Powerflex® 700L Liquid-Cooled Adjustable Frequency Ac Drive: Hardware Service Manual

PowerFlex® 700L Liquid-Cooled
Adjustable Frequency AC Drive
HARDWARE SERVICE MANUAL
Frame 2
Important User Solid state equipment has operational characteristics differing from those of
Information electromechanical equipment. Safety Guidelines for the Application, Installation and
Maintenance of Solid State Controls (Publication SGI-1.1 available from your local
Rockwell Automation sales office or online at http://www.rockwellautomation.com/
literature) describes some important differences between solid state equipment and
hard-wired electromechanical devices. Because of this difference, and also because of
the wide variety of uses for solid state equipment, all persons responsible for applying
this equipment must satisfy themselves that each intended application of this
equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of
information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety
considerations.
WARNING: Identifies information about practices or

! circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property
damage, or economic loss.
Important: Identifies information that is critical for successful application and

understanding of the product.
ATTENTION: Identifies information about practices or

! circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard,
avoid a hazard, and recognize the consequences.
Shock Hazard labels may be located on or inside the equipment

(e.g., drive or motor) to alert people that dangerous voltage may be
present.
Burn Hazard labels may be located on or inside the equipment

(e.g., drive or motor) to alert people that surfaces may be at
dangerous temperatures.
Allen-Bradley and PowerFlex are registered trademarks of Rockwell Automation, Inc.
PowerFlex® 700L Frame 2 Drive Hardware Service Manual

Summary of Changes
This is the first release of the PowerFlex 700L Liquid-Cooled AC Drive

Frame 2 Hardware Service Manual.

Publication 20L-TG002A-EN-P
soc-ii Summary of Changes

Table of Contents
Preface Overview
Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
What is in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
What is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Understanding Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Cross References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Additional Support Available on Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Class 1 LED Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Chapter 1 Troubleshooting and Error Codes

Creating Fault Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Addressing Active Converter Hardware Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Addressing 700 Vector Control Hardware Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Addressing 700S Phase II Control Hardware Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Diagnostic Procedures by Symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
No HIM Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Circuit Breaker Tripped – Blown Input Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Over-Temperature Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Chapter 2 Component Test Procedures

Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Viewing the PowerFlex 700 Vector Control Diagnostic Indicators . . . . . . . . . . . . . . . . . 2-2
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Viewing the PowerFlex 700S Control Diagnostic Indicators . . . . . . . . . . . . . . . . . . . . . . 2-3
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Removing Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Periodic Inspections with No Power Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Coolant Hoses/Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Terminal Bolts, Mounting Bolts, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Periodic Inspections with Power Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Checking the Power Module Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Checking the Input Filter Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Forward Biased Diode Tests for the Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

ii Table of Contents
Chapter 3 Access Procedures

Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Understanding Torque Figures in Assembly Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Removing Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Removing the Drive Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Removing the HIM Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Removing the Communications Adapter Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Removing the Inverter Control Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
700 Vector Control Cassette (24V or 115V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
700S Phase II Control Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Removing the Active Converter Control Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Removing the Power Section Stirring Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Removing the Drive Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Replacing the Inverter Power Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Replacing the Converter Power Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Replacing the PCB Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Replacing the Input Filter Fan Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Replacing the Control Transformer Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Replacing the Control Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Replacing the Input Filter Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Replacing the J1-to-J6 Power Interface Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Replacing the J3-to-J4 Power Interface Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Table of Contents iii
Replacing the J2-to-J5 Power Interface Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Replacing the PWR (Power) Interface Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Replacing the Voltage Feedback Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Replacing the Motor Voltage Feedback PCB (700S Phase II Control only) . . . . . . . . . 3-25
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Chapter 4 Start-Up After Repair

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

Software Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Appendix B Connector Descriptions

J1-to-J6 Power Interface Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
PWR (Power) Interface Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Voltage Feedback Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Motor Voltage Feedback PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Converter Power Interface Board to Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Converter Control Board to Power Supply and DC Bus. . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Temperature Switches to Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Power and Ground to Contactors and Voltage Feedback . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Control Transformer and Converter Control to Contactors . . . . . . . . . . . . . . . . . . . . . . . B-5
Power Supply to Stirring Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Appendix C Connection Diagram and Schematics

Frame 2 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Frame 2 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

iv Table of Contents

Preface
Overview
Who Should Use this This manual is intended for qualified service personnel responsible for
Manual? troubleshooting and repairing PowerFlex 700L Liquid-Cooled Frame 2
Drives. You should have previous experience with, and basic understanding
of, electrical terminology, procedures, required troubleshooting equipment,
equipment protection procedures and methods, and safety precautions.
What is in this Manual This manual contains hardware service information for PowerFlex 700L
Frame 2 drives only. Verify that you are working on a Frame 2 drive by
checking the data nameplates on the inside of the bay doors and on the
Power Modules. The frame number is printed just above the serial number.
Figure P.1 shows the data nameplate locations.

P-2 Overview
Figure P.1 PowerFlex 700L Frame 2 Drive Data Nameplate Locations
Cat No. 20LC360N3ENNAN10WA

NEMA Type
Complete Regenerative Drive
Series: A
Nominal Voltage Original Firmware V. x.xxx
Normal Duty Power
Input: 3 Phase, 47-63 Hz
AC Voltage Range
Amps
Output: 3 Phase, 0-400Hz
AC Voltage Range
Base Hz (default)
Continuous Amps
Rated Coolant
Nom. Coolant Pressure
MFD. in 2007 on JUL 05
Frame: 2
Serial Number: MEAE2WJ0
Made in the U.S.A. (FAC1C)
SIDE VIEW
Cat No. 20LC360N3ENNAN10WA

NEMA Type
Complete Regenerative Drive
Series: A
Nominal Voltage Original Firmware V. x.xxx
Normal Duty Power
Input: 3 Phase, 47-63 Hz
AC Voltage Range
Amps
Output: 3 Phase, 0-400Hz
AC Voltage Range
Base Hz (default)
Continuous Amps
Rated Coolant
Nom. Coolant Pressure
MFD. in 2007 on JUL 05
Frame: 2
Serial Number: MEAE2WJ0
Made in the U.S.A. (FAC1C)
FRONT VIEW (Cover Removed)

Overview P-3
What is Not in this Manual This manual does not contain in-depth fault information for
troubleshooting. Depending on the control cassette installed in the drive,
that information is available in the PowerFlex 700 Adjustable Frequency AC
Drive - Series B User Manual (publication 20B-UM002) or the PowerFlex
700S High Performance AC Drive - Phase II Control User Manual
(publication 20D-UM006). Additional information is also contained in the
PowerFlex 700L Liquid-Cooled Adjustable Frequency AC Drive User
Manual (publication 20L-UM001) and the PowerFlex 700L Active
Converter Power Module User Manual (publication PFLEX-UM002).
Reference Materials You can view or download publications at www.rockwellautomation.com/

literature. To order paper copies of technical documentation, contact your
local Rockwell Automation distributor or sales representative.
To find your local Rockwell Automation distributor or sales representative,

visit www.rockwellautomation.com/locations.
The following publications provide general drive information.
Title Publication
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001
Safety Guidelines for the Application, Installation and Maintenance of Solid State SGI-1.1
Control
A Global Reference Guide for Reading Schematic Diagrams 0100-2.10
Guarding Against Electrostatic Damage 8000-4.5.2
The following publications provide specific PowerFlex drive information.

Title Publication
PowerFlex 700L Liquid-Cooled Adjustable Frequency AC Drive User Manual 20L-UM001
PowerFlex 700L Active Converter Power Module User Manual PFLEX-UM002
PowerFlex 700 Adjustable Frequency AC Drive User Manual - Series B 20B-UM002
PowerFlex 700S High Performance AC Drive - Phase II Control User Manual 20D-UM006
Hi-Resolution Feedback Option Card Installation Instructions for PowerFlex 700S 20D-IN001
Drives
Multi-Device Interface Option Card Installation Instructions for PowerFlex 700S 20D-IN004
Drives
PowerFlex Adjustable Frequency Drive Reference Manual (Volume 1 - 70 & 700) PFLEX-RM001
PowerFlex Adjustable Frequency Drive Reference Manual (Volume 2 - 700S) PFLEX-RM002
The following publications provide information that is necessary when

applying the DriveLogix Controller.
Title Publication
User Manual - DriveLogix System 20D-UM002
Installation Instructions - DriveLogix Controller 20D-IN002
Installation Instructions - Memory Expansion for DriveLogix Controller 20D-IN007
ControlNet Daughtercard Installation Instructions 1788-IN002
ControlNet Daughtercard Installation Instructions 1788-IN005

P-4 Overview
Understanding Manual Terms

Conventions
The following words are used throughout the manual to describe an action:
Word Meaning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Must Unavoidable, you must do this
Shall Required and necessary
Should Recommended
Should Not Not recommended
Cross References
“Figure 2.1 on page 2-2” is a hyperlinked cross reference to Figure 2.1 on
page 2 of Chapter 2.
Additional Support Additional troubleshooting information and software tools are available on
Available on Internet the Allen-Bradley Drives Support Web site:
www.ab.com/support/abdrives

Overview P-5
General Precautions Class 1 LED Product
ATTENTION: Hazard of permanent eye damage exists when

