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Powerflex 700h PDF

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0% found this document useful (0 votes)
434 views120 pages

Powerflex 700h PDF

Uploaded by

Evandro Pavesi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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700S High Performance

AC Drive
and
700H Adjustable Frequency
AC Drive

Frame 12
450-560kW, 400V
700-900HP, 480V
630-800kW, 690V
700-900HP 600V

Hardware Service Manual


Important User Information
Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available
from your local Rockwell Automation sales office or online at 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:
x identify a hazard
x avoid the hazard
x recognize the consequences

Shock Hazard labels may be located on or inside the equipment


(e.g., drive or motor) to alert people that dangerous voltage may be
present.

Burn Hazard labels may be located on or inside the equipment


(e.g., drive or motor) to alert people that surfaces may be at
dangerous temperatures.

PowerFlex is a registered trademark of Rockwell Automation, Inc.


DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.
PLC is a registered trademark of Rockwell Automation, Inc.
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Preface Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1


What is in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
What is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Understanding Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Additional Support Available on Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4

Chapter 1 Creating Fault Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2


Addressing 700S Hardware Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Addressing 700H Hardware Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Diagnostic Procedures by Symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Chapter 2 Viewing the 700H Diagnostic LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1


Viewing the 700S Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Performing Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Conducting Forward and Reverse Biased Diode Tests for Major Power Components. . . 2-4
Checking Fiber Optic Connections to the Gate Driver Boards . . . . . . . . . . . . . . . . . . . . . 2-8
Conducting Gate Driver Board Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Checking Rectifying Module (on AC Input Drives Only) . . . . . . . . . . . . . . . . . . . . . . . 2-14
Checking the DC Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Checking the Main Fan Inverters and Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Chapter 3 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1


Removing Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Removing the DPI / HIM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Removing the 700S Phase II Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Removing the 700S High Power Fiber Optic Interface Circuit Board . . . . . . . . . . . . . . . 3-8
Removing the 700S Control Assembly Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Removing the 700H I/O Boards and Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Removing the 700H Star Coupler Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Removing the Covers from the Power Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Removing the 700S Voltage Feedback Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Removing the Gate Driver and Adapter Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Removing the Power Structures from the Drive Enclosure . . . . . . . . . . . . . . . . . . . . . . 3-25
Removing the Main Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Removing the ASIC Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Removing the Rectifying Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Removing the Left-Side Output Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Removing the Right-Side Output Power Modules and Rectifying Modules . . . . . . . . . 3-33
Removing the Fan Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Removing the DC Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Chapter 4 Before Applying Power to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1


Testing with the External DC Power Supply Without Load (Optional) . . . . . . . . . . . . . . 4-2
Testing Without a Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Performing the Power Circuit Diagnostic Test on a 700S. . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Testing With the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
2

Appendix A Software Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1


Service tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Appendix B List of Schematic Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Appendix C Circuit Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1


Hardware Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10

Appendix D Disassembly/Assembly Diagrams and Spare Parts Numbers . . . . . . . . . . . . . . . . . . . . . . D-1


Preface

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.

Cat No. 20D J 500 N 0 NNNBNNNN


UL Open Type/IP00
540V 650V Series: A
Standard I/O: NONE
Normal Duty Power 250 kW 450 kW Original Firmware No. 2.04
Heavy Duty Power
Frame #: 10

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

Normal Duty Power


Heavy Duty Power
Input: DC,
J 300 N 0 NNNBNNNN

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

MADE IN THE USA (FAC 1B) 2622381652

MADE IN THE USA (FAC 1B)

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

Reference Materials Allen-Bradley publications are available on the internet at


www.rockwellautomation.com/literature.

The following publications provide general drive information.


Title Publication
Wiring and Grounding Guide, (PWM) AC Drives DRIVES-IN001…
Safety Guidelines for the Application, Installation and Maintenance of SGI-1.1
Solid State 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
Programming Manual - PowerFlex 700H AC Drive 20C-PM001…
User Manual - PowerFlex 700S with Phase II Control High 20D-UM006…
Performance Drive
Installation Instructions - Hi-Resolution Feedback Option Card for 20D-IN001…
PowerFlex 700S Drives
Installation Instructions - Multi Device Interface Option for PowerFlex 20D-IN004…
700S Drives
Installation Instructions - Main Control Board PowerFlex 700S Drives 20D-IN005…
Installation Instructions - Control Assembly Cover for PowerFlex 700S 20D-IN006…
Drives
Installation Instructions - PowerFlex 700S /700H High Power 20D-IN014…
Maintenance Stand
Installation Instructions - PowerFlex 700S and 700H Drives PFLEX-IN006…
Reference Manual - PowerFlex 700S with Phase II Control Adjustable PFLEX-RM003…
Frequency Drives

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…

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
Overview P-3

Cross References
“Figure 2.2 on page 2-6” is a cross reference to figure 2.2 on page 5 of
Chapter 2.

“Figure C.1 on page C-2” is a cross reference to figure C.1 on page 2 of


Appendix C.

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

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: 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: This drive contains ESD (Electrostatic
! Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with
static control procedures, reference A-B publication 8000-4.5.2,
“Guarding Against Electrostatic Damage” or any other applicable
ESD protection handbook.
ATTENTION: 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 high
! power PowerFlex 700S and 700H 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 before performing
any work on the drive. Measure the DC bus voltage at the DC+ &
DC- terminals. The voltage must be zero.
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.
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.
ATTENTION: To avoid an electric shock hazard, verify that the
! voltage on the bus capacitors has discharged before performing
any work on the drive. Measure the DC bus voltage at the DC+ &
DC- terminals. The voltage must be zero.
ATTENTION: HOT surfaces can cause severe burns. Do not
! touch the heatsink surface during operation of the drive. After
disconnecting power allow time for cooling.
ATTENTION: This drive contains ESD (Electrostatic
! Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with
static control procedures, reference A-B publication 8000-4.5.2,
“Guarding Against Electrostatic Damage” or any other
applicable ESD protection handbook.
1-2 Troubleshooting and Error Codes

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:

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

Addressing 700S Hardware


Fault No. Description Action (if appropriate)
Faults HiHp In PhaseLs 65 AC Input Phase Loss - AC voltage is 1. Check for voltage on each
not present on one or two input input phase.
phases. 2. Check the status of each
external input fuses.
HiHp Bus Com Dly 66 Bus Communication Time Delay - the Check fiber-optic connections
processor has not received proper between the Power Interface
periodic feedback information. Circuit Board and Voltage
Feedback Circuit Board.
HiHp Bus Link LS 67 Bus Communication Link Loss - bus Check fiber-optic connections
communication between the Power between the Power Interface
Interface Circuit Board and Voltage Circuit Board and Voltage
Feedback Circuit Board has halted. Feedback Circuit Board.
HiHp Bus CRC Er 68 Bus Communication CRC Error - too Check fiber-optic connections
many Cycling Ring Checksum (CRC) between the Power Interface
errors have occurred in the Circuit Board and Voltage
communication bus. Feedback Circuit Board.

