Powerflex 700h PDF
Powerflex 700h PDF
AC Drive
and
700H Adjustable Frequency
AC Drive
Frame 12
450-560kW, 400V
700-900HP, 480V
630-800kW, 690V
700-900HP 600V
Important: Identifies information that is critical for successful application and understanding of the product.
Overview
Who Should Use this This manual is intended for qualified service personnel responsible for
Manual? troubleshooting and repairing high power PowerFlex 700H and 700S AC
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 Frame 12
PowerFlex 700H and 700S drives only. Verify that you are working on a
Frame 12 drive by checking the data nameplate on the Control Frame. The
frame number is printed just above the serial number.
200 kW 500 kW
Input: DC, C UL
Æ US
DC Voltage Range 462 - 594 583 - 713 LISTED
Amps 350 350 IND CONT EQ
9D42
Output: 3 Phase, 0 - 320Hz
AC Voltage Range 0 - 400 0 - 460
Base Hz (default) 50 Hz 60 Hz
Continuous Amps 420/500 420/500
1 Min Overload Amps 630/550 630/550
2 Sec Overload Amps 840/630 840/630
MFD. in 1989 on Nov 9
Cat No. 20D
UL Open Type/IP00
540V
160 kW
132 kW
650V
250 kW
200 kW
Series: A
Standard I/O: NONE
Original Firmware No. 2.04
C UL US
Frame #: 12
Serial Number: 2622381652
Æ
DC Voltage Range 462 - 594 583 - 713 LISTED
Amps 350 350 IND CONT EQ
Output: 3 Phase, 0 - 320Hz
AC Voltage Range 0 - 400 0 - 460
Base Hz (default) 50 Hz 60 Hz
Continuous Amps 300/245 300/245
1 Min Overload Amps 330/368 330/368
2 Sec Overload Amps
2622381652
450/490 450/490
MFD. in 2005 on Feb 29
Serial Number: 2622381652
What is Not in this Manual This manual does not contain in depth fault information for troubleshooting.
That information is available in publications 20C-PM001, Programming
Manual - PowerFlex 700H Adjustable Frequency AC Drive, PFLEX-IN006,
Installation Instructions - PowerFlex 700S and 700H Adjustable Frequency
AC Drive and 20D-UM006, User Manual - PowerFlex 700S with Phase II
Control High Performance AC Drive.
P-2 Overview
Cross References
“Figure 2.2 on page 2-6” is a cross reference to figure 2.2 on page 5 of
Chapter 2.
Additional Support Additional troubleshooting information and software tools are available on
Available on Internet the Allen-Bradley Drives Support Website (http://www.ab.com/support/
abdrives/).
P-4 Overview
Creating Fault Reports Clear and complete fault reports are critical for analysis and repair of
modules returned to the factory.
x Record the contents of the fault queue (faults and times of occurrence)
x Make record of any burn marks on the rectifying module, DC-capacitors,
inverter bridge, charging resistors, balancing/precharging resistors,
printed circuit boards, bus bars, cabling and fiber-optic cabling
x Make record of any liquid and condensation marks on printed circuit
boards, components and mechanical parts
x Make record of the amount of dust and other additional particles on drive
and drive components
x Make record of any mechanical damage to the drive and drive
components
x Record the size and type of main fuses
x Record any other important marks and damage
A fast power cycle may cause the Wait five minutes before
700S Main Control Board to attempt re-energizing the drive.
to communicate with the ASIC Board
before the ASIC Board is energized.
HiHp Bus WtchDog 69 Bus Communication Watchdog Error - 1. Check fiber-optic
communication has halted in the connections between the
communication bus, causing the Power Interface Circuit Board
watch dog timer to expire. and Voltage Feedback Circuit
Board.
2. Check connections between
the Main Control Board and
the Power Interface Circuit
Board.
3. Replace the Voltage
Feedback Circuit Board.
4. Replace the Power Interface
Circuit Board.
5. Replace the Main Control
Board.
HiHp Fan Fdbk Ls 70 Fan Feedback Loss - a fan feedback 1. Check the main cooling fan.
signal has been lost. 2. Check the Main Control
Board cooling fan.
Troubleshooting and Error Codes 1-3
Diagnostic Procedures by The following charts list drive symptoms, symptom descriptions and
Symptom recommended actions.
Yes
Yes
Examine Bus
Capacitors for Capacitors Replace
No Capacitors
Charring and OK?
Damaged Reliefs
Yes
Yes
No
Are There
Any Line to Yes
Line Shorts?
Reconnect Reconnect
No AC Motor
Choke Leads
1-6 Troubleshooting and Error Codes
No Output Voltage
Use this procedure when there is no voltage present at the drive output
terminals, even though the drive indicates the motor is running:
Yes
Examine Bus
Capacitors for Capacitors Replace
Yes No
Charring and OK? Capacitors
Damaged Reliefs
Yes
Yes
No
No
No
Replace Voltage
Feedback Board
(on 700S)
Troubleshooting and Error Codes 1-7
No HIM Display
Use this procedure when the HIM does not function:
Yes
Yes
Examine Bus
Capacitors for Capacitors Replace
Yes No
Charring and OK? Capacitors
Damaged Reliefs
Yes
Yes
Yes
Replace Output
Power Module
(on 700H)
No
Replace HIM
1-8 Troubleshooting and Error Codes
Over-Temperature Faults
Use this procedure to troubleshoot drive over-temperature faults (14 - Inv
Otemp Pend and 15 - Inv Otemp Trip in 700S or 8 - Heatsink OvrTemp and
9 - Trnsistr OvrTemp in 700H):
Temperature Provide
Check Surrounding
Exceeds Yes Additional Airflow
Air Temperature Specification? or Air Conditioning
No
No
Frequency Too
Check PWM High for Lead Length Lower PWM
Yes
Frequency and Surrounding Frequency
Temp?
No
Yes
Remove
Airlflow
Yes Air Flow
Blockages?
Blockages
No
Fans
Running Yes
Properly?
No
Yes
Check Connection
Between ASIC Repair
Board and Fan Connection No
Good? Connection
Inverters
Yes
Yes
No
Contact
Allen-Bradley
Drives
Technical
Support
Chapter 2
Viewing the 700H Diagnostic The Control Assembly on 700H drives contains a diagnostic LED which is
LED visible through the cover of the Control Assembly. the Control Assembly is
located in the upper, left-hand drive enclosure.
LED Indication
Steady The drive is operational and has
no faults
Flashing Quickly x Switching power supply
overload
x Rectifier Board fault
x Fan or fan inverter fault
x Brake Chopper fault
x Fiber Optic Adapter Board Fault
Flashing Slowly Bad connection between circuit
boards, check all connections
Viewing the 700S Diagnostic The PowerFlex 700S contains a Run LED, controller LEDs, and SynchLink
LEDs LEDs. These LEDs are only operational when the drive is energized and are
only visible when the drive door is open. The status of these LEDs can also
be viewed from the HIM or from an application program (e.g.,
DriveExplorer™) in parameter 554 [LED Status]. This feature is only
available with DriveLogix version 15.03 or later.
ATTENTION: The RUN LED and the controller LEDs are only operational when the drive is energized.
Servicing energized equipment can be hazardous. Severe injury or death can result from electrical shock, burn
! or unintended actuation of controlled equipment. Follow Safety related practices of NFPA 70E, ELECTRICAL
SAFETY FOR EMPLOYEE WORKPLACES. DO NOT work alone on energized equipment!
Component Test Procedures 2-3
➊
➋
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.
2-4 Component Test Procedures
Performing Visual Inspections Visually inspect the cooling tunnels and power structures before energizing
the drive.
Conducting Forward and A forward biased diode test checks the semiconductor junctions between
Reverse Biased Diode Tests the terminals and measures the voltage drop across those junctions. To pass
for Major Power Components each test, the meter must display a voltage near 0.5V. 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” (zero load).