! using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into module ports or
fiber-optic cable connectors.
ATTENTION: This drive contains ESD (Electrostatic

! Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with
static control procedures, refer to Allen-Bradley publication
8000-4.5.2, “Guarding Against Electrostatic Damage” or any
other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can
! result in component damage or a reduction in product life. Wiring
or application errors, such as undersizing the motor, incorrect or
inadequate AC supply, or excessive ambient temperatures may
result in malfunction of the system.
ATTENTION: Only qualified personnel familiar with
! PowerFlex 700L Drives and associated machinery should plan or
implement the installation, start-up, and subsequent maintenance
of the system. Failure to comply may result in personal injury
and/or equipment damage.
ATTENTION: To avoid an electric shock hazard, verify that the
! voltage on the bus capacitors has discharged completely before
servicing. After removing power to the drive, wait 5 minutes for
the bus capacitors to discharge. With the cover of the drive
removed, measure the DC bus voltage at the DC+ and DC-
TESTPOINT sockets on the lower front of the power module (see
Figure 2.2 on page 2-5 for details). The measured voltage must be
zero (0).
ATTENTION: Potentially fatal voltages may result from
! improper usage of an oscilloscope and other test equipment. The
oscilloscope chassis may be at a potentially fatal voltage if not
properly grounded. If an oscilloscope is used to measure high
voltage waveforms, use only a dual-channel oscilloscope in the
differential mode with X 100 probes. It is recommended that the
oscilloscope be used in the A minus B Quasi-differential mode
with the oscilloscope chassis correctly grounded to an earth
ground.

P-6 Overview
Notes:

Chapter 1
Troubleshooting and Error Codes
ATTENTION: To avoid an electric shock hazard, ensure that all

! power to the drive has been removed before performing the
following.
servicing. After removing power to the drive, wait 5 minutes for
the bus capacitors to discharge. With the cover of the drive
removed, measure the DC bus voltage at the DC+ TESTPOINT
and DC- TESTPOINT sockets on the lower front of the power
module. The voltage must be zero.
ATTENTION: HOT surfaces can cause severe burns. Do not
! touch the heatsink surface during operation of the drive. After
disconnecting power allow time for cooling.
static control procedures, reference Allen-Bradley publication
Creating Fault Reports Clear and complete fault reports are critical for analysis and repair of
modules returned to the factory.
At a minimum, perform and record the following:
• Record the contents of the fault queue (faults and times of occurrence).
• Make record of any burn marks on the input inductor, filter capacitor
assembly, precharge resistors, precharge contactors, printed circuit
boards, bus bar, and cabling.
• Make record of any liquid or condensation marks on printed circuit

boards, complete drive hose assemblies, and other mechanical parts.
• Make record of the amount of dust and other additional particles on drive
and drive components.

1-2 Troubleshooting and Error Codes
• Make record of any mechanical damage to the drive and drive

components.
• Record the size and type of main fuses.
• Record any other important marks and damages.
Addressing Active The following table describes active converter hardware faults.
Converter Hardware Faults Fault No. Description Action
HW Over Current 1 Control board detected excessive Check cables and motor.
phase current. Verify that the grounding tabs in
the back of the control
cassettes are making a solid
connection.
HW Over Voltage 2 Control board detected excessive DC Check input voltage.
Link voltage.
HW Ground Fault 3 Control board detected a ground fault. Check cables and motor.
Verify that the grounding tabs in
connection.
HW Disabled 4 Enable signal is not present. Verify hardware enable is
present.
HW Latch Error 5 Control board detected an unidentified Verify that the grounding tabs in
fault. the back of the control
connection.
Contact Technical Support.
Precharge Open 6 The precharge contactor opened Verify operation of precharge
when it was commanded closed. contactor.
Precharge Closed 7 The precharge contactor closed when Verify operation of precharge
it was commanded open. contactor.
DPI Mastr ComLos 8 DPI communication with the inverter Verify DPI cable installation.
was lost.
Inverter Fault 9 Inverter detected a fault. Examine inverter fault code.
PS1 Desat Phase R 10 Power structure 1 detected a desat Contact Technical Support.
fault on phase R.
PS1 Desat Phase S 11 Power structure 1 detected a desat Contact Technical Support.
fault on phase S.
PS1 Desat Phase T 12 Power structure 1 detected a desat Contact Technical Support.
fault on phase T.
PS1 Over Current 13 Power structure 1 detected excessive Check motor, cables, and
phase current. application for cause.
PS1 Over Voltage 14 Power structure 1 detected excessive Check input power and
DC Link voltage. application for cause.
PS1 Asym DC Link 15 Power structure 1 detected an Verify load balance resistors.
asymmetrical DC Link voltage.
PS1 Power Supply 16 Power structure 1 detected a power Replace power supply if
supply out of tolerance. problem persists.
PS1 HW Disable 17 Power structure 1 hardware enable is Verify drive enable is present.
not present.
PS1 Latch Error 18 Power structure 1 detected an Contact Technical Support.
unidentified fault.
PwrBd Incompat 30 Power board incompatible with control Load new file into power board.
board.
PB Ver Corrupted 31 Power board version number is Load new file into power board.
corrupted.

Troubleshooting and Error Codes 1-3
Fault No. Description Action

Default Corrupted 32 Power board default data file is Load new file into power board.
corrupted.
Rating Corrupted 33 Power board rating data file is Load new file into power board.
corrupted.
New ControlBoard 34 New converter control board was Reset to defaults is required.
detected.
Elapsed Checksum 35 Elapsed operation checksum is invalid Reset to defaults is required.
at power up.
Param Checksum 36 Parameter data checksum is invalid at Reset to defaults is required.
power up.
Param Checksum B 37 Parameter data checksum error when Reset to defaults is required.
writing a BYTE value.
Param Checksum W 38 Parameter data checksum error when Reset to defaults is required.
writing a WORD value.
Param Checksum L 39 Parameter data checksum error when Reset to defaults is required.
writing a LONG value.
Ac Line Lost 40 AC line synchronization was lost when Verify proper input line voltage
power turned off. is present.
Ac Phase Lost 41 AC line synchronization was lost when Verify proper input line voltage
when a phase was lost. is present.
Ac Sync Low Vac 42 AC line synchronization was lost Verify proper input line voltage
because voltage was low. is present.
AC Sync Low Freq 43 AC line synchronization was lost Verify proper input line voltage
because frequency was low. is present.
AC Sync High Freq 44 AC line synchronization was lost Verify proper input line voltage
because frequency was high. is present.
AC Sync Conflict 45 Conflict in AC line synchronization Contact Technical Support.
state machine.
PWM Sync Lost 46 PWM Carrier synchronization was Verify wiring of carrier
lost. synchronization twisted pair.
Ac Low Voltage 50 AC line voltage was below the Verify proper input line voltage
configured limit for the configured is present.
time.
Ac High Voltage 51 AC line voltage exceeded the Verify proper input line voltage
time.
Ac Low Frequency 52 AC line frequency was below the Verify proper input line voltage
time.
Ac High Frequency 53 AC line frequency exceeded the Verify proper input line voltage
time.
Ac High dFdT 54 Change in line frequecy exceeded the Verify proper input line voltage
configured limit. is present.
Ac I Imbalance 55 AC current balance exceeded the Verify proper input line voltage
time.
Ac V Imbalance 56 AC voltage balance exceeded the Verify proper input line voltage
time.
DcLink Low Volt 57 DC link voltage was below the Verify proper input line voltage
precharge open level. is present.
Ride Thru Expire 58 Power dip ride through expired with Verify proper input line voltage
the precharge open. is present.
Ride Thru Expire 59 Power dip ride through expired with Verify proper input line voltage
the precharge closed. is present.
IT Over Load 60 Operating current levels exceeded the Verify application operates
rated overload. within limits.
Ambnt Over Temp 61 Measured ambient temperature Take steps to lower ambient.
exceeded the maximum limit.


Base Over Temp 62 IGBT base temperatures exceeded Verify the required drive cooling
the maximum limit. is present.
Jnct Over Temp 63 IGBT junction temperature exceeded Verify drive cooling and
the maximum limit. excessive current levels.
Ntc Range Low 64 NTC temperature below rated Check for open or shorted NTC
temperature range. device.
Ntc Range High 65 NTC temperature above rated Check for open or shorted NTC
temperature range. device.
PS1 Fan Loss 66 Power structure 1 detected a Verify internal circulating fans
circulating fan was lost. are turning.
PS1 Reactor Temp 67 Power structure 1 detected the reactor Verify reactor cooling fans are
thermal switch opened. turning.
For additional information regarding the active converter, please refer to the
PowerFlex 700 Active Converter Power Module User Manual (publication
PFLEX-UM002).
Addressing 700 Vector The following table describes two groups of 700 Vector Control faults. The
Control Hardware Faults first group contains faults common to both the 20B and 20L products. The
second group contains faults existing only in the 20L product.
Faults Common to 20B and 20L Products
Auxiliary Input 2 Auxiliary input interlock is open. Check remote wiring.
Power Loss 3 DC bus voltage remained below 85% Monitor input voltage for low
of nominal longer than [Power Loss voltage or line power
Time]. interruptions.
Under Voltage 4 DC bus level fell below minimum Monitor input voltage for low
value. voltage or line power
interruptions.
Over Voltage 5 DC bus level exceeded maximum Monitor input voltage for high
value. line or transient voltage.
Motor Overload 7 Internal electronic overload trip. Reduce load so drive output
current does not exceed the
current set by [Motor NP FLA].
Heatsink OvrTemp 8 Heatsink temperature exceeded Check water loop.
100% of [Drive Temp]. Check for excess load.
Trnsistr OvrTemp 9 Output transistors have exceeded Check water loop.
their maximum operating limit. Check for excess load.
HW OverCurrent 12 The drive output current has Check programming. Check for
exceeded the hardware current limit. excess load, improper DC
boost or other causes of excess
load.
connection.
Ground Fault 13 A current path to ground greater than Check motor and external
25% of drive rating exists. wiring to drive output terminals
for a grounded condition.
connection.
Load Loss 15 Drive output current is below [Load Verify the connections between
Loss Level] for a time greater than motor and load. Verify level and
[Load Loss Time]. time.