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

Fault No. Description Action (if appropriate)


HiHp Drv OvrLoad 71 Drive Overload - the circuit board on Measure output current of the
the Power Module has detected an drive. If the level is ever greater
overload. than the maximum drive rated
output current level reduce the
load. If the levels are always
well below the drive rated
levels, then replace the power
module.
HiHp PwrBd PrcEr 72 Power Board Processor Error - a 1. Check fiber-optic
microprocessor on the Power Board connections between the
has detected a communication error. Power Interface Circuit Board
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 PrChrg Cntc 73 Precharge Contactor Fault - proper x Check precharge circuit
contactor feedback has not occurred. wiring.
The precharge contactor has probably x Check for loose connections
failed to pick up or the feedback signal on X50 terminal block and/or
has failed. This fault only applies to the X9 and X15 connectors
DC input drives. on the ASIC Board.
HiHp PwrEE Error 74 Power EEPROM Error - the rating of Replace output power module
the drive and data in the Power or program a new power board.
EEPROM on the Power Board do not
match.
HiHP PwrBd OTemp 75 Power Board Over-Temperature - Check the main cooling fan and
temperature of the Power Board on fan power supply, replace if
has exceeded 85q C. necessary.
HiHP HardwareVer 76 (High Horse Power Star-coupler board Check the version of each
frame 12 drives only) The left side and inverter (left and right units),
right side inverter units have different then replace the units in pairs.
current ratings, or the ASIC on power
board is not functioning.
HiHP CurrUnblnce 77 (High Horse Power Star-coupler board Check motor wiring for each
- frame 12 drives only) The output unit.
current between the left side and right
side inverter units are unbalanced
(20% of current feedback rating, e.g.
184A = 920A * 0.2).
HiHP VoltUnblnce 78 (High Horse Power Star-coupler board Check input power and wiring
- frame 12 drives only) The bus for each unit.
voltage for the left and right side
inverter units is unbalanced (6% of
normal bus voltage, e.g. 41Vdc =
675Vdc * 0.06).
1-4 Troubleshooting and Error Codes

Addressing 700H Hardware


Name No. Description Action (if appropriate)
Faults Auxiliary In 2 Auxiliary input interlock is open. Check remote wiring.
Power Loss 3 DC bus voltage remained below Monitor the incoming AC line for
parameter 186 [Power Loss Volts] for low voltage or line power
longer than parameter 185 [Power interruption.
Loss Time]. Enable/Disable with
parameter 238 [Fault Config 1]. For
more information refer to publication
20C-PM001, Programming Manual -
PowerFlex 700H.
UnderVoltage 4 DC bus voltage fell below the Monitor the incoming AC line for
minimum value of 333V for 400/480V low voltage or power
drives and 461V for 600/ 690V drives. interruption.
Enable/Disable with parameter 238
[Fault Config 1]. For more information
refer to publication 20C-PM001,
Programming Manual - PowerFlex
700H.
OverVoltage 5 DC bus voltage exceeded maximum Monitor the AC line for high line
value. voltage or transient conditions.
Bus overvoltage can also be
caused by motor regeneration.
Extend the decel time or install
and external dynamic brake
option.
Input Phase 17 One input line phase missing. Check user-supplied fuses
Check AC input line voltage.
OutPhasMissng 21 Zero current in one output motor Check motor wiring.
phase. Check motor for open phase.
Ground Fault 13 A current path to earth ground greater Check the motor and external
than 25% of drive rating. Ground fault wiring to the drive output
level is 50% of the drive's heavy duty terminals for a grounded
current rating. The current must condition.
appear for 800ms before the drive will
fault.
InverterFault 14 Hardware problem in the power Cycle power.
structure. Replace drive.
System Fault 10 Hardware problem exists in the power Cycle power.
structure. Replace drive.
Load Loss 15 Do not use this fault in 700H Check that parameter 238
applications [Fault Config 1] / bit 0 “Power
Loss” and parameter 259
[Alarm Config 1] / bit 13 “Load
Loss” are set to zero.
Precharge Error 31 The precharge function has failed to Verify the value in parameter
complete within 30 seconds (default) 410 [PreChrg TimeOut]
of the precharge request. The Verify the bit value in parameter
precharge time out is configurable by 411 [PreChrg Control] / bit 01
Par 410 [PreChrg TimeOut] “PreChrg Enable”.
A precharge request is initiated when
the DC Bus voltage is above the
Undervoltage Trip level and the
precharge input is high (the
requirement for the precharge being
high can be bypassed by setting Par
411 [PreChrg Control] / bit 01
“PreChrg Enable” to be off.
Power Unit 70 One or more of the output transistors Clear fault.
were operating in the active region
instead of desaturation. This can be
caused by excessive transistor current
or insufficient base drive voltage.
Troubleshooting and Error Codes 1-5

Diagnostic Procedures by The following charts list drive symptoms, symptom descriptions and
Symptom recommended actions.

Blown Input Fuses


Use this procedure when a drive clears any of its external circuit breaker or
power fuses:

Perform Forward Replace


Disconnect Motor Rectifying Rectifying
Diode Tests on No
Leads Module Module
Rectifying Module
OK?

Yes

Perform Forward Replace


Power
Diode Tests on No Power
Modules
Output Power Modules
OK?
Modules

Yes

Examine Bus
Capacitors for Capacitors Replace
No Capacitors
Charring and OK?
Damaged Reliefs

Yes

Check Motor and Motor and Remedy Motor


Lead Resistances Lead Resistances No and Lead
at 1000V > 1 Mohm? Problems

Yes

Disconnect AC Are There Replace


Choke from Any Line to Yes AC
Rectifying Module Load Shorts? Choke

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:

DC Bus Perform forward


Measure DC Bus Voltage within Rectifying Replace Rectifying
No diode tests on No
Voltage Specification? Module OK? Module
Rectifying Module

Yes

Examine Bus
Capacitors for Capacitors Replace
Yes No
Charring and OK? Capacitors
Damaged Reliefs

Yes

Measure Power Voltages within Replace Power


No
Supply Voltages Specification? Supply

Yes

Check Board Does Drive


Connections Run?

No

Replace Main Does Drive


Control Board Run?

No

Replace Power Does Drive


Interface Board Run?
(on 700S)

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:

Check HIM Properly


Reseat or
Connection Connected?
No reconnect
and Seating HIM

Yes

DC Bus Perform forward


Measure DC Bus Voltage within Rectifying Replace Rectifying
No diode tests on No
Voltage Specification? Module OK? Module
Rectifying Module

Yes

Examine Bus
Capacitors for Capacitors Replace
Yes No
Charring and OK? Capacitors
Damaged Reliefs

Yes
Yes

Measure Power Voltage Replace Power


Supply on X4 of Equal 12V dc? No
Interface Board
DPI Circuit Board
(on 700S)

Yes

Replace Output
Power Module
(on 700H)

Check DPI and Does HIM


Power Supply Function?
Connections

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

Current Reduce Load or


Check Motor
Exceeds Yes Procure a Drive
Current and Load
Specification? With a Higher
Levels
Rating

No

Frequency Too
Check PWM High for Lead Length Lower PWM
Yes
Frequency and Surrounding Frequency
Temp?

No

Check Fans and Remedy


Air Flow Proper Space No Spacing at
Through the Drive At Inlet? Inlet

Yes

Remove
Airlflow
Yes Air Flow
Blockages?
Blockages

No

Fans
Running Yes
Properly?

No

Check Power Power Voltage


Voltage on Fan Check Fan Inverter
Equals Bus No
Inverters Fuses (F1 and F2)
Voltage?

Yes

Check Connection
Between ASIC Repair
Board and Fan Connection No
Good? Connection
Inverters

Yes

Check Fan Output Equals Replace


Inverter Outputs 50 Hz / 220V rms? No
Fan Inverter(s)
on X1, X4 and X5

Yes

Check Fan Motors Fan Motor has Replace


for Short and Open or Short Yes
Fan Motor(s)
Open Circuits Circuits?

No

Contact
Allen-Bradley
Drives
Technical
Support
Chapter 2

Component Test Procedures

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


! power to the drive has been removed before performing the
following.
ATTENTION: To avoid an electric shock hazard, verify that the
! voltage on the bus capacitors has discharged before performing
any work on the drive. Measure the DC bus voltage at the DC+ &
DC- terminals. The voltage must be zero.
ATTENTION: HOT surfaces can cause severe burns. Do not
! touch the heatsink surface during operation of the drive. After
disconnecting power allow time for cooling.
ATTENTION: This drive contains ESD (Electrostatic
! Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with
static control procedures, reference A-B publication 8000-4.5.2,
“Guarding Against Electrostatic Damage” or any other
applicable ESD protection handbook.