A reverse biased diode test should find an open circuit, and the meter should
display “.0L” (zero load).
- +
~0.5V ~.0L
-
+
Forward biased test Reverse biased test
on PN-junction on PN-junction
Component Test Procedures 2-5
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
1V/T2 2V/T2
Cat No.
1234567890-*
DANGER DANGER
DC BUS CONDUCTORS AND CAPACITORS
DC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE. REMOVE POWER
OPERATE AT HIGH VOLTAGE. REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
AND WAIT 5 MINUTES BEFORE SERVICING
1L1 2L1
1L2 2L2
1L3 2L3
Power Structure #1 Power Structure #2
Table 2.A Forward Biased Diode Tests on Rectifying Module for Power Structure #1
Meter Leads
- + Nominal meter reading
DC+/R+(1) 1L1
DC+/R+ 1L2
DC+/R+ 1L3 Meter should beep once and value
1L1 DC- should gradually rise to about 0.5V
1L2 DC-
1L3 DC-
(1)
If the drive does not contain the brake chopper option, the DC+/R+
terminal will be labeled DC+.
2-6 Component Test Procedures
Table 2.B Forward Biased Diode Tests on Rectifying Module for Power Structure #2
Meter Leads
- + Nominal meter reading
DC+/R+(1) 2L1
DC+/R+ 2L2
DC+/R+ 2L3 Meter should beep once and value
2L1 DC- should gradually rise to about 0.5V
2L2 DC-
2L3 DC-
(1)
If the drive does not contain the brake chopper option, the DC+/R+
terminal will be labeled DC+.
Table 2.C Reverse Biased Diode Tests on Rectifying Module for Power Structure #1
Meter Leads
+ - Nominal meter reading
1L1 DC-
1L2 DC-
1L3 DC-
Meter should display “.0L” (zero load)
DC+/R+(1) 1L1
DC+/R+ 1L2
DC+/R+ 1L3
(1)
If the drive does not contain the brake chopper option, the DC+/R+
terminal will be labeled DC+.
Table 2.D Reverse Biased Diode Tests on Rectifying Module for Power Structure #2
Meter Leads
+ - Nominal meter reading
2L1 DC-
2L2 DC-
2L3 DC-
Meter should display “.0L” (zero load)
DC+/R+(1) 2L1
DC+/R+ 2L2
DC+/R+ 2L3
(1)
If the drive does not contain the brake chopper option, the DC+/R+
terminal will be labeled DC+.
4. Conduct forward and reverse biased diode tests on the Output Power
Modules.
Table 2.E Forward Biased Diode Tests on Output Power Modules for Power Structure
#1
Meter Leads
+ - Nominal meter reading
DC- 1U/T1
DC- 1V/T2
DC- 1W/T3
Meter should display “.0L” (zero load)
1U/T1 DC+/R+(1)
1V/T2 DC+/R+
1W/T3 DC+/R+
(1) If the drive does not contain the brake chopper option, the DC+/R+
terminal will be labeled DC+.
Component Test Procedures 2-7
Table 2.F Forward Biased Diode Tests on Output Power Modules for Power Structure
#2
Meter Leads
+ - Nominal meter reading
DC- 2U/T1
DC- 2V/T2
DC- 2W/T3
Meter should display “.0L” (zero load)
2U/T1 DC+/R+(1)
2V/T2 DC+/R+
2W/T3 DC+/R+
(1)
If the drive does not contain the brake chopper option, the DC+/R+
terminal will be labeled DC+.
Table 2.G Reverse Biased Diode Tests on Output Power Modules for Power Structure
#1
Meter Leads
+ - Nominal meter reading
1U/T1 DC-
1V/T2 DC-
1W/T3 DC- Meter should beep once and value
DC+/R+(1) 1U/T1 should gradually rise to about 0.5V
DC+/R+ 1V/T2
DC+/R+ 1W/T3
(1)
If the drive does not contain the brake chopper option, the DC+/R+
terminal will be labeled DC+.
Table 2.H Reverse Biased Diode Tests on Output Power Modules for Power Structure
#2
Meter Leads
+ - Nominal meter reading
2U/T1 DC-
2V/T2 DC-
2W/T3 DC- Meter should beep once and value
DC+/R+(1) 2U/T1 should gradually rise to about 0.5V
DC+/R+ 2V/T2
DC+/R+ 2W/T3
(1)
If the drive does not contain the brake chopper option, the DC+/R+
terminal will be labeled DC+.
If the drive fails any of these measurements, replace both Output Power
Modules for the appropriate Power Structure.
2-8 Component Test Procedures
Checking Fiber Optic Damaged or improperly connected fiber optic cables can cause apparent
Connections to the Gate Gate Driver Board malfunctions.
Driver Boards 1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
3. On Power Structure #1, locate the Gate Driver Board on the front of the
power structure.
H8 H6 H4 H9 H7 H5
X3 X8
X4 X9
X5 X10
X6 X11
X7 X12
X13
X14
X15
X1
4. Verify the fiber optic cables are properly connected (refer to Figure
B.4 on page B-5, Figure B.5 on page B-6, Figure B.6 on page B-7 or
Figure B.7 on page B-8).
5. Disconnect the cables and inspect them for scratches and cracks.
Conducting Gate Driver 1. Remove power from the drive. Refer to Removing Power from the
Board Measurements Drive on page 3-3.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
X3 X8
~500 ohms ~500 ohms
~500 ohms ~500 ohms
Emitter Emitter
Gate Interface for W High (WH) Gate Interface for W High (WH)
in Left Power Output Module in Right Power Output Module
X4 X9
~500 ohms ~500 ohms
~500 ohms ~500 ohms
Emitter H8 H6 H4 H9 H7 H5 Emitter
Gate Interface for V High (VH) X3 X8 Gate Interface for V High (VH)
in Left Power Output Module X4 X9
in Right Power Output Module
X5 X10
X6 X11
X5 X10
~500 ohms ~500 ohms
~500 ohms ~500 ohms
Emitter Emitter
X7 X12
Gate Interface for U High (UH) Gate Interface for U High (UH)
Gate Interface Resistance
X14
X15
X1
Gate Interface
for W Low (WL) X6
~500 ohms
in Left Power ~500 ohms Gate Interface
Output Module for V Low (VL)
~500 ohms
~500 ohms in Left Power
Output Module
Gate Interface
for U Low (UL) Gate Interface
~500 ohms
in Left Power ~500 ohms
X11 for W Low (WL)
Output Module ~500 ohms
Gate Interface ~500 ohms in Left Power
for V Low (VL) Output Module
~500 ohms
in Left Power ~500 ohms
Output Module
Gate Interface
Component Test Procedures
Preparing the Drive for Active Measurements on the Gate Driver Boards
Important: This procedure requires special equipment and training. Only
qualified and trained personnel should perform these
procedures. If you do not have the special equipment, replace
each Gate Driver Board to determine if the boards are
malfunctioning.
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
3. On Power Structure #1, disconnect the fiber optic cables which connect
the ASIC Board to the Gate Driver Board at the Gate Driver Board
ends.
4. You may want to remove the fuses for the Main Fan Inverters in order to
prevent them from running during these tests.
5. Disconnect the DC+ and DC- wires from the bus bars above the Gate
Driver Board. These wires connect the DC bus to the circuit boards in
the power structure.
6. Connect the minus (-) probe of the multimeter to the DC- wire. Make
sure these DC+ and DC- connections are insulated from all objects.
DC-
DC+
8. Set the current limit on the High Voltage DC Test Power Supply to less
than or equal to 1A. Energize the Supply and increase its output to the
drive’s nominal DC bus voltage (650V dc for drives with 380-500V ac
input or 775V dc for drives with 600-690V ac input).