Motor Thermistor 16 Thermistor output is out of range. Verify the thermistor is
connected. Motor is
overheated. Reduce load.
Output Phase Loss 21 Current in one or more of the phases Check the drive and motor
has been lost or is below a preset wiring.
level.
Phase U to Grnd 38 A phase to ground short has been Check the wiring between the
Phase V to Grnd 39 detected between the drive and the drive and the motor. Check
Phase W to Grnd 40 motor in this phase. motor for ground. Replace
power module.
Phase UV Short 41 Excessive current has been detected Check the motor and the drive
Phase VW Short 42 between these two output terminals. output terminal wiring for a
Phase UW Short 43 shorted condition. Replace
power module.
Drive Overload 64 Drive rating of 110% for 1 minute or Reduce load.
150% for 3 seconds has been
exceeded.
Port 1-6 Adapter 71-76 Communications adapter on port Check communication cable
reported a fault. and check adapter fault queue
for information about the fault.
Port 1-6 DPI Fault 81-86 DPI communications to port was lost. If adapter was not intentionally
disconnected, check wiring.
Replace wiring, port expander,
or Main Control Board as
needed. Check HIM
connection.
Faults Existing Only in 20L Products
700L Dsat U 170 Phase U Desat fault on 700L power Contact Technical Support.
structure.
700L Dsat V 171 Phase V Desat fault on 700L power Contact Technical Support.
structure.
700L Dsat W 172 Phase W Desat fault on 700L power Contact Technical Support.
structure.
700L OvrCurnt 173 Over current on 700L power structure. Check programming. Check for
cause of excessive current.
700L OvrVolt 174 Over voltage on 700L power structure. Check programming. Check for
cause of excessive voltage.
700L Asym Vdc 175 Asymmetrical voltage on 700L power Verify load balance resistors.
structure DC link.
700L PwrSply 176 Power supply failed on 700L power Replace power supply if
structure. problem persists.
700L HW Disable1 177 Hardware disable asserted on 700L Verify drive enable is present.
power structure.
700L Latch Err 178 Fault reporting failure on 700L power Verify that the grounding tabs in
structure. the back of the control
connection.
700L Fan Loss 179 Fan failure on 700L power structure. Verify internal circulating fans
are turning.
Cnv NotLogin 190 Active converter did not begin Check DPI connection. Check
communication. for proper versions.
Cnv Not Start 191 Active converter did not start when Check start inhibits. Check
requested. parameter 214 - [Start Inhibit].
700L NTC Open 192 Thermal sensor failed on 700L power Contact Technical Support.
structure.
For additional information regarding 700 Vector Control, please refer to the
PowerFlex 700 Adjustable Frequency AC Drive User Manual - Series B
(publication 20B-UM002).

Addressing 700S Phase II The following table describes two groups of 700S Phase II faults. The first
Control Hardware Faults group contains faults common to both the 20D and 20L products. The
second group contains faults existing only in the 20L product.
Name No. Description Action
Faults Common to 20D and 20L Products
Motor OLoad Trip 11 Internal electronic overload trip. Reduce load so drive output
current does not exceed the
current set by [Motor NP FLA].
Inv OTemp Trip 15 P313 [Heatsink Temp] is above the Reduce the mechanical load.
maximum limit. Check cooling loop.
Inv OLoad Trip 17 The drive’s operating point has Reduce the mechanical load
exceeded the intermittent current configured with P377 [Inv OL
rating and a foldback to the Trip Cnfg].
continuous rating has occurred.
DC Bus OverVolt 24 An over voltage has occurred on the Check programming. Check for
DC bus. cause of excessive voltage.
Ground Fault 26 A current to earth exceeds 35% of the Check the motor and external
peak drive rating. wiring to the drive output
terminal for a grounded
condition.
connection.
DC Bus Undervolt 42 Bus voltage has fallen below the level Monitor input voltage for low
configured by P409 [Line Undervolts]. voltage.
DPI Loss Port 1-6 49-54 The device at DPI Port 1-6 has Verify the DPI device is present
stopped communicating. and functional at the port.
Net Loss DPI 1-6 55-60 A communication fault has occurred Verify network connection.
between the adapter at port 1-6. Verify status of network.
Faults Existing Only in 20L Products
700L Dsat U1 97 Phase U Desat fault on 700L power Contact Technical Support.
structure 1.
700L Dsat V1 98 Phase V Desat fault on 700L power Contact Technical Support.
structure 1.
700L Dsat W1 99 Phase W Desat fault on 700L power Contact Technical Support.
structure 1.
700L OvrCurnt1 100 Over current on 700L power structure Check programming. Check for
1. cause of excessive current.
connection.
700L OvrVolt1 101 Over voltage on 700L power structure Check programming. Check for
1. cause of excessive voltage.
700L AsymDcLink1 102 Asymmetrical voltage on 700L power Verify load balance resistors.
structure 1 DC link.
700L PwrSply1 103 Power supply failed on 700L power Replace power supply if
structure 1. problem persists.
700L HW Disable1 104 Hardware disable asserted on 700L Verify drive enable is present.
power structure 1.
700L Latch Err 1 105 Fault reporting failure on 700L power Verify that the grounding tabs in
structure 1. the back of the control
connection.
700L Fan Fail 1 106 Fan failure on 700L power structure 1. Verify internal circulating fans
are turning.
700L Cnv Faulted 110 Active converter has faulted. Check active converter fault
log.

Name No. Description Action

Cnv NotLogin 111 Active converter did not begin Check DPI connection. Check
communication. for proper versions.
Cnv Not Start 112 Active converter did not start when Check start inhibits. Check
requested. parameter 214 [Start Inhibits].
For additional information regarding 700S Phase II Control, please refer to

the PowerFlex 700S High Performance AC Drive - Phase II User Manual
(publication 20D-UM006).
Diagnostic Procedures by The following charts list drive symptom, symptom descriptions, and
Symptom recommended actions.
No HIM Display
Use this procedure when the HIM does not function:
Check HIM
Properly Reseat or
Connection No
Connected? Reconnect HIM
and Seating
Yes
Check Cable Connections:

34-Pin Power Supply Cable
40-Pin MCB Cable Properly Reseat or
30-Pin Comm. I/F Cable Connected? No
Reconnect Cables
Comm. I/F PCB
Internal DPI Cables
External DPI Cables
Yes
Replace
Replace HIM Display? No Power Supply
PCB

Circuit Breaker Tripped – Blown Input Fuses

Use this procedure when a drive clears any of its circuit breaker or power
fuses (branch circuit protection):
Disconnect Power Inspect for Yes Replace Drive or

Damage Visible?
Lock Out/Tag Out Visible Damage Damaged Components
No
Check Control Control Replace Transformer

Transformer Transformer Yes Fuses and Check/Repair
Primary Fuses Blown? Control Wiring
No
Check Control
Is Transformer Replace
Transformer for Yes
Damaged? Transformer
Shorts/Visible Damage
No
Temporarily
Remove (1) Control
Transformer Fuse
Disconnect Converter
Module AC Terminals
from the Input Filter
Short is on the Load Side

Check for Line-to-Line Measures less of the Contactors or
and Line-to-Ground than 100 ohms? Yes Wiring to the Converter or
Shorts at the Drive Input Filter Section --
Isolate and Repair
No
Perform Diode Did Converter Replace the

Tests on the Yes
Module Fail Test? Converter Module
Converter Module
No
Perform Diode Did Inverter Replace the

Tests on the Yes
Module Fail Test? Inverter Module
Inverter Module
No
Contact Allen-Bradley
Perform Any Problems Yes Drives
Start-Up Procedure Found? Technical Support

Over-Temperature Faults
Use this procedure to troubleshoot drive over-temperature faults:
Temperature Provide Additional

Check Surrounding
Exceeds Yes Airflow or Air
Air Temperature
Specification? Conditioning
No
Current Reduce Load or

Check Motor Current
Exceeds Yes Procure a Drive with a
and Load Levels
Specification? Higher Rating
No
Check PWM Frequency Too High Lower PWM

for Lead Length and Yes
Frequency Surrounding Temp?
Frequency
No
Fluid
Check Fluid Flow Meets Remedy Fluid Flow
No
Through the Drive Specification? Rate and Temperature
Yes
Check Fan and Air Flow Proper Space No Remedy Space at Inlet
Through the Drive at Inlet?
Yes
Air Flow Remove Air Flow

Blockages? Yes
Blockages
No
Fan Running
Yes
Properly?
No
Check Connection Between

Connection Repair
Power Module Fan and No
Power Supply PCB Good? Connection
Yes
Check Fan Winding Resistance =

7.3 Ohms No Replace Fan
Resistance
± 5%?
No
Contact Allen-Bradley
Drives
Technical Support

Notes:

Chapter 2
Component Test Procedures

following.
! voltage on the Power Module DC bus capacitors has discharged
completely before performing any work on the drive.
1. Turn off and lock out input power. Wait 5 minutes.