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.

ATTENTION: The Control Assembly LED is only operational


! when the drive is energized, and only visible with the door of the
drive enclosure is 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!
2-2 Component Test Procedures

LED visible through


this hole

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


Table C Drive Status Indicator Descriptions


# 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


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.

Inspecting the Cooling Tunnels


1. Remove the main cooling fans from the bottom of the power structures.
Refer to Removing the Main Fans on page 3-26.

2. Inspect the tunnels. Clean the heatsinks and tunnels if necessary.

Inspecting the Power Structures


1. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.

2. Check components for burn marks, breakage or foil delamination on


circuit boards. Check all the boards on the power structures, including
those on the Output Power Modules and the Rectifying Modules (if
present).

Replace any of these components without further testing if they show


evidence of burn marks, breakage or foil delamination.

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.

2. Disconnect all motor leads from the drive.

3. Conduct forward and reverse biased diode tests on the Rectifying


Modules (if present).
Figure 2.1 Measurement Points for Forward and Reverse Diode Tests

DC- DC+ DC- DC+

1V/T2 2V/T2
Cat No.
1234567890-*

FIELD INSTALLED OPTIONS:

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

1U/T1 1W/T3 2U/T1 2W/T3

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+.

If the drive fails any of these measurements, replace the appropriate


Rectifying Module.

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

Note: There is one Gate Driver Board


for each Power Structure in the drive.

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.

6. Reconnect the cables, replacing any damaged cables.


7. Repeat steps 3 - 6 for Power Structure #2.

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

in Left Power Output Module in Right Power Output Module


X13

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

for U Low (UL)


~500 ohms
appropriate (left or right) Output Power Module per Power Structure.

~500 ohms in Left Power


Output Module
be about 500 ohms. If any of the gate interfaces fails this test, replace the
Measure the gate interface resistance for each output power transistor. The
resistance from each gate and collector pin to the branch emitter pin should
2-9
2-10 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.

ATTENTION: Running the drive without the Main Fan


! Inverters could cause the drive to overheat or fault. Possible
equipment damage could occur. You must replace the fuses
before running the drive.

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.

ATTENTION: Running the drive with the DC bus wires


! disconnected will damage the ASIC Boards. You must reconnect
these wires before running the drive.
Component Test Procedures 2-11

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+

7. Connect the High Voltage DC Test Power Supply to these wires.

ATTENTION: The sheet metal cover and mounting screws on


! the ASIC Boards located on the power structures are energized at
(-) DC bus potential high voltage. Risk of electrical shock,
injury, or death exists if someone comes into contact with the
assembly. 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!
ATTENTION: Certain pins in connectors X7 and X12 on the
! Gate Driver Boards will be energized at DC bus potential high
voltage. Risk of electrical shock, personal injury or death, property
damage, or economic loss exists if personnel or equipment comes
into contact with these pins.

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

Checking the Opto-Couplers


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.

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.

2. Measure the DC voltage at the WH gate and collector pins on X3 with


respect to DC-. It should be -15V dc.
Should measure -15V dc with respect to DC- with no light in WH cable
Should measure +15V dc with respect to DC- with light in WH cable
X3

Should measure -15V dc with respect to DC- with no light in WH cable


Should measure +15V dc with respect to DC- with light in WH cable

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.

4. Repeat steps 3 and 4 with connector X4 and the VH cable. X4 provides


the gate interface for the VH output power transistor in the left-hand
Output Power Module. If the drive fails any of these tests, replace the
Gate Driver Board.

5. Repeat steps 3 and 4 with connector X5 and the UH cable. X5 provides


the gate interface for the UH output power transistor in the left-hand
Output Power Module. If the drive fails any of these tests, replace 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.

Should measure -15V dc with respect to DC- with no light in WL cable


Should measure +15V dc with respect to DC- with light in WL cable
X6
Should measure -15V dc with respect to DC- with no light in VL cable
Should measure -15V dc with respect to DC- with no light in WL cable Should measure +15V dc with respect to DC- with light in VL cable
Should measure +15V dc with respect to DC- with light in WL cable
Should measure -15V dc with respect to DC- with no light in UL cable Should measure -15V dc with respect to DC- with no light in VL cable
Should measure +15V dc with respect to DC- with light in UL cable Should measure +15V dc with respect to DC- with light in VL cable

Should measure -15V dc with respect to DC- with no light in UL cable


Should measure +15V dc with respect to DC- with light in UL cable

7. Repeat steps 3 and 4 with connector X8 and the WH cable. X8 provides


the gate interface for the WH output power transistor in the right-hand
Component Test Procedures 2-13

Output Power Module. If the drive fails any of these tests, replace the
Gate Driver Board.

8. Repeat steps 3 and 4 with connector X9 and the VH cable. X9 provides


the gate interface for the VH output power transistor in the right-hand
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.

10. Repeat steps 1 - 9 for Power Structure #2.

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).

ATTENTION: Running the drive with the DC bus wires


! disconnected will damage the ASIC Boards. You must reconnect
these wires before running the drive.

Figure 2.2 Opto-Coupler Checks for Left-Hand Output Power Module


Should measure -15V dc with respect to DC- with no light in WH cable
Should measure +15V dc with respect to DC- with light in WH cable
X3

Should measure -15V dc with respect to DC- with no light in WH cable


Should measure +15V dc with respect to DC- with light in WH cable

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
X4

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 light in UH cable


X5

Should measure -15V dc with respect to DC- with no light in UH cable X7 X12

Should measure +15V dc with respect to DC- with light in UH cable


X13

X14

X15

Should measure -15V dc with respect to DC- with no light in WL cable


X1

Should measure +15V dc with respect to DC- with light in WL cable


X6
Should measure -15V dc with respect to DC- with no light in VL cable
Should measure -15V dc with respect to DC- with no light in WL cable Should measure +15V dc with respect to DC- with light in VL cable
Should measure +15V dc with respect to DC- with light in WL cable
Should measure -15V dc with respect to DC- with no light in UL cable Should measure -15V dc with respect to DC- with no light in VL cable
Should measure +15V dc with respect to DC- with light in UL cable Should measure +15V dc with respect to DC- with light in VL cable

Should measure -15V dc with respect to DC- with no light in UL cable


Should measure +15V dc with respect to DC- with light in UL cable
2-14 Component Test Procedures

Figure 2.3 Opto-Coupler Checks for Right-Hand Output Power Module


Should measure -15V dc with respect to DC- with no light in WH cable
X8 Should measure +15V dc with respect to DC- with light in WH cable

Should measure -15V dc with respect to DC- with no light in WH cable


Should measure +15V dc with respect to DC- with light in WH cable

Should measure -15V dc with respect to DC- with no light in VH cable


X9 Should measure +15V dc with respect to DC- with light in VH cable

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

Should measure -15V dc with respect to DC- with no light in WL cable


Should measure +15V dc with respect to DC- with light in WL cable
X11
Should measure -15V dc with respect to DC- with no light in VL cable
Should measure -15V dc with respect to DC- with no light in WL cable Should measure +15V dc with respect to DC- with light in VL cable
Should measure +15V dc with respect to DC- with light in WL cable
Should measure -15V dc with respect to DC- with no light in UL cable Should measure -15V dc with respect to DC- with no light in VL cable
Should measure +15V dc with respect to DC- with light in UL cable Should measure +15V dc with respect to DC- with light in VL cable

Should measure -15V dc with respect to DC- with no light in UL cable


Should measure +15V dc with respect to DC- with light in UL cable

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.

