Download 700S and 700H Frame 11 Replacement Power Structures

Installation Instructions
PowerFlex® 700S and 700H Frame 11
Replacement Power Structures
Introduction
Use this document to install a replacement power structure on a PowerFlex
700S or 700H frame 11 drive. This document covers the following
replacement power structures:
Spare Module Catalog PowerFlex 700H
String
AC Input
SK-H1-PWRMOD-E460 20CE460
20CF460
SK-H1-PWRMOD-E502 20CE502
20CF502
SK-H1-PWRMOD-E590 20CE590
20CF590
SK-H1-PWRMOD-D590 20CC590
20CD590
SK-H1-PWRMOD-D650 20CC650
20CD650
SK-H1-PWRMOD-D730 20CC730
20CD730
What You Need to Do
PowerFlex 700H
DC Input
20CK460
20CM460
20CK502
20CM502
20CK590
20CM590
20CH590
20CJ590
20CH650
20CJ650
20CH730
20CJ730
PowerFlex 700S
AC Input
20DE460
20DF460
20DE502
20DF502
20DE590
20DF590
20DC590
20DD590
20DC650
20DD650
20DC730
20DD730
PowerFlex 700S
DC Input
20DK460
20DM460
20DK502
20DM502
20DK590
20DM590
20DH590
20DJ590
20DH650
20DJ650
20DH730
20DJ730
❐ Step 1: Configure new power structure
❐ Step 2: Remove power from existing drive
❐ Step 3: Remove old power structure
❐ Step 4: Install new power structure
❐ Step 5: Connect new power structure to components in drive
❐ Step 6: Install product identification label on new power structure
❐ Step 7: Start drive
2
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
Step 1: Configuring the
New Power Structure
Before configuring the power structure you must remove the protective
covers from the drive. Refer to publication PFLEX-IN006…, Installation
Instructions - PowerFlex 700S and 700H High Power Drives, for assistance
in removing these covers.
Configuring a DC Input Drive
Power structures are shipped from the factory pre-configured for DC input
operation.
Connecting an AC Input Drive
Power structures are shipped from the factory pre-configured for DC input
operation. When installing a replacement power structure on a drive with
AC input, you must remove the X2 plug from it’s protective sleeve and plug
the cable into the ASIC and Rectifier board(s).
Task
A
Description
Remove the cover from the ASIC board assembly.
E
Disconnect the ASIC fan from the assembly by unplugging the cable from X1 on the ASIC
board (see Figure 1 on page 3 for location).
Remove the cover from the connector on the loose cable (bundled with the flat gate driver
board cables) and connect the cable to the X2 connector on the ASIC board (see Figure
1 on page 3 for location).
Connect the other end of the cable connected to X2 on the ASIC board to the X13
connector for the Rectifier board(s) on the V Phase and W Phase (if present) power stack
(see Figure 2 on page 3 for location).
Connect the fan cable to the X1 connector on the ASIC board.
F
Install the cover on the ASIC board assembly.
B
C
D
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
Figure 1 ASIC Board Connections
X6
X9
X15
H1 H2 H3 H4 H5 H6 H7
Connect cable to
X2 connector
X2
X1
X1 connector
H8 H9 H10 H11 H12 H13
X3
X4
X5
Figure 2 Rectifier Board Connectors
Cable connected to
X2 on ASIC board
X13
connectors
for Rectifier
boards
3
4
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
Configuring the EMC Filter
Frame 11 size drives are equipped with common mode capacitors. To guard
against drive damage, these capacitors should be disconnected depending
upon the type of ground system on which the drive is installed.
Installation on an Ungrounded Distribution System or High Resistive Ground
If you are installing a 400/480V AC input drive on an ungrounded
distribution system or high resistive ground, you:
• Must move the common mode jumper to the disconnected position refer to Move the Common Mode Jumper to the Disconnected
Position on page 6.
• Should insulate terminal X4 on the Rectifier circuit board- refer to
Insulate Terminal X4 on the Rectifier Circuit Board on page 7.