L1 L2 L3
I
2. With the cover of the drive removed, measure the DC bus

voltage at the DC+ and DC- TESTPOINT sockets on the
lower front of the power module (see Figure 2.2 on page 2-5
for details). The measured voltage must be zero (0).
static control procedures, refer to Allen-Bradley publication
Drive Status The condition or state of your 700L drive is constantly monitored. Any
changes will be indicated through the HIM option (if present) and/or four
sets of status indicators:
• Power Module status indicators (for both 700S and 700 vector control).
• SynchLink option indicators (for 700S control only).
• DriveLogix communications option indicators (for 700S control only).
• Network communication adapter option indicators (if installed).

2-2 Component Test Procedures
The drive status indicators are located on the top front of the drive.
Figure 2.1 Drive Status Indicators
POWER
STS
➋
PORT
MOD
NET A
NET B
Viewing the PowerFlex 700 The PowerFlex 700L power module contains Power and Status indicators
Vector Control Diagnostic and, if installed, Communication Adapter indicators (Figure 2.1). These
Indicators indicators are only operational when the drive is energized.
ATTENTION: The indicators are only operational when the

! drive is energized. Servicing energized equipment can be
hazardous. Severe injury or death can result from electrical
shock, burn or unintended actuation of controlled equipment.
Follow Safety related practices of NFPA 70E, ELECTRICAL
SAFETY FOR EMPLOYEE WORKPLACES. DO NOT work
alone on energized equipment!
Status Indicators
Item Name Color State Description
➊ POWER Green Steady Illuminates when power is applied to the drive.
➋ STS Green Flashing Drive ready, but not running and no faults are present.
(Status) Steady Drive running, no faults are present.
Yellow Flashing, A type 2 alarm condition exists, the drive cannot be started.
Drive Stopped Check parameter 211 [Drive Alarm 2].
Flashing, An intermittent type 1 alarm condition is occurring.
Drive Running Check parameter 211 [Drive Alarm 1].
Steady, A continuous type 1 alarm condition exists.
Drive Running Check parameter 211 [Drive Alarm 1].
Red Flashing Fault has occurred. Check [Fault x Code] or Fault Queue.
Steady A non-resettable fault has occurred.
➌ PORT Refer to the Communication Status of DPI port internal communications (if present).
MOD Adapter User Manual. Status of communications module (when installed).
NET A Status of network (if connected).
NET B Status of secondary network (if connected).

Component Test Procedures 2-3
Viewing the PowerFlex 700S In addition to the PowerFlex 700L power module indicators (Figure 2.1),
Control Diagnostic the 700S control cassette contains Run, controller, and SynchLink
Indicators indicators. These indicators are only operational when the drive is energized
and only visible when the drive door is open. The status of these indicators
can also be viewed from the HIM or from an applications program (for
example, DriveExplorer) in parameter 554 (LED Status). This feature is
only available with PowerFlex 700S Phase II control version 3.001 or later.
ATTENTION: The Run and controller indicators are only

! operational when the drive is energized. Servicing energized
equipment can be hazardous. Severe injury or death can result
from electrical shock, burn or unintended actuation of controlled
equipment. Follow Safety related practices of NFPA 70E,
ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES.
DO NOT work alone on energized equipment!
Status Indicators
Item Name Color State Description
➊ PWR Green Steady Illuminates when power is applied to the drive.
(Power)
➋ STS Green Flashing Drive ready, but not running & no faults are present.
(Status) Steady Drive running, no faults are present.
Power Structure
Yellow Flashing When running, a type 2 (non-configurable) alarm

condition exists, drive continues to run. When stopped, a
start inhibit exists and the drive cannot be started.
Steady A type 1 (user configurable) alarm condition exists, but
drive continues to run.
Red Flashing A fault has occurred.
Steady A non-resettable fault has occurred.
Red / Flashing The drive is in flash recovery mode. The only operation
Yellow Alternately permitted is flash upgrade.
DRIVE
➌
Communications
PORT Refer to the Status of DPI port internal communications (if present).
MOD Communication Status of communications module (when installed).
NET A Adapter User Manual Status of network (if connected).
NET B Status of secondary network (if connected).
Control Assembly
(1)
SYNCHLINK Green Steady The module is configured as the time keeper.
– or –
The module is configured as a follower and
synchronization is complete.
Control
Green Flashing The follower(s) are not synchronized with the time keeper.
Red Flashing The module is configured as a time master on SynchLink
and has received time information from another time
master on SynchLink.
ENABLE Green On The drive’s enable input is high.
Green Off The drive’s enable input is low.
(1)
SynchLink LEDs are located on the SynchLink daughtercard on the main circuit board in the control cassette.

Removing Power from the 1. Turn off and lock out input power. Wait five (5) minutes.
Drive L1 L2 L3
I
2. Remove and save the drive cover (see Removing the Drive Front
Cover on page 3-4).
(5 Captive Screws)
3. Check for zero (0) volts between the DC+ and DC- testpoints. Using 4
mm (0.158 in.) socket probes, connect the voltmeter to DC+ and DC-
TESTPOINT sockets on the lower front of the power module. The
measured voltage must be zero (0).

Component Test Procedures 2-5
Figure 2.2 Measuring the DC Bus Voltage at the DC Testpoint Sockets
DC+ DC-
Testpoint Testpoint
A A
Section A-A
Periodic Inspections with Coolant Hoses/Connections

No Power Applied
Visually inspect the inlet and outlet coolant hose assemblies, and filter
section-to-power section coolant connections for leaks. Replace hoses if
leaks cannot be stopped.
Terminal Bolts, Mounting Bolts, etc.

Ensure all power conductor terminal bolts and mounting bolts are tight.
Tighten loose bolts. Refer to Chapter 3 for torque specifications.
Periodic Inspections with Checking the Power Module Fan

Power Applied
Check for vibration and noise. Fan failure may be imminent if vibration
and/or increasing noise in the fan bearings occurs. Fan replacement is
recommended at this time. Refer to Removing the Power Section Stirring
Fan on page 3-9.

Checking the Input Filter The Frame 2 input filter has two fans just above the input terminals of the
Fans drive.
ATTENTION: Fans are only operational when the drive is

! energized and only visible with cabinet doors open. Servicing
energized equipment can be hazardous. Severe injury or death
can result from electrical shock, burn or unintended actuation of
controlled equipment. Follow safety-related practices of NFPA
70E, ELECTRICAL SAFETY FOR EMPLOYEE
WORKPLACES. DO NOT work alone on energized equipment!
Check for vibration and noise. Fan failure may be imminent if vibration
and/or increasing noise in the fan bearings occurs. Fan replacement is
recommended at this time.
Forward Biased Diode Tests A forward biased diode test checks the semiconductor junctions between
for the Power Module the terminals and measures the voltage drop across those junctions. To run
the test, use a digital multi-meter with a diode check mode. To pass each
test, the meter must display a voltage within the specification shown in the
table. If the test finds a short, the meter will display “.000.” If the test finds
an open circuit or reversed polarity, the meter will display “.0L.”
1. Remove power from the drive (see Removing Power from the Drive on
page 2-4).
2. Disconnect power conductors from R/L1, S/L2, T/L3, U/T1, V/T2, and
W/T3 terminals on the power module. For power module terminal
names and locations, refer to Figure 2.1 or Figure 2.11 in the PowerFlex
700L User Manual.
3. Perform forward biased diode tests on the points listed in Table 2.A. If
the power module fails any of these tests, then replace the power
module.
Table 2.A Forward Biased Diode Tests for the Power Module
Meter Leads
+ - Nominal Meter Reading
DC+ DC- Value should gradually rise to 0.75V or greater.
R/L1 DC+
S/L2 DC+
T/L3 DC+
DC- R/L1
DC- S/L2
DC- T/L3
0.30…0.40V
U/T1 DC+
V/T2 DC+
W/T3 DC+
DC- U/T1
DC- V/T2
DC- W/T3

Chapter 3
Access Procedures

following.
servicing. Measure the DC bus voltage at the DC+ and DC-
TESTPOINT sockets on the lower front of the power module.
The measured voltage must be zero (0).
ATTENTION: The sheet metal cover and mounting screws on
! the ASIC Board located on the power structure are energized at
(-) DC bus potential high voltage. Risk of electrical shock, injury,
or death exists if someone comes into contact with the assembly.
ATTENTION: 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.
static control procedures, reference Allen-Bradley publication