3. On Power Structure #1, visually inspect the pre-charging resistors. If


pre-charging resistors are damaged:

A. Replace the Rectifying Module (See Removing the Right-Side


Output Power Modules and Rectifying Modules on page 3-33).
B. Check the capacitors, rectifiers and external connections for
short-circuits. (See Checking the DC Bus Capacitors on page 2-17)

C. Check the Output Power Modules (See Conducting Forward


and Reverse Biased Diode Tests for Major Power Components on
page 2-4).
Component Test Procedures 2-15

4. Verify that the plugs on the cable that connects X13 on the Rectifying
Board to X2 on the ASIC Board are properly seated.

5. Verify that the jumper at X50 on the Rectifying board is in place.

Taking Measurements on the Rectifying Module


6. Disconnect connectors X13, X12, X11 and X10.

7. Perform resistance measurements, using a digital multimeter, on the


points listed in Table 2.I on page 2-15 (on AC Three-Phase drives).
These points are on the back of the X10, X11 and X12 plugs which you
have disconnected from the board. 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).
Table 2.I Rectifying Module Resistance Measurements
Measurement points Resistance
X10: red to X10: black
X11: red to X11: black 18:r:
X12: red to X12: black

8. Without applying power to X13 verify that there is no resistance


between the following points: J3 and X9, J7 and X9, and J11 and X9.
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).

9. Connect the DC Test Power Supply to X13 (positive to pin 5 and


common to pin 1). Raise the output of the DC Test Power Supply to
24V dc.

Important: Power supply polarity is critical during these tests. Reversing


the polarity will damage components on the circuit board.

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).

11. Repeat steps 3 - 10 for Power Structure #2.


2-16 Component Test Procedures

Figure 2.4 Rectifying Board Layout and Measurement Points


Precharging
Resistors

X4
X1 X2 X3

X41

J3

J7
J11

X8 X13 X6 X10 X11


X101 X100 X9
X50 X12

X13: Pin 1 X13: Pin 5


(24V dc Common) (24V dc Power)
X10: Pin 1 X11: Pin 1 X12: Pin 1 X9

Table 2.J Rectifying Board Charge Relay Test Results


No Power on X13 24V dc Power on X13
Meter Leads Meter Leads
+ - Results + - Results
J3 X9 J3 X10: Pin 1
J7 X9 0: J7 X11: Pin 1 0:0V
J11 X9 J11 X12: Pin 1
Component Test Procedures 2-17

Checking the DC Bus Important: This procedure requires special equipment and training. Only
Capacitors qualified and trained personnel should perform these
procedures.

These tests require the recommended high voltage DC-power supply.

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.

6. Switch on the external DC power supply.

7. Slowly increase the external DC power supply output voltage 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).

8. Monitor the current while testing.

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.

12. As a precaution, use a resistor to discharge each capacitor after testing.


Use a resistor with the proper resistance and power handling capability
for the discharge current.

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).

14. Repeat steps 3 - 13 for Power Structure #2.


2-18 Component Test Procedures

Checking the Main Fan Checking Inverter LEDs


Inverters and Fans
A frame 12 drive has four fans and four fan inverters; two fans and two fan
inverters per Power Structure. Each fan inverter has a red and a green
diagnostic LED.

ATTENTION: The inverter LEDs are only operational when


! the drive is energized, and only visible with the covers removed
from the power structure. 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!

LED
Red Green Indication
Steady Steady Inverter Idle
Off Flashing Inverter Running
Flashing Steady Inverter Faulted
or
No Control from ASIC Board

Checking Fan Inverter Fuses


A pair of fuses (F1 and F2) feed DC Bus power to both inverters on each
Power Structure. Locate these fuses and, using a multi-meter, verify that
they are not open.

Isolating a Faulty Fan Inverter


The ASIC Board (one on each of the Power Structures) controls a pair of
fan inverters. A cable connects X11 on the ASIC Board to X8 on the
left-hand fan inverter. Another cable connects X3 of the left-hand fan
inverter to X8 on the right-hand fan inverter. A jumper terminates X3 on the
right-hand fan inverter. Refer to Figure B.8 on page B-9. Use the following
procedure to isolate a faulty fan inverter if the fans are not running:

1. On Power Structure #1, disconnect the cable from X3 of the left-hand


inverter.

2. Remove the jumper from X3 of the right-hand inverter, and connect it to


X3 of the left-hand inverter.
3. Energize the drive. If the left-hand fan runs, then the right-hand fan
inverter is faulty.

4. Repeat steps 1 - 3 for Power Structure #2.


Component Test Procedures 2-19

Checking the Main Fan Motors


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 left-hand fan motor from its
inverter.

4. Measure the resistance of the fan windings. If the resulting


measurements are not similar to those in Table 2.K below, replace the
fan (See Removing the Main Fans on page 3-26).
Table 2.K Correct Fan Measurements
Connection Wires Resistance ± 5%
Black-Brown 60
Brown-Blue 26
Blue-Black 34
Resistance to ground .0L (Zero Load)

5. Reconnect the left-hand fan motor to its inverter.

6. Repeat steps 3 and 4 for the right-hand fan motor.

7. Repeat steps 3 - 6 for Power Structure #2.


2-20 Component Test Procedures

Notes:
Chapter 3

Access Procedures

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


! power to the drive has been removed before performing the
following.
ATTENTION: To avoid an electric shock hazard, verify that the
! voltage on the bus capacitors has discharged before performing
any work on the drive. Measure the DC bus voltage at the DC+ &
DC- terminals. The voltage must be zero.
ATTENTION: The sheet metal cover and mounting screws on
! the ASIC Board located on the power structure are energized at
(-) DC bus potential high voltage. Risk of electrical shock,
injury, or death exists if someone comes into contact with the
assembly.
ATTENTION: HOT surfaces can cause severe burns. Do not
! touch the heatsink surface during operation of the drive. After
disconnecting power allow time for cooling.
ATTENTION: Hazard of permanent eye damage exists when
! using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber-optic ports or
fiber-optic cable connectors.
ATTENTION: This drive contains ESD (Electrostatic
! Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with
static control procedures, reference A-B publication 8000-4.5.2,
“Guarding Against Electrostatic Damage” or any other
applicable ESD protection handbook.

Torque Specifications The following table lists fastener torque specifications:


Item Screw Final Torque
DPI / HIM Assembly Door M3 x 6 Phillips® 0.9 N-m
(8 lb.-in.)
DPI / HIM Assembly (mounting) M3 x 6 Phillips 0.9 N-m
(8 lb.-in.)
700S High Power Fiber M3 x 6 Phillips 0.9 N-m
Optic-Interface Circuit Board (8 lb.-in.)
(mounting)
700H I/O and Control Assembly M4 x 8 self-tapping 0.8 N-m
(7 lb.-in.)
3-2 Access Procedures