If you are installing a 600/690V AC input drive on an ungrounded
distribution system or high resistive ground, you:
• Must move the common mode jumper to the disconnected position refer to Move the Common Mode Jumper to the Disconnected
Position on page 6.
• Must insulate terminal X4 on the Rectifier circuit board- refer to Insulate
Terminal X4 on the Rectifier Circuit Board on page 7.
Installation on a Grounded B Phase Delta System
If you are installing a drive on a grounded B phase Delta system, you:
• Must move the common mode jumper to the disconnected position refer to Move the Common Mode Jumper to the Disconnected
Position on page 6.
• Must insulate terminal X4 on the Rectifier circuit board- refer to Insulate
Terminal X4 on the Rectifier Circuit Board on page 7.
Note: Refer to Wiring and Grounding Guidelines for Pulse Width
Modulated (PWM) AC Drives - Installation Instructions,
publication DRIVES-IN001…, for additional information on an
ungrounded distribution system or high resistive ground
installation.
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
5
The jumper is located on the Rectifying Module(s). For drives with one
Rectifying Module, it is located on the upper-right side of the middle power
stack (V Phase). For drives with two Rectifying Modules, they are located
on the upper-right side of the middle (V Phase) and right-side (W Phase)
power stacks.
Voltage Class
400/480V AC
600/690V AC
Amps
590
650
730
460
502
590
Number of Rectifying Modules
2
2
2
1
1
2
Figure 3 Common Mode Jumper and Rectifier Circuit Board Location
Common
Mode jumper
There is one jumper located on each Rectifying
Module. The Rectifying Modules are located on
the upper-right side of the center and right side
power stack of the drive’s power structure.
Front View
of Assembly
Rectifier Circuit Board
6
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
Move the Common Mode Jumper to the Disconnected Position
1. Follow the lettered steps below to move the common mode jumper to the
disconnected position (refer to Figure 3 on page 5 for jumper location).
Task
A
Description
Loosen the upper screw.
B
Remove the lower screw.
Move the jumper to the horizontal position.
C
Install and tighten the screws.
D
A
Front View of
Power Structure
D
C
B
Rectifying Circuit Board
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
7
Insulate Terminal X4 on the Rectifier Circuit Board
1. Follow the lettered steps below to insulate terminal X4 on the Rectifier
circuit board (refer to Figure 3 on page 5 for jumper location).
Task
A
Description
Remove the screw from the X4 connection on the Rectifier circuit board.
B
Insulate the top and bottom of the X4 connection on the Rectifier circuit board.
Important: Do not install the screw and washer that was removed from this
connection.
A
Side View of Power Structure
B
X4
X4
X1
X1
X41
X41
Rectifier Circuit Board
8
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
Step 2: Removing Power
From the Existing Drive
ATTENTION: To avoid an electric shock hazard, verify that
the voltage on the bus capacitors has discharged before servicing
the drive. Check the DC bus voltage at the Power Terminal
Block by measuring between the +DC and -DC terminals,
between the +DC terminal and the chassis, and between the -DC
terminal and the chassis. The voltage must be zero for all three
measurements.
!
Remove power before making or breaking cable connections.
When you remove or insert a cable connector with power
applied, an electrical arc may occur. An electrical arc can cause
personal injury or property damage by:
• sending an erroneous signal to your system’s field devices,
causing unintended machine motion
• causing an explosion in a hazardous environment
Electrical arcing causes excessive wear to contacts on both the
module and its mating connector. Worn contacts may create
electrical resistance.
1. Turn off and lock out input power. Wait five minutes.
2. Verify that there is no voltage at the drive’s input power terminals.
3. Measure between the +DC and -DC terminals, between the +DC
terminal and the chassis, and between the -DC terminal and the chassis.
The voltage must be zero for all three measurements.
L1
L2
L3
I
O
Step 3: Removing the Old
Power Structure
Refer to the PowerFlex 700H/S Frame 11 Hardware Service Manual,
publication PFLEX-TG003…, for information about removing the power
structure.
Step 4: Installing the New
Power Structure
Refer to the PowerFlex 700H/S Frame 11 Hardware Service Manual,
publication PFLEX-TG003…, for information about installing the power
structure.
