PowerFlex 700S and 700H Frames 1012 Rectifier …® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit ... the main DC- and DC+ bus bars and one to cover the rectifier module
50
Publication PFLEX-IN023A-EN-P PowerFlex® 700S and 700H Frames 10…12 Rectifier Module Replacement Kit Installation Instructions What This Kit Includes • Rectifier module • Rectifier DC+ bus bar (2) • Bus bar insulator sheet • Rectifier insulator sheet Do not begin the installation before reading Important Parts Information on page 2 . ATTENTION: To avoid an electric shock hazard, ensure that all power to the drive has been removed before performing the following. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing. Check the DC bus voltage at the Power Terminal Block by measuring between the +DC and -DC terminals, between the +DC terminal and the chassis, and between the -DC terminal and the chassis. The voltage must be zero for all three measurements. ATTENTION: HOT surfaces can cause severe burns. Do not touch the heatsink surface during operation of the drive. After disconnecting power allow time for cooling. ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into SynchLink fiber-optic ports or SynchLink fiber-optic cable connectors. ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook. ATTENTION: The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage. Risk of electrical shock, injury, or death exists if someone comes into contact with the assembly.
Do not begin the installation before reading Important Parts Information on page 2
ATTENTION To avoid an electric shock hazard ensure that all power to the drive has been removed before performing the following
ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage at the Power Terminal Block by measuring between the +DC and -DC terminals between the +DC terminal and the chassis and between the -DC terminal and the chassis The voltage must be zero for all three measurements
ATTENTION HOT surfaces can cause severe burns Do not touch the heatsink surface during operation of the drive After disconnecting power allow time for cooling
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into SynchLink fiber-optic ports or SynchLink fiber-optic cable connectors
ATTENTION This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A-B publication 8000-452 ldquoGuarding Against Electrostatic Damagerdquo or any other applicable ESD protection handbook
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
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2
Important Parts Information Important Due to a change in the SCR modules used in the rectifier module provided in this kit the rectifier module DC+ bus bars and insulator material provided in this kit must be used Therefore the existing rectifier module DC+ bus bar and insulator material must not be reused when installing this rectifier module kit See details below
Rectifier Modules
Rectifier Module DC+ Bus Bars
Rectifier module with round terminals Rectifier module with rectangular terminals provided in this kit
A
B
A gt B
A
B
A gt B
Frame 10 and 12 rectifier DC+ bus bar Frame 11 rectifier DC+ bus bar
Bus bar for round SCR terminals
Bus bar for rectangular SCR terminals provided in this kit
Bus bar for round SCR terminals
Bus bar for rectangular SCR terminals provided in this kit
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3
Bus Bar and Rectifier Module Insulator Material The insulator sheet that is placed between the main DC- and DC+ bus bars for rectifier modules with round SCR terminals is one piece The insulator material provided with this kit is two pieces one sheet for between the main DC- and DC+ bus bars and one to cover the rectifier module
Tools That You Need bull POZIDRIV screwdriver
bull Hexalobular screwdriver
bull Socket wrenches and extensions
bull Torque wrench
bull Wire cutter
bull PowerFlex 700H and 700S maintenance stand for Rittal TS8 enclosures only (catalog string 20-MAINSTD) (recommended)
bull Lifting equipment capable of securing holding and lifting the 210 kg (463 lb) frame 11 power structure
bull Multi-meter - Digital multi meter capable of ac and dc voltage continuity resistance capacitance measurements and forward diode bias tests
POZIDRIVreg is a registered trademark of Phillips Screw Company
Bus bar insulator material provided in this kit
Rectifier module insulator material provided in this kit
Publication PFLEX-IN023A-EN-P
4
Understanding Torque Figures in Illustrations
Icons and numbers in the assembly illustrations indicate how to tighten hardware after re-assembly
What You Need to Do Step 1 Remove power from the drive
Step 2 Remove the protective covers from the drive
Step 3 Remove the power structure from the enclosure
Step 4 Remove the existing rectifier module
Step 5 Install the new rectifier module
Step 6 Install the power structure in the enclosure
Step 7 Complete the circuit tests
Step 8 Install the protective covers
Step 9 Document the change
ATTENTION A hazard of personal injury andor equipment damage exists if the hardware securing power components in the drive is not installed in the same location from which it was removed according to size and the specified torque is not applied where indicated Take the appropriate steps to ensure that the location and size of hardware has been noted during disassembly and that proper torque is applied as indicated during re-assembly
PZ24 Nbullm(35 lbbullin)
Tool Type and SizePZ = POZIDRIV screwdriver bitT = Hexalobular (TORX) screwdriver bitxx mm = Socket wrenchHEX = Hexagonal screwdriverbit
Tightening Torque
Fastener Type
POZIDRIV Screw
Hexalobular (TORX) Screw
Hexagonal Screw
Hexagonal Bolt
Hexagonal Nut
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5
Step 1 Remove Power from the Drive
1 Turn off and lock out input power Wait five minutes
2 Verify that there is no voltage at the driversquos input power terminals
3 Check the DC bus voltage at the Power Terminal Block by measuring between the +DC and -DC terminals between the +DC terminal and the chassis and between the -DC terminal and the chassis The voltage must be zero for all three measurements
ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage at the Power Terminal Block by measuring between the +DC and -DC terminals between the +DC terminal and the chassis and between the -DC terminal and the chassis The voltage must be zero for all three measurements
Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by
bull sending an erroneous signal to your systemrsquos field devices causing unintended machine motion
bull causing an explosion in a hazardous environment
Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance
L1 L2 L3
O
I
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6
Step 2 Remove the Protective Covers from the Drive
To remove the protective covers you must first move the control frame and then remove the air flow plate
1 Loosen the T8 hexalobular screws that hold the control frame to the drive enclosure (remove screws on early frame 10 drives)
2 Swing the control frame out and away from the power structure
Frame 10 drives from early production runs have holes instead of slots for these screws You must completely remove the screws from these drives in order to move the control frame
or
Screws
600 mm wide control frame shown
=
Publication PFLEX-IN023A-EN-P
7
3 Remove the four T8 hexalobular screws that secure the airflow plate to the drive and slide the airflow plate off the enclosure frame
Screws
Frame 10 enclosure shown
Airflow plate
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8
4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers
5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover
6 On frame 10 and 12 drives only remove the side protective covers
Frame 10 covers shown
PZ230 Nbullm(265 lbbullin)
4
4
4
4
5
5
5
5
6
6
5
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9
Step 3 Remove the Power Structure from the Enclosure
In order to remove the power structure from the enclosure you must first remove the power and ground wiring
For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives
1 Remove the insulator material from between the input terminals
2 Remove the input wiring from the following terminals
ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure
ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure
3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure
4 Remove the ground connection from the power structure
Figure 1 Frame 10 and 12 Drives
Motor Connection Terminals
AC Input Power Connection Terminals
Ground Connection
DC Input Power Connection Terminals
Frame 10 power structure shown
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
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10
Figure 2 Frame 11 Drives
H LH LH L
Motor Connection Terminals
AC Input Power Connection Terminals
DC Input Power Connection Terminals
Ground Connection
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
11
5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)
6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand
Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures
7 Remove the power structure by sliding it onto the rails of the maintenance stand
Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure
Figure 3 Frame 10 and 12 Drives
Remove bolts
Frame 10 power structure shown
Remove bolts
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12
Figure 4 Frame 11 Drives
Step 4 Remove the Existing Rectifier Module(s)
The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22
H LH LH L
Remove bolts
Remove bolts
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13
Remove the Rectifier Module(s) from a Frame 10 or 12 Drive
The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
Rectifier module(s) located on right side of power structure(s)
Frame 10
Frame 12
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14
1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires
2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive
3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)
DC-
DC+ T2010 Nbullm(88 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Loosen but do not remove hex nuts
Rectifier board
Remove screws
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15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
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16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
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17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
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18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
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20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
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21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
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22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
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23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
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24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
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25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
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26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
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30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
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34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
2
Important Parts Information Important Due to a change in the SCR modules used in the rectifier module provided in this kit the rectifier module DC+ bus bars and insulator material provided in this kit must be used Therefore the existing rectifier module DC+ bus bar and insulator material must not be reused when installing this rectifier module kit See details below
Rectifier Modules
Rectifier Module DC+ Bus Bars
Rectifier module with round terminals Rectifier module with rectangular terminals provided in this kit
A
B
A gt B
A
B
A gt B
Frame 10 and 12 rectifier DC+ bus bar Frame 11 rectifier DC+ bus bar
Bus bar for round SCR terminals
Bus bar for rectangular SCR terminals provided in this kit
Bus bar for round SCR terminals
Bus bar for rectangular SCR terminals provided in this kit
Publication PFLEX-IN023A-EN-P
3
Bus Bar and Rectifier Module Insulator Material The insulator sheet that is placed between the main DC- and DC+ bus bars for rectifier modules with round SCR terminals is one piece The insulator material provided with this kit is two pieces one sheet for between the main DC- and DC+ bus bars and one to cover the rectifier module
Tools That You Need bull POZIDRIV screwdriver
bull Hexalobular screwdriver
bull Socket wrenches and extensions
bull Torque wrench
bull Wire cutter
bull PowerFlex 700H and 700S maintenance stand for Rittal TS8 enclosures only (catalog string 20-MAINSTD) (recommended)
bull Lifting equipment capable of securing holding and lifting the 210 kg (463 lb) frame 11 power structure
bull Multi-meter - Digital multi meter capable of ac and dc voltage continuity resistance capacitance measurements and forward diode bias tests
POZIDRIVreg is a registered trademark of Phillips Screw Company