Item Screw Final Torque


700H Star Coupler Board M4 x 8 POZIDRIV ® 0.9 N-m
(mounting) (8 lb.-in.)
700S Voltage Feedback Circuit M3 x 6 Phillips 0.9 N-m
Board (mounting) (8 lb.-in.)
AC Input Terminals on Power M10 nut 40 N-m
Structure (354 lb.-in.)
Motor Output Terminals on Power M8 x 20 hexagonal screw 20 N-m
Structure (177 lb.-in.)
Main Fan (Mounting) M6 x 20 POZIDRIV 3 N-m
(27 lb.-in.)
Main Fan M4 x 8 POZIDRIV 1.7 N-m
(15 lb.-in.)
Touch Cover (Main Fan) M5 x 16 3 N-m
(27 lb.-in.)
ASIC Fan M4 x 16 POZIDRIV 0.4 N-m
(3.5 lb.-in.)
Rectifier board (Mounting) M4 x 8 POZIDRIV 1 N-m
(9 lb.-in.)
Output Power Module Output M8 x 20 hexagonal screw 14 N-m
Terminals (U,V,W) (124 lb.-in.)
Rectifying Module Input M10 x 20 hexagonal screw 12 N-m
Terminals (L1,L2,L3) (106 lb.-in.)
Y-Bus Bar M10 nut 40 N-m
(354 lb.-in.)
Capacitor M4 x 8 self tapping 1 N-m
(9 lb.-in.)
Capacitor Bus Bar M6 x 16 POZIDRIV 4 N-m
(35 lb.-in.)
Capacitor Bus Bar M6 x 20 POZIDRIV 4 N-m
(35 lb.-in.)
DC- / DC+ Terminals M6 x 20 POZIDRIV 5 N-m
(44 lb.-in.)
Block (Mounting) M10 x 12 hexagonal screw 20 N-m
(177 lb.-in.)
700S Voltage Feedback Circuit M3 x 0.5 thread - 37 mm x 0.9 N-m
Board (mounting) 37 mm hex standoff (8 lb.-in.)
POZIDRIV® is a registered trademark of the Phillips Screw Company
Phillips® is a registered trademark of Phillips Screw Company
Access Procedures 3-3

Understanding the Torque Figures in Assembly Diagrams


Icons and numbers in the assembly diagrams indicate how to tighten
hardware:
Fastener Type Tool Type and Size
PZ indicates POZIDRIV screwdriver bit
POZIDRIV Screw P indicates Phillips screwdriver bit

Phillips Screw

Hexagonal Bolt
or Standoff PZ2
Hexagonal 4 N-m
Screw Tightening Torque
(35 lb.-in.)
Hexagonal Nut

Torx Head Screw

Removing Power from the


Drive ATTENTION: To avoid an electric shock hazard, verify that the
! voltage on the bus capacitors has discharged before performing
any work on the drive. Measure the DC bus voltage at the DC+ &
DC- terminals. 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. An electrical arc can cause
personal injury or property damage by:

x sending an erroneous signal to your system’s field devices,


causing unintended machine motion
x causing an explosion in a hazardous environment

Electrical arcing causes excessive wear to contacts on both the


module and its mating connector. Worn contacts may create
electrical resistance.
3-4 Access Procedures

Removing Power
1. Turn off and lock out input power. Wait five minutes.

2. Verify that there is no voltage at the drive’s input power terminals.

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

Removing the DPI / HIM Removal


Assembly
1. Remove power from the drive (Removing Power from the Drive on
page 3-3).

Important: Before removing connections and wires, mark the connections


and wires to avoid incorrect wiring during assembly.

2. Remove the two screws from front of DPI / HIM assembly.


Screws

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

Back view of DPI


Circuit Board which
should remain mounted
on the back of
the assembly

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.

Removing the 700S Phase II Removal


Control Assembly
1. Remove power from the drive (Removing Power from the Drive on
page 3-3).
Important: Before removing connections and wires, mark the connections
and wires to avoid incorrect wiring during assembly.

2. Unplug any fiber optic ControlNet and SynchLink cables from the
Control 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.

Important: Minimum inside bend radius for SynchLink and ControlNet


fiber-optic cable is 25.4 mm (1 in.). Any bends with a shorter
inside radius can permanently damage the fiber-optic cable.
Signal attenuation increases with decreased inside bend radii.

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.

Disconnect ribbon cables.

Note: Control mounting plate


not shown for clarity only.
3-8 Access Procedures

6. Loosen the two mounting screws on the front of the Control Assembly
and slide the control cassette off the mounting bracket.

Note: Ribbon cables not shown


for clarity only.

Installation
Install the 700S Phase II Control Assembly in reverse order of removal,
while referring to Torque Specifications on page 3-1.

Removing the 700S High Removal


Power Fiber Optic Interface
1. Remove power from the drive (Removing Power from the Drive on
Circuit Board page 3-3).

2. Remove the 700S Control Assembly (Removing the 700S Phase II


Control Assembly on page 3-6).

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.

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.
Access Procedures 3-9

Important: Minimum inside bend radius for fiber-optic cable is 25.4 mm (1


in.). Any bends with a shorter inside radius can permanently
damage the fiber-optic cable. Signal attenuation increases with
decreased inside bend radii.

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.)

6. Remove the circuit board from the Control Frame.

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

Removing the 700S Control Removal


Assembly Mounting Plate
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.

2. Remove the 700S Phase II Control Assembly. Refer to Removing the


700S Phase II Control Assembly on page 3-6.

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

Removing the 700H I/O Removal


Boards and Control
1. Remove power from the drive. Refer to Removing Power from the
Assembly Drive on page 3-3.

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

4. Unplug the serial connection from X7 of the Control Board.


X7
Serial Port

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.)

6. Remove the Control Assembly.

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

Removing the 700H Star Removal


Coupler Board
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.

2. Referring to Removing the 700H I/O Boards and Control Assembly on


page 3-11, remove the I/O boards and Control Assembly.

3. Move the Control Frame to expose its back, while referring to


Removing the Covers from the Power Structures on page 3-15.

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.

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.
3-14 Access Procedures

Important: Minimum inside bend radius for fiber-optic cable is 25.4 mm (1


in.). Any bends with a shorter inside radius can permanently
damage the fiber-optic cable. Signal attenuation increases with
decreased inside bend radii.

6. Remove the 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.)

7. Remove the Star Coupler Board from the Control Frame.

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

Removing the Covers from Moving the Control Frame


the Power Structures
Removal

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

Install the Control Frame in reverse order of removal, while referring to


Torque Specifications on page 3-1.
3-16 Access Procedures

Removing the Airflow Plates


The drive is equipped with metal plates, at the top of both enclosures, that
manage airflow through the drive. You must remove these plates in order to
access the protective covers.

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

3. On Power Structure 1, remove the T8 Torx-head screws (four per plate)


that secure the airflow plate to the drive.

4. Slide the airflow plate off of the drive.

5. Repeat steps 3 and 4 to remove the airflow plate from Power Structure
2.
Access Procedures 3-17

Installation

Install the Airflow Plates in reverse order of removal, while referring to


Torque Specifications on page 3-1.

Removing the Protective Covers from the Power Structures


You must remove the protective covers to gain access to the power
structures.

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).

3. Remove the Airflow Plates (Removing the Airflow Plates on


page 3-16).

4. On Power Structure 1, remove the four M5 Pozi-drive screws, which


secure the top and bottom protective covers to the main front protective
cover, then remove the top and bottom protective covers.

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.

6. Remove the side protective covers.


3-18 Access Procedures

7. Repeat step 4 - 6 to remove the protective covers from Power Structure


2.

5
4 5

Installation

Install the Protective Covers in reverse order of removal, while referring to


Torque Specifications on page 3-1.
Access Procedures 3-19

Removing the 700S Voltage Removal


Feedback Circuit Board
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. Carefully disconnect the fiber-optic cables from J4 and J5 sockets along


the top of the Voltage Feedback Circuit Board, and carefully set them
aside.

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.

Important: Minimum inside bend radius for fiber-optic cable is 25.4 mm (1


in.). Any bends with a shorter inside radius can permanently
damage the fiber-optic cable. Signal attenuation increases with
decreased inside bend radii.

4. Disconnect the cable from J8 socket of the Voltage Feedback Circuit


Board, and set it aside.

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

Removing the Gate Driver Removal


and Adapter Boards
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, 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.

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.

Important: Minimum inside bend radius for fiber-optic cable is 25.4 mm (1


in.). Any bends with a shorter inside radius can permanently
damage the fiber-optic cable. Signal attenuation increases with
decreased inside bend radii.