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
Step 5: Connecting the
Power Structure to
Components in the Drive
9
You must connect the power structure to control components on the control
frame. If the drive has DC input, you must also connect the precharge
circuit.
Connections to the 700S Control Frame
When installing a power structure in a PowerFlex 700S drive, you must
make the following connections between the ASIC and Fiber Optic
Interface, Power Supply Voltage Feedback, Common Mode Filter and
Rectifier boards.
Connect this component: termination
point in the Power Structure to …
ASIC Board: H1 (fiber optic connector)
ASIC Board: H2 (fiber optic connector)
ASIC Board: H3 (fiber optic connector)
ASIC Board: H4 (fiber optic connector)
ASIC Board: H5 (fiber optic connector)
ASIC Board: H6 (fiber optic connector)
ASIC Board: H7 (fiber optic connector)
ASIC Board: X10
ASIC Board: X2
Power Supply Voltage Feedback Board: J8
Power Supply Voltage Feedback Board: J5
(fiber optic connector)
Power Supply Voltage Feedback Board: J4
(fiber optic connector)
…this component : termination point on the
Control Frame
Fiber Optic Interface Board: J8 (fiber optic connector)
Fiber Optic Interface Board: J9 (fiber optic connector)
Fiber Optic Interface Board: J10 (fiber optic connector)
Fiber Optic Interface Board: J11 (fiber optic connector)
Fiber Optic Interface Board: J12 (fiber optic connector)
Fiber Optic Interface Board: J14 (fiber optic connector)
Fiber Optic Interface Board: J13 (fiber optic connector)
Insulate and do not connect
Rectifier Board: X13 (AC input drives only)
Common Mode Filter Board: J5
Fiber Optic Interface Board: J6
Fiber Optic Interface Board: J7
Figure 4 Connections for 700S Drives with Phase II Control
Make and verify these connections
To X13 Connector for Rectifier Board (AC Input Drives Only)
ASIC Board
X2
H1 (Gate Enable)
H2 (U Gate)
RJ45
Connector
P1
Embedded P2
EtherNet I/P
Option Board
H3 (V Gate)
H4 (W Gate)
H5 (ADconv)
P1
TX
SynchLink
Option Board
RX
H6 (Vbus Tx)
RS232
CompactFlash
Memory
Compact I/O
P3
P2
P2
80
H7 (Vbus Rx)
P7
P10
P1
Inside Power Structure
P1
NetLinx
Daughtercard
34
P1
Feedback
Option
Board
40
34
P3
P12
Main
Control
Board
J2
2
J1
Fiber Optic
Interface
Board
-12 V
+5V
J6 Tx
+24V
8
9
9
8
9
10
P21
P5
TB1
TB2
J4 Tx
80W
Power
Supply
J2
DCDC+
J1
-U
-V
-W
Power Supply
Voltage
Feedback
X2 20-VB00601
J4
J17
2
P4
J5 Rx
Fiber
J7 Rx
16
P13
J8
2
J5
J3
P6
Second Encoder
P3
or
Safe Off Option Board
J5
+12 V
J1
P1
P11
P2
Common Mode Filter Board
J8 J9 J10 J11 J12 J14 J13
+24 V Iso
30
P2
Feedback
Inputs
X10
120
Logix
Expansion
Board
P3
Comm
Input
Fiber Optic Cables
P9
J16
J18
2
J15
X4
DPI
Interface X1
Board
J2
DPI
Bezel
X3
J3
J1
HIM
DOOR
DriveLogix
2
Battery
700S Control Assembly (Phase II)
M6
Control
Pan Fan
M
2
External
24V DC
1 = 24V
3 = Common
(75W min)
20
DPI
Comm
Option
PWR
STS
EXAMPLE:
20-HIM-A3
PORT
MOD
NET A
NET B
DPI Assembly
HIM
EXTERNAL DPI
10
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
Figure 5 Termination Points on the ASIC Board
Fiber Optic connections to the
Fiber Optic Interface board
X6
X9
X15
H1 H2 H3 H4 H5 H6 H7
Connect to Pre-charge
circuitry on DC input drives
X2
X1
Connects to fan on
ASIC assembly cover
Connects to X13
connector for the Rectifier
boards on the center and
right side power stacks on
AC input drives
H8 H9 H10 H11 H12 H13
X3
X4
X5
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
11
Figure 6 Termination Points on 700S Boards
Power Supply Voltage Feedback Board
Fiber Optic Interface Board
J4 J5
J8
J8
J9
J10
J11
Common Mode Filter Board
J12
J14
J13
J1
J6
J7
J5
J5
12
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
Connections to the 700H Control Frame
When installing a power structure in a PowerFlex 700H drive, you must
make eight connections between the ASIC and Fiber Optic Adapter and
Rectifier boards.