Bus bar insulator material provided in this kit
Rectifier module insulator material provided in this kit
Publication PFLEX-IN023A-EN-P
4
Understanding Torque Figures in Illustrations
Icons and numbers in the assembly illustrations indicate how to tighten hardware after re-assembly
What You Need to Do Step 1 Remove power from the drive
Step 2 Remove the protective covers from the drive
Step 3 Remove the power structure from the enclosure
Step 4 Remove the existing rectifier module
Step 5 Install the new rectifier module
Step 6 Install the power structure in the enclosure
Step 7 Complete the circuit tests
Step 8 Install the protective covers
Step 9 Document the change
ATTENTION A hazard of personal injury andor equipment damage exists if the hardware securing power components in the drive is not installed in the same location from which it was removed according to size and the specified torque is not applied where indicated Take the appropriate steps to ensure that the location and size of hardware has been noted during disassembly and that proper torque is applied as indicated during re-assembly
PZ24 Nbullm(35 lbbullin)
Tool Type and SizePZ = POZIDRIV screwdriver bitT = Hexalobular (TORX) screwdriver bitxx mm = Socket wrenchHEX = Hexagonal screwdriverbit
Tightening Torque
Fastener Type
POZIDRIV Screw
Hexalobular (TORX) Screw
Hexagonal Screw
Hexagonal Bolt
Hexagonal Nut
Publication PFLEX-IN023A-EN-P
5
Step 1 Remove Power from the Drive
1 Turn off and lock out input power Wait five minutes
2 Verify that there is no voltage at the driversquos input power terminals
3 Check the DC bus voltage at the Power Terminal Block by measuring between the +DC and -DC terminals between the +DC terminal and the chassis and between the -DC terminal and the chassis The voltage must be zero for all three measurements
ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage at the Power Terminal Block by measuring between the +DC and -DC terminals between the +DC terminal and the chassis and between the -DC terminal and the chassis The voltage must be zero for all three measurements
Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by
bull sending an erroneous signal to your systemrsquos field devices causing unintended machine motion
bull causing an explosion in a hazardous environment
Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance
L1 L2 L3
O
I
Publication PFLEX-IN023A-EN-P
6
Step 2 Remove the Protective Covers from the Drive
To remove the protective covers you must first move the control frame and then remove the air flow plate
1 Loosen the T8 hexalobular screws that hold the control frame to the drive enclosure (remove screws on early frame 10 drives)
2 Swing the control frame out and away from the power structure
Frame 10 drives from early production runs have holes instead of slots for these screws You must completely remove the screws from these drives in order to move the control frame
or
Screws
600 mm wide control frame shown
=
Publication PFLEX-IN023A-EN-P
7
3 Remove the four T8 hexalobular screws that secure the airflow plate to the drive and slide the airflow plate off the enclosure frame
Screws
Frame 10 enclosure shown
Airflow plate
Publication PFLEX-IN023A-EN-P
8
4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers
5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover
6 On frame 10 and 12 drives only remove the side protective covers
Frame 10 covers shown
PZ230 Nbullm(265 lbbullin)
4
4
4
4
5
5
5
5
6
6
5
Publication PFLEX-IN023A-EN-P
9
Step 3 Remove the Power Structure from the Enclosure
In order to remove the power structure from the enclosure you must first remove the power and ground wiring
For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives
1 Remove the insulator material from between the input terminals
2 Remove the input wiring from the following terminals
ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure
ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure
3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure
4 Remove the ground connection from the power structure
Figure 1 Frame 10 and 12 Drives
Motor Connection Terminals
AC Input Power Connection Terminals
Ground Connection
DC Input Power Connection Terminals
Frame 10 power structure shown
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
10
Figure 2 Frame 11 Drives
H LH LH L
Motor Connection Terminals
AC Input Power Connection Terminals
DC Input Power Connection Terminals
Ground Connection
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
11
5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)
6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand
Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures
7 Remove the power structure by sliding it onto the rails of the maintenance stand
Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure
Figure 3 Frame 10 and 12 Drives
Remove bolts
Frame 10 power structure shown
Remove bolts
Publication PFLEX-IN023A-EN-P
12
Figure 4 Frame 11 Drives
Step 4 Remove the Existing Rectifier Module(s)
The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22
H LH LH L
Remove bolts
Remove bolts
Publication PFLEX-IN023A-EN-P
13
Remove the Rectifier Module(s) from a Frame 10 or 12 Drive
The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
Rectifier module(s) located on right side of power structure(s)
Frame 10
Frame 12
Publication PFLEX-IN023A-EN-P
14
1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires
2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive
3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)
DC-
DC+ T2010 Nbullm(88 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Loosen but do not remove hex nuts
Rectifier board
Remove screws
Publication PFLEX-IN023A-EN-P
15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
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37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
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38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
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39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
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47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
3
Bus Bar and Rectifier Module Insulator Material The insulator sheet that is placed between the main DC- and DC+ bus bars for rectifier modules with round SCR terminals is one piece The insulator material provided with this kit is two pieces one sheet for between the main DC- and DC+ bus bars and one to cover the rectifier module
Tools That You Need bull POZIDRIV screwdriver
bull Hexalobular screwdriver
bull Socket wrenches and extensions
bull Torque wrench
bull Wire cutter
bull PowerFlex 700H and 700S maintenance stand for Rittal TS8 enclosures only (catalog string 20-MAINSTD) (recommended)
bull Lifting equipment capable of securing holding and lifting the 210 kg (463 lb) frame 11 power structure
bull Multi-meter - Digital multi meter capable of ac and dc voltage continuity resistance capacitance measurements and forward diode bias tests
POZIDRIVreg is a registered trademark of Phillips Screw Company
Bus bar insulator material provided in this kit
Rectifier module insulator material provided in this kit
Publication PFLEX-IN023A-EN-P
4
Understanding Torque Figures in Illustrations
Icons and numbers in the assembly illustrations indicate how to tighten hardware after re-assembly
What You Need to Do Step 1 Remove power from the drive
Step 2 Remove the protective covers from the drive
Step 3 Remove the power structure from the enclosure
Step 4 Remove the existing rectifier module
Step 5 Install the new rectifier module
Step 6 Install the power structure in the enclosure
Step 7 Complete the circuit tests
Step 8 Install the protective covers
Step 9 Document the change
ATTENTION A hazard of personal injury andor equipment damage exists if the hardware securing power components in the drive is not installed in the same location from which it was removed according to size and the specified torque is not applied where indicated Take the appropriate steps to ensure that the location and size of hardware has been noted during disassembly and that proper torque is applied as indicated during re-assembly
PZ24 Nbullm(35 lbbullin)
Tool Type and SizePZ = POZIDRIV screwdriver bitT = Hexalobular (TORX) screwdriver bitxx mm = Socket wrenchHEX = Hexagonal screwdriverbit
Tightening Torque
Fastener Type
POZIDRIV Screw
Hexalobular (TORX) Screw
Hexagonal Screw
Hexagonal Bolt
Hexagonal Nut
Publication PFLEX-IN023A-EN-P
5
Step 1 Remove Power from the Drive
1 Turn off and lock out input power Wait five minutes
2 Verify that there is no voltage at the driversquos input power terminals
3 Check the DC bus voltage at the Power Terminal Block by measuring between the +DC and -DC terminals between the +DC terminal and the chassis and between the -DC terminal and the chassis The voltage must be zero for all three measurements
ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage at the Power Terminal Block by measuring between the +DC and -DC terminals between the +DC terminal and the chassis and between the -DC terminal and the chassis The voltage must be zero for all three measurements
Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by
bull sending an erroneous signal to your systemrsquos field devices causing unintended machine motion
bull causing an explosion in a hazardous environment
Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance
L1 L2 L3
O
I
Publication PFLEX-IN023A-EN-P
6
Step 2 Remove the Protective Covers from the Drive
To remove the protective covers you must first move the control frame and then remove the air flow plate
1 Loosen the T8 hexalobular screws that hold the control frame to the drive enclosure (remove screws on early frame 10 drives)
2 Swing the control frame out and away from the power structure
Frame 10 drives from early production runs have holes instead of slots for these screws You must completely remove the screws from these drives in order to move the control frame
or
Screws
600 mm wide control frame shown
=
Publication PFLEX-IN023A-EN-P
7
3 Remove the four T8 hexalobular screws that secure the airflow plate to the drive and slide the airflow plate off the enclosure frame
Screws
Frame 10 enclosure shown
Airflow plate
Publication PFLEX-IN023A-EN-P
8
4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers
5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover
6 On frame 10 and 12 drives only remove the side protective covers
Frame 10 covers shown
PZ230 Nbullm(265 lbbullin)
4
4
4
4
5
5
5
5
6
6
5
Publication PFLEX-IN023A-EN-P
9
Step 3 Remove the Power Structure from the Enclosure
In order to remove the power structure from the enclosure you must first remove the power and ground wiring
For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives
1 Remove the insulator material from between the input terminals
2 Remove the input wiring from the following terminals
ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure
ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure
3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure
4 Remove the ground connection from the power structure
Figure 1 Frame 10 and 12 Drives
Motor Connection Terminals
AC Input Power Connection Terminals
Ground Connection
DC Input Power Connection Terminals
Frame 10 power structure shown
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
10
Figure 2 Frame 11 Drives
H LH LH L
Motor Connection Terminals
AC Input Power Connection Terminals
DC Input Power Connection Terminals
Ground Connection
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
11
5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)
6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand
Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures
7 Remove the power structure by sliding it onto the rails of the maintenance stand
Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure
Figure 3 Frame 10 and 12 Drives
Remove bolts
Frame 10 power structure shown
Remove bolts
Publication PFLEX-IN023A-EN-P
12
Figure 4 Frame 11 Drives
Step 4 Remove the Existing Rectifier Module(s)
The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22
H LH LH L
Remove bolts
Remove bolts
Publication PFLEX-IN023A-EN-P
13
Remove the Rectifier Module(s) from a Frame 10 or 12 Drive
The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
Rectifier module(s) located on right side of power structure(s)
Frame 10
Frame 12
Publication PFLEX-IN023A-EN-P
14
1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires
2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive
3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)
DC-
DC+ T2010 Nbullm(88 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Loosen but do not remove hex nuts
Rectifier board
Remove screws
Publication PFLEX-IN023A-EN-P
15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
4
Understanding Torque Figures in Illustrations
Icons and numbers in the assembly illustrations indicate how to tighten hardware after re-assembly
What You Need to Do Step 1 Remove power from the drive
Step 2 Remove the protective covers from the drive
Step 3 Remove the power structure from the enclosure
Step 4 Remove the existing rectifier module
Step 5 Install the new rectifier module
Step 6 Install the power structure in the enclosure