3-2 Access Procedures
Torque Specifications The following table lists fastener torque specifications for the Frame 2
complete drive spare parts kits:
Torque
Kit Catalog Number Description Fastener Final
SK-L1-CVR1-F2 Front Cover Slotted captive 3.1 N•m
screw (27 lb•in)
20L-VECTB-C0 Inverter Vector Control Cassette, 24V Slotted captive 0.6 N•m
20L-VECTB-D0 Inverter Vector Control Cassette, 115V screw (5 lb•in)
20D-P2-CKE1 Inverter 700S Phase II Control Cassette
20D-DL2-CKE1 Inverter 700S Phase II Control Cassette
with DriveLogix 5730
SK-L1-ACC1-F3D Active Converter Control Cassette,
400/480V
SK-L1-ACC1-F3F Active Converter Control Cassette,
600/690V
SK-L1-FAN2-F2 Power Section Stirring Fan M5 x 10 mm 3.2 N•m
Torx screw (28 lb•in)
SK-L1-PIABI1-F2 Inverter Power Interface PCB M5 x 10 mm 3.2 N•m
SK-L1-PIAC1-F3 Converter Power Interface PCB Torx screw (28 lb•in)
M4 x 10 mm 1.7 N•m
SK-L1-PWRS1-F2 PCB Power Supply M5 x 10 mm 3.2 N•m
M4 x 10 mm 1.7 N•m
SK-L1-PWRS2-F2 Input Filter Fan Power Supply M5 x 10 mm 3.2 N•m
M4 x 10 mm 1.7 N•m
SK-L1-FUSE1-F2 Control Transformer Fuses M5 x 10 mm 3.2 N•m
SK-L1-XFMR1-F2 Control Transformer, 200VA Torx screw (28 lb•in)
SK-L1-FAN1-F2 Input Filter Fan Assembly M4 x 20 mm 1.7 N•m
SK-L1-HPWRS1-F2 J1-to-J6 Power Interface Harness M5 x 10 mm 3.2 N•m
M6 x 12 mm 6.8 N•m
SK-L1-CBL2-F2 Converter-to-Inverter PWR (Power) Torx screw (28 lb•in)
Interface Jumper
SK-L1-HGD1-F2 Voltage Feedback Harness
SK-L1-MVF1-C Motor Voltage Feedback PCB, 400V Nylon snap-on standoffs —
and nylon rivets
Phillips® is a registered trademark of the Phillips Screw Company.

Access Procedures 3-3
Understanding Torque Figures in Assembly Diagrams

Icons and numbers in the assembly diagrams indicate how to tighten
hardware:
Tool Type and Size
Symbol Fastener Type T indicates Torx driver bit
Torx Head
Screw
Slotted Captive T25
Screw 3.2 N•m Tightening Torque
(28 lb•in)
Removing Power from the

Drive
! voltage on the Power Module DC bus capacitors has discharged
completely before performing any work on the drive.
1. Turn off and lock out input power. Wait 5 minutes.
L1 L2 L3
I
2. Measure the DC bus voltage at the DC+ and DC-

TESTPOINT sockets on the lower front of the power module
(see Figure 2.2 on page 2-5 for details). The measured
voltage must be zero (0).
Remove power before making or breaking cable connections.

When you remove or insert a cable connector with power
applied, an electrical arc may occur. An electrical arc can cause
personal injury or property damage by:
• Sending an erroneous signal to your system’s field devices,

causing unintended machine motion.
• Causing an explosion in a hazardous environment.
Electrical arcing causes excessive wear to contacts on both the

module and its mating connector. Worn contacts may create
electrical resistance.

Removing the Drive Front Removal

Cover
page 3-3).
2. Unfasten the five (5) M5 x 16 mm (0.63 in.) long slotted captive screws
that secure the drive cover, and remove the cover.
(5 Captive Screws)
Installation
1. Place the cover on the front of the drive and align it to the edges of the
drive.
2. Tighten the five (5) M5 x 16 mm (0.63 in.) long slotted captive screws
to secure the cover to the drive.
Removing the HIM Option Removal/Installation

The HIM can be removed or installed while the drive is powered.
Important: HIM removal is only permissible in Auto mode. If the HIM is

removed while in Manual mode or the HIM is the only
remaining control device, a fault will occur.
Step Key(s) Example Displays
To remove the HIM:
ALT + Remove Op Intrfc:
1. Press ALT and then Enter (Remove). The Press Enter to
Remove HIM confirmation screen appears. Disconnect Op Intrfc?
2. Press Enter to confirm you want to remove HIM. (Port 1 Control)
3. Remove the HIM from the drive.
To install the HIM, insert into drive or connect cable.

Removing the Removal

Communications Adapter
Option page 3-3).
2. Remove the drive front cover (see Removing the Drive Front Cover on
page 3-4).
3. Disconnect the communications adapter cable from its mating

connector on the communications adapter.
4. Unfasten the four (4) M3 x 6 mm (0.24 in.) long Phillips captive screws
that secure communications adapter, and remove the adapter.
HIM Bezel
Phillips Captive Screw

M3 x 6 mm Long
4X
P0
0.6 N•m
(5 lb•in)
Cable Connector
Communications Adapter
Communications
Adapter Cable
Installation
Install the communications adapter in reverse order of removal, while
referring to the torque specification shown in the drawing.

Removing the Inverter Depending on the drive control option, the inverter is equipped with either
Control Cassette the 700 Vector Control or the 700S Phase II Control cassette.
700 Vector Control Cassette (24V or 115V)
Removal
page 3-3).
page 3-4).
3. Follow standard ESD procedures.
4. Disconnect the 700 vector control synchronization cable terminal block

TB2.
5. Disconnect the 40-Pin MCB cable from connector J2. Leave the cable's
other end connected to the addressable power PCB.
6. Disconnect the 30-Pin communications interface cable from connector

J3. Leave the cable's other end connected to the communications
interface PCB.
7. Disconnect the I/O terminal block TB1.
8. Disconnect the encoder terminal block J1 (if installed).

9. Loosen the two (2) screw latches on the front of the cassette and slide
the cassette out from the cassette mounting bracket.
Pin 1
Detail
Installation
Install the cassette in reverse order of removal. Hand tighten the two (2)
cassette screw latches to the cassette mounting bracket.

700S Phase II Control Cassette
Removal
page 3-3).
page 3-4).
4. Disconnect the 40-Pin MCB cable from connector P1. Leave the cable's
5. Disconnect the 30-Pin communications interface cable from connector
P2. Leave the cable's other end connected to the communications
interface PCB.
6. Disconnect four (4) I/O terminal blocks TB1 and TB2.
7. Loosen the two (2) screw latches on the front of the cassette and slide
8. Disconnect the 700S synchronization cable connector P6. Remove and

save the tape holding the cable to the cassette.
Detail
TB1 Terminals
TB2 Terminals
Installation

Removing the Active Removal

Converter Control Cassette
page 3-3).
page 3-4).
4. Disconnect the internal DPI cable from connector J4.

5. Disconnect the 700S control synchronization cable (if installed) from
connector J9.
6. Disconnect the 40-Pin MCB cable from connector J1. Leave the cable's
7. Disconnect the I/O terminal block P1.
Important: Do not disconnect the 700 vector control synchronization

cable (if installed) from P1-7 and P1-8.
8. Disconnect the voltage feedback resistor PCB terminal block P2.
9. Loosen the (2) two screw latches on the front of the cassette and slide
Pin 1 Detail
Synchronization Cable 40-Pin
(For use with 700S Phase II Control only) Ribbon Cable
Internal DPI Cable

P1
Synchronization Cable
(For use with 700 Vector Control only)
P2
Installation

Removing the Power Removal

Section Stirring Fan
page 3-3).
page 3-4).
4. Unfasten the seven (7) M5 x 10 mm (0.39 in.) long Torx screws that
secure the bottom drive cover, and remove the cover.
Torx Screw
M5 x 10 mm Long
7X
T25
3.2 N•m
(28 lb•in)
5. Unfasten two (2) M5 x 10 mm (0.39 in.) long Torx bracket screws that
secure the fan, disconnect the fan power leads (two fastons), and lift the
fan from the drive.
Torx Screw
M5 x 10 mm Long
2X
T25
3.2 N•m
(28 lb•in)
Installation
Install the fans and fan harness in reverse order of removal while referring
to torque specifications shown in the drawings.
Important: Fan airflow direction is into the Power Section.

Removing the Drive Front In most cases, the drive front panel must be removed first to access the drive
Panel component for its removal and replacement.
Removal
1. Remove the power section stirring fan from the drive (see Removing the
Power Section Stirring Fan on page 3-9).

