Installation Instructions PowerFlex 700L Frame 3A DC Bus Bar Conversion Kit ATTENTION: To avoid an electric shock hazard, ensure that all power to the power module has been removed before performing any steps of these instructions. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has completely discharged before performing any work on the power module. After removing power to the power module, wait 5 minutes for the bus capacitors to discharge. Remove the lower front cover of the power module. Measure the DC bus voltage at the DC+ TESTPOINT and DC- TESTPOINT sockets on the front of the power module. The voltage must be zero. ATTENTION: HOT surfaces can cause severe burns. Do not touch the heatsink surface during operation of the power module. After disconnecting power allow time for cooling. ATTENTION: This power module 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. What This Kit Includes DC Bus bar spacers and plastic rivets DC- Bus bar and hardware DC+ Bus bar and hardware Bus bar Support Angles and hardware Front Shield and plastic rivets Rear Shield and plastic rivets Torque Seal Tools That You Need Phillips screwdriver (#2) Standard flat tip screwdriver Malleable hammer 10 mm socket 13 mm socket Socket wrench Torque wrench Pliers Phillips is a registered trademarks of Phillips Screw Company.
2 PowerFlex 700L Frame 3A DC Bus Bar Conversion Kit What You Need to Do To install the PowerFlex 700L Frame 3A DC Bus Bar Conversion Kit: Step 1: Step 2: Step 3: Step 4: Step 5: Step 6: Step 7: Step 8: Remove power from the power module Remove the power module top cover Assemble spacers to the top cover Assemble the kit parts Install assembled kit parts to the power module Tighten fasteners Install shields Document change Step 1: Removing Power from the ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has completely discharged before performing any work on the power module. After removing power to the power module, wait 5 minutes for the bus capacitors to discharge. Remove the lower front cover of the power module. Measure the DC bus voltage at the DC+ TESTPOINT and DC- TESTPOINT sockets on the front of the power module. The voltage must be zero. Remove power before making or breaking cable connections. When you remove or insert a cable connector with power applied, an electrical arc may occur, which 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. 1. Turn off and lock out input power. Wait 5 minutes. L1 L2 L3 I O 2. Verify that there is no voltage at the power module s input power terminals.
PowerFlex 700L Frame 3A DC Bus Bar Conversion Kit 3 3. Remove the lower front cover of the power module. Loosen the two (2) captive screws and pull the cover off the power module. Set the cover aside to be reinstalled later. 4. Measure the DC bus voltage at the DC+ TESTPOINT and DC- TESTPOINT sockets on the front of the power module chassis. The voltage must be zero. Step 2: Removing the Top Cover 1. Remove the ten (10) M5 x 16 mm (0.63 in.) long Philips screws that hold the top cover to the power module chassis, and remove the top cover. Set the top cover and screws aside to be reinstalled later. Rear Shield 6X Front Shield 6X TOP Screw M5 X 16mm Long 10X Top Cover Chassis 2. Using the malleable hammer, apply force to the back side of the twelve (12) plastic rivets that secure the front and rear shields to the top cover, and remove them with pliers. Discard the shields and rivets.