Connect this component: termination point in …this component : termination point on the
the Power Structure to …
Control Frame
ASIC Board: H1 (fiber optic connector)
Fiber Optic Adapter Board: H1
(fiber optic connector)
ASIC Board: H2 (fiber optic connector)
Fiber Optic Adapter Board: H2
(fiber optic connector)
ASIC Board: H3 (fiber optic connector)
Fiber Optic Adapter Board: H3
(fiber optic connector)
ASIC Board: H4 (fiber optic connector)
Fiber Optic Adapter Board: H4
(fiber optic connector)
ASIC Board: H5 (fiber optic connector)
Fiber Optic Adapter Board: H5
(fiber optic connector)
ASIC Board: H6 (fiber optic connector)
Fiber Optic Adapter Board: H6
(fiber optic connector)
ASIC Board: H7 (fiber optic connector)
Fiber Optic Adapter Board: H7
(fiber optic connector)
ASIC Board: X10
Fiber Optic Adapter Board: X2
ASIC Board: X2
Rectifier Board: X13
Figure 7 Connections Between the Power Structure and Control Frame (700H Drives)
Make and verify these connections
X10
H1
ASIC
Board
H2
H3
H4
H5
H6
H7
To X13 Connector for Rectifier Board (AC Input Drives Only)
X2
Inside Power Structure
Fiber Optic Cables
X2
H1 H2 H3 H4 H5 H6 H7
X3
+24V 1
Common 2
Fiber Optic Adapter Board
X1
37
X2
X1
700H Control Board
X2
(Slot A)
20C-DA1-A
(24V dc Digital Input
w/ Analog I/O)
or
20C-DA1-B
(115V ac Digital Input
w/ Analog I/O)
10
Analog
I/O
8 / 10
Digital
Inputs
X3
(Slot B)
X4
(Slot C)
X5
(Slot D)
20C-DO1
(Digital Output
Option)
Option
Board
Option
Board
X7
(RS-232
Programming
Port)
X6
(Slot E)
X1
20C-DPI1
(DPI Communications
Option)
X3
3
3
Digital
Digital
Outputs Outputs
DPI
Interface
X1
J2
X4
HIM
Bezel
X3
20
HIM
DPI
COMM
(Option)
PWR
STS
PORT
MOD
NET A
NET B
X2
DPI Assembly
700H Control Assembly
J1
J3
HIM
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
Figure 8 Termination Points on Fiber Optic Adapter Board (700H Drives)
Back View
H7
H6
H5
H4
H3
H2
H1
X2
13
14
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
Pre-Charge Connections on Drives with DC Input
You must connect the ASIC board connectors X9 and X15 to the X50
terminal block for the pre-charge circuit. The X50 terminal block is located
on the Control Frame. Refer to the Installation Instructions - PowerFlex
700S and 700H High Power Drives, publication PFLEX-IN006…, for
information regarding the pre-charge circuit.
X50 Terminal Block Connections
ASIC Board
Connector Terminal
X9
25
26
X15
21
23
to X50 Terminal
...
1
...
2
...
3
...
4
Pre-Charge Circuit Connection Description
Pre-charge Complete Signal (+24V DC)
Pre-charge Complete Signal (Common)
Charge Relay Contact
Charge Relay Contact
Figure 9 Sample Pre-charge Wiring Diagram
Customer Connections - External precharge
circuitry is shown as dashed lines.