Step 7 Complete the circuit tests
Step 8 Install the protective covers
Step 9 Document the change
ATTENTION A hazard of personal injury andor equipment damage exists if the hardware securing power components in the drive is not installed in the same location from which it was removed according to size and the specified torque is not applied where indicated Take the appropriate steps to ensure that the location and size of hardware has been noted during disassembly and that proper torque is applied as indicated during re-assembly
PZ24 Nbullm(35 lbbullin)
Tool Type and SizePZ = POZIDRIV screwdriver bitT = Hexalobular (TORX) screwdriver bitxx mm = Socket wrenchHEX = Hexagonal screwdriverbit
Tightening Torque
Fastener Type
POZIDRIV Screw
Hexalobular (TORX) Screw
Hexagonal Screw
Hexagonal Bolt
Hexagonal Nut
Publication PFLEX-IN023A-EN-P
5
Step 1 Remove Power from the Drive
1 Turn off and lock out input power Wait five minutes
2 Verify that there is no voltage at the driversquos input power terminals
3 Check the DC bus voltage at the Power Terminal Block by measuring between the +DC and -DC terminals between the +DC terminal and the chassis and between the -DC terminal and the chassis The voltage must be zero for all three measurements
ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage at the Power Terminal Block by measuring between the +DC and -DC terminals between the +DC terminal and the chassis and between the -DC terminal and the chassis The voltage must be zero for all three measurements
Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by
bull sending an erroneous signal to your systemrsquos field devices causing unintended machine motion
bull causing an explosion in a hazardous environment
Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance
L1 L2 L3
O
I
Publication PFLEX-IN023A-EN-P
6
Step 2 Remove the Protective Covers from the Drive
To remove the protective covers you must first move the control frame and then remove the air flow plate
1 Loosen the T8 hexalobular screws that hold the control frame to the drive enclosure (remove screws on early frame 10 drives)
2 Swing the control frame out and away from the power structure
Frame 10 drives from early production runs have holes instead of slots for these screws You must completely remove the screws from these drives in order to move the control frame
or
Screws
600 mm wide control frame shown
=
Publication PFLEX-IN023A-EN-P
7
3 Remove the four T8 hexalobular screws that secure the airflow plate to the drive and slide the airflow plate off the enclosure frame
Screws
Frame 10 enclosure shown
Airflow plate
Publication PFLEX-IN023A-EN-P
8
4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers
5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover
6 On frame 10 and 12 drives only remove the side protective covers
Frame 10 covers shown
PZ230 Nbullm(265 lbbullin)
4
4
4
4
5
5
5
5
6
6
5
Publication PFLEX-IN023A-EN-P
9
Step 3 Remove the Power Structure from the Enclosure
In order to remove the power structure from the enclosure you must first remove the power and ground wiring
For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives
1 Remove the insulator material from between the input terminals
2 Remove the input wiring from the following terminals
ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure
ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure
3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure
4 Remove the ground connection from the power structure
Figure 1 Frame 10 and 12 Drives
Motor Connection Terminals
AC Input Power Connection Terminals
Ground Connection
DC Input Power Connection Terminals
Frame 10 power structure shown
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
10
Figure 2 Frame 11 Drives
H LH LH L
Motor Connection Terminals
AC Input Power Connection Terminals
DC Input Power Connection Terminals
Ground Connection
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
11
5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)
6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand
Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures
7 Remove the power structure by sliding it onto the rails of the maintenance stand
Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure
Figure 3 Frame 10 and 12 Drives
Remove bolts
Frame 10 power structure shown
Remove bolts
Publication PFLEX-IN023A-EN-P
12
Figure 4 Frame 11 Drives
Step 4 Remove the Existing Rectifier Module(s)
The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22
H LH LH L
Remove bolts
Remove bolts
Publication PFLEX-IN023A-EN-P
13
Remove the Rectifier Module(s) from a Frame 10 or 12 Drive
The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
Rectifier module(s) located on right side of power structure(s)
Frame 10
Frame 12
Publication PFLEX-IN023A-EN-P
14
1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires
2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive
3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)
DC-
DC+ T2010 Nbullm(88 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Loosen but do not remove hex nuts
Rectifier board
Remove screws
Publication PFLEX-IN023A-EN-P
15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
5
Step 1 Remove Power from the Drive
1 Turn off and lock out input power Wait five minutes
2 Verify that there is no voltage at the driversquos input power terminals
3 Check the DC bus voltage at the Power Terminal Block by measuring between the +DC and -DC terminals between the +DC terminal and the chassis and between the -DC terminal and the chassis The voltage must be zero for all three measurements
ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage at the Power Terminal Block by measuring between the +DC and -DC terminals between the +DC terminal and the chassis and between the -DC terminal and the chassis The voltage must be zero for all three measurements
Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by
bull sending an erroneous signal to your systemrsquos field devices causing unintended machine motion
bull causing an explosion in a hazardous environment
Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance
L1 L2 L3
O
I
Publication PFLEX-IN023A-EN-P
6
Step 2 Remove the Protective Covers from the Drive
To remove the protective covers you must first move the control frame and then remove the air flow plate
1 Loosen the T8 hexalobular screws that hold the control frame to the drive enclosure (remove screws on early frame 10 drives)
2 Swing the control frame out and away from the power structure
Frame 10 drives from early production runs have holes instead of slots for these screws You must completely remove the screws from these drives in order to move the control frame
or
Screws
600 mm wide control frame shown
=
Publication PFLEX-IN023A-EN-P
7
3 Remove the four T8 hexalobular screws that secure the airflow plate to the drive and slide the airflow plate off the enclosure frame
Screws
Frame 10 enclosure shown
Airflow plate
Publication PFLEX-IN023A-EN-P
8
4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers
5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover
6 On frame 10 and 12 drives only remove the side protective covers
Frame 10 covers shown
PZ230 Nbullm(265 lbbullin)
4
4
4
4
5
5
5
5
6
6
5
Publication PFLEX-IN023A-EN-P
9
Step 3 Remove the Power Structure from the Enclosure
In order to remove the power structure from the enclosure you must first remove the power and ground wiring
For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives
1 Remove the insulator material from between the input terminals
2 Remove the input wiring from the following terminals
ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure
ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure
3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure
4 Remove the ground connection from the power structure
Figure 1 Frame 10 and 12 Drives
Motor Connection Terminals
AC Input Power Connection Terminals
Ground Connection
DC Input Power Connection Terminals
Frame 10 power structure shown
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
10
Figure 2 Frame 11 Drives
H LH LH L
Motor Connection Terminals
AC Input Power Connection Terminals
DC Input Power Connection Terminals
Ground Connection
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
11
5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)
6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand
Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures
7 Remove the power structure by sliding it onto the rails of the maintenance stand
Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure
Figure 3 Frame 10 and 12 Drives
Remove bolts
Frame 10 power structure shown
Remove bolts
Publication PFLEX-IN023A-EN-P
12
Figure 4 Frame 11 Drives
Step 4 Remove the Existing Rectifier Module(s)
The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22
H LH LH L
Remove bolts
Remove bolts
Publication PFLEX-IN023A-EN-P
13
Remove the Rectifier Module(s) from a Frame 10 or 12 Drive
The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
Rectifier module(s) located on right side of power structure(s)
Frame 10
Frame 12
Publication PFLEX-IN023A-EN-P
14
1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires
2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive
3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)
DC-
DC+ T2010 Nbullm(88 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Loosen but do not remove hex nuts
Rectifier board
Remove screws
Publication PFLEX-IN023A-EN-P
15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
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1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
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1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
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5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
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1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
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1 color
100gsm bond
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B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
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Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
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2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
6
Step 2 Remove the Protective Covers from the Drive
To remove the protective covers you must first move the control frame and then remove the air flow plate
1 Loosen the T8 hexalobular screws that hold the control frame to the drive enclosure (remove screws on early frame 10 drives)
2 Swing the control frame out and away from the power structure
Frame 10 drives from early production runs have holes instead of slots for these screws You must completely remove the screws from these drives in order to move the control frame
or
Screws
600 mm wide control frame shown
=
Publication PFLEX-IN023A-EN-P
7
3 Remove the four T8 hexalobular screws that secure the airflow plate to the drive and slide the airflow plate off the enclosure frame
Screws
Frame 10 enclosure shown
Airflow plate
Publication PFLEX-IN023A-EN-P
8
4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers
5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover
6 On frame 10 and 12 drives only remove the side protective covers
Frame 10 covers shown
PZ230 Nbullm(265 lbbullin)
4
4
4
4
5
5
5
5
6
6
5
Publication PFLEX-IN023A-EN-P
9
Step 3 Remove the Power Structure from the Enclosure
In order to remove the power structure from the enclosure you must first remove the power and ground wiring
For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives
1 Remove the insulator material from between the input terminals
2 Remove the input wiring from the following terminals
ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure
ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure
3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure
4 Remove the ground connection from the power structure
Figure 1 Frame 10 and 12 Drives
Motor Connection Terminals
AC Input Power Connection Terminals
Ground Connection
DC Input Power Connection Terminals
Frame 10 power structure shown
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
10
Figure 2 Frame 11 Drives
H LH LH L
Motor Connection Terminals
AC Input Power Connection Terminals
DC Input Power Connection Terminals
Ground Connection
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
11
5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)
6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand
Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures
7 Remove the power structure by sliding it onto the rails of the maintenance stand
Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure
Figure 3 Frame 10 and 12 Drives
Remove bolts
Frame 10 power structure shown
Remove bolts
Publication PFLEX-IN023A-EN-P
12
Figure 4 Frame 11 Drives
Step 4 Remove the Existing Rectifier Module(s)
The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22
H LH LH L
Remove bolts
Remove bolts
Publication PFLEX-IN023A-EN-P
13
Remove the Rectifier Module(s) from a Frame 10 or 12 Drive
The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
Rectifier module(s) located on right side of power structure(s)
Frame 10
Frame 12