2-12 Component Test Procedures
1. On Power Structure #1, locate the fiber optic receiver which transmits
the signals for W High (WH) gate interface and connector X3 on the
Gate Driver Board. X3 provides the gate interface for the WH output
power transistor in the left-hand Output Power Module.
3. While shining an intense light (like a flashlight) into the fiber optic
receiver for the WH cable, measure the DC voltage at the WH gate and
collector pins on X3 with respect to DC-. It should be +15V dc. If the
drive fails any of these tests, replace the fiber optic cable or the Gate
Driver Board.
6. Repeat steps 3 and 4 with connector X6 and the cables for WL, VL and
UL. If the drive fails any of these tests, replace the Gate Driver Board.
Output Power Module. If the drive fails any of these tests, replace the
Gate Driver Board.
9. Repeat steps 3 and 4 with connector X10 and the cables for WL, VL
and UL. If the drive fails any of these tests, replace the Gate Driver
Board.
11. Reconnect the DC+ and DC- wires on the bus bars above the Gate
Driver Board on both Power Structures (Refer to Step 4 on page 2-10).
H8 H6 H4 H9 H7 H5
Should measure -15V dc with respect to DC- with no light in VH cable
Should measure +15V dc with respect to DC- with light in VH cable X3 X8
X4 X9
X5 X10
Should measure -15V dc with respect to DC- with no light in UH cable X6 X11
Should measure -15V dc with respect to DC- with no light in UH cable X7 X12
X14
X15
H8 H6 H4 H9 H7 H5
Should measure -15V dc with respect to DC- with no light in VH cable
X3 X8
Should measure +15V dc with respect to DC- with light in VH cable
X4 X9
X5 X10
X6 X11
Should measure -15V dc with respect to DC- with no light in UH cable
X10 Should measure +15V dc with respect to DC- with light in UH cable
X7 X12
Should measure -15V dc with respect to DC- with no light in UH cable
Should measure +15V dc with respect to DC- with light in UH cable
X13
X14
X15
X1
Checking Rectifying Module Important: This procedure requires special equipment and training. Only
(on AC Input Drives Only) qualified and trained personnel should perform these
procedures.
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
4. Verify that the plugs on the cable that connects X13 on the Rectifying
Board to X2 on the ASIC Board are properly seated.
10. Verify that the voltage and resistance between the following points is
zero: J3 and X10: Pin 1, J7 and X11: Pin 1, and J11 and X12: Pin 1.
Refer to Rectifying Board Charge Relay Test Results on page 2-16. If
the Rectifying Module fails any of these tests, replace it (See
Removing the Right-Side Output Power Modules and Rectifying
Modules on page 3-33).
X4
X1 X2 X3
X41
J3
J7
J11
Checking the DC Bus Important: This procedure requires special equipment and training. Only
Capacitors qualified and trained personnel should perform these
procedures.
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
3. Set the current limit of the DC power supply to less than 50mA.
4. On Power Structure #1, connect the power supply’s DC+ to the drive’s
DC+ terminal and the power supply’s DC- to the drive’s DC- terminal.
5. Set the power supply voltage setting to zero.
9. Leakage current should be less than 3mA when voltage has stabilized.
10. Abort test if current leakage is significantly higher when voltage has
stabilized.
11. Decrease the DC power supply output voltage to zero. Wait until DC
bus voltage has decreased to zero. Switch off the external DC power
supply.
13. If any capacitor has failed. Replace all the capacitors in the same series
connection (See Removing the DC Bus Capacitors on page 3-40).
LED
Red Green Indication
Steady Steady Inverter Idle
Off Flashing Inverter Running
Flashing Steady Inverter Faulted
or
No Control from ASIC Board
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
3. On Power Structure #1, disconnect the left-hand fan motor from its
inverter.
Notes:
Chapter 3
Access Procedures
Phillips Screw
Hexagonal Bolt
or Standoff PZ2
Hexagonal 4 N-m
Screw Tightening Torque
(35 lb.-in.)
Hexagonal Nut
Removing Power
1. Turn off and lock out input power. Wait five minutes.
3. Measure the DC bus voltage at the DC+ & DC- terminals on the Power
Terminal Block. The voltage must be zero.
L1 L2 L3
I
O
Access Procedures 3-5
P1
0.9 N-m
(8 lb.-in.)
3. Open the door, which holds the DPI interface and HIM.
4. Unplug the DPI cable from X2 connector on the DPI Interface Circuit
Board.
X2 X4
5. On 700S drives only, unplug the cable from X4 connector on the circuit
board.
6. Remove the four mounting screws and the assembly from the Control
3-6 Access Procedures
Frame.
Mounting Screws
P1
0.9 N-m
(8 lb.-in.)
Installation
Install the DPI / HIM Assembly in reverse order of removal, while referring
to Torque Specifications on page 3-1.
2. Unplug any fiber optic ControlNet and SynchLink cables from the
Control Assembly.
3. Unplug any remaining I/O and communications cables from the Control
Assembly and set them aside.
Access Procedures 3-7
4. Loosen the captive screw on the Control Assembly mounting plate and
swing the Control Assembly away from drive.
Captive Screw
5. Carefully disconnect the ribbon cables from the sockets on the High
Power Fiber Optic Interface Circuit Board on the back of the control
mounting plate, and carefully set them aside.
6. Loosen the two mounting screws on the front of the Control Assembly
and slide the control cassette off the mounting bracket.
Installation
Install the 700S Phase II Control Assembly in reverse order of removal,
while referring to Torque Specifications on page 3-1.
3. Carefully disconnect the fiber-optic cables from the sockets along the
right side of the High Power Fiber Optic Interface Circuit Board (on the
backside of the Control Assembly), and carefully set them aside.
4. Disconnect the other cables from the sockets on the High Power Fiber
Optic Interface Circuit Board and set them aside.
5. Remove the five screws which secure the High Power Fiber Optic
Interface Circuit Board to the Control Frame.
Remove five
screws
Disconnect
Fiber-Optic cables
P1
0.9 N-m
(8 lb.-in.)
Installation
Install the 700S High Power Fiber Optic Interface Circuit Board in reverse
order of removal, while referring to Torque Specifications on page 3-1.
3-10 Access Procedures
3. Remove the 700S High Power Fiber Optic Interface Circuit Board.
Refer to Removing the 700S High Power Fiber Optic Interface Circuit
Board on page 3-8.
4. Lift the Control Assembly mounting plate up and off the hinge.
Installation
Install the 700S Control Assembly mounting plate in reverse order of
removal.
Access Procedures 3-11
2. Open the enclosure that contains the Control and I/O Boards and
carefully unplug the DPI cable and any I/O cables.
3. Remove the I/O Boards from the Control Board and enclosure. Note the
order of the boards and the keys which prevent placement of boards in
incorrect slots.
Do not remove enclosure cover.
Enclosure is illustrated without
the cover for clarity.
Keys
X2 X3 X4 X5 X6
(Slot A) (Slot B) (Slot C) (Slot D) (Slot E)
3-12 Access Procedures
5. Remove the three screws which secure the Control Assembly to the
drive.
Do not remove enclosure cover.
Enclosure is illustrated without
the cover for clarity.
PZ2
3 N-m
(27 lb.-in.)
Installation
Install the 700H Control and I/O Boards in reverse order of removal, while
referring to Torque Specifications on page 3-1.
Access Procedures 3-13
4. Disconnect the control power cable from X2 of the Star Coupler Board.
H8
H7
H6
X1 connects to Main H5
Control Board
H4
H3
H2
H1
H18
H1 - H23 sockets for
H17 Fiber-Optic cables
H16
H15
H14
H13
X2 connects to H12
24V dc power H11
X2
H23
H22
H21
5. Carefully disconnect the fiber-optic cables from right side of the Star
Coupler Board, and carefully set them aside.
6. Remove the six screws which secure the Star Coupler Board to the
stand-offs on the back of the Control Frame.