3. Verify each wire connected to the TB1 terminal block is labeled with
the terminal designation to which it is connected. If not, label the wire
accordingly. Thereafter, disconnect all wires from TB1. The drawing
below shows all of the wires connected to TB1.
Green/Yellow
White
White
Black
Black
Black
Black
Black
Black
Blue
Blue
Red
Red
Red
Ia15
Ia14
Ia13
Ia12
Ia11
Ia10
Ia 9
Ia 8
Ia 7
Ia 6
Ia 5
Ia 4
Ia 3
Ia 2
Ia 1
PS+
PE1
PE2
PS-
Ib15
Ib14
Ib13
Ib12
Ib11
Ib10
Ib 9
Ib 8
Ib 7
Ib 6
Ib 5
Ib 4
Ib 3
Ib 2
Ib 1
PS+
PE1
PE2
PS-
Black 2X
Black 2X
Black 2X
Black
Black
Black
Black
Black
Black
Orange
Orange
Black
White 2X
4. See Figure 3.1 and remove the three (3) tie wraps securing the PS-
(black) and PS+ (red) wires to the drive front panel.

5. See Figure 3.1 and unfasten the nine (9) M5 x 10 mm (0.39 in.) long
Torx screws that secure the drive front panel. Then remove the drive
front panel.
Figure 3.1 Removing the Drive Front Panel
Torx Screw
M5 x 10 mm Long
9X
T25
3.2 N•m
(28 lb•in)
Red Wire
to PS+
on TB1
Black Wire
to PS-
on TB1
Installation
Install the drive front panel in reverse order of removal while referring to the
torque specification shown in the drawing.

Replacing the Inverter Removal

Power Interface PCB
1. Remove the drive front panel (see Removing the Drive Front Panel on
page 3-10).
2. Disconnect the stirring fan power leads (two fastons) from the input
filter fan power supply PCB.
3. Detach the eight (8) cable connectors (items ➊ through ➑ as shown in

the following drawing) from the inverter power interface PCB.

Torx Screw

M4 x 10 mm Long
6X
T20
1.7 N•m
(15 lb•in)

Inverter Power
Interface PCB
4. Remove the six (6) M4 x 10 mm (0.39 in.) long Torx screws that secure
the inverter power interface PCB, and remove the board.
Installation
Install the inverter power interface PCB in reverse order of removal, while
referring to the torque specifications shown in the drawings.

Replacing the Converter Removal

Power Interface PCB
page 3-10).
2. Disconnect the stirring fan power leads (two fastons) from the input
filter fan power supply PCB.
3. Detach the six (6) cable connectors (items ➊ through ➏ as shown in the
following drawing) from the converter power interface PCB.
Torx Screw
M4 x 10 mm Long
6X
T20
1.7 N•m
(15 lb•in)
Converter Power
Interface PCB


4. Remove the six (6) M4 x 10 mm (0.39 in.) long Torx screws that secure
the converter power interface PCB, and remove the board.
Installation
Install the converter power interface PCB in reverse order of removal, while
Replacing the PCB Power Removal

Supply
page 3-10).
2. See Figure 3.2 on page 3-15 and unfasten the ten (10) M5 x 10 mm
(0.39 in.) long Torx screws that secure the right side panel at the top,
side, and bottom of the panel. Then remove the right side panel.
3. Disconnect the three (3) ribbon cables from the inverter power interface
PCB.
4. Unfasten the four (4) M4 x 10 mm (0.39 in.) long Torx screws that
secure the PCB power supply, and remove the board.

Figure 3.2 Removing the Drive Right Side Panel

Torx Screw
M5 x 10 mm Long
Torx Screw
10X
M4 x 10 mm Long
4X T25
3.2 N•m
T20
(28 lb•in)
1.7 N•m
(15 lb•in)
Right
Side Panel
Installation
Install the PCB power supply in reverse order of removal, while referring to
the torque specifications shown in the drawings.

Replacing the Input Filter Removal

Fan Power Supply
page 3-10).
secure the bottom drive cover. Then remove the bottom drive cover.
3. Disconnect the red and white wires from the DC bus, and the cable
connector from the filter fan.
secure the input filter fan power supply, and remove the power supply.
Torx Screw
M4 x 10 mm Long
4X
T20
1.7 N•m Torx Screw
(15 lb•in) M5 x 10 mm Long
7X
T25
3.2 N•m
(28 lb•in)
Installation
Install the input filter fan power supply in reverse order of removal, while

Replacing the Control Removal

Transformer Fuses
1. Remove the power section stirring fan (see Removing the Power
Section Stirring Fan on page 3-9) to access the control transformer
fuses.
690V
600V
480V
400V
2. Replace the blown fuse(s) with the same type and equivalent-rated
fuse(s).
Installation
Install all drive components in reverse order of removal, while referring to

Replacing the Control Removal

Transformer
1. Remove the power section stirring fan (see Removing the Power
Section Stirring Fan on page 3-9) to access the control transformer.
page 3-10).
3. Disconnect the three (3) black wires from the control transformer.
4. Remove the four (4) M5 x 10 mm (0.39 in.) long Torx screws that
secure the control transformer, and remove the transformer.
Torx Screw
M5 x 10 mm Long
4X
T25
3.2 N•m
(28 lb•in)
Installation
Install the control transformer in reverse order of removal, while referring to

Replacing the Input Filter Removal

Fan Assembly
page 3-3).
2. See Figure 3.2 and unfasten the ten (10) M5 x 10 mm (0.39 in.) long
Torx screws that secure the right side panel at the top, side, and bottom
of the panel. Then remove the right side panel.
secure the bottom drive cover. Then remove the bottom drive cover.
secure the input filter fan assembly, and remove the assembly.
Input Filter Fan

Ass’y Power
Connector
Torx Screw
M5 x 10 mm Long
7X
T20
3.2 N•m
(28 lb•in)
Torx Screw
M4 x 20 mm Long
4X
T20
1.7 N•m
(15 lb•in)
5. Locate the input filter fan assembly power connector (see drawing
above) and disconnect it from the input filter fan power supply.
Installation
Install the input filter fan assembly in reverse order of removal, while

Replacing the J1-to-J6 Removal

Power Interface Harness
page 3-10).
2. See Figure 3.3 and unfasten the ten (10) M5 x 10 mm (0.39 in.) long
Torx screws that secure the right side panel at the top, side, and bottom
of the panel. Then remove the right side panel.
Figure 3.3 Drive Harness Locations
J2-to-J5 Power
Interface Harness
Torx Screw
J1-to-J6 Power M5 x 10 mm Long
Interface Harness 10X
T25
3.2 N•m
(28 lb•in)
Right
Side Panel
PWR (Power)
Interface Jumper
Voltage Feedback Harness
3. Disconnect the J1-to-J6 power interface harness from both the power
supply PCB and the inverter power interface PCB.
Installation
Install the J1-to-J6 power interface harness in reverse order of removal,
while referring to the torque specifications shown in the drawings.


page 3-10).
3. Unfasten the three (3) M5 x 10 mm (0.39 in.) long Torx screws that
secure the left side panel. Then remove the left side panel.
Torx Screw
M6 x 12 mm Long
2X
J3-to-J4 Power
T30 Interface Harness
6.8 N•m (also includes two
(60 lb•in) ring lugs to the bus)
Torx Screw
M5 x 10 mm Long
3X
T25
3.2 N•m
(28 lb•in)
Left
Side Panel

4. Unfasten the two (2) M6 x 12 mm (0.47 in.) long Torx screws that
secure the ring lugs of the J3-to-J4 power interface harness to the DC
bus. Then remove the ring lugs and disconnect the J3-to-J4 power
interface harness from the inverter power interface PCB.
Installation

page 3-10).
3. Disconnect the J2-to-J5 power interface harness from both the power
supply PCB and the inverter power interface PCB.
J2-to-J5 Power
Interface Harness
Installation

Replacing the PWR (Power) Removal

Interface Jumper
page 3-10).
2. Disconnect the PWR (Power) interface jumper from both the inverter
power interface PCB and the converter power interface PCB.
PWR (Power)
Interface Jumper
Installation
Install the PWR (Power) interface jumper in reverse order of removal, while

Replacing the Voltage Removal

Feedback Harness
page 3-10).
3. Disconnect the voltage feedback harness from both the power supply
PCB and the inverter power interface PCB.
Voltage
Feedback
Harness
Installation
Install the voltage feedback harness in reverse order of removal, while

Replacing the Motor Voltage Removal

Feedback PCB (700S Phase
II Control only) page 3-10).
2. Remove the two (2) nylon rivets that secure the Nomex insulator, and
remove the insulator. (Note: New rivets are included in the motor
voltage feedback PCB spare parts kit.)
3. Unsnap the five (5) nylon standoffs that secure the motor voltage
feedback PCB, and remove the board. (Note: New nylon standoffs are
included in the motor voltage feedback PCB spare parts kit.)
Nomex Motor Voltage

Insulator Feedback PCB
Nomex
Insulator
Nylon
Standoff
5X
Nylon Rivet
2X
Installation
Install the motor voltage feedback PCB in reverse order of removal, while
Important: Make sure that both Nomex insulators are in position as shown
in the drawing above when installing the replacement motor
voltage feedback PCB.