Publication PFLEX-IN023A-EN-P
14
1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires
2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive
3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)
DC-
DC+ T2010 Nbullm(88 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Loosen but do not remove hex nuts
Rectifier board
Remove screws
Publication PFLEX-IN023A-EN-P
15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
7
3 Remove the four T8 hexalobular screws that secure the airflow plate to the drive and slide the airflow plate off the enclosure frame
Screws
Frame 10 enclosure shown
Airflow plate
Publication PFLEX-IN023A-EN-P
8
4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers
5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover
6 On frame 10 and 12 drives only remove the side protective covers
Frame 10 covers shown
PZ230 Nbullm(265 lbbullin)
4
4
4
4
5
5
5
5
6
6
5
Publication PFLEX-IN023A-EN-P
9
Step 3 Remove the Power Structure from the Enclosure
In order to remove the power structure from the enclosure you must first remove the power and ground wiring
For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives
1 Remove the insulator material from between the input terminals
2 Remove the input wiring from the following terminals
ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure
ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure
3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure
4 Remove the ground connection from the power structure
Figure 1 Frame 10 and 12 Drives
Motor Connection Terminals
AC Input Power Connection Terminals
Ground Connection
DC Input Power Connection Terminals
Frame 10 power structure shown
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
10
Figure 2 Frame 11 Drives
H LH LH L
Motor Connection Terminals
AC Input Power Connection Terminals
DC Input Power Connection Terminals
Ground Connection
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
11
5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)
6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand
Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures
7 Remove the power structure by sliding it onto the rails of the maintenance stand
Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure
Figure 3 Frame 10 and 12 Drives
Remove bolts
Frame 10 power structure shown
Remove bolts
Publication PFLEX-IN023A-EN-P
12
Figure 4 Frame 11 Drives
Step 4 Remove the Existing Rectifier Module(s)
The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22
H LH LH L
Remove bolts
Remove bolts
Publication PFLEX-IN023A-EN-P
13
Remove the Rectifier Module(s) from a Frame 10 or 12 Drive
The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
Rectifier module(s) located on right side of power structure(s)
Frame 10
Frame 12
Publication PFLEX-IN023A-EN-P
14
1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires
2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive
3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)
DC-
DC+ T2010 Nbullm(88 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Loosen but do not remove hex nuts
Rectifier board
Remove screws
Publication PFLEX-IN023A-EN-P
15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
8
4 Remove the four M5 POZIDRIV screws that secure the top and bottom protective covers to the main front protective cover and remove the top and bottom protective covers
5 Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive and remove the protective cover
6 On frame 10 and 12 drives only remove the side protective covers
Frame 10 covers shown
PZ230 Nbullm(265 lbbullin)
4
4
4
4
5
5
5
5
6
6
5
Publication PFLEX-IN023A-EN-P
9
Step 3 Remove the Power Structure from the Enclosure
In order to remove the power structure from the enclosure you must first remove the power and ground wiring
For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives
1 Remove the insulator material from between the input terminals
2 Remove the input wiring from the following terminals
ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure
ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure
3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure
4 Remove the ground connection from the power structure
Figure 1 Frame 10 and 12 Drives
Motor Connection Terminals
AC Input Power Connection Terminals
Ground Connection
DC Input Power Connection Terminals
Frame 10 power structure shown
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
10
Figure 2 Frame 11 Drives
H LH LH L
Motor Connection Terminals
AC Input Power Connection Terminals
DC Input Power Connection Terminals
Ground Connection
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
11
5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)
6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand
Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures
7 Remove the power structure by sliding it onto the rails of the maintenance stand
Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure
Figure 3 Frame 10 and 12 Drives
Remove bolts
Frame 10 power structure shown
Remove bolts
Publication PFLEX-IN023A-EN-P
12
Figure 4 Frame 11 Drives
Step 4 Remove the Existing Rectifier Module(s)
The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22
H LH LH L
Remove bolts
Remove bolts
Publication PFLEX-IN023A-EN-P
13
Remove the Rectifier Module(s) from a Frame 10 or 12 Drive
The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
Rectifier module(s) located on right side of power structure(s)
Frame 10
Frame 12
Publication PFLEX-IN023A-EN-P
14
1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires
2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive
3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)
DC-
DC+ T2010 Nbullm(88 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Loosen but do not remove hex nuts
Rectifier board
Remove screws
Publication PFLEX-IN023A-EN-P
15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
9
Step 3 Remove the Power Structure from the Enclosure
In order to remove the power structure from the enclosure you must first remove the power and ground wiring
For terminal locations refer to Figure 1 below for frame 10 and 12 drives and Figure 2 on page 10 for frame 11 drives
1 Remove the insulator material from between the input terminals
2 Remove the input wiring from the following terminals
ndash Frames 10 and 12 - L1 L2 L3 and DC- DC+ (if present) on the power structure
ndash Frame 11 - 1L1 1L2 1L3 and 2L1 2L2 2L3 (except 690V AC input 460A and 502A drives 1L1 1L2 1L3 only) and DC- DC+ (if present) on the power structure
3 Remove the motor wiring from terminals UT1 VT2 WT3 on the power structure
4 Remove the ground connection from the power structure
Figure 1 Frame 10 and 12 Drives
Motor Connection Terminals
AC Input Power Connection Terminals
Ground Connection
DC Input Power Connection Terminals
Frame 10 power structure shown
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
10
Figure 2 Frame 11 Drives
H LH LH L
Motor Connection Terminals
AC Input Power Connection Terminals
DC Input Power Connection Terminals
Ground Connection
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
11
5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)
6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand
Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures
7 Remove the power structure by sliding it onto the rails of the maintenance stand
Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure
Figure 3 Frame 10 and 12 Drives
Remove bolts
Frame 10 power structure shown
Remove bolts
Publication PFLEX-IN023A-EN-P
12
Figure 4 Frame 11 Drives
Step 4 Remove the Existing Rectifier Module(s)
The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22
H LH LH L
Remove bolts
Remove bolts
Publication PFLEX-IN023A-EN-P
13
Remove the Rectifier Module(s) from a Frame 10 or 12 Drive
The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
Rectifier module(s) located on right side of power structure(s)
Frame 10
Frame 12
Publication PFLEX-IN023A-EN-P
14
1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires
2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive
3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)
DC-
DC+ T2010 Nbullm(88 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Loosen but do not remove hex nuts
Rectifier board
Remove screws
Publication PFLEX-IN023A-EN-P
15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
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NA
NA
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1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
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5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
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5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
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1
5
Post External
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B3
D5
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1
5
Post Internal
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B3 Primary B5
D5
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5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
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2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
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1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
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4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
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Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
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1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
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2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
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1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
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2 color
160gsm tab
90 index
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2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
10
Figure 2 Frame 11 Drives
H LH LH L
Motor Connection Terminals
AC Input Power Connection Terminals
DC Input Power Connection Terminals
Ground Connection
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
19 mm40 Nbullm(354 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Remove Insulator Material from between Terminals
Publication PFLEX-IN023A-EN-P
11
5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)
6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand
Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures
7 Remove the power structure by sliding it onto the rails of the maintenance stand
Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure
Figure 3 Frame 10 and 12 Drives
Remove bolts
Frame 10 power structure shown
Remove bolts
Publication PFLEX-IN023A-EN-P
12
Figure 4 Frame 11 Drives
Step 4 Remove the Existing Rectifier Module(s)
The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22
H LH LH L
Remove bolts
Remove bolts
Publication PFLEX-IN023A-EN-P
13
Remove the Rectifier Module(s) from a Frame 10 or 12 Drive
The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
Rectifier module(s) located on right side of power structure(s)
Frame 10
Frame 12
Publication PFLEX-IN023A-EN-P
14
1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires
2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive
3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)
DC-
DC+ T2010 Nbullm(88 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Loosen but do not remove hex nuts
Rectifier board
Remove screws
Publication PFLEX-IN023A-EN-P
15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
11
5 Remove the bolts that secure the power structure to the drive enclosure (see Figure 3 below for frame 10 and 12 and Figure 4 on page 12 for frame 11)
6 Follow the instructions in the PowerFlex 700S and 700H High Power Maintenance Stand Installation Instructions publication PFLEX-IN014 to assemble the maintenance stand
Note The maintenance stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures only An alternate means of removal is necessary for other types of enclosures
7 Remove the power structure by sliding it onto the rails of the maintenance stand
Important Do not pull on any of the cables terminals or circuit board mounts when removing the power structure from the enclosure
Figure 3 Frame 10 and 12 Drives
Remove bolts
Frame 10 power structure shown
Remove bolts
Publication PFLEX-IN023A-EN-P
12
Figure 4 Frame 11 Drives
Step 4 Remove the Existing Rectifier Module(s)
The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22
H LH LH L
Remove bolts
Remove bolts
Publication PFLEX-IN023A-EN-P
13
Remove the Rectifier Module(s) from a Frame 10 or 12 Drive
The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
Rectifier module(s) located on right side of power structure(s)
Frame 10
Frame 12
Publication PFLEX-IN023A-EN-P
14
1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires
2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive
3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)
DC-
DC+ T2010 Nbullm(88 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Loosen but do not remove hex nuts
Rectifier board
Remove screws
Publication PFLEX-IN023A-EN-P
15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