PZ2
0.9 N-m
(8 lb.-in.)
Installation
Install the 700H Star Coupler Board in reverse order of removal, while
referring to Torque Specifications on page 3-1.
Access Procedures 3-15
1. Remove power from the drive (Removing Power from the Drive on
page 3-3).
2. Loosen the T8 Torx-head screws, which secure the Control Frame to the
drive enclosure.
3. Swing the Control Frame out and away from the power structure.
Screws
Installation
Removal
1. Remove power from the drive (Removing Power from the Drive on
page 3-3).
2. Move the Control Frame away from the power structure in the left-hand
enclosure (Removing the Covers from the Power Structures on
page 3-15).
Screws
5. Repeat steps 3 and 4 to remove the airflow plate from Power Structure
2.
Access Procedures 3-17
Installation
Removal
1. Remove power from the drive (Removing Power from the Drive on
page 3-3).
2. Move the Control Frame away from the power structure in the left-hand
enclosure (Removing the Covers from the Power Structures on
page 3-15).
Note: you only need to remove the top and bottom covers to gain access
to the power terminals. You can remove the other covers without
removing the top and bottom ones
5. Remove the four M5 Pozi-drive screws, which secure the main front
protective cover to the drive, then remove the protective cover.
5
4 5
Installation
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
J4 J5
J8
5. Remove the five screws which secure the Voltage Feedback Circuit
Board to the drive.
6. Remove the circuit board from the drive.
3-20 Access Procedures
P1
0.9 N-m
(8 lb.-in.)
Remove
five screws
Installation
Install the 700S Voltage Feedback Circuit Board in reverse order of
removal, while referring to Torque Specifications on page 3-1.
Access Procedures 3-21
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
3. On Power Structure 1, disconnect the wires from the fuse block that
holds the fuses for the Fan Inverters. Then remove the fuses.
4. Remove the screws that secure the fuse block to the bracket beneath it,
and remove the fuse block.
5. Carefully disconnect the fiber-optic cables from sockets along the top of
the Gate Driver Board, and carefully set them aside.
6. Disconnect the other cables from sockets of the Gate Driver Board, and
set them aside.
3-22 Access Procedures
7. Remove the six screws which secure the brackets to the drive. Then
remove the brackets.
8. Remove eight of the stacker connectors from the Gate Driver Board,
leaving the two connectors that are third from the top.
H8 H6 H4 H9 H7 H5
X3 X8
X4 X9
Do Not remove this Do Not remove this
stacker connector X5 X10 stacker connector
X6 X11
X12
X7
X13
X14
X15
X1
Access Procedures 3-23
10. Remove the cable ties that secure the Adapter Board to the circuit
boards on the Output Power Modules, and remove the Adapter Board.
11. Repeat steps 3 - 10 to remove the Gate Driver and Adapter Boards from
Power Structure 2.
3-24 Access Procedures
Installation
1. On Power Structure 1, replace the Adapter Board and install the cable
ties, which secure it to the circuit boards on the Output Power Modules.
2. Plug the old stacker connectors into the new Gate Driver Board so the
pins do not protrude through the connectors on the back of the board.
3. Align the Gate Driver Board so that its connectors align with the mating
connectors on the Adapter Board.
4. While supporting the Adapter Board from behind, press the Gate Driver
Board onto it.
5. Verify the proper alignment of the mounting with a mirror. Verify that
none of the pins in the stacker connectors have missed the mating
connectors.
6. Install the brackets, and install and tighten the mounting screws.
7. Connect all of the cables on the new Gate Driver Board.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
4. Remove the ground connection from the lower right rear corner of the
power structure.
5. Remove the input (AC or DC) and brake wiring (if equipped) from the
incoming terminals at the top of the power structure.
AC Power Connection
Terminals
Ground
Motor Connection
Connection
Terminals
Installation
Install the power structures in reverse order of removal, while referring to
Torque Specifications on page 3-1. Refer to the publication
PFLEX-IN006}, Installation Instructions - PowerFlex 700S and 700H
High Power Drives, for tightening torques of motor terminations.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
5. Repeat steps 3 and 4 to remove the main fans from Power Structure 2.
Access Procedures 3-27
Installation
Install the fans in reverse order of removal, while referring to Torque
Specifications on page 3-1.
1. Remove power from the drive (Removing Power from the Drive on
page 3-3).
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
3. On Power Structure 1, remove the cover from the ASIC assembly and
the -DC bus connection from the cover.
4. Unplug the fan that mounts on the cover from connector X1 of the
ASIC board.
5. Disconnect the Feedback board that mounts on the ASIC assembly
cover from connector X26 on the ASIC board.
X11 X2
H8
X9
H9
Fiber-Optic
cable H10 X15
X26
connections H11
H12 H1
H13 H2
H3
Fiber-Optic
X3 H4
X1 cable
H5 connections
H6
X4
H7
X5 X6
3-28 Access Procedures
7. Disconnect the other cables from sockets on the front of the ASIC
Board, and set them aside.
11. Repeat steps 3 - 10 to remove the ASIC Board from Power Structure 2.
Installation
Install the ASIC Boards in reverse order of removal, while referring to
Torque Specifications on page 3-1. Reconnect cables to ASIC Boards, while
referring to (refer to Figure B.3 on page B-4).
Access Procedures 3-29
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
4. Remove the screws that secure the circuit board to the Rectifying
Module, and remove the board.
5. Repeat steps 3 and 4 for the Rectifying Board from Power Structure 2.
X4
X1 X2 X3
X41
J3
J7
J11
Installation
Install the Rectifying Boards in reverse order of removal, while referring to
Torque Specifications on page 3-1.
3-30 Access Procedures
Important: Always replace the Output Power Modules in pairs (do not
replace just one module).
1. Remove power from the drive (Removing Power from the Drive on
page 3-3).
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
3. Remove the power structures from the drive cabinet (Removing the
Power Structures from the Drive Enclosure on page 3-25).
5. Disconnect the output leads from the bottom of the Output Power
Module.
6. Loosen, but do not remove, the screws that secure the Y Bus Bars to the
drive.
Y Bus Bars
Access Procedures 3-31
Balancing Resistors
Snubber Capacitors
Snubber Capacitor
Fastening Screws
8. Remove the screws that secure the Snubber Capacitors, and remove the
Snubber Capacitors.
9. Remove the screws that secure the DC Bus Bars to the left side of the
power structure, and remove the DC Bus Bars.
10. Remove the screws which secure the Output Power Module to the drive.
11. Disconnect the Power Module Circuit Board from the Adapter Board.
3-32 Access Procedures
13. Repeat steps 4 - 12 to remove the left-side Output Power Module from
Power Structure 2.
Installation
Install the Output Power Modules in reverse order of removal, while
referring to Torque Specifications on page 3-1.
Access Procedures 3-33
1. Remove power from the drive (Removing Power from the Drive on
page 3-3).
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
3. Remove the power structures from the drive cabinet (Removing the
Power Structures from the Drive Enclosure on page 3-25).
5. Remove the cables from X13, X14 and X15 sockets on the Gate Driver
Board, and carefully set them aside. Also, disconnect DC Bus wiring
from the Gate Driver Board.
6. Remove the cable-tie which secures the Power Module Circuit Board to
the Adapter Board.
7. Disconnect the output leads from the bottom of the Output Power
Module.
3-34 Access Procedures
8. Loosen, but do not remove, the screws that secure the Y Bus Bars to the
drive.
Y Bus Bars
Balancing Resistors
AC Input
Terminals
Balancing Resistor Wires
(L1, L2, L3)
10. Disconnect all wiring from the circuit board on the Rectifying Module.
11. Disconnect the cables from the AC input terminals on the Rectifying
Module.
12. Remove the circuit board from the Rectifying Module (refer to
Removing the Rectifying Boards on page 3-29).