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

9. Carefully remove the board and the remaining connectors.

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.

8. Repeat steps 1 - 7 to install the Gate Driver and Adapter Boards on


Power Structure 2.
Access Procedures 3-25

Removing the Power Removal


Structures from the Drive
1. Remove power from the drive (Removing Power from the Drive on
Enclosure 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 motor wiring from the power


structure at the front of the power structure.

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

6. Follow the instructions in publication PFLEX-IN014, Installation


Instructions - PowerFlex 700S /700H High Power Maintenance Stand,
to install the Maintenance Stand. Remove the power structure by sliding
it onto the rails of the Maintenance Stand.

Note: The Maintenance Stand is designed for removing power


structures from drives supplied in Rittal TS8 enclosures. Alternate
means of removal will be necessary for other types of enclosures.

7. Repeat steps 3 - 6 to remove Power Structure 2 from its enclosure.


3-26 Access Procedures

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.

Removing the Main Fans Removal


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, disconnect the fan cable connectors under the


power structure.
4. Remove the two screws that secure each fan assembly to the drive. Then
remove the fans.

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.

Removing the ASIC Boards Removal

ATTENTION: The sheet metal cover and mounting screws on


! the ASIC Boards located on the power structures are energized at
(-) DC bus potential high voltage. Risk of electrical shock,
injury, or death exists if someone comes into contact with the
assembly.

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.

X26 Feedback Board connection X1 Fan connection

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

6. Carefully disconnect the fiber-optic cables from sockets of the ASIC


Board, and carefully set them aside.

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.

Important: Minimum inside bend radius for fiber-optic cable is 25.4 mm (1


in.). Any bends with a shorter inside radius can permanently
damage the fiber-optic cable. Signal attenuation increases with
decreased inside bend radii.

7. Disconnect the other cables from sockets on the front of the ASIC
Board, and set them aside.

8. Remove the fan from the ASIC Board.

9. Slide the ASIC Board assembly out of its chassis.

10. Remove the plastic board holder.

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

Removing the Rectifying Removal


Boards
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, disconnect all the wiring from the Rectifying


Board and carefully set it aside.

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

X8 X13 X6 X10 X11


X101 X100 X9
X50 X12

Installation
Install the Rectifying Boards in reverse order of removal, while referring to
Torque Specifications on page 3-1.
3-30 Access Procedures

Removing the Left-Side Removal


Output Power Modules
Important: Do not attempt to disassemble the Output Power Modules.

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).

4. On Power Structure 1, remove the cable-tie which secures the Power


Module Circuit Board to the Adapter Board.

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

7. Remove the balancing resistor wires from bus bars.

Balancing Resistors

Balancing Resistor Wires

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

12. Remove the Output Power Module from the drive.

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

Removing the Right-Side Removal


Output Power Modules and
Important: Do not attempt to disassemble the Output Power Modules.
Rectifying Modules
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).

4. On Power Structure 1, carefully disconnect the fiber-optic cables from


the Gate Driver Board, and carefully set them aside.

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.

Minimum inside bend radius for fiber-optic cable is 25.4 mm (1 in.).


Any bends with a shorter inside radius can permanently

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

9. Remove the balancing resistor wires from 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

Removing the Fan Inverters Removal


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).

4. Prepare Power Structure 1 for Inverter Assembly Removal.

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

5. Remove the Inverter Assemblies.

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).

Note: This step is not shown.


Carefully remove the inverters by sliding them out towards the front of
E the drive.

Bottom View
of Power Structure
C C

Important: Do not damage the output transformer when removing or


installing the inverter.
Access Procedures 3-39

6. Remove the Inverter from the old Inverter Assembly.

Task Description
Disconnect the cables at connectors X4 (Blue) and X5 (Black).
A

Right-hand Inverter Shown


=

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

7. Repeat steps 4 - 6 to remove the Fan Inverters from Power Structure 2.

Installation
Install the fan inverters in reverse order of removal, while referring to
Torque Specifications on page 3-1.
3-40 Access Procedures

Removing the DC Bus Removal


Capacitors
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).

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.

7. Repeat steps 4 - 6 to remove the DC Bus Capacitors from Power


Structure 2.
3-42 Access Procedures

Installation
Install the capacitors in reverse order of removal, while referring to Torque
Specifications on page 3-1.
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
then 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
States/Canada the Internet:
Go to http://www.ab.com
Click on Support (http://
support.rockwellautomation.com/)
Under Contact Customer Support, click on Phone
Support
Internet Ÿ Go to http://www.ab.com/support/abdrives/
E-mail Ÿ [email protected]

Be prepared to provide the following information when you contact


support:

x Product Catalog Number


x Product Serial Number
x Firmware Revision Level

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.

1. Verify that the DC Test Power Supply is de-energized.

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.

3. Set the power supply voltage setting to zero.

4. Switch on the external DC Test Power Supply.


5. Slowly increase the DC Test Power Supply output voltage 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).

6. Measure the DC bus voltage and verify that the value is reflected in:

– parameter 306 [DC Bus Voltage] (700S)

– parameter 012 [DC Bus Voltage] (700H)

7. Make configuration changes which allow the HIM to issue start and
speed commands.

8. Make configuration changes which allow operation without an encoder


and motor.
9. Start the drive, by pressing (the start button).

10. Increase the speed command from zero to base speed, by pressing
(the up button).
11. Stop the drive, by pressing (the stop button).

12. Re-configure the drive to suit the application.

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.

1. Verify that input power wiring and grounding is connected.

1. Verify that the motor cables are disconnected.

2. Energize the drive.


3. Make configuration changes which allow the HIM to issue start and
speed commands.

4. Make configuration changes which allow operation without an encoder


and motor.

5. Start the drive, by pressing (the start button).

6. Increase the speed command from zero to base speed, by pressing


(the up button).

7. Measure the output voltage on each phase and verify that it is balanced.
If it is unbalanced troubleshoot the drive.

8. Stop the drive, by pressing (the stop button).


9. Re-configure the drive to suit the application.

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.

1. Verify that input power wiring and grounding is connected.

2. Verify that the motor cables are connected.


3. Energize the drive.

4. From the Monitor menu on the HIM press Esc (the escape button) to
navigate to the Main menu.

5. Use (the down button) to move the cursor to the Start-Up


selection, and to select Start-Up. Then press again to
verify your intention to continue with the Start-Up menu.
6. Use (the down button) to move the cursor to Power Circuit
Diagnostics (Pwr Circuit Diag), and to select Power Circuit
Diagnostics.

7. Press to begin the Power Circuit Diagnostic routine. Follow


indications and instructions on the HIM.
4-4 Start-Up After Repair

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 and verify that the value is reflected in:

– parameter 308 [Output Current] (700S)

– parameter 003 [Output Current] (700H)

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.
A-2 Service Tools and Equipment

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).