12
Figure 4 Frame 11 Drives
Step 4 Remove the Existing Rectifier Module(s)
The steps for removing the rectifier module(s) from a frame 10 and 12 size drive are different than a frame 11 size drive Refer to Remove the Rectifier Module(s) from a Frame 10 or 12 Drive on page 13 or Remove the Rectifier Module from a Frame 11 Drive on page 22
H LH LH L
Remove bolts
Remove bolts
Publication PFLEX-IN023A-EN-P
13
Remove the Rectifier Module(s) from a Frame 10 or 12 Drive
The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
Rectifier module(s) located on right side of power structure(s)
Frame 10
Frame 12
Publication PFLEX-IN023A-EN-P
14
1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires
2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive
3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)
DC-
DC+ T2010 Nbullm(88 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Loosen but do not remove hex nuts
Rectifier board
Remove screws
Publication PFLEX-IN023A-EN-P
15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
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NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
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NA
NA
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NA
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(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
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A2 Primary A1
NA
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5
100
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C2 Primary C1
NA
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1
50
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NA
NA
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1
50
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NA
NA
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5
50
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A5 A6 A9
D5
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NA
NA Confidential
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E-only
E-only D5
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5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
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5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
13
Remove the Rectifier Module(s) from a Frame 10 or 12 Drive
The rectifier module(s) on frame 10 and 12 drives are contained in the right side of the power structure(s)
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured with cable ties in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
Rectifier module(s) located on right side of power structure(s)
Frame 10
Frame 12
Publication PFLEX-IN023A-EN-P
14
1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires
2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive
3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)
DC-
DC+ T2010 Nbullm(88 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Loosen but do not remove hex nuts
Rectifier board
Remove screws
Publication PFLEX-IN023A-EN-P
15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
14
1 Remove the two M4x8 hexalobular screws that secure the control power supply wires to the DC- and DC+ bus bars above the Gate Driver board and remove the wires
2 Loosen but do not remove the eight M10 hex nuts that secure the DC- and DC+ connective bus bars to the drive
3 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the board (see Figure 5 on page 15) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 6 on page 15)
DC-
DC+ T2010 Nbullm(88 lbbullin)
17 mm40 Nbullm(354 lbbullin)
Loosen but do not remove hex nuts
Rectifier board
Remove screws
Publication PFLEX-IN023A-EN-P
15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
15
Figure 5 Series A Rectifier Circuit Board
Figure 6 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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Order Min
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NA - Puttman
NA
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NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
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100
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AR
NA
NA
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NA
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(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
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A2 Primary A1
NA
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100
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C2 Primary C1
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1
50
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50
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NA
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5
50
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A5 A6 A9
D5
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NA
NA Confidential
CP
E-only
E-only D5
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5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
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NA
Presale Internal
DI
A1 A3
NA
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5
100
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DM
NA
NA
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5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
16
4 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
5 Remove the eight hexalobular screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
6 Lift the insulator material and remove the M10x20 bolts and washers that secure the AC input cables and SCR terminal bus bars to the rectifier modulersquos SCR terminals and remove the AC input cables and terminal bus bars
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
Remove bolts
17 mm14 Nbullm(124 lbbullin)
AC input cables
Terminal bus bars
Publication PFLEX-IN023A-EN-P
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
17
7 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars and power cable to the SCRs on the rectifier module and remove the bus bars and power cable
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts
17 mm14 Nbullm(124 lbbullin)
Remove bolts
Do Not reuse existing DC+ bus bar
Top of Power Structure
Power cable
Publication PFLEX-IN023A-EN-P
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
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B3
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Price List
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B2
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1
5
Post External
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A3
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5
100
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QR
B2 primary B3 B5
D5 D6
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1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
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Post External
RM
B2
D5 D6
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1
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B3
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1
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B1 Primary B4
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A1 A2 A3 A4
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100
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B2 Primary B3 B4 B5
D5 D6
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50
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B2 B3
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1
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Post External
UM
B2 Primary B4
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1
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B3
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1
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B3 Primary B5
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Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
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1 color
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Category being deleted
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Category being deleted
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Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
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Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
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90 Cover50 matte sheet text
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Catalogs
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AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
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4 color text
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Canada LA US Paper Requirements
D1
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Gray shading indicates Obsolete Print Catagories
18
8 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
9 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
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YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
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19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
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D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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Off Set Print Category Spec (See table below)
JIT Spec (See table below)
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Order Min
Order Max
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AD
NA - Puttman
NA
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NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
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NA
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NA
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(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
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A2 Primary A1
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100
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C2 Primary C1
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1
50
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50
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NA
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5
50
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A5 A6 A9
D5
Company Confidential Information
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NA
NA Confidential
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E-only
E-only D5
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5
50
NA Confidential
DC
E-only
E-only
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NA
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DI
A1 A3
NA
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5
100
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NA
NA
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5
50
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DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
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Post External
RM
B2
D5 D6
Reference Manual
1
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Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
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4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
19
10 Remove the bus bars and insulator sheets from the drive The steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 20
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar T3040 Nbullm(354 lbbullin)
DC- Bus Bar T3050 Nbullm(442 lbbullin)
DC+ Bus Bar T3050 Nbullm(442 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
20
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Do Not reuse this insulator sheet Replace with new insulator sheet
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
21
11 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
12 Continue with Step 5 Install the New Rectifier Module on page 43
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
22
Remove the Rectifier Module from a Frame 11 Drive
The rectifier module(s) on frame 11 drives are contained in the V and W phase power structure(s) 690V AC input 460A and 502A frame 11 drives only have one rectifier module contained in the V phase power structure
Note Cut any cable ties securing control and power cables as necessary in order to complete the following procedures When re-assembling the drive components all control and power cables must be secured in the same manner as they were prior to removal
Important Mark all connections and wires before removal to avoid incorrect wiring during reassembly
H LH LH L
Rectifier modules located on sides of power structures
U Phase
V Phase
W Phase
Publication PFLEX-IN023A-EN-P
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
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B2
D5 D6
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1
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B3
D5
Release Notes
1
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B1 Primary B4
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50
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B2
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50