Access Procedures 3-35
13. Remove the screws that secure the Snubber Capacitors, and remove the
Snubber Capacitors.
Snubber Capacitors
Snubber Capacitor
Fastening Screws
14. Remove the screws that secure DC Bus Bars to right side of power
structure, and remove the DC Bus Bars.
3-36 Access Procedures
15. Remove the screws that secure the Rectifying Module to the power
structure, and remove the Rectifying Module.
16. Remove the screws that secure the Output Power Module to the power
structure, and remove the Output Power Module.
17. Repeat steps 4 - 16 to remove the right-side Output Power Module and
Rectifying Module from Power Structure 2.
Installation
Install the Output Power Modules and Rectifying Modules in reverse order
of removal, while referring to Torque Specifications on page 3-1.
Access Procedures 3-37
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
3. Remove the power structures from the drive cabinet (Removing the
Power Structures from the Drive Enclosure on page 3-25).
Task Description
Remove the cable-ties that secure the cables with orange insulation
A (on both left-hand and right-hand sides). This will allow you to move the
cables while removing the inverter assemblies.
Left-hand
Inverter
Right-hand
Inverter
A
Left-hand
Side
View
Front View
on Left-hand Side
3-38 Access Procedures
Task Description
Remove the two M5 Pozi-drive screws, which secure the front of the
A fan inverter to the drive.
Proper tightening torque for reassembly is 4 N-m (35 lb.-in.).
Disconnect the fan motor cable under the inverter.
B
Remove the four M5 Pozi-drive screws, which secure the bottom of the
C fan inverter to the drive.
Proper tightening torque for reassembly is 4 N-m (35 lb.-in.).
Disconnect the cables at X2, X8 and X3 (on left-hand and center
D inverters); and X2 and X8 (on right-hand inverter).
Bottom View
of Power Structure
C C
Task Description
Disconnect the cables at connectors X4 (Blue) and X5 (Black).
A
A A
Task Description
Remove two M5 Pozi-drive screws, which secure the inverter board
B and its heatsink to the assembly carriage.
Proper tightening torque for reassembly is 4 N-m (35 lb.-in.).
Carefully remove the inverter board and its heatsink from the assembly
C carriage.
B B
Installation
Install the fan inverters in reverse order of removal, while referring to
Torque Specifications on page 3-1.
3-40 Access Procedures
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
3. Remove the power structures from the drive cabinet (Removing the
Power Structures from the Drive Enclosure on page 3-25).
4. For Power Structure 1, remove the balancing resistor wires from bus
bars.
Balancing Resistors
AC Input
Terminals
Balancing Resistor Wires
(L1, L2, L3)
Access Procedures 3-41
5. Remove the screws that secure DC Bus Bars to right side of power
structure, and remove the DC Bus Bars.
6. Remove the four (4) screws that secure the capacitor to the power
structure, and remove the capacitor.
Installation
Install the capacitors in reverse order of removal, while referring to Torque
Specifications on page 3-1.
Chapter 4
Before Applying Power to 1. Check for zero volts between DC+ and DC-.
the Drive 2. Perform forward and reverse biased diode tests, using a digital
multimeter. Refer to Conducting Forward and Reverse Biased Diode
Tests for Major Power Components on page 2-4.
4-2 Start-Up After Repair
Testing with the External DC This is a low current - low risk test for the Output Power Module and drive
Power Supply Without Load Control board. It requires the recommended High Voltage DC Test Power
(Optional) Supply.
2. Connect the power supply’s DC+ to the drive’s DC+ terminal and the
power supply’s DC- to the drive’s DC- terminal.
6. Measure the DC bus voltage and verify that the value is reflected in:
7. Make configuration changes which allow the HIM to issue start and
speed commands.
10. Increase the speed command from zero to base speed, by pressing
(the up button).
11. Stop the drive, by pressing (the stop button).
13. Decrease the DC Test Power Supply output voltage to zero. Wait until
DC bus voltage has decreased to zero. Switch off the external DC power
supply.
Start-Up After Repair 4-3
Testing Without a Motor This test allows you to measure several operating parameters and diagnose
problems without connecting the motor.
7. Measure the output voltage on each phase and verify that it is balanced.
If it is unbalanced troubleshoot the drive.
Performing the Power The Power Circuit Diagnostic Test, on the 700S, allow you to diagnose
Circuit Diagnostic Test on a problems in the drive’s power structure without applying large amounts of
700S power.
4. From the Monitor menu on the HIM press Esc (the escape button) to
navigate to the Main menu.
Testing With the Motor This test allows you to measure several operating parameters and diagnose
problems without connecting the motor to its mechanical load.
5. Start the drive and increase the speed from zero to base speed.
6. Measure drive output current and verify that the value is reflected in:
Service tools This list of basic service tools which will cover needs of tools for repair and
maintenance measurements.
Item Description Details
1 Oscilloscope Portable, digitizing, dual channel scope, with isolation
2 Current clamp 1000A(ac, rms), signal output
3 Soldering station Soldering / de soldering
4 Adjustable power supply 0...1300Vdc, 1A, adjustable current limit. Efore LPS
750-HV or equivalent.
5 Adjustable power supply 0...690Vac (+10%), 10A, 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 1000Vdc
8 Torque wrench 1...12Nm
9 Torque wrench 6...50Nm
10 box wrench 7mm, 8mm, 10mm, 13mm, 17mm, 19mm, 22mm
11 socket extension 230mm
12 Wrench 7mm, 8mm, 10mm, 13mm, 17mm, 19mm, 22mm
13 Wire cutter
14 Nose pliers
15 Crimping tools For cable terminals 1,5...240
16 Angle wrench
17 Screw driver
18 *Flat nose 7*2(mm)
19 *POZIDRIV 1, 2, 3
20 *Phillips 1, 2, 3
21 *Torx 25
22 Hexagonal wrench 4, 5, 6
23 ESD-protected place of work Working surface, Floor covering, seat and ground
connections
24 ESD-protective clothing Wrist wrap, shoes, overall clothing (coat)
25 Power supply (service) Capacity of three phase service 400/500/690Vac, 30A
26 20-MAINSTND maintenance stand Maintenance stand for removing power structure from
drive cabinet
27 Fiber-optic repair kit Agilent HFBR-4593 Polishing Kit, consisting of a
Polishing Fixture, 600 grit abrasive paper and 3 mm
pink lapping film (3M Company, OC3-14).
Schematics
7 80
RS-232
Port
P3 P7 P9 ENet
Option
RJ45
Phase II P2 P1 Connector
Control
RX Synchlink Board
Option P1
TX 120 with all 10
P10 Options P6
Compact 16 30
P2 P1 34
I/O Option P2
Fdbk P2 P11
Fdbk P1 Option
50 34 40
Compact P4
Inputs Board P3 P12 P1
Flash Option LEOB
80 (Optional) 16 2
Comm. P1 P13 Elect.
