nose pliers Crimping tools Angle wrench Flat nose screw driver Pozidrive screw driver Phillips screw driver Torx screw driver Hexagonal wrench ESD-protected place of work ESD-protective clothing Power supply (service)
For cable terminals 1, 5240 27 mm 1, 2, 3 1, 2, 3 25, 30 4, 5, 6 Working surface, floor covering, seat, and earthings Wrist wrap, shoes, overall clothing (coat) Capacity of three phase service 400/500/690Vac, 250A
A-2
Notes:
Appendix
For Details on DC Bus to 400/480V Power Supply Board and DC Bus Resistors DC Bus to 600/690V Power Supply Board and DC Bus Resistors Power Supply Board to Power Module Terminal Block TB5 & TB6 Power Supply Board to Power Module Cooling Fans Power Supply Board to Addressable Power Supply Board Addressable Power Board to Rating Plug Board Addressable Power Board to Frame 3A Current Sensors Addressable Power Board to Frame 3B Current Sensors Addressable Power Board to Frame 3A Temperature Sensors Addressable Power Board to Frame 3B Temperature Sensors Addressable Power Board to Frame 3A Phase U IGBT Addressable Power Board to Frame 3A Phase V IGBT Addressable Power Board to Frame 3A Phase W IGBT Addressable Power Board to Frame 3B Phase U IGBT Addressable Power Board to Frame 3B Phase V IGBT Addressable Power Board to Frame 3B Phase W IGBT Addressable Power Board to Motor Voltage Feedback Board
See Page B-1 B-2 B-2 B-2 B-3 B-4 B-4 B-4 B-5 B-5 B-5 B-6 B-6 B-6 B-7 B-7 B-8
Power Supply Board Connections
The following tables detail the connection points for the PowerFlex 700L power supply board.
Table B.A DC Bus to 400/480V Power Supply Board and DC Bus Resistors
Laminated DC Bus Pin Connector Number -Neg Mid Pt +Pos Pin Number 1 1 3 1 5 2 Power Supply Board and DC Bus Resistor Connector Power Supply J2 Resistor R1 Power Supply J2 Resistor R2 Power Supply J2 Resistor R2
to ... ... ... ... ... ...
Description DCMidpoint DC+
B-2
Table B.B DC Bus to 600/690V Power Supply Board and DC Bus Resistors
Laminated DC Bus Pin Connector Number -Neg Mid 1 Mid 2 +Pos Pin Number 1 1 3 2 5 1 7 2 Power Supply Board and DC Bus Resistor Connector Power Supply J3 Resistor R1 Power Supply J3 Resistor R1 Power Supply J3 Resistor R3 Power Supply J3 Resistor R3
to ... ... ... ... ... ... ... ...
Description DCLower Midpoint Upper Midpoint DC+
Table B.C Power Supply Board to Power Module Terminal Block TB5 & TB6
Power Supply Board Connector J4 Pin Number 1 2 4 5 6 7 Pin to Number Terminal Block ... 1 TB5/TB6 ... 2 TB5/TB6 ... 3 TB5/TB6 ... 4 TB5/TB6 ... 5 TB5/TB6 ... 6 TB5/TB6 ... 7 TB5/TB6 Description 120 VAC Line Precharge Coil 120 VAC Neutral (1) +24 VDC Precharge Feedback Gate Enable Inductor Overtemp
(1)
No connection to power supply board. Pass-thru connection to input filter.
Table B.D Power Supply Board to Power Module Cooling Fans

Power Supply Board Connector J6 Pin Number 1 2 3 1 2 3 Pin to Number Fan Connector ... 1 Fan 1 ... 2 ... 3 ... 1 Fan 2 ... 2 ... 3 Description Fan1 Positive Fan 1 Tach Fan 1 Negative Fan 2 Positive Fan 2 Tach Fan 2 Negative
J7
B-3
Table B.E Power Supply Board to Addressable Power Supply Board