Notes:

Chapter 4
Start-Up After Repair
ATTENTION: Power must be applied to the drive to perform

! the following start-up procedure. Some of the voltages present
are at incoming line potential. To avoid electric shock hazard or
damage to equipment, only qualified service personnel should
perform the following procedure. Thoroughly read and
understand the procedure before beginning. If an event does not
occur while performing this procedure, Do Not Proceed. Remove
Power including user-supplied control voltages. User-supplied
voltages may exist even when main AC power is not applied to
the drive. Correct the malfunction before continuing.
Phone United States/ 1.262.512.8176 (7 AM - 6 PM CST)

Canada 1.440.646.5800 (24 hour support)
Outside United You can access the phone number for your country via the
States/Canada Internet:
Go to http://www.ab.com
Click on Support (http://support.rockwellautomation.com/)
Under Contact Customer Support, click on Phone Support
Internet ⇒ Go to http://www.ab.com/support/abdrives/
E-mail ⇒ [email protected]
Be prepared to provide the following information when you contact

support:
• Product Catalog Number

• Product Serial Number
• Firmware Revision Level
Performing the Power The Power Circuit Diagnostic Test, for the PowerFlex 700L with 700S
Circuit Diagnostic Test Phase II Control, allows you to diagnose problems in the drive’s power
(700S Phase II Control only) structure without applying large amounts of power.
1. Verify that input power wiring and grounding is connected.
2. Verify that the motor cables are connected.
3. Energize the drive.

4-2 Start-Up After Repair
4. From the Monitor menu on the HIM, press the Esc (Escape) key to
navigate to the Main menu.
5. Use the (Down) key to select Start-Up and press the

(Enter) key to enter Start-Up. Then press the (Enter) key again to
verify your intention to continue with the Start-Up menu.
6. Use the (Down) key to select Pwr Circuit Diag and press the
(Enter) key to enter Power Circuit Diagnostics.
7. Press the (Start) key to start the Power Circuit Diagnostic routine.
Follow indications and instructions on the HIM.
Testing With the Motor This test allows you to measure several operating parameters and diagnose
problems without connecting the motor to its mechanical load.
1. Verify that input power wiring and grounding is connected.
2. Verify that the motor cables are connected.
3. Verify that the motor load is disconnected.
4. Energize the drive.
5. Start the drive and increase the speed from zero to base speed.
6. Measure drive output current on all three phases, and verify that the
value is reflected in:
– parameter 003 [Output Current] (700 Vector Control)
– parameter 308 [Output Current] (700S Phase II Control)
7. Stop the drive.

Appendix A
Service Tools and Equipment
Software Tools DriveTools™ SP, DriveExecutive, DriveExplorer™, and DriveObserver™

are software tools for uploading, downloading, and monitoring system
parameters.
Service Tools Service of the PowerFlex 700L Frame 2 drive requires certain kinds of
tools, devices, and test equipment. Basic tools, devices, and test equipment
have to meet requirements of professional services. The tools have to be in
good condition and have to fit how and where they are going to be used.
This list of basic service tools covers the needs of tools for repair and
maintenance measurements.
Item Description Details
1 Oscilloscope Portable, digitizing, dual channel scope, with isolation
2 Current clamp 1000 A (AC, rms), signal output
3 Soldering station Soldering / de-soldering
4 Adjustable power supply 0…1300V DC, 1 A, adjustable current limit. Efore LPS
750-HV or equivalent.
5 Adjustable power supply 0…690V AC (+10%), 10 A, three phase, galvanic isolation
6 Multi-meter Digital multi-meter, capable of AC and DC voltage, continuity,
resistance, capacitance measurements, and forward diode
bias tests. Fluke model 87 III or equivalent.
7 Insulation tester 1000V DC
8 Torque wrench 1…12 N•m
9 Torque wrench 6…50 N•m
10 Nose pliers
11 Flat blade screw driver 2…7 mm
12 Phillips screw driver 1, 2, 3
13 Torx screw driver T25, T30, T35
14 ESD-protected place of work Working surface, floor covering, seat, and earthings
15 ESD-protective clothing Wrist wrap, shoes, overall clothing (coat)
16 Power supply (service) Capacity of three phase service 400/500/690V AC, 250 A

A-2 Service Tools and Equipment
Notes:

Appendix B
Connector Descriptions
For Details on… See Page…

J1-to-J6 Power Interface Harness B-1
PWR (Power) Interface Jumper B-2
Voltage Feedback Harness B-2
Motor Voltage Feedback PCB B-3
Converter Power Interface Board to Terminal Block B-3
Converter Control Board to Power Supply and DC Bus B-4
Temperature Switches to Fan B-4
Power and Ground to Contactors and Voltage Feedback B-4
Control Transformer and Converter Control to Contactors B-5
Power Supply to Stirring Fan B-5
J1-to-J6 Power Interface

80W Power Supply Pin Pin Inverter Power
Harness Board Number to Number Interface Board Description
J1 1 … 1 J6 FB Bus
2 … 2 AD Gnd
3 … 3 AD Gnd
4 … 4 +5V
5 … 5 +5V
6 … 6 -12VDC
7 … 7 AD Gnd
8 … 8 +12V
9 … 9 24V Com
10 … 10 +24VDC
11 … 11 24V Fan
12 … 12 —
13 … 13 —

80W Power Supply Pin Pin
Harness Board Number to Number Terminal Block Description
J2 1 … 1 J5 —
2 … 2 —
3 … 3 GPWR Rtn W-
4 … 4 Gate PWR W-
5 … 5 GPWR Rtn V-
6 … 6 Gate PWR V-
7 … 7 GPWR Rtn U-
8 … 8 Gate PWR U-

B-2 Connector Descriptions

80W Power Supply Pin Pin Inverter Power
Harness Board Number to Number Interface Board Description
J3 1 … 1 J4 +Bus
2 … 2 —
3 … 3 —
4 … 4 -Bus
5 … 5 —
6 … 6 —
7 … 7 Gate PWR W+
8 … 8 GPWR Rtn W+
9 … 9 —
10 … 10 —
11 … 11 Gate PWR V+
12 … 12 GPWR Rtn V+
13 … 13 —
14 … 14 —
15 … 15 Gate PWR W+
16 … 16 GPWR Rtn W+
PWR (Power) Interface

Inverter Power Pin Pin Converter Power
Jumper Interface Board Number to Number Interface Board Description
J8 1 … 11 J6 FB Bus
2 … 10 AD Gnd
3 … 9 AD Gnd
4 … 8 +5V
5 … 7 +5V
6 … 6 -12VDC
7 … 5 AD Gnd
8 … 4 +12V
9 … 3 24V Com
10 … 2 +24VDC
11 … 1 24V Fan
Voltage Feedback Harness

Inverter Power Pin Pin
Interface Board Number to Number Gate Board Description
J7 1 … 1 +DC
2 … 2 —
3 … 3 —
4 … 4 -DC
5 … 5 -DC
6 … 6 22V - ISO PWR
7 … 7 —
8 … 8 —
9 … 9 W
10 … 10 —
11 … 11 —
12 … 12 V
13 … 13 —
14 … 14 —
15 … 15 U

Connector Descriptions B-3
Motor Voltage Feedback

Motor Voltage Pin Pin Inverter Power
PCB Feedback PCB Number to Number Interface Board Description
P3 1 … 1 J11 POS_BUS
2 … 2 —
3 … 3 —
4 … 4 WN_GATE (NC)
5 … 5 VN_GATE (NC)
6 … 6 UN_GATE (NC)
7 … 7 NEG_RTN
8 … 8 UVWN_EMIT
9 … 9 NEG_PWR (-DC)
10 … 10 BRAKE_GATE (NC)
11 … 11 —
12 … 12 —
13 … 13 W_POS_RTN (NC)
14 … 14 WP_EMIT
15 … 15 W_POS_PWR (NC)
16 … 16 WP_GATE (NC)
17 … 17 —
18 … 18 —
19 … 19 V_POS_RTN (NC)
20 … 20 VP_EMIT
21 … 21 V_POS_PWR (NC)
22 … 22 VP_GATE (NC)
23 … 23 —
24 … 24 —
25 … 25 U_POS_RTN (NC)
26 … 26 UP_EMIT
27 … 27 U_POS_PWR (NC)
28 … 28 UP_GATE (NC)
Converter Power Interface

Converter Power Pin Pin
Board to Terminal Block Interface Board Number to Number Terminal Block Description
J3 1 … 1a-4 TB1 Temp Switch
2 …
3 … 1a-1 Precharge Aux
4 … 1a-3 +24V (digin)
5
6
7 … 1a-9 Precharge Coil
8 … 1a-11 120V
Converter Power Pin Pin

Interface Board Number to Number Terminal Block Description
J2 1 … 1a-5 TB1 +12V from Cooling Loop
2 … 1a-6 Cooling Loop Return
3 … 1a-7 +24V (digin)
4 … 1a-8 Gate Enable

Converter Control Board to

Power Supply Board
Power Supply and DC Bus Converter Control Pin Pin and DC Bus
Board Number to Number Resistor Connector Description
J2 9 … 1a-12 TB1 Terminal Block Aux Out NO
10 … 1a-10 Aux Out Com
13 … 3 M2-m - Male Signal Safety HWEN
14 … 3 Aux In 24V
15 … 4 Aux In
Temperature Switches to
Pin Pin Fan
Fan Temperature Switches Number to Number Connector Description
3% Reactor Temp Sw — … 1b-3 TB1 3% Reactor Temp Sw
9% Reactor Temp Sw — … 1b-13 9% Reactor Temp Sw
Converter Snubber Temp Sw — … 1b-14 Converter Snubber Temp Sw
Inverter Snubber Temp Sw — … 1b-15 Inverter Snubber Temp Sw
Pin Pin
Power Section Stirring Fan Number to Number Description
E1-2 … PE-2 TB1 Fan Terminal 1 (Ground)
F1-2 … 1b-12 Fan Terminal 2
Power and Ground to