Terminal Block
DC+
M
Drive Connections
X50
ASIC Board
X9
F1
R1 CR2
1
25
2
26
3
21
M
DC Source
4
23
Precharge
Complete
Charge
Relay*
X15
CR1
Pilot Relay
M
F2
R2 CR2
DC-
*Refer to the “ASIC Board
Charge Relay Contact
Ratings” table below.
CR1
M
Main DC Contactor
M
CR2
Precharge
Important: For DC Input Only.
Do Not Install on AC Input Drives
ASIC Board Charge Relay Contact Ratings
Load
Rated load
Rated carry current
Max. switching voltage
Max. switching current
Max. switching power
Failure rate (reference value)
Resistance load (cos φ = 1)
8 A at 250 VAC: 5 A at 30 VDC
8A
250 VAC; 30 VDC, (400 VAC)
AC 8 A; DC 5 A
2,000 VA; 150 W
5 VDC 10 mA (for gold plating 0.35 µ min.)
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
15
All frame 11 replacement power structures are shipped from the factory
Step 6: Installing the
Product Identification Label without a product identification label on the drive. If you are installing the
power structure in a 700S drive, you should label it with the accompanying
on New Power Structure
PowerFlex 700S label. If you are installing the power structure in a 700H
drive, you should label it with the accompanying PowerFlex 700H label.
! D
ANG
ER
Risk
of
Disco electric sh
nn
oc
verify ect powe k and de
ath.
r, wa
DC bu
it 5 mi
Follo
nu
w ins s voltage
tructi
befor tes and
Earth
groun ons in ma e servicin
d req
uired nual befor g.
.
e use.
OR
! DA
NGER
Risk
of
Disco electric shoc
nnec
t powe k and
verify
DC bus r, wait death.
Follo
5 minu
w instru voltage
befor tes and
Earth
ction
e servi
s
grou
cing.
nd requ in manu
al befor
ired.
e use.
Step 7: Starting the Drive
1. Install the protective covers on the drive. Refer to publication
PFLEX-IN006…, Installation Instructions - PowerFlex 700S and 700H
High Power Drives, for assistance in installing these covers.
2. Start up the drive. Refer to the Start Up procedures in the appropriate
publication:
– User Manual - PowerFlex 700S Drives with Phase II Control,
20D-UM006….
– Programming Manual - PowerFlex 700H Drives, 20C-PM001….
Reference Materials
Allen-Bradley publications are available on the internet at
www.rockwellautomation.com/literature.
The following manuals are recommended for general drive information:
Title
Wiring and Grounding Guidelines for Pulse Width Modulated Drives
Industrial Automation Wiring and Grounding Guidelines
Preventive Maintenance of Industrial Control and Drive System Equipment
Safety Guidelines for the Application, Installation and Maintenance of Solid
State Control
A Global Reference Guide for Reading Schematic Diagrams
Guarding Against Electrostatic Damage
Publication
DRIVES-IN001…
1770-4.1
DRIVES-TD001…
SGI-1.1
0100-2.10
8000-4.5.2
The following manuals are recommended for detailed PowerFlex 700H and
700S information:
Title
Reference Manual - PowerFlex 700S Drives with Phase II Control
User Manual - PowerFlex 700S Drives with Phase II Control
Programming Manual - PowerFlex 700H Drives
Installation Instructions - PowerFlex 700S and 700H High Power Drives
Hardware Service Manual - PowerFlex 700S and 700H Frame 11 Drives
Publication
PFLEX-RM003…
20D-UM006…
20C-PM001…
PFLEX-IN006…
PFLEX-TG003…
For Allen-Bradley Drives Technical Support:
Title
Allen-Bradley Drives Technical Support
Online at...
www.ab.com/support/abdrives
www.rockwellautomation.com
Power, Control and Information Solutions Headquarters
Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204 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-IN011C-EN-P - August 2008
Supersedes PFLEX-IN011B-EN-P - March 2006
16 360399-P03
Copyright © 2008 Rockwell Automation. All rights reserved. Printed in the U.S.A.