For Agilent HFBR-4532 latching connectors and


HFBR-RL cable. Refer to Agilent publications
5988-9777EN and 5988-3625EN.
Appendix B

Schematics

List of Schematic Diagrams


For a Schematic Diagram on… See...
Circuit Board Connections for 700S Drives with Phase II Control page B-2
Circuit Board Connections for 700H Drives page B-3
ASIC Circuit Board Connections page B-4
Power Circuitry for Drives with AC Input (Power Structure #1) page B-5
Power Circuitry for Drives with AC Input (Power Structure #2) page B-6
Power Circuitry for Drives with DC Input (Power Structure #1) page B-7
Power Circuitry for Drives with DC Input (Power Structure #2) page B-8
Fan Power Supply Connections page B-9
AC Input Motor Connections page B-10
DC Input Motor Connections page B-11
B-2 Schematics

Circuit Board Connections for 700S Drives with


Phase II Control

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

To Feedback Board #1 - H903 To Feedback Board #2 - H903

Fiber Optic Connections Fiber Optic Connections


to ASIC Board #1 on to ASIC Board #2 on
Power Structure #1 Power Structure #2

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

To Feedback Board #1 - H903 To Feedback Board #2 - H903

Fiber Optic Connections Fiber Optic Connections


to ASIC Board #1 on to ASIC Board #2 on
To ASIC Board #1 - X10 Power Structure #1 Power Structure #2 3
To Feedback Board #1
H900, H901, and H902
2 Fiber Fiber Fiber
Optic Optic Optic
T 7 6 5 4 3 2 1 T 7 6 5 4 3 2 1 23 22 21

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

ASIC Circuit Board Connections


To 700S
HiHP Fiber Note: External Wiring Shown as
Optic Dashed Lines. For DC Input Only
Interface (Do Not Install on AC Input Drives).
Board J28 Feedback
Board #1
Or
H903 ASIC
700H Star 3 6 DC+
Coupler H900 X900 X26 Board 1
From DC Bus
X6 2
Board H8 H901 1 X9 +24V #1 3 in Power Circuitry
H902 25
DC-
M 26 0EVA
2

X15 X2 To Rectifying Board X13


To 700H Star 3

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

Ports (See Note). CR1 X50 X1 X5 To Gate Driver Board X15


CR1
21 - 23 M 1 +24VDC H8 To Gate Driver Board H4
To 700H Star 2 DC-
CR2 H9 To Gate Driver Board H5
To 700S Coupler Board X2 M H10 To Gate Driver Board H6
HiHP Fiber Optic 2 To Gate Driver Board H7
X10 24V Power H11
Interface Board H12 To Gate Driver Board H8
Ports 1 - 7 for 1 H1 To Gate Driver Board H9
ASIC Board #1 H13
2 H2
X600
3 H3 3
Or 4 H4 Fan X11
To Left Fan X8

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

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 #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

with AC Input (Power Structure #1)


DC+

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

6 Fiber Optic Cables


I_U
I_W

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

Figure B.5 Power Circuitry for Drives with AC


Input (Power Structure #2)
Structure #1)
Note:
400V/600V Capacitor Configuration
To 700S Control Board J2 400V - 2 Caps in series To 700S Control Board J1
3 Caps in parallel
600V - 3 Caps in series
2 Caps in parallel
DC+ Right Side Module
Power Circuitry for Drives with DC Input (Power

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

Figure B.6 Power Circuitry for Drives


with DC Input (Power Structure #1)
B-7
Note:
B-8
400V/600V Capacitor Configuration
400V - 2 Caps in series

Structure #2)
3 Caps in parallel
600V - 3 Caps in series
2 Caps in parallel
DC+ Right Side Module
Schematics

Power Circuitry for Drives with DC Input (Power

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

Figure B.7 Power Circuitry for Drives


with DC Input (Power Structure #2)
Schematics B-9

Fan Power Supply Connections


From DC Bus in Power Structure

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

From DC Bus in Power Structure

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

4 In Power Structure #2 (Right Side)

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

AC Input Motor Connections

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

Figure B.9 AC Input Motor Connections


DC Input Motor Connections

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

Figure B.10 DC Input Motor Connections


B-11
B-12 Schematics

Notes:
Appendix C

Connector Descriptions

For a Schematic Diagram on… See...


ASIC Board on Power Structure #1 to Gate Driver Board on Power page C-3
Structure #1 - Phase U Connections
ASIC Board on Power Structure #1 to Gate Driver Board on Power page C-3
Structure #1 - Phase V Connections
ASIC Board on Power Structure #1 to Gate Driver Board on Power page C-4
Structure #1 - Phase W Connections
ASIC Board on Power Structure #2 to Gate Driver Board on Power page C-4
Structure #2 - Phase U Connections
ASIC Board on Power Structure #2 to Gate Driver Board on Power page C-5
Structure #2 - Phase V Connections
ASIC Board on Power Structure #2 to Gate Driver Board on Power page C-5
Structure #2 - Phase W Connections
ASIC Board on Power Structure #1 to Rectifier/Precharge Circuit page C-6
Board on Power Structure #1 Connections
ASIC Board on Power Structure #2 to Rectifier/Precharge Circuit page C-6
Board on Power Structure #2 Connections
PowerFlex 700H and 700S Interface Board to ASIC Board on Power page C-8
Structure #1 Fiber Optic Connections
PowerFlex 700H and 700S Interface Board to ASIC Board on Power page C-9
Structure #2 Fiber Optic Connections
ASIC Feedback Board on Power Structure #1 to ASIC Board on page C-9
Power Structure #1 Connections
ASIC Feedback Board on Power Structure #2 to ASIC Board on page C-9
Power Structure #2 Connections
ASIC Feedback Board to PowerFlex 700S High Power Star Interface page C-10
Board Connections
ASIC Feedback Board to PowerFlex 700H Star Coupler Board page C-10
Connections
ASIC Board to Left Side Main Cooling Fan Inverter Connections page C-10
Left Side Main Cooling Fan Inverter to Right Side Main Cooling Fan page C-10
Inverter Connections
Right Side Main Cooling Fan Inverter Connections page C-11
X50 Terminal Block Precharge Circuit Connections page C-11

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

Figure C.1 ASIC Board Connectors

X11 X2
H8
X9
H9
H10 X15
X26
H11
H12 H1
H13 H2
H3
X3 H4
X1
H5
H6
X4
H7

X5 X6

Figure C.2 Gate Driver Board Connectors

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

Note: See page C-4 for footnotes.

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

Note: See page C-4 for footnotes.


C-4 Connector Descriptions

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

Note: See page C-5 for footnotes.


Connector Descriptions C-5

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

Note: Refer to footnotes below Table C.F.

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

Figure C.3 Rectifier/Precharge Circuit Board Connectors


X4
X1 X2 X3

X41

J3

J7
J11

X8 X13 X6 X10 X11


X101 X100 X9
X50 X12

Table C.G ASIC Board on Power Structure #1 to Rectifier/Precharge Circuit Board on


Power Structure #1 Connections
ASIC Board Rectifier Board
Connector Pin Number to Pin Number Connector Description
X2 1 ... 1 X13 SWTS_DRV
2 ... 2 SWTS_FB
3 ... 3 W_DTR
4 ... 4 Mains Fault
5 ... 5 +24V

Table C.H ASIC Board on Power Structure #2 to Rectifier/Precharge Circuit Board on


Power Structure #2 Connections
ASIC Board Rectifier Board
Connector Pin Number to Pin Number Connector Description
X2 1 ... 1 X13 SWTS_DRV
2 ... 2 SWTS_FB
3 ... 3 W_DTR
4 ... 4 Mains Fault
5 ... 5 +24V
Connector Descriptions C-7

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

Figure C.5 PowerFlex 700H Star Coupler Circuit Board Connectors

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.