4 PowerFlex 700L Frame 3A DC Bus Bar Conversion Kit Step 3: Assembling Spacers to the Top Cover 1. Place two (2) DC Bus bar spacers on a sturdy flat work surface. 2. Locate the spacers beneath the top cover such that all five (5) holes in each spacer align with the five (5) holes in the top cover. 3. Using the malleable hammer, drive two plastic rivets through the top cover and into each spacer at their hole locations 2 and 4. 10 mm 5.5 (N m) 48.5 (lb in) Rear Shield Screw M6 X 30 mm Long (2)-Places M6 Lock Washer (2)-Places M6 Flat Washer (2)-Places Screw M6 X 55 mm Long 3X (2)-Places 10 mm M6 Lock Washer 3X (2)-Places 5.5 (N m) 48.5 (lb in) M6 Flat Washer 3X (2)-Places 2X (2)-Places Support Angle (DC-) Support Angle (DC+) Top Cover 5X 6X Front Shield Screw M5 X 16 mm Long 10X P2 2.8 (N m) 24.5 (lb in) Spacer (DC-) Spacer (DC+) DC- Bus Bar DC+ Bus Bar TOP Screw M8 X 25 mm Long Qty. per Catalog String Position 4 Code (2)-Places M8 Lock Washer M8 Flat Washer 13 mm 13.5 (N m) 119.5 (lb in) See Step 5.3 Chassis Laminate Bus Bar
PowerFlex 700L Frame 3A DC Bus Bar Conversion Kit 5 Step 4: Parts Assembling the Kit 1. Feed the long narrow end of the DC- Bus bar through the slot in the top cover. 2. Assemble a M6 flat washer, M6 lock washer and M6 x 55 mm (2.17 in.) long screw through the top cover and into the DC- Bus bar at two locations. Do not tighten 3. Assemble a M6 flat washer, M6 lock washer and M6 x 55 mm (2.17 in.) long screw through the Support Angle, top cover and into the DC- Bus bar. Do not tighten 4. Feed the long narrow end of the DC+ Bus bar through the slot in the top cover. 5. Assemble a M6 flat washer, M6 lock washer and M6 x 55 mm (2.17 in.) long screw through the top cover and into the DC+ Bus bar at two locations. Do not tighten 6. Assemble a M6 flat washer, M6 lock washer and M6 x 55 mm (2.17 in.) long screw through the Support Angle, top cover and into the DC+ Bus bar. Do not tighten 7. Assemble a M6 flat washer, M6 lock washer and M6 x 30 mm (1.18 in.) long screw through each Support Angle and into each DC Bus bar. Do not tighten Step 5: Installing the Assembled Kit Parts to the 1. Position the assembled kit parts onto the power module and start ten (10) screws M5 x 16 mm (0.63 in.) long into chassis. Do not tighten 2. Align holes in each of the DC Bus bars with the holes in each side of the laminate bus bar inside the power module. 3. Install M8 hardware to connect DC+ and DC- Bus bars to the laminate bus bar. Do not tighten The quantity of M8 hardware is based on rated voltage (catalog string position 4) of the power module. Rated Voltage Quantity M8 Hardware 400/480V AC 6 places 600/690V AC 10 places Step 6: Tightening the Hardware 1. Refer to the table below for tightening order and torque requirement. Tightening Order Screw Size Tightening Torque 1 M8 12 15 N m (106 133 lb in) 2 M6 5 6 N m (44 53 lb in) 3 M5 2.5 3.1 N m (22 27 lb in) 2. Apply a thin stripe of Torque Seal from each M8 screw head to the bus bar.
POWER STS PORT MOD NET A NET B DANGER Step 7: Shields Installing the 1. Align six (6) holes in the Front Shield with holes in the top cover and assemble six (6) plastic rivets. Apply force with the malleable hammer as required to completely install the plastic rivets. 2. Align five (5) holes in the Rear Shield with holes in the top cover and assemble five (5) plastic rivets. Apply force with malleable hammer as required to completely install the plastic rivets. Step 8: Change Documenting the 1. Record the change on the Field Installed Option label. Use a marker to write in the kit catalog number (SK-L1-DCBS1-F3). Lower Front Cover Cutaway FIELD INSTALLED OPTIONS Firmware #: Date Firmware #: Date 20-HIM 28-IO- 20-COMM- 20B_-DB1- HIM I/O COM Module Internal Dynamic Brake 2. Replace the power module lower front cover. U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives www.rockwellautomation.com Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444 Europe/Middle East/Africa: Rockwell Automation, Pegasus Park, De Kleetlaan 12a, 1831 Diegem, 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-IN004A-EN-P September, 2006 P/N 181694-P01 Copyright 2006 Rockwell Automation, Inc. All rights reserved. Printed in USA.