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A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
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100
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B2 B3
D5 D6
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100
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TD
B2 Primary B3 B4 B5
D5 D6
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50
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B2 B3
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1
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B2 Primary B4
D6
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1
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B3
D5
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1
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WP
B3 Primary B5
D5
White Paper
5
50
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Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
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2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
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1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
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4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
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4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
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2 color
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Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
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1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
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1 color
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50 matte sheet text self cover
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2 color
160gsm Colortech amp 100gsm Bond
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Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
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4 color cover
270gsm Gloss 80gsm silk
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32-33 Coated Sheet
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Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
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Cover 170gsm with Body 120gsm
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1 color
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90 index
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20 bond self cover
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Gray shading indicates Obsolete Print Catagories
23
1 Remove the four M4x8 POZIDRIV screws that secure the ASIC board cover to the assembly and lift the cover off the assembly - you must unplug the cable for the ASIC board assembly fan from connector X1 on the ASIC board in order to remove the cover
ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly
Remove screws
Upper-left corner of drive
PZ215 Nbullm(133 lbbullin)
ASIC assembly
Publication PFLEX-IN023A-EN-P
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
24
2 Carefully disconnect the fiber-optic cables from sockets H1hellipH13 of the ASIC board and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
3 Disconnect the cables from connectors X2 X3 X4 X5 X6 X10 and X11 (and X9 and X15 if present) on the front of the ASIC board and set them aside
4 Remove the five POZIDRIV screws that secure the ASIC assembly to the drive and remove the assembly
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
H11 H12 H13H8 H9 H10
X9 X15
X3 X4 X5
X2
H4 H5 H6H1 H2 H3 H7
X11
X1
X6
X10
Fiber Optics
Fiber Optics
PZ230 Nbullm(265 lbbullin)
Publication PFLEX-IN023A-EN-P
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
25
5 Carefully disconnect the fiber-optic cables from sockets H15 and H16 on each of the three gate driver boards and carefully set them aside (see illustration below)
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
6 Remove the cables from connectors X6 and the DC+DC- terminals from the connector at the bottom of the three gate driver boards
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
X6
H16H15
+ -
Fiber Optics
Gate driver board locations
Remove wires from terminals + ndash
Publication PFLEX-IN023A-EN-P
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
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D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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NA - Puttman
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Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
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NA
NA
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NA
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(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
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A2 Primary A1
NA
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5
100
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C2 Primary C1
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1
50
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50
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NA
NA
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5
50
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A5 A6 A9
D5
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NA Confidential
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E-only
E-only D5
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5
50
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E-only
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A1 A3
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5
100
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NA
NA
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5
50
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DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
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5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
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4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
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4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
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2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
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4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
26
7 Remove the two screws that secure the wires for the ASIC board power supply to the DC+ and DC- bus bars and disconnect the cables for the fan power and control from the connectors as indicated below The fan power wires connect to the base of the fuse holder on the V phase module
8 Remove the air flow sheet from below the gate driver boards
DC-
DC+
Rectifier signal connectors
Fan signal connectors
Fan power connections on fuse holder
ASIC board power connections
Fan signal connector
Remove air flow sheet
Remove screws
PZ250 Nbullm(442 lbbullin)
Publication PFLEX-IN023A-EN-P
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
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(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
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D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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NA - Puttman
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Presale Internal
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A3
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Application Solution or Customer Success Story
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100
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NA
NA
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NA
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(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
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A2 Primary A1
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100
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C2 Primary C1
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1
50
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NA
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5
50
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A5 A6 A9
D5
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NA Confidential
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E-only
E-only D5
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5
50
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E-only
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A1 A3
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5
100
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NA
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5
50
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DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
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1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
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5
50
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PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
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PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
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Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
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4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
27
9 For PowerFlex 700H drives continue with step 12 on page 28For PowerFlex 700S drives only carefully disconnect the fiber-optic cables from sockets J4 and J5 on the voltage feedback board and carefully set them aside
Important Minimum inside bend radius for fiber-optic cable is 254 mm (10 in) Any bends with a shorter inside radius can permanently damage the fiber-optic cable Signal attenuation increases with decreased inside bend radii
10 Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J3 on the voltage feedback board
11 Disconnect the cable from connector J8 on the voltage feedback board
ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber-optic ports or fiber-optic cable connectors
J4 J5
J8
J2 J3
Voltage feedback board location
Publication PFLEX-IN023A-EN-P
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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NA - Puttman
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Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
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NA
NA
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NA
NA
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(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
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A2 Primary A1
NA
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100
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C2 Primary C1
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1
50
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50
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NA
NA
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5
50
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A5 A6 A9
D5
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NA Confidential
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E-only
E-only D5
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5
50
NA Confidential
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E-only
E-only
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NA
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DI
A1 A3
NA
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5
100
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NA
NA
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5
50
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DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
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5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
28
12 The V and W phase modules must be removed from the power structure in order to remove the rectifier modules Therefore you must lift the power structure off the maintenance stand and place it rear side of the unit down on a clean suitable work surface Follow the steps below to lift and move the power structure
a Fasten the lifting hardware to the holes in the flanges on the top of the power structure symmetrically in at least two holes The maximum angle between the cables must be no more than 45 degrees
b Lift the power structure off of the maintenance stand and place it rear side down on the work surface
Maximum angle 45 degrees
210 kg (463 lb)
Note Power structure shown with protective covers Complete the previous steps to remove the covers and disconnect control wiring before lifting and moving the power structure
Publication PFLEX-IN023A-EN-P
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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NA - Puttman
NA
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NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
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AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
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BR
A2 Primary A1