Figure C.6 Termination Points on ASIC Feedback Boards

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

Hardware Connections Figure C.7 Fan Inverter Circuit Board Connectors

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

Table C.Q Right Side Main Cooling Fan Inverter Connections


Fan Inverter Fan Inverter
Description Connector Pin Number Pin Number Connector Description
+15V dc power X3 2 4 X3 +15V dc power
Fan Alarm 4 2 Fan Alarm

Figure C.8 X50 Terminal Block Connectors


Customer Connections Terminal Blocks Drive Connections

Example External Precharge Circuitry X50 #1 ASIC Board #1


X9
1 25 +24V DC
M
2 26 0V DC

3 21
Charge
Relay
4 23
X15
CR1
Pilot Relay

CR1 M
Main DC Contactor

M CR2 X50 #2 ASIC Board #2


Precharge
X9
1 25 +24V DC
M
2 26 0V DC

3 21
Charge
Relay
4 23
X15
For DC Input Only
(Do Not Install on AC Input Drives)

Table C.R X50 Terminal Block Precharge Circuit Connections


ASIC Board
Connector Terminal to X50 Terminal Block Description
X9 on ASIC 25 ... 1 Precharge Complete Signal
Board #1 26 ... 2 Precharge Complete Signal
X15 on ASIC 21 ... 3 Charge Relay Contact
Board #1 23 ... 4 Charge Relay Contact
X9 on ASIC 25 ... 1 Precharge Complete Signal
Board #2 26 ... 2 Precharge Complete Signal
X15 on ASIC 21 ... 3 Charge Relay Contact
Board #2 23 ... 4 Charge Relay Contact
C-12 Connector Descriptions

Notes:
Appendix D

Disassembly / Assembly Diagrams

For a Diagram on… See...


Main Power Structure Assembly page D-2
Right Side of Power Structure page D-4
Left Side of Power Structure page D-6
Fan Inverter Assembly page D-7
ASIC Assembly page D-8
ASIC Assembly page D-8
Main Fan Assembly page D-9

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.

Cat No. 20D J 500 N 0 NNNBNNNN


UL Open Type/IP00
540V
Normal Duty Power 250 kW 450 kW
Heavy Duty Power
Frame #: 10

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

Normal Duty Power


Heavy Duty Power
Input: DC,
J 300 N 0 NNNBNNNN

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

MADE IN THE USA (FAC 1B) 2622381652

MADE IN THE USA (FAC 1B)

A complete list of spare parts for PowerFlex 700H/S drives is available on


the Allen-Bradley web site at:
http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf
D-2 Disassembly / Assembly Diagrams

Figure D.1 Main Power Structure Assembly

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.

Main Terminal Covers

Touch Cover, Front

Touch Cover, Side Plates

Input Terminal Cable Insulator

Input Terminal Assembly

Bus Bar Motor Connector Assembly


Insulator for Bus Bar Gate Driver Board
DC Fuse Base
Left Side Board Bracket Right Side Board Bracket
ASIC Assembly
Upgrade Kit Adapter Board
Plastic Cover
Base, Top Right Fan Inverter Capacitor
Plastic Cover
Base, Top Left Fan Inverter Assembly,
Left

Fan Inverter Assembly,


Right
Disassembly / Assembly Diagrams D-3

Table D.A Main Power Structure Assembly Part Numbers


Part Name Part No.
Adapter Board 20-VB00330
Air Flow Guide Right NA
ASIC Assembly Upgrade Kit (without ASIC Board) 20-FR10850
Bus Bar NA
Fan Inverter Assembly, Left 20-FR10844
Fan Inverter Assembly, Right 20-FR10845
Fan Inverter Capacitor 7Pf 450V ac 20-PP00060
Gate Driver Board 400/480V SK-H1-GDB1-F10D
600/690V SK-H1-GDB1-F10E
Input Terminal Assembly NA
Input Terminal Cable Insulator NA
Insulator For Bus Bar NA
Left Side Board Bracket NA
Main Terminal Cover NA
Plastic Cover Base, Top Left NA
Plastic Cover Base, Top Right NA
Right Side Board Bracket NA
Touch Cover Front NA
Touch Cover Side Plate NA
D-4 Disassembly / Assembly Diagrams

Figure D.2 Right Side of Power Structure

Air Flow Guide, Right

Snubber Capacitor Assembly

Rectifying Board

DC Bus Bar

DC Bus Bar Insulator

DC Bus Bar

DC Bus Bar Insulator

DC Bus Bar

DC Bus Bar Insulator Rectifying Module

Discharging Resistor
Output Power Module

Frame Electrolytic Capacitor

Table D.B Right Side of Power Structure Part Numbers


Part Name Part No.
Air Flow Guide Right NA
DC Bus Bar 20-FR10044
20-FR10052
20-FR10190
DC Bus Bar Insulator 20-FR10027
20-FR10028
20-FR10143
Discharging Resistor 2x16k 20-PP00056
Electrolytic Capacitor ELKO 3300Pf 420V for 400/480V Drives 20-PP01005
ELKO 5600Pf 420V for 600/690V Drives 20-PP01099
Frame NA
Disassembly / Assembly Diagrams D-5

Part Name Part No.


Output Power Module 400/480V NA
600/690V NA
Rectifying Board 400/480V 20-VB00459
600/690V 20-VB00460
Rectifying Module 400/480V 20-FR10820
600/690V 20-FR10821
Snubber Capacitor Assembly 20-PP10019
D-6 Disassembly / Assembly Diagrams

Figure D.3 Left Side of Power Structure

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.

ASIC Assembly (without ASIC Board) Snubber Capacitor Assembly

DC Bus Bar

DC Bus Bar Insulator

DC Bus Bar

DC Bus Bar Insulator

DC Bus Bar

DC Bus Bar Insulator

Cover Plate

Output Power Module

Insulation Support

Discharging Resistor

Electrolytic Capacitor

Frame
Disassembly / Assembly Diagrams D-7

Table D.C Left Side of Power Structure Part Numbers


Part Name Part No.
ASIC Assembly (without ASIC Board) NA
Cover Plate NA
DC Bus Bar 20-FR10048
20-FR10052
20-FR10191
DC Bus Bar Insulator 20-FR10026
20-FR10028
20-FR10143
Discharging Resistor 2x16k 20-PP00056
Electrolytic Capacitor ELKO 3300Pf 420V for 400/480V Drives 20-PP01005
ELKO 5600Pf 420V for 600/690V Drives 20-PP01099
Frame NA
Insulation Support NA
Output Power Module 400/480V NA
600/690V NA
Snubber Capacitor Assembly 20-PP10019

Figure D.4 Fan Inverter Assembly

Fan Inverter Capacitor Fan Inverter Board

Fan Inverter Assembly, Left and Right

Table D.D Fan Inverter Assembly Part Numbers


Part Name Part No.
Fan Inverter Assembly, Left 20-FR10844
Fan Inverter Assembly, Right 20-FR10845
Fan Inverter Board 20VB00299
Fan Inverter Capacitor 7Pf 450V ac 20-PP00060
D-8 Disassembly / Assembly Diagrams

Figure D.5 ASIC Assembly

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.

ASIC Assembly Cover

ASIC Board

ASIC Assembly Bracket

ASIC Assembly Bracket

ASIC Assembly Bracket

ASIC Assembly Bracket

Table D.E ASIC Assembly Part Numbers


Part Name Part No.
ASIC Assembly Bracket
ASIC Assembly Bracket
ASIC Assembly Bracket Included in 20-FR10850
ASIC Assembly Bracket
ASIC Assembly Cover
ASIC Board for 400/480V Drives SK-H1-ASICBD-D820
SK-H1-ASICBD-D920
SK-H1-ASICBD-D1030
ASIC Board for 600/690V Drives SK-H1-ASICBD-E650
SK-H1-ASICBD-E750
SK-H1-ASICBD-E820
Disassembly / Assembly Diagrams D-9

Figure D.6 Main Fan Assembly

Main Fan

Main Fan Housing, Left and Right

Intake Cone

Table D.F Main Fan Assembly Part Numbers


Part Name Part No.
Intake Cone NA
Main Fan 230W 20-PP01080
Main Fan Housing, Left and Right NA
D-10 Disassembly / Assembly Diagrams

Notes:
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 PFLEX-TG004A-EN-P – May 2006


Copyright © 2006 Rockwell Automation, Inc. All rights reserved. Printed in USA.

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