Power Supply Board Connector J1 Pin Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Pin Addressable Power to Number Board Connector ... 1 J9 ... 2 ... 3 ... 4 ... 5 ... 6 ... 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Description +24V (Isolated) +24V Com (Isolated) +24V (Isolated) +24V Com (Isolated) ADGND Precharge ADGND Precharge Feedback ADGND Asymmetrical Bus Fault ADGND External Gate Kill ADGND Power Supply Fault ADGND DC Bus Raw ADGND Fan Fail ADGND Inductor Overtemp +12V +12V +12V -12V +15V +15V +15V +15V +15V ADGND +24V +24V +24V -24V
B-4
Addressable Power Board Connections
The following tables detail the connection points for the PowerFlex 700L addressable power board.
Table B.F Addressable Power Board to Rating Plug Board
Addressable Power Pin Board Connector Number J11 1 2 3 4 5 6 7 8 9 10 Pin Rating Plug Board to Number Connector ... 2 J5 ... 1 ... 4 ... 3 ... 6 ... 5 ... 8 ... 7 ... 10 ... 9 Description ISNSGND +5V ISNSGND ADGND IW EE_SK IV EE_IO IU EE_CS
Table B.G Addressable Power Board to Frame 3A Current Sensors

Addressable Power Pin Board Connector Number J7 1 14 10 11 16 20 12 18 19
(1)
Pin Frame 3A Current to Number Sensor Connector ... 1 L1/U ... 2 ... 3 ... 1 L2/V ... 2 ... 3 ... 1 L3/W ... 2 ... 3
Description (1) +VLEM IU -VLEM +VLEM IV -VLEM +VLEM IW -VLEM
When the addressable power board is used as a converter: Phase U = Phase L1, Phase V = Phase L2, Phase W = Phase L3
Table B.H Addressable Power Board to Frame 3B Current Sensors

Addressable Power Pin Board Connector Number J7 10 14 1 20 16 11 19 18 12 3 5 7
(1)
Pin Frame 3B Current to Number Sensor Connector ... 1 L1/U ... 2 ... 3 ... 1 L2/V ... 2 ... 3 ... 1 L3/W ... 2 ... 3 ... 13 J7 ... 15 ... 17
Description (1) -VLEM IU +VLEM -VLEM IV +VLEM -VLEM IW +VLEM IU (Jumper) IV (Jumper) IW (Jumper)
When the addressable power board is used as a converter: Phase U = Phase L1, Phase V = Phase L2, Phase W = Phase L3
B-5
Table B.I Addressable Power Board to Frame 3A Temperature Sensors

Addressable Power Pin Board Connector Number J1 11 1 12 2 15 5 Pin Number 1 3 1 3 1 2 Frame 3A Temperature Sensor Connector Description #1 #3 J4 NTC1NTC1+ #2 #4 J4 NTC2NTC2+ NTC CHILLPLATECHILLPLATE+
to ... ... ... ... ... ...
Table B.J Addressable Power Board to Frame 3B Temperature Sensors

Addressable Power Pin Board Connector Number J1 11 1 12 2 13 3 14 4 15 5 Pin Number 1 3 1 3 1 3 1 3 1 2 Frame 3B Temperature Sensor Connector Description #1 J4 NTC1NTC1+ #2 J4 NTC2NTC2+ #3 J4 NTC3NTC3+ #4 J4 NTC4NTC4+ NTC CHILLPLATECHILLPLATE+
to ... ... ... ... ... ... ... ... ... ...
Table B.K Addressable Power Board to Frame 3A Phase U IGBT (1)

Addressable Power Pin Board Connector Number J4 13 17 5 19 23 11 16 4 22 10
(1)
Pin Frame 3A Phase U to Number IGBT Connector ... 1 #2 #4 J1 ... 4 ... 5 ... 6 ... 9 ... 10 ... 4 #1 #3 J1 ... 5 ... 9 ... 10
Description U+COLLECTOR U+GATE U+EMITTER U-COLLECTOR U-GATE U-EMITTER U+GATE U+EMITTER U-GATE U-EMITTER
When the addressable power board is used as a converter: Phase U = Phase L1
B-6
Table B.L Addressable Power Board to Frame 3A Phase V IGBT (1)

(1)
Pin Frame 3A Phase V to Number IGBT Connector ... 1 #2 #4 J2 ... 4 ... 5 ... 6 ... 9 ... 10 ... 4 #1 #3 J2 ... 5 ... 9 ... 10
Description V+COLLECTOR V+GATE V+EMITTER V-COLLECTOR V-GATE V-EMITTER V+GATE V+EMITTER V-GATE V-EMITTER
When the addressable power board is used as a converter: Phase V = Phase L2
Table B.M Addressable Power Board to Frame 3A Phase W IGBT (1)