NA
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5
100
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C2 Primary C1
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1
50
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NA
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1
50
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NA
NA
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5
50
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CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
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5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
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5
100
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DM
NA
NA
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5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
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1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
29
13 For drives with DC bus supply terminals remove the six M10 nuts and washers that secure the bus bars that connect the DCndash and DC+ terminals to the horizontal bus bars and remove the bus bars
17 mm40 Nbullm(354 lbbullin)
Remove nuts
17 mm40 Nbullm(354 lbbullin)
Remove nuts
DC- DC+
Remove bus bars
Note Power cables not shown for clarity only
Publication PFLEX-IN023A-EN-P
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
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D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
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Order Max
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NA - Puttman
NA
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NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
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AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
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5
100
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C2 Primary C1
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1
50
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NA
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50
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NA
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5
50
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A5 A6 A9
D5
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NA Confidential
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E-only
E-only D5
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5
50
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E-only
E-only
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DI
A1 A3
NA
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5
100
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NA
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5
50
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DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
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PM
B2
D6
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1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
30
14 Remove the four M10 bolts and washers that secure the power cables to the rectifier circuit output terminals
15 Remove the four M10 nuts and washers that secure the other end of the power cables to the DCndash and DC+ collector bus bars and remove the cables
Remove nuts from bus bars
17 mm20 Nbullm(177 lbbullin)
Remove bolts from output terminals
17 mm20 Nbullm(177 lbbullin)
Power cables
Publication PFLEX-IN023A-EN-P
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
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NA
NA
Catalogue Guide
1
50
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NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
31
16 Remove the four remaining nuts and washers that secure the DCndash and DC+ collector bus bars to the drive and remove the bus bars and insulator material between them
Important The insulator material must be installed between the bus bars during installation
Remove nuts
17 mm20 Nbullm(177 lbbullin)
DC- and DC+ bus bars
Publication PFLEX-IN023A-EN-P
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
32
17 Remove the six M10 nuts and washers that secure the AC supply cables to the AC input terminals and remove the cables Note Frame 11 690V AC input 460A and 502A drives only have one set of AC input terminals and therefore one set of AC supply cables
Remove nuts
17 mm40 Nbullm(354 lbbullin)
AC supply cables
Publication PFLEX-IN023A-EN-P
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
33
18 Remove the eight POZIDRIV screws that secure the terminal assembly to the drive and remove the assembly
Remove screws
Remove screwsRemove screws
PZ240 Nbullm(354 lbbullin)
Terminal assembly
Publication PFLEX-IN023A-EN-P
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
34
19 Remove the four M10 hexagonal screws that secure each of the V and W phase modules to the drive frame
Remove screws
Remove screwsHEX820 Nbullm(177 lbbullin)
HEX820 Nbullm(177 lbbullin)
Rectifier circuit board(on side of phase module)
Publication PFLEX-IN023A-EN-P
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
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Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
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Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
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2 color
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90 index
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80gsm bond
20 bond self cover
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Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
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Gray shading indicates Obsolete Print Catagories
35
20 Remove the six M5 and six M6 POZIDRIV screws that secure the upper sheet metal plate of the power structure frame to the lower frame and remove the upper metal plate
21 Carefully remove the phase module from the top of the drive frame
22 For drives with a series ldquoArdquo rectifier circuit board (catalog number 20-VB00459 for 400480V AC input drives 20-VB00460 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 and X13 on the rectifier board (see Figure 7 on page 36) For drives with a series ldquoBrdquo rectifier circuit board (catalog number 20-VB00461 for 400480V AC input drives 20-VB00462 for 600690V AC input drives) disconnect the wires from connectors X10 X11 X12 X13 X21 and X31 X22 and X32 and X23 and X33 on the rectifier board (see Figure 8 on page 36)
Remove M5 screws
Remove M5 screws
Remove M6 screws
Remove M6 screws
PZ250 Nbullm(443 lbbullin)
PZ350 Nbullm(443 lbbullin)
Publication PFLEX-IN023A-EN-P
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
36
Figure 7 Series A Rectifier Circuit Board
Figure 8 Series B Rectifier Circuit Board
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8X101X50
J3J7
J11T2015 Nbullm(133 lbbullin)
X13X6X10X11X12X9 X100
X3 X2 X1
X4
X41
X8
X101X50X33 X23 X32 X22 X31 X21
T2015 Nbullm(133 lbbullin)
Publication PFLEX-IN023A-EN-P
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
37
23 If the common mode jumper is in the lowered position (as show below) remove the M4x8 hexalobular screw that secures the jumper to the bracket connected to the rectifier board
Important Note the position of the jumper before removal and ensure that it is placed in the same position when the rectifier board is installed
24 Remove the eight screws that secure the rectifier board to the drive (do not remove the screw at X41) and remove the board from the rectifier module Two M4x12 screws at X8 and X9 The remaining screws are M4x8
25 Remove the three M5 nuts and three M4x8 hexalobular screws that secure the snubber capacitors to the DC+ bus bar and SCR terminal bus bars and remove the capacitors
Rectifier circuit board
Do not remove screw at X41 on rectifier circuit board
Remove screw
T2015 Nbullm(133 lbbullin)
Top of Power Structure
Common mode jumper
T2015 Nbullm(133 lbbullin)
Remove nuts
8 mm15 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
38
26 Remove the M10 bolts and washers that secure the AC input supply cables and SCR terminal bus bars to the rectifier module and remove the cables and bus bars from the rectifier module
27 Remove the six M10x20 bolts and washers that secure the DC- and DC+ rectifier bus bars to the rectifier module and remove the bus bars
Important Do Not reuse the existing DC+ rectifier bus bar
Remove bolts 17 mm12 Nbullm(106 lbbullin)
AC supply cables
Terminal bus bars
Remove bolts
17 mm12 Nbullm(106 lbbullin)
Do Not reuse existing DC+ bus bar
Publication PFLEX-IN023A-EN-P
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
39
28 For 400480V AC input drives remove the three hexalobular screws that secure the balancing resistor wires to the main bus bars For 600690V AC input drives remove the four hexalobular screws that secure the balancing resistor wires to the main bus bars
Important Note the color (if unique) and location of each resistor connector wire Mark all connections and wires before removal to avoid incorrect wiring during reassembly
29 Remove the six M6x20 hexalobular screws that secure the snubber capacitor assembly to the power module and bus bars
Remove M4x8 screws
Remove M4x8 screw
600690V AC Input Drives
Remove M6x20 screw
Balancing resistors
Balancing resistors
T2015 Nbullm(133 lbbullin)
T3040 Nbullm(354 lbbullin)
400480V AC Input Drives
T2015 Nbullm(133 lbbullin)
Remove M4x8 screws
T2015 Nbullm(133 lbbullin)
Remove screws
T3050 Nbullm(442 lbbullin)
Snubber capacitor assembly
Publication PFLEX-IN023A-EN-P
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
40
30 Remove the bus bars and insulator sheets - the steps to remove the bus bars from a 400480V AC input drive are different than the steps to remove the bus bars from a 600690V AC input drive Refer to Remove the Bus Bars from a 400480V AC Input Drive below or Remove the Bus Bars from a 600690V AC Input Drive on page 41
Remove the Bus Bars from a 400480V AC Input Drive
ndash Remove the six M6x20 POZIDRIV screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the three M6x20 POZIDRIV screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
Outer Bus Bar PZ350 Nbullm(442 lbbullin)
DC- Bus Bar PZ350 Nbullm(442 lbbullin)
DC+ Bus Bar PZ350 Nbullm(442 lbbullin)
Bus bar insulator sheetsCapacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
Publication PFLEX-IN023A-EN-P
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
41
Remove the Bus Bars from a 600690V AC Input Drive
ndash Remove the four M6x25 hexalobular screws that secure the outer bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the four M6x20 hexalobular screws that secure the next bus bar to the drive and remove the bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x20 hexalobular screws that secure the main DC- bus bar to the drive and remove the main DC- bus bar and the loose bus bar insulator sheet
ndash Remove the two M6x16 hexalobular screws that secure the main DC+ bus bar to the drive and remove the main DC+ bus bar and the loose capacitor insulator sheet
T3040 Nbullm(354 lbbullin)
Bus bar insulator sheets
Capacitor insulator sheet
Do Not reuse this insulator sheet Replace with new insulator sheet
T3040 Nbullm(354 lbbullin)
Outer Bus Bar
DC- Bus Bar
DC+ Bus Bar
Publication PFLEX-IN023A-EN-P
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
42
31 Remove the eight M4x8 POZIDRIV screws that secure the rectifier module to the drive frame and remove the module
32 Continue with Step 5 Install the New Rectifier Module below
PZ215 Nbullm(133 lbbullin)
Remove screws
Publication PFLEX-IN023A-EN-P
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
43
Step 5 Install the New Rectifier Module
Install the new rectifier module in the reverse order of removalRefer to Step 4 Remove the Existing Rectifier Module(s) on page 12
Important You must only install the rectifier DC+ bus bar provided with this kit See illustration below
Important You must only install the new insulator sheet provided with the kit over the rectifier module
ATTENTION A hazard of personal injury andor equipment damage exists if the rectifier DC+ bus bar for round SCR terminals is installed on the rectifier module provided with this kit Do Not reuse the rectifier DC+ bus bar that was used on the round SCR terminals and install the rectifier DC+ bus bar provided with this kit only
Bus bar may touch SCR terminal if installed
Bus bar provided in this kit does not touch SCR terminal
DC+ bus bar for round SCR terminals (Do Not reuse this bus bar)
DC+ bus bar for rectangular SCR terminals provided in this kit(install this bus bar only)
Align holes in new insulator sheet over rectifier AC input terminal tabs
New insulator sheet
Publication PFLEX-IN023A-EN-P
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
44
Step 6 Install the Power Structure in the Enclosure
Install the power structure in the drive enclosure in the reverse order of removalRefer to Step 3 Remove the Power Structure from the Enclosure on page 9
Step 7 Complete the Circuit Tests
Forward and Reverse Biased Diode Tests for Major Power Components
A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 05V If the test finds a short the meter will display ldquo000rdquo If the test finds an open circuit or reversed polarity the meter will display ldquo0Lrdquo (zero load)