Terminal Block - TB1
Contactors and Voltage Male Power Pin Pin Ground - PE2
Feedback Connector Number to Number Power - 3 Phase Description
M1-m 1 … 1b-9 TB1 Coil Terminal 1 on K2
Precharge Contactor
2 … 1b-10 Coil Terminal 1 on K1
Filter Contactor
3 …
4 … PE2 PE2 Ground
5 … PE2 Ground
6 …
7 … 7 3 Phase T Phase
8 … 4 S Phase
9 … 1 R Phase
Filter Contactor - K1
Female Power Pin Pin Precharge Contactor - K2
Connector Number to Number Voltage Feedback PCB - P3 Description
M1-f 1 … A1 K1 Coil Terminal 1
2 … A1 K2 Coil Terminal 1
3 …
6 …
7 … 7 P3 T Phase
8 … 4 S Phase
9 … 1 R Phase

Connector Descriptions B-5
Control Transformer and

Control Transformer - T1
Converter Control to Male Signal Pin Pin Converter Control Board - P1
Contactors Connector Number to Number Terminal Block - TB1 Description
M2-m 1 … P1 T1 Primary In
2 … P2
3 … 14 P1 Aux In 24V
4 … 15 Aux In
5 … 1b-1 TB1 Aux Cont 1
6 … 1b-2 Aux Cont 2
Female Signal Pin Pin Filter Contactor - K1

Connector Number to Number Precharge Contactor - K2 Description
M2-f 1 … T Phase
2 … S Phase
3 … 13 K1 Aux Cont 1
4 … 14 Aux Cont 2
5 … 13 K2 Aux Cont 1
6 … 14 Aux Cont 2
Power Supply to Stirring

80W Power Pin Pin
Fan Supply Number to Number 2x Input Filter Stirring Fan Description
J1 8 … +24V Fan1
7 … Com Fan1/Fan2
6 … -24V Fan2

Notes:

Appendix C
Connection Diagram and Schematics
The connection diagram is shown on the following pages.

C-2 Connection Diagram and Schematics
Frame 2 Connection Diagram
Green + Yellow strip (12 AWG) Black (Common)

PE1 PE1
PE2 PE2
J13 Black
(18 AWG 280mm) J4 Red
Temp Switch 1 (22AWG 875mm)
+300Vdc Ps+ 1 +PS 1 Customer
Black
2 Aux Vdc
Black (22AWG 875mm)
-300Vdc Ps- 2 -PS 2 Supply
(18 AWG 280mm)
Precharge Aux 3
Blue
(18 AWG 280mm)
80W Power Supply
+24V (digin) 4 TB1
5 1a-1 1b-1
6 1a-2 1b-2
Jumper
White
(18 AWG 280mm)
Precharge Coil 7 1a-3 1b-3
Red
(18 AWG 280mm)
120V 8 J2 1a-4 1b-4
Red
+12V/+24V from (22 AWG 450mm)
J3 on Converter Cooling Loop
1
White
1a-5 1b-5
Power Interface PCB (22 AWG 450mm)
Cooling Loop Return 2 1a-6 1b-6
Blue
(22 AWG 450mm)
+24V (digin) 3 1a-7 1b-7
Jumper
Black
(22 AWG 450mm)
Gate Enable 4 1a-8 1b-8
J2 on Converter 1a-9 1b-9

Power Interface PCB
1a-10 1b-10
P1 1a-11 1b-11
Jumper
Black (18 AWG 435mm)
Aux Out NO 9 1a-12 1b-12
Aux out Com 10 1a-13 1b-13
Safety HW EN 13 1a-14 1b-14

Yellow (18 AWG 900mm)
Aux IN 24V 14 1a-15 1b-15
Aux In 15 Terminal Block
P1 on Converter
Control PCB Inv Snubber
Temp Switch Black (22 AWG 900mm)
Black 2x (22 AWG 900mm)
Conv Snubber
Temp Switch

9% Reactor
Temp Switch
3% Reactor White (22 AWG 304mm)

Temp Switch Fans Terminal 1 E1-2
Fans Terminal 2 F1-2
Power Section
Stirring Fan

Connection Diagram and Schematics C-3
T1-Control
Tap Transformer
Changing Primary In (Molex)
Fuse F1 (¾ Amp)
P1
Black M2-m M2-f
Fuse F2 (¾ Amp) (18 AWG 290mm) Black (18 AWG 350mm)
P2 1 1 Phase T
Black
Black Fuse F3 (2 ½ Amp) (18 AWG 200mm) Black (18 AWG 350mm)
Secondary S3 2 2 Phase S
Out Yellow (18 AWG 1100mm)
3 3 13 Aux Cont 1
4 4 14 Aux Cont 2
Orange (18 AWG 900mm) Orange (18 AWG 1100mm)
5 5 A1 Coil terminal 1
Orange (18 AWG 900mm) Orange (18 AWG 1100mm)
Male Female K1-Filter

Signal Signal
Connector Connector Contactor
(Molex)
Customer M1-m M1-f
Terminal Block Black (18 AWG 965mm)
1 1 13 Aux Cont 1
2 2 14 Aux Cont 2
Black (18 AWG 585mm) White (18 AWG 965mm)
White (18 AWG 1016mm)
5 5 K2-Precharge
White 2X (18 AWG 585mm)
Contactor
P3 6 6
White (18 AWG 535mm) White (18 AWG 584mm)
T phase 7 7 7 Phase T
Red (18 AWG 535mm) Red (18 AWG 584mm)
S phase 4 8 8 Phase S
Blue (18 AWG 535mm) Blue (18 AWG 584mm)
R phase 1 9 9 Phase R
P3 on Voltage Male Female

Feedback PCB Signal Signal
Connector Connector
Red (22 AWG 660mm)

Red (22 AWG 225mm) +24Vdc J1-8 +24V Fan1
+DC Bus J3-1
Blue (22 AWG 660mm)
Com J1-7 Com Fan1
White (22 AWG 225mm)
-DC Bus J3-4 Black (22 AWG 660mm)
-24Vdc J1-6 Com Fan2
80W Power Supply -24V Fan2

(319433-A07) 2X Input Filter
Stirring Fan

C-4 Connection Diagram and Schematics
Frame 2 Schematics For PowerFlex 700L Frame 2 schematics, see the PowerFlex 700L
Liquid-Cooled Adjustable Frequency AC Drive User Manual (publication
20L-UM001).

U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives
www.rockwellautomation.com
Power, Control and Information Solutions Headquarters

Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA,Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
Europe/Middle East/Africa: Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium,Tel: (32) 2 663 0600, Fax: (32) 2 663 0640
Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong,Tel: (852) 2887 4788, Fax: (852) 2508 1846
Publication 20L-TG002A-EN-P – November, 2008 P/N 385509-P01

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. Printed in USA.

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PowerFlex® 700L Liquid-Cooled

Adjustable Frequency AC Drive

HARDWARE SERVICE MANUAL

WARNING: Identifies information about practices or

Important: Identifies information that is critical for successful application and

ATTENTION: Identifies information about practices or

Shock Hazard labels may be located on or inside the equipment

Burn Hazard labels may be located on or inside the equipment

Allen-Bradley and PowerFlex are registered trademarks of Rockwell Automation, Inc.

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

This is the first release of the PowerFlex 700L Liquid-Cooled AC Drive

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

Chapter 1 Troubleshooting and Error Codes

Chapter 2 Component Test Procedures

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

Chapter 3 Access Procedures

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

Replacing the J2-to-J5 Power Interface Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Chapter 4 Start-Up After Repair

Appendix A Service Tools and Equipment

Appendix B Connector Descriptions

Appendix C Connection Diagram and Schematics

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

Figure P.1 PowerFlex 700L Frame 2 Drive Data Nameplate Locations

Cat No. 20LC360N3ENNAN10WA

Cat No. 20LC360N3ENNAN10WA

FRONT VIEW (Cover Removed)

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

Reference Materials You can view or download publications at www.rockwellautomation.com/

To find your local Rockwell Automation distributor or sales representative,

The following publications provide specific PowerFlex drive information.

The following publications provide information that is necessary when

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

Understanding Manual Terms

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

General Precautions Class 1 LED Product

ATTENTION: Hazard of permanent eye damage exists when

ATTENTION: This drive contains ESD (Electrostatic

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

Troubleshooting and Error Codes

ATTENTION: To avoid an electric shock hazard, ensure that all

At a minimum, perform and record the following:

• Make record of any liquid or condensation marks on printed circuit

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

• Make record of any mechanical damage to the drive and drive

• Record the size and type of main fuses.

• Record any other important marks and damages.

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

Fault No. Description Action

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

Fault No. Description Action

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

Fault No. Description Action

PowerFlex® 700L Frame 2 Drive Hardware Service Manual

PowerFlex® 700L Frame 2 Drive Hardware Service Manual