(1)
Pin Frame 3A Phase W to Number IGBT Connector ... 1 #2 #4 J3 ... 4 ... 5 ... 6 ... 9 ... 10 ... 4 #1 #3 J3 ... 5 ... 9 ... 10
Description W+COLLECTOR W+GATE W+EMITTER W-COLLECTOR W-GATE W-EMITTER W+GATE W+EMITTER W-GATE W-EMITTER
When the addressable power board is used as a converter: Phase W = Phase L3
Table B.N Addressable Power Board to Frame 3B Phase U IGBT (1)

Addressable Power Pin Board Connector Number J4 13 18 6 19 24 12 17 5 23 11 16 4 22 10 15 3 21 9
(1)
Pin Frame 3B Phase U to Number IGBT Connector ... 1 #4 J1 ... 4 ... 5 ... 6 ... 9 ... 10 ... 4 #3 J1 ... 5 ... 9 ... 10 ... 4 #2 J1 ... 5 ... 9 ... 10 ... 4 #1 J1 ... 5 ... 9 ... 10
Description U+COLLECTOR U+GATE U+EMITTER U-COLLECTOR U-GATE U-EMITTER U+GATE U+EMITTER U-GATE U-EMITTER U+GATE U+EMITTER U-GATE U-EMITTER U+GATE U+EMITTER U-GATE U-EMITTER
When the addressable power board is used as a converter: Phase U = Phase L1
B-7
Table B.O Addressable Power Board to Frame 3B Phase V IGBT (1)

(1)
Pin Frame 3B Phase V to Number IGBT Connector ... 1 #4 J2 ... 4 ... 5 ... 6 ... 9 ... 10 ... 4 #3 J2 ... 5 ... 9 ... 10 ... 4 #2 J2 ... 5 ... 9 ... 10 ... 4 #1 J2 ... 5 ... 9 ... 10
Description V+COLLECTOR V+GATE V+EMITTER V-COLLECTOR V-GATE V-EMITTER V+GATE V+EMITTER V-GATE V-EMITTER V+GATE V+EMITTER V-GATE V-EMITTER V+GATE V+EMITTER V-GATE V-EMITTER
When the addressable power board is used as a converter: Phase V = Phase L2
Table B.P Addressable Power Board to Frame 3B Phase W IGBT (1)

(1)
Pin Frame 3B Phase W to Number IGBT Connector ... 1 #4 J3 ... 4 ... 5 ... 6 ... 9 ... 10 ... 4 #3 J3 ... 5 ... 9 ... 10 ... 4 #2 J3 ... 5 ... 9 ... 10 ... 4 #1 J3 ... 5 ... 9 ... 10
Description W+COLLECTOR W+GATE W+EMITTER W-COLLECTOR W-GATE W-EMITTER W+GATE W+EMITTER W-GATE W-EMITTER W+GATE W+EMITTER W-GATE W-EMITTER W+GATE W+EMITTER W-GATE W-EMITTER
When the addressable power board is used as a converter: Phase W = Phase L3
B-8
Table B.Q Addressable Power Board to Motor Voltage Feedback Board

Addressable Power Pin Board Connector Number J2 1 4 5 6 7 8 9 10 13 14 15 16 19 20 21 22 25 26 27 28 J3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Pin Number 1 4 5 6 7 8 9 10 13 14 15 16 19 20 21 22 25 26 27 28 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Motor Voltage Feedback Board Connector P3
to ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
P2
Description POS_BUS WN_GATE VN_GATE UN_GATE NEG_RTN UVWN_EMIT NEG_PWR BRAKE_GATE W_POS_RTN WP_EMIT W_POS_PWR WP_GATE V_POS_RTN VP_EMIT V_POS_PWR VP_GATE U_POS_RTN UP_EMIT U_POS_PWR UP_GATE BRAKE AD_GND1 P12VDC N12VDC VSNSGND B P5VDC A AD_GND2 FB_BUS U_NEG_ANODE U_POS_ANODE V_NEG_ANODE V_POS_ANODE W_NEG_ANODE W_POS_ANODE
Appendix
Schematics
For PowerFlex 700L Frame 3A and Frame 3B schematics, see the PowerFlex 700L Liquid-Cooled Adjustable Frequency AC Drive User Manual.
C-2
Schematics
Notes:
U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives
www.rockwellautomation.com
Power, Control and Information Solutions Headquarters
Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA,Tel: (1) 414.382.2000, Fax: (1) 414.382.4444 Europe/Middle East/Africa: Rockwell Automation, Vorstlaan/Boulevard 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
Publication 20L-TG001A-EN-P May, 2007
P/N 181671-P01
Copyright 2007 Rockwell Automation, Inc. All rights reserved. Printed in USA.