P3 Second Encoder P2 P21
Option Battery
Safe Off Option P4 P5
Comm. Input
TB1 TB2
T 6 4 2 T 6 4 2
7 5 3 1 7 5 3 1
J5
J28
J13
J14
J12
J11
J10
J27
J24
J25
J23
J22
J21
J20
J19
+24 V Iso
J9
J8
J3
+12 V
-12 V 8
+5V J6 Tx
J17 J7 Rx
9
J1 DPI J4
HiHP Fiber Optic
Interface Board Fan Power
LED
J16
J2 J15 STATUS
J18
2 External 24V DC
1=24V, 3=Common (75W min)
9
X2 HIM
DPI BEZEL
From Power Structure #1
9 2 80 W J2
2 Interface J1 J8 Power -DC- DC-
X4 X1 J2 HIM +24V Supply -DC+ DC+
X3 DOOR J1
J3 FIBER 9 -U U/T1
RxJ4 Voltage -V V/T2
20 PWR 8 TxJ5 Feedback -W W/T3
STS Example: 20-HIM-A3 FIBER
9
DPI PORT
COMM MOD
OPTION NET A
NET B HIM
DPI Assembly Figure B.1 Circuit Board Connections
External DPI for 700S Drives with Phase II Control
Circuit Board Connections for 700H Drives
X2
H5
H8
H4
H7
H6
H1
H3
H2
H11
H14
H17
H18
H16
H12
H15
H23
H22
H13
H21
1 +24VDC
2 GND
Star Coupler Board
X1
37
X1
20-VB00601
X2 HIM
DPI BEZEL
Control Board Interface
9
X4 X1 J2 J1
X3 J3
HIM
X2 X3 X4 X5 X6
(slot A) (slot B) (slot C) (slot D) (slot E) Door
Programming 20 PWR 9
Port X7 Example: 20-HIM-A3
DPI PORT
Analog I/O X1 Comm. MOD
Plus Digital Input Digital Ouput Option NET A
Option Option Option DPI Option NET B
24V OR 115V 20C-DPI1
Board Board 20C-DPI1 9 HIM
20C-DA1-A 20C-D01 DPI Assembly
2OC-DA1-B X3 EXTERNAL DPI
Analog I/O Digital 3 3
Schematics
(10) Input
(8/10)
Figure B.2 Circuit Board Connections for
700H Drives
B-3
B-4 Schematics
Coupler Board
21
Charge X3 To Gate Driver Board X13
22
On Power Structure #1
External Pre-Charge Relay X4 To Gate Driver Board X14
Fiber Optic Example Circuitry 4
23
5 H5 Control
700H Star
Coupler Board 6 H6
Ports 1 - 7 for 7 H7
ASIC Board #1 Fiber Optic
Feedback
Board #2
To 700S
HiHP Fiber
Optic H903 ASIC
6
Board DC+
Interface H900 X900 X26 1
From DC Bus
Board J27 H901 #2 X6 2
1 X9
+24V
3 in Power Circuitry
H902 25
DC-
Or M 2
26 0EVA
X15 X2 To Rectifying Board X13
3
700H Star 21
Charge X3 To Gate Driver Board X13
On Power Structure #2
22
Coupler Board 4
23 Relay X4 To Gate Driver Board X14
H18 X5 To Gate Driver Board X15
X50 X1
1 +24VDC To Gate Driver Board H4
H8
2 DC-
H9 To Gate Driver Board H5
X10 24V Power H10 To Gate Driver Board H6
To 700S H11 To Gate Driver Board H7
HiHP Fiber Optic H12 To Gate Driver Board H8
Interface Board 1 H1
H13 To Gate Driver Board H9
Ports 1 - 7 for ASIC 2 H2
X600
Board #2 3 H3 3
H4 Fan X11 To Left Fan X8
4
Control
Or 5 H5
6 H6
700H Star 7 H7
Coupler Board Fiber Optic
Ports 1 - 7 for ASIC
Board #2
Figure B.3 ASIC Circuit Board Connections
Structure #1)
DC+
To 700S Control Board J2
DC-
Power Circuitry for Drives with AC Input (Power
Note:
400V/600V Capacitor Configuration
400V - 2 Caps in series
K3 3 Caps in parallel
600V - 3 Caps in series To 700S Control Board J1
K2
K1 2 Caps in parallel
Right Side Module
X9 X10 X11 X12
Line Reactor
LI/R X1 X2 X3
X1
L2/S X1 X2 X3
See Note
X2
L3/T X1 X2 X3
X3
Remove Junper For:
Non-CE Listed Units,
X8
DC Units on Regenerative 5
5 5
Front Ends, or
Grounded Delta X4
Connected Inputs Mains Voltage X5 X1. . .
I_U
I_V
X6
I_W
X41 Supression X5
X8
TERM U
TERM V
PE
TERM W
U_HI
V_HI
U_LO
X4
W_HI
V_LO
X10
W_LO
Adapter Board
Left Side Module U/TI
X2 V/T2
2 W/T3
DC-
TB1
X6 Common Mode 4
Filter Board TB2
DC+
See Note
X1 X11
X8.. X12
X3..X5 X13. . . X15 X13
Ribbon Cable X12 X17
To ASIC Board #1
Gate Driver X19
Board 5 5 5
H8..H13 H4. . . H9 X1 X4
X2 X5
6 Fiber Optic Cables X3.. X1. . .
I_V
I_U
I_W
X3 X6
Schematics
X7 X7 X8 X5
TERM V
TERM U
TERM W
V_HI
U_HI
W_HI
V_LO
X9
U_LO
X10
W_LO
Power Board #2
Figure B.4 Power Circuitry for Drives
B-5
B-6
Note:
DC- 400V/600V Capacitor Configuration
400V - 2 Caps in series
Structure #2)
3 Caps in parallel
600V - 3 Caps in series
2 Caps in parallel
K3
K2
Schematics
K1
Right Side Module
X9 X10 X11 X12
Line Reactor
LI/R X1 X2 X3
X1
L2/S X1 X2 X3
Power Circuitry for Drives with AC Input (Power
See Note
X2
L3/T X1 X2 X3
X3
Remove Junper For:
Non-CE Listed Units,
X8
DC Units on Regenerative 5
5 5
Front Ends, or
Grounded Delta X4
Connected Inputs Mains Voltage X5 X1. . .
I_U
I_V
X6
I_W
X41 Supression X5
TERM U
X8
TERM V
PE
TERM W
U_HI
V_HI
U_LO
W_HI
X4
V_LO
X10
W_LO
Rectifier Board X50 Power Board #1
X13 X6
Adapter Board
Left Side Module U/TI
X2 V/T2
2 W/T3
DC-
TB1
X6 Common Mode 4
Filter Board TB2
DC+
See Note
X1 X11
X8.. X12
X3..X5 X13. . . X15 X13
Ribbon Cable X12 X17
To ASIC Board #2
Gate Driver X19
Board 5 5 5
H8..H13 H4. . . H9 X1 X4
X2 X5
X3.. X1. . .
I_V
X3 X6
X7 X7 X8 X5
TERM V
TERM U
TERM W
V_HI
U_HI
W_HI
V_LO
X9 X10 U_LO
W_LO
Power Board #2
See Note
DC-
5 5 5
X4
X5 X1. . . I_V
I_U
I_W
PE X6
X8 X5
TERM V
TERM U
TERM W
U_HI
X10
V_HI
W_HI
U_LO
V_LO
W_LO
Power Board #1
DC-
Adapter Board
X6 Left Side Module U/TI
DC+ V/T2
2 W/T3
X3..X5 TB1 Common Mode
TB2 Filter Board
To ASIC Board #1
H8..H13 4
Ribbon Cable
X1
X11
X2
X13 . . . X15 X8 . . . X3
X12 X7 See Note
X9
Gate Driver 5 5 5
Board
H4 . . . H9 X4
6 Fiber Optic Cables X12
X5
I_V
I_U
X13 X1. .
I_W
X3 . . . X6
X7 X17 X5
TERM V
TERM U
X8
TERM W
X19
U_HI
V_HI
W_HI
X10
U_LO
V_LO
W_LO
Power Board #2
Schematics
Structure #2)
3 Caps in parallel
600V - 3 Caps in series
2 Caps in parallel
DC+ Right Side Module
Schematics
See Note
DC-
5 5 5
X4
X5 X1. . .
I_V
I_U
I_W
PE X6
X8 X5
TERM V
TERM U
TERM W
U_HI
X10
V_HI
W_HI
U_LO
V_LO
W_LO
Power Board #1
DC-
Adapter Board
X6 Left Side Module U/TI
DC+ V/T2
2 W/T3
X3..X5 TB1 Common Mode
TB2 Filter Board
To ASIC Board #2
H8..H13 4
Ribbon Cable
X1
X11
X2
X13 . . . X15 X8 . . . X3
X12 X7 See Note
X9
Gate Driver 5 5 5
Board
H4 . . . H9 X4
6 Fiber Optic Cables X12
X5
I_V
I_U
X13 X1. .