A reverse biased diode test should find an open circuit and the meter should display ldquo0Lrdquo (zero load)
There is a series A and series B rectifier circuit board for each voltage class The tests you can perform and the results of those tests vary depending on which series of board is in your drive Verify the board catalog number before completing the appropriate tests below
1 Verify that no power is applied to the drive
2 Disconnect all motor leads from the drive
3 Complete the forward and reverse biased diode tests on the rectifier modules (if present) as indicated in Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives on page 45 or Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives on page 47
~0L
+
-
~05V
+
-Forward biased test on PN-junction
Reverse biased test on PN-junction
Voltage ClassRectifier Circuit Board Catalog NumberSeries A Series B
400480V AC 20-VB00459 20-VB00461600690V AC 20-VB00460 20-VB00462
Publication PFLEX-IN023A-EN-P
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
45
Measurement Points for Forward and Reverse Diode Tests Frame 10 and 12 Drives
Series A Rectifier Circuit Board - Rectifier Module Tests
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER DANGERDC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Cat No
1234567890-
FIELD INSTALLED OPTIONSFIELD INSTALLED OPTIONS
DC- DC+ DC- DC+
1L11L2
1L3
2L12L2
2L3
1UT1
1VT2
1WT3 2UT1
2VT2
2WT3
Power Structure 1 Power Structure 2
Table A Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-1L2 DC-1L3 DC-
Publication PFLEX-IN023A-EN-P
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
46
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Table B Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Table C Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading- +DC+ 1L1
Meter should beep once and value should gradually rise to about 10 V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
DC+ 1L2DC+ 1L31L1 DC-
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module and the Output Power modules
1L2 DC-1L3 DC-
Table D Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -1L1 DC-
Meter should display ldquo0Lrdquo (zero load)
1L2 DC-1L3 DC-DC+ 1L1DC+ 1L2DC+ 1L3
Publication PFLEX-IN023A-EN-P
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
47
Measurement Points for Forward and Reverse Diode Tests Frame 11 Drives
Figure 9 Measurement Points for Forward and Reverse Diode Tests
Series A Rectifier Circuit Board - Rectifier Module Tests
Table E Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 05V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 05V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1DC- L2DC- L3
2L12L2
2L31L11L2
1L3
UT1 VT2 WT3
DC-DC+
Note 600V ac input 460A and 502A frame 11 drives only have one rectifier module
Publication PFLEX-IN023A-EN-P
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
48
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Series B Rectifier Circuit Board - Rectifier Module Tests
Important If the drive fails any of these measurements verify that all connections have been properly made for the appropriate rectifier module
Step 8 Install the Protective Covers
Install the protective covers on the drive in reverse order of removalRefer to Step 2 Remove the Protective Covers from the Drive on page 6
Table F Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Table G Forward Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC+
The value should gradually rise to about 10V(1)
(1) The actual voltage reading may vary depending upon your equipment If your readings are not near 10V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
L2 DC+L3 DC+DC- L1
The value should gradually rise to about 035V(2)
(2) The actual voltage reading may vary depending upon your equipment If your readings are not near 035V verify that the actual voltage measured is consistent for the Rectifier module(s) and the Output Power modules
DC- L2DC- L3
Table H Reverse Biased Diode Tests on Rectifier Module(s)Meter Leads
Nominal meter reading+ -L1 DC-
The meter should display ldquo0Lrdquo (zero load)
L2 DC-L3 DC-DC+ L1DC+ L2DC+ L3
Publication PFLEX-IN023A-EN-P
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
49
Step 9 Documenting the Change
Record the rectifier module installation on the Field Installed Option label
Related Documentation Allen-Bradley publications are available on the internet at wwwrockwellautomationcomliterature
For Read this document Publication NoProgramming and troubleshooting information on PowerFlex 700H drives
PowerFlex 700H Programming Manual 20C-PM001
Programming and troubleshooting information on PowerFlex 700S Phase II drives
PowerFlex 700S with Phase II Control User Manual 20D-UM006
Information on installing Frame 9-14 PowerFlex 700H and 700S drives
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
D1
4 color
170gsm white silk
80 gloss cover coated 2 sides
D2
4 color
120gsm white silk
80 gloss text coated 2 sides self cover
D3
4 color
Cover 170gsm with Body 120gsm
80 gloss cover 80 gloss text coated 2 sides
D4
1 color
160gsm tab
90 index
D5
1 color
80gsm bond
20 bond self cover
D6
1 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D7
2 color
160gsm tab
90 index
D8
2 color
80gsm bond
20 bond self cover
D9
2 color
Cover 160gsm tab with Body 80gsm bond
90 index 20 bond
D10
Combination 4 color cover with 2 color body
Cover 160gsm with Body 80gsm
90 index 20 bond
Gray shading indicates Obsolete Print Catagories
wwwrockwellautomationcom
Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel (1) 4143822000 Fax (1) 4143824444
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)
Catalogs
DbleParll
Used in Manufacturing
NO
A5 (583rdquo x 826rdquo) (148 x 210 mm)
C1
Offset Z
Fold
None
Sample
Comments
C2
Short
Part Number
JIT POD
V
D1
Z
D2
Microfold
D3
D4
D5
D6
D7
D8
D9
This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printingFind your publication type in the first section below Use the assigned Printing Category information to determine the standard print specifications for that document type The Printing Categories are defined below the Publication Type section Note there may be slightly different print specifications for the categories depending on the region (EMEA or Americas)For more information on Global Sales and Marketing Printing Standards see publication RA-CO004 in DocMan
Publication Type and Print Category
Publication Type
Off Set Print Category Spec (See table below)
JIT Spec (See table below)
Description
Order Min
Order Max
Life Cycle Usage Release Option
AD
NA - Puttman
NA
Advertisement Reprint Colour
NA
NA
Presale Internal
AP
A3
D2
Application Solution or Customer Success Story
5
100
Presale External
AR
NA
NA
ArticleEditorialByline
NA
NA
Presale Internal
(press releases should not be checked into DocMan or printed)
AT
B3 B4
D5
Application techniques
5
100
Presale External
BR
A2 Primary A1
NA
Brochures
5
100
Presale External
CA
C2 Primary C1
NA
Catalogue
1
50
Presale External
CG
NA
NA
Catalogue Guide
1
50
Presale External
CL
NA
NA
Collection
5
50
Presale External
CO
A5 A6 A9
D5
Company Confidential Information
NA
NA
NA Confidential
CP
E-only
E-only D5
Competitive Information
5
50
NA Confidential
DC
E-only
E-only
Discount Schedules
NA
NA
Presale Internal
DI
A1 A3
NA
Direct Mail
5
100
Presale Internal
DM
NA
NA
Product Demo
5
50
Presale Internal
DS
B3
D5
Dimensions Sheet
1
5
Post External
DU
B3
D5
Document Update
1
5
Post External
GR
B2
D6
Getting Results
1
5
Post External
IN
B3 Primary B2
D5 D6
Installation instructions
1
5
Post External
LM
NA
NA
Launch Materials
5
50
Presale Internal
PC
B3
D5
Packaging Contents
PL
E-only primary B3
E-only
Price List
5
50
Presale Internal
PM
B2
D6
Programming Manual
1
5
Post External
PP
A3
D1
Profile (Single Product or Service) NOTE Application Solutions are to be assigned the AP pub type
5
100
Presale External
QR
B2 primary B3 B5
D5 D6
Quick Reference
1
5
Post External
QS
B2 primary B3 B5
D5 D6
Quick Start
1
5
Post External
RM
B2
D5 D6
Reference Manual
1
5
Post External
RN
B3
D5
Release Notes
1
5
Post External
SG
B1 Primary B4
D5 D6
Selection Guide Colour
5
50
Presale External
SG
B2
D5 D6
Selection Guide BW
5
50
Presale External
SP
A1 A2 A3 A4
NA
Sales Promotion NOTE Service profiles are to be assigned the PP pub type
5
100
Presale Internal
SR
B2 B3
D5 D6
Specification Rating Sheet
5
100
Presale External
TD
B2 Primary B3 B4 B5
D5 D6
Technical Data
5
50
Presale External
TG
B2 B3
D6
Troubleshooting Guide
1
5
Post External
UM
B2 Primary B4
D6
User Manual BW
1
5
Post External
WD
B3
D5
Wiring Diagrams Dwgs
1
5
Post Internal
WP
B3 Primary B5
D5
White Paper
5
50
Presale External
Minimum order quantities on all JIT items are based on the publication length
Publication length
Minimum Order Quantity
77 or more pages
1 (no shrink wrap required)
33 to 76 pages
25
3 to 32 pages
50
1 or 2 pages
100
Pre-sale Marketing
All paper in this category is White Brightness 90 or better Opacity 90 or better
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
A1
4 color
170 gsm 2pp
100 gloss cover 100 gloss text
A2
4 color
170 gsm folded 4pp
100 gloss cover 80 gloss text
A3
4 color
Cover 170 gsm with Body 120 gsm gt 4pp
80 gloss cover 80 gloss text
A4
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 gloss text
A5
2 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A6
1 color
170gsm Silk ndash 120gsm Silk
80 gloss cover 80 matt sheet text
A7
4 color cover2 color textSelection Guide
Category being deleted
10 Point Cover C2S50 matte sheet text
A8
4 color cover
Category being deleted
50 matte sheet text self cover
2 color text
Selection Guide
A9
2 color
100gsm bond
50 matte sheet text self cover
Selection Guide
Gray shading indicates Obsolete Print Catagories
Post Sale Technical Communication
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
B1
4 color cover
270gsm Gloss 100gsm bond
10 Point Cover C2S
2 color text
50 matte sheet text
B2
1 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B3
1 color
100gsm bond
50 matte sheet text self cover
B4
2 color
160gsm Colortech amp 100gsm Bond
90 Cover50 matte sheet text
B5
2 color
100gsm bond
50 matte sheet text self cover
Catalogs
Category
Color Options
AP EMEA Paper Requirements
Canada LA US Paper Requirements
C1
4 color cover
270gsm Gloss 90gsm silk
10 Point Cover C2S
4 color text
45 Coated Sheet
C2
4 color cover
270gsm Gloss 80gsm silk
10 Point Cover C2S
2 color text
32-33 Coated Sheet
JIT POD
All paper in this category is White Brightness 82 or better Opacity 88 or better
Select Print Category ABC or D from category list on Introduction_Catagory Types tab
11rdquo x 17rdquo
LOOSE -Loose Leaf
YES
Pre-sale Marketing
TOP
(required) Finished Trim Size Width
85rdquo x 11rdquo
85rdquo x 11rdquo
PERFECT - Perfect Bound
A1
LEFT
(required) Publication Number
PFLEX-IN023A-EN-P
Sample 2030-SP001B-EN-P
3rdquo x 5rdquo
SADDLE - Saddle Stitch
A2
RIGHT
CORNER
Use Legacy Number
NO
YES or NO
18rdquo x 24rdquo Poster
PLASTCOIL - Plastic Coil (Coil Bound)
A4
BOTTOM
SIDE
Legacy Number if applicable
Sample Legacy Number 0160-533
24rdquo x 36rdquo Poster
STAPLED1 -1 position
A3
Publication Title
PowerFlex 700S and 700H Frames 10hellip12 Rectifier Module Replacement Kit
Sample ElectroGuard Selling Brief
36rdquo x 24rdquo Poster
STAPLED1B - bottom 1 position
A5
(required) Business Group
Marketing Commercial
As entered in DocMan
4rdquo x 6rdquo
STAPLED2 - 2 positions
A6
(required) Cost Center
19010
As entered in DocMan - enter number only no description Example - 19021
CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 19105
475rdquo x 7rdquo (slightly smaller half-size)
THERMAL - Thermal bound (Tape bound)
A7
BindingStitching
STAPLED2 - 2 positions
Review key on right
Saddle-Stitch Items All page quantities must be divisible by 480 pgs max on 20 (text and cover)76 pgs max on 20 (text) and 24 (cover)72 pgs max on 24 (text and cover)Perfect Bound Items940 pgs max wcover (90 index unless indicated otherwise)Coil Bound Items580 pgs max of 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)Tape Bound Items250 pgs max on 20 no cover240 pgs max wcover (90 index unless indicated otherwise)Double Wire Bound Items80 pgs max on 20 (if adding cover deduct equivalent number of pages to equal cover thickness) (90 index unless indicated otherwise)
475rdquo x 775rdquo
THERMALO - Thermal Bound (Tape bound - offline)
A8
(required) Page Count of Publication
50
Total page count including cover
55rdquo x 85rdquo (half-size)
Wire O - Double Wire Bound (offline)
A9
Paper Stock Color
White is assumed For color options contact your vendor
6rdquo x 4rdquo
Post Sale Technical Communication
Number of Tabs Needed
5 tab in stock at RR Donnelley
7385rdquo x 9rdquo (RSI Std)
B1
Stitching Location
SIDE
Blank Corner or Side
825rdquo x 10875rdquo
B2
Drill Hole YESNO
NO
All drilled publications use the 5-hole standard 516 inch-size hole and a minimum of frac14 inch from the inner page border
825rdquo x 11rdquo (RA product profile std)
B3
None
Glue Location on Pad
Glue location on pads
8375rdquo x 10875
B4
Half
Number of Pages per Pad
Average sheets of paper 25 50 75100 Max
9rdquo x 12rdquo (Folder)
B5
C
Ink Color
One color assumes BLACK 4 color assume CMYK Indicate PMS number herehellip
A4 (8 frac14rdquo x 11 frac34rdquo) (210 x 297 mm)