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Liquid-Cooled Adjustable Frequency AC Drive

Hardware Service Manual

Important User Information

PowerFlex 700L Frames 3A and 3B Hardware Service Manual

PowerFlex 700L Frames 3A and 3B Hardware Service Manual Publication 20L-TG001A-EN-P

PowerFlex 700L Frames 3A and 3B Hardware Service Manual Publication 20L-TG001A-EN-P

Troubleshooting and Error Codes

Component Test Procedures

PowerFlex 700L Frames 3A and 3B Hardware Service Manual Publication 20L-TG001A-EN-P

PowerFlex 700L Frames 3A and 3B Hardware Service Manual Publication 20L-TG001A-EN-P

Start-Up After Repair

Service Tools and Equipment

PowerFlex 700L Frames 3A and 3B Hardware Service Manual Publication 20L-TG001A-EN-P

PowerFlex 700L Frames 3A and 3B Hardware Service Manual Publication 20L-TG001A-EN-P

Who Should Use this Manual?

What is in this Manual

PowerFlex 700L Frames 3A and 3B Hardware Service Manual Publication 20L-TG001A-EN-P

Figure P.1 Complete Drive Data Nameplate Locations (Frame 3B shown)

Complete Regenerative Drive (Label on inside front of door)

UL Open Type/IP00 Input Filter Assembly

NEMA Type 1/IP20 Complete Regenerative Drive

Nominal Voltage Normal Duty Power

Original Firmware V. 2.005

Nominal Voltage Normal Duty Power

Original Firmware V. 2.005

Listed Ind. Cont. Eq. 966X

Continuous Amps Rated Coolant Nom. Coolant Pressure

Continuous Amps Rated Coolant Nom. Coolant Pressure

Serial Number: MEAE2WJ0

Serial Number: MEAE2WJ0

Input Filter Bay

Power Module Bay

UL Open Type/IP00 Inverter Power Module - Coupled With Converter

Nominal Voltage Normal Duty Power

Original Firmware V. 2.005

Power Module Bay Door Cutaway

Input: DC DC Voltage Range Amps Output: 3 Phase, 0-400Hz AC Voltage Range

Continuous Amps Rated Coolant Nom. Coolant Pressure

Serial Number: MEAE2WJ0

Inverter Power Module

Power Module Front, Bottom Covers Removed

Firmware # : Firmware # : 20-HIM20-I/O20-COMM-

Converter Power Module

Date: Date: HIM I/O COMM Module Internal Dynamic Brake

UL Open Type/IP00 Converter Power Module

Nominal Voltage Normal Duty Power

Original Firmware V. 2.005

Input: AC, 47-63 Hz DC Voltage Range Amps Output: DC DC Voltage Range

Continuous Amps Rated Coolant Nom. Coolant Pressure

Serial Number: MEAE2WJ0

PowerFlex 700L Frames 3A and 3B Hardware Service Manual Publication 20L-TG001A-EN-P

What is Not in this Manual

The following publications provide specific PowerFlex drive information.

PowerFlex 700L Frames 3A and 3B Hardware Service Manual Publication 20L-TG001A-EN-P

Understanding Manual Conventions

Additional Support Available on Internet

PowerFlex 700L Frames 3A and 3B Hardware Service Manual Publication 20L-TG001A-EN-P

Class 1 LED Product

PowerFlex 700L Frames 3A and 3B Hardware Service Manual Publication 20L-TG001A-EN-P

PowerFlex 700L Frames 3A and 3B Hardware Service Manual Publication 20L-TG001A-EN-P

Troubleshooting and Error Codes

PowerFlex 700L Frames 3A and 3B Hardware Service Manual Publication 20L-TG001A-EN-P