I_W
X3 . . . X6
X7 X17 X5
TERM V
TERM U
X8
TERM W
X19
U_HI
V_HI
W_HI
X10
U_LO
V_LO
W_LO
Power Board #2
DC+ DC-
6A From ASIC Board #2 - X11
3
F1 F2
2 BLUE
6
X2-3 (+) X8 BLK
U1 X4-1 BLK 2 2.2uf M1
5 300VAC
10Meg
4 Y/GRN Main Fan
X2-1 (-) BLK
DC/AC 4
Left Side
1 2 3 4 V1 X5-1 BLK 2.2uf 230V AC
Off Off On Off BLK 1 300VAC 10Meg 50 Hz
3 BLACK
Setup Switch
3
Fan Frequency Converter X3 BLK 7uf 1 BRN
4
In Power Structure #1 (Left Side)
2 BLUE
6
X2-3 (+) X8 BLK
U1 X4-1 BLK 2 2.2uf M2
5 300VAC 10Meg
4 Y/GRN Main Fan
X2-1 (-) BLK
DC/AC 4 Right Side
1 2 3 4 V1 X5-1 BLK 2.2uf 230V AC
Off Off On Off BLK 1 300VAC 10Meg
3 BLACK 50 Hz
3
Setup Switch BLK
Fan Frequency Converter X3 7uf
2 4 1 BRN
Jumper
DC+ DC-
6A From ASIC Board #1 - X11
3
F1 F2
2 BLUE
6
X2-3 (+) X8 BLK
U1 X4-1 BLK 2 2.2uf M3
5 300VAC 10Meg
4 Y/GRN Main Fan
X2-1 (-) BLK
DC/AC 4 Left Side
V1 X5-1 2.2uf 230V AC
1 2 3 4 BLK
BLK 1 300VAC 10Meg
3 BLACK 50 Hz
Off Off On Off 3
Setup Switch Fan Frequency Converter X3 BLK
7uf 1 BRN
2 BLUE
6
X2-3 (+) X8 BLK
U1 X4-1 BLK 2 2.2uf M4
5 300VAC 10Meg
4 Y/GRN Main Fan
X2-1 (-) BLK
DC/AC 4 Right Side
V1 X5-1 BLK 2.2uf 230V AC
1 2 3 4 10Meg
Off Off On Off
BLK 1 300VAC
3 BLACK 50 Hz
3
Setup Switch Fan Frequency Converter X3 BLK
7uf 1
2 4 BRN
Jumper
Figure B.8 Fan Inverter Connections
B-10
DC+ DC-
L1 U / T1
Cable Length >= 5 M
Power Structure #1 Symmetrical Layout
L2 V / T2
Schematics
L3 W / T3
PE
L1
L2 Motor
L3
DC+ DC-
L1 U / T1
Power Structure #2
L2 V / T2
= Customer Connections
L3 W / T3
PE
DC+ U / T1
Cable Length >=5M
Power Structure #1 Symmetrical Layout
V / T2
DC- W / T3
PE
Motor
M
DC+ DC+ U / T1
Power Structure #2
F1 R1CR2
V / T2
M
DC- DC- W / T3
Customer Supplied
F2 R2CR2 PE
Schematics
Notes:
Appendix C
Connector Descriptions
Circuit Board Connections The following tables detail the connection points for the frame 12
PowerFlex 700S and 700H AC input drives circuit boards and components.
C-2 Connector Descriptions
X11 X2
H8
X9
H9
H10 X15
X26
H11
H12 H1
H13 H2
H3
X3 H4
X1
H5
H6
X4
H7
X5 X6
H8 H6 H4 H9 H7 H5
X3 X8
X4 X9
X5 X10
X6 X11
X12
X7
X13
X14
X15
X1
Connector Descriptions C-3
Table C.A ASIC Board on Power Structure #1 to Gate Driver Board on Power
Structure #1 - Phase U Connections
Gate Driver
ASIC Board Board
Connector Pin Number to Pin Number Connector Description
X3 1 ... 1 X13 U_Feedback
2 ... 2 U_Power_OK
3 ... 3 U_DTR(1) See Note Below
4 ... 4 U_ETR(2)
5 ... 5 U_ITR(3)
6 ... 6 U_DC-
7 ... 7 UI
8 ... 8 U_DC-_I
9 ... 9 U_TEMP
10 ... 10 U_DC-T
H8 (fiber optic) H8 ... H4 H4 (fiber optic) UH or Gate Top
H9 (fiber optic) H9 ... H5 H5 (fiber optic) UL or Gate Bottom
Table C.B ASIC Board on Power Structure #1 to Gate Driver Board on Power
Structure #1 - Phase V Connections
ASIC Board Gate Driver Board
Connector Pin Number to Pin Number Connector Description
X4 1 ... 1 X14 V_Feedback
2 ... 2 V_Power_OK
3 ... 3 V_DTR(1)
4 ... 4 V_ETR(2)
5 ... 5 V_ITR(3)
6 ... 6 V_DC-
7 ... 7 VI
8 ... 8 V_DC-_I
9 ... 9 V_TEMP
10 ... 10 V_DC-T
H10 (fiber optic) H10 ... H6 H6 (fiber optic) VH or Gate Top
H11 (fiber optic) H11 ... H7 H7 (fiber optic) VL or Gate Bottom
Table C.C ASIC Board on Power Structure #1 to Gate Driver Board on Power
Structure #1 - Phase W Connections
ASIC Board Gate Driver Board
Connector Pin Number to Pin Number Connector Description
X5 1 ... 1 X15 W_Feedback
2 ... 2 W_Power_OK
3 ... 3 W_DTR(1)
4 ... 4 W_ETR(2)
5 ... 5 W_ITR(3)
6 ... 6 W_DC-
7 ... 7 WI
8 ... 8 W_DC-_I
9 ... 9 W_TEMP
10 ... 10 W_DC-T
H12 (fiber optic) H12 ... H8 H8 (fiber optic) WH or Gate Top
H13 (fiber optic) H13 ... H9 H9 (fiber optic) WL or Gate Bottom
(1)
DTR = N Desat
(2)
ETR = Phase I2T
(3)
ITR = Phase Overcurrent
Table C.D ASIC Board on Power Structure #2 to Gate Driver Board on Power
Structure #2 - Phase U Connections
Gate Driver
ASIC Board Board
Connector Pin Number to Pin Number Connector Description
X3 1 ... 1 X13 U_Feedback
2 ... 2 U_Power_OK
3 ... 3 U_DTR(1) See Note Below
4 ... 4 U_ETR(2)
5 ... 5 U_ITR(3)
6 ... 6 U_DC-
7 ... 7 UI
8 ... 8 U_DC-_I
9 ... 9 U_TEMP
10 ... 10 U_DC-T
H8 (fiber optic) H8 ... H4 H4 (fiber optic) UH or Gate Top
H9 (fiber optic) H9 ... H5 H5 (fiber optic) UL or Gate Bottom
Table C.E ASIC Board on Power Structure #2 to Gate Driver Board on Power
Structure #2 - Phase V Connections
ASIC Board Gate Driver Board
Connector Pin Number to Pin Number Connector Description
X4 1 ... 1 X14 V_Feedback
2 ... 2 V_Power_OK
3 ... 3 V_DTR(1)
4 ... 4 V_ETR(2)
5 ... 5 V_ITR(3)
6 ... 6 V_DC-
7 ... 7 VI
8 ... 8 V_DC-_I
9 ... 9 V_TEMP
10 ... 10 V_DC-T
H10 (fiber optic) H10 ... H6 H6 (fiber optic) VH or Gate Top
H11 (fiber optic) H11 ... H7 H7 (fiber optic) VL or Gate Bottom
Table C.F ASIC Board on Power Structure #2 to Gate Driver Board on Power
Structure #2 - Phase W Connections
ASIC Board Gate Driver Board
Connector Pin Number to Pin Number Connector Description
X5 1 ... 1 X15 W_Feedback
2 ... 2 W_Power_OK
3 ... 3 W_DTR(1)
4 ... 4 W_ETR(2)
5 ... 5 W_ITR(3)
6 ... 6 W_DC-
7 ... 7 WI
8 ... 8 W_DC-_I
9 ... 9 W_TEMP
10 ... 10 W_DC-T
H12 (fiber optic) H12 ... H8 H8 (fiber optic) WH or Gate Top
H13 (fiber optic) H13 ... H9 H9 (fiber optic) WL or Gate Bottom
(1)
DTR = N Desat
(2) ETR = Phase I2T
(3)
ITR = Phase Overcurrent
C-6 Connector Descriptions
X41
J3
J7
J11
Figure C.4 PowerFlex 700S High Power Star Interface Circuit Board Connectors
J28
J13
J14
J12
J11
J10
J9
J8
J7
J6
J27
J24
J25
J23
J22
J21
J20
J19
J5
C-8 Connector Descriptions
H8
H7
H6
H5
H4
H3
H2
H1
H18
H17
H16
H15
H14
H13
H12
H11
X2
H23
H22
H21
Table C.I PowerFlex 700H and 700S Interface Board to ASIC Board on Power
Structure #1 Fiber Optic Connections
Interface Board Fiber ASIC Board
Optic Connector Fiber Connector Description: Reference to ASIC
700H 700S Type to Type (1) Board
H1 J8 TX . . . RX H1 Gate_Enable
H2 J9 TX . . . RX H2 U_Gate
H3 J10 TX . . . RX H3 V_Gate
H4 J11 TX . . . RX H4 W_Gate
H5 J12 TX . . . RX H5 A/D Convert
H6 J14 TX . . . RX H6 VBUS_RX
H7 J13 RX . . . TX H7 VBUS_TX
(1) Refer to Figure C.1 on page C-2 for ASIC board fiber-optic connectors.
Connector Descriptions C-9
Table C.J PowerFlex 700H and 700S Interface Board to ASIC Board on Power
Structure #2 Fiber Optic Connections
Interface Board Fiber ASIC Board
Optic Connector Fiber Connector Description: Reference to ASIC
700H 700S Type to Type (1) Board
H11 J19 TX . . . RX H1 Gate_Enable
H12 J20 TX . . . RX H2 U_Gate
H13 J21 TX . . . RX H3 V_Gate
H14 J22 TX . . . RX H4 W_Gate
H15 J23 TX . . . RX H5 A/D Convert
H16 J25 TX . . . RX H6 VBUS_RX
H17 J24 RX . . . TX H7 VBUS_TX
(1)
Refer to Figure C.1 on page C-2 for ASIC board fiber-optic connectors.
H900
H901
X900
H902
H903
Table C.K ASIC Feedback Board on Power Structure #1 to ASIC Board on Power
Structure #1 Connections
ASIC Feedback ASIC Board
Board Connector Pin to Pin Connector Description: Reference to ASIC Board
X900 1 ... 1 X26 PHU
2 ... 2 PHV
3 ... 3 PHW
4 ... 4 Trip_Out
5 ... 5 +5V
6 ... 6 +5V
Table C.L ASIC Feedback Board on Power Structure #2 to ASIC Board on Power
Structure #2 Connections
ASIC Feedback ASIC Board
Board Connector Pin to Pin Connector Description: Reference to ASIC Board
X900 1 ... 1 X26 PHU
2 ... 2 PHV
3 ... 3 PHW
4 ... 4 Trip_Out
5 ... 5 +5V
6 ... 6 +5V
C-10 Connector Descriptions
Table C.M ASIC Feedback Board to PowerFlex 700S High Power Star Interface Board
Connections
ASIC Feedback Board High Power Star Interface Description: Reference to
Connector to Board Connector Star Interface Board
H903 on Power Structure #1 . . . J28 Trip_P1
H903 on Power Structure #2 . . . J27 Trip_P2
Table C.N ASIC Feedback Board to PowerFlex 700H Star Coupler Board Connections
ASIC Feedback Board Description: Reference to
Connector to Star Coupler Board Connector Star Coupler Board
H900 on Power Structure #1 ... H21 PHU
H901 on Power Structure #1 ... H22 PHV
H902 on Power Structure #1 ... H23 PHW
H903 on Power Structure #1 ... H8 Trip_P1
H903 on Power Structure #2 ... H18 Trip_P2
X3
X8
Note: There is a left and right main cooling fan inverter on both Power
Structures. The connections for each pair of fan inverters are the same.
Table C.O ASIC Board to Left Side Main Cooling Fan Inverter Connections
ASIC Board Fan Inverter
Description Connector(1) Pin Number Pin Number Connector Description
+15V dc power to X11 2 2 X8 +15V dc power
Fan Inverter board from ASIC board
Fan Control 3 3 Fan Control
Alarm from Fans 4 7 Fan Alarm to
ASIC board
(1) Refer to Figure C.1 on page C-2 for ASIC board fiber-optic connectors.
Table C.P Left Side Main Cooling Fan Inverter to Right Side Main Cooling Fan Inverter
Connections
Left Side Fan Right Side
Inverter Fan Inverter
Description Connector Pin Number Pin Number Connector Description
+15V dc power X11 2 2 X8 +15V dc power
Fan Control 3 3 Fan Control
Fan Alarm 4 7 Fan Alarm
Connector Descriptions C-11
3 21
Charge
Relay
4 23
X15
CR1
Pilot Relay
CR1 M
Main DC Contactor
3 21
Charge
Relay
4 23
X15
For DC Input Only
(Do Not Install on AC Input Drives)
Notes:
Appendix D
Disassembly/Assembly Diagrams on the following pages illustrate disassembly and assembly of the
Diagrams and Spare Parts drive and its sub-systems and are followed by a list of spare part numbers
Numbers where applicable.
When ordering spare parts, you must provide the serial number of the drive.
The serial number is located on the data nameplate on the Control Frame
just above the bar code.
200 kW 500 kW
Input: DC,
DC Voltage Range 462 - 594 583 - 713
Amps 350 350
Output: 3 Phase, 0 - 320Hz
AC Voltage Range 0 - 400 0 - 460
Base Hz (default) 50 Hz 60 Hz
Continuous Amps 420/500 420/500
1 Min Overload Amps 630/550 630/550
2 Sec Overload Amps 840/630 840/630
MFD. in 1989 on Nov 9
Cat No. 20D
UL Open Type/IP00
540V
160 kW
132 kW
650V
250 kW
200 kW
Series: A
Standard I/O: NONE
Original Firmware No. 2.04
C UL US
Frame #: 12
Serial Number: 2622381652
Æ
DC Voltage Range 462 - 594 583 - 713 LISTED
Amps 350 350 IND CONT EQ
Output: 3 Phase, 0 - 320Hz
AC Voltage Range 0 - 400 0 - 460
Base Hz (default) 50 Hz 60 Hz
Continuous Amps 300/245 300/245
1 Min Overload Amps 330/368 330/368
2 Sec Overload Amps
26223816
450/490 450/490
MFD. in 2005 on Feb 29
Serial Number: 2622381652
Rectifying Board
DC Bus Bar
DC Bus Bar
DC Bus Bar
Discharging Resistor
Output Power Module
DC Bus Bar
DC Bus Bar
DC Bus Bar
Cover Plate
Insulation Support
Discharging Resistor
Electrolytic Capacitor
Frame
Disassembly / Assembly Diagrams D-7
ASIC Board
Main Fan
Intake Cone
Notes:
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