Download pflex-tg003 - Rockwell Automation

700S High Performance
AC Drive
and
700H Adjustable Frequency
AC Drive
Frame 11
315-400KW / 400V
500-600HP / 480V
500-600HP / 600V
450-560KW / 690V
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:
• identify a hazard
• avoid the hazard
• 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? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Support Available on Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Class 1 LED Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P-1
P-1
P-1
P-2
P-2
P-2
P-3
P-3
P-4
P-4
Chapter 1
Creating Fault Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Addressing 700S Hardware Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Addressing 700H Hardware Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Procedures by Symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blown Input Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No Output Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No HIM Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Over-Temperature Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-3
1-5
1-5
1-6
1-7
1-8
Chapter 2
Viewing the 700H Diagnostic LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Viewing the 700S Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Performing Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Inspecting the Cooling Tunnels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Inspecting the Power Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Conducting Forward and Reverse Biased Diode Tests for Major Power Components. . . 2-4
Checking Fiber Optic Connections to the Gate Driver Boards . . . . . . . . . . . . . . . . . . . . . 2-7
Conducting Gate Driver Board Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Gate Interface Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Preparing the Drive for Active Measurements on the Gate Driver Board . . . . . . . . . . 2-8
Checking the Opto-Couplers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Checking the Rectifying Module(s) on AC Input Drives . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Testing 600V AC Input, 460A and 502A Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Taking Measurements on Rectifying Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Testing 400V AC Input, 590A, 650A or 730A, or 600V AC Input, 590A Drives . . . 2-14
Taking Measurements on Rectifying Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Checking the DC Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Checking the Main Fan Inverters and Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Checking Inverter LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Checking Fan Inverter Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Isolating a Faulty Fan Inverter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Checking the Main Fan Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2
Chapter 3
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Understanding Torque Figures in Assembly Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Removing Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Removing Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Removing the DPI / HIM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Removing the 700S Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Removing the 700S High Power Fiber Optic Interface Circuit Board . . . . . . . . . . . . . . . 3-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Removing the 700S Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Removing the 700H I/O Boards and Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Removing the 700H Fiber Optic Adapter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Removing the Covers from the Power Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Moving the Control Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Removing the Airflow Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Removing the Protective Covers from Power Structure . . . . . . . . . . . . . . . . . . . . . . . 3-16
Removing the 700S Voltage Feedback Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Removing the Gate Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Removing the ASIC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Removing the Power Structure from the Drive Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Removing the Main Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Removing the Fan Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Removing the U Phase (Left-Side) Output Power Module . . . . . . . . . . . . . . . . . . . . . . . 3-29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Removing the V Phase (Middle) Rectifying Board, Rectifying Module and Output Power
Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3
Removing the W Phase (Right-Side) Rectifying Board, Rectifying Module and Output Power
Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Removing the DC Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Chapter 4
Before Applying Power to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing with the External DC Power Supply Without Load (Optional) . . . . . . . . . . . . . .
Testing Without a Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performing the Power Circuit Diagnostic Test on a 700S. . . . . . . . . . . . . . . . . . . . . . . . .
Testing With the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A
Software Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Appendix B
List of Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Power Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Control Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
Appendix C
Circuit Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Hardware Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
Appendix D
Disassembly/Assembly Diagrams and Spare Parts Numbers . . . . . . . . . . . . . . . . . . . . . . D-1
4-1
4-2
4-3
4-3
4-4
4
Preface
Overview
Who Should Use this
Manual?
This manual is intended for qualified service personnel responsible for
troubleshooting and repairing high power PowerFlex 700S and 700H 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 11
PowerFlex 700S and 700H drives only. Verify that you are working on a
Frame 11 drive by checking the data nameplate on the Control Frame. The
frame number is printed just above the serial number.
Cat No.
20D
500 N 0 NNNBNNNN
J
UL Open Type/IP00
540V
250 kW
Normal Duty Power
200 kW
Heavy Duty Power
Input: DC,
462 - 594
DC Voltage Range
Amps
350
Output: 3 Phase, 0 - 320Hz
AC Voltage Range
0 - 400
50 Hz
Base Hz (default)
Continuous Amps
420/500
630/550
1 Min Overload Amps
840/630
2 Sec Overload Amps
MFD. in 1989 on Nov 9
Cat No.
20D
J
300 N 0 NNNBNNNN
UL Open Type/IP00
540V
650V
Normal Duty Power
160 kW
250 kW
Heavy Duty Power
132 kW
200 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
50 Hz
60 Hz
Base Hz (default)
Continuous Amps
300/245
300/245
1 Min Overload Amps
330/368
330/368
2 Sec Overload Amps
450/490
450/490
Series: A
Standard I/O: NONE
Original Firmware No. 2.04
C
UL
Æ
US
LISTED
IND CONT EQ
MFD. in 1989 on Nov 9
Serial Number: 2622381652
MADE IN THE USA (FAC 1B)
2622381652
MADE IN THE USA (FAC 1B)
What is Not in this Manual
Series: A
650V
450 kW
500 kW
Standard I/O: NONE
Original Firmware No. 2.04
C
583 - 713
350
UL
Æ
US
LISTED
IND CONT EQ
9D42
0 - 460
60 Hz
420/500
630/550
840/630
Frame #: 11
Serial Number: 2622381652
2622381652
This manual does not contain in depth fault information for troubleshooting.
Fault 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 High
Performance AC Drive Phase II Control.
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
Wiring and Grounding Guide, (PWM) AC Drives
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...
SGI-1.1
0100-2.10
8000-4.5.2
The following publications provide specific PowerFlex drive information.
Title
Programming Manual - PowerFlex 700H AC Drive
User Manual - PowerFlex 700S High Performance Drive Phase II
Control
Installation Instructions - Hi-Resolution Feedback Option Card for
PowerFlex 700S Drives
Installation Instructions - Multi Device Interface Option for PowerFlex
700S Drives
Installation Instructions - Main Control Board PowerFlex 700S Drives
Installation Instructions - Control Assembly Cover for PowerFlex 700S
Drives
Installation Instructions - PowerFlex 700S /700H High Power
Maintenance Stand
Installation Instructions - PowerFlex 700S and 700H Drives
Reference Manual - PowerFlex 700S Adjustable Frequency Drive
Phase II Control
Publication
20C-PM001...
20D-UM006...
20D-IN001...
20D-IN004...
20D-IN005...
20D-IN006...
20D-IN014...
PFLEX-IN006...
PFLEX-RM003...
The following publications provide information that is necessary when
applying the DriveLogix™ Controller.
Title
User Manual - DriveLogix System
Installation Instructions - DriveLogix Controller
Installation Instructions - Memory Expansion for DriveLogix Controller
ControlNet Daughtercard Installation Instructions
ControlNet Daughtercard Installation Instructions
Understanding Manual
Conventions
Publication
20D-UM002...
20D-IN002...
20D-IN007...
1788-IN002...
1788-IN005...
Terms
The following words are used throughout the manual to describe an action:
Word
Can
Cannot
May
Must
Shall
Should
Should Not
Meaning
Possible, able to do something
Not possible, not able to do something
Permitted, allowed
Unavoidable, you must do this
Required and necessary
Recommended
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
Available on Internet
Additional troubleshooting information and software tools are available on
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
Complete fault reports are critical for analysis and repair of modules
returned to the factory.
At a minimum, perform and record the following:
• Record the contents of the fault queue (faults and times of occurrence)
• Make record of any burn marks on the rectifying module, DC-capacitors,
inverter bridge, charging resistors, balancing/precharging resistors,
printed circuit boards, bus bars, cabling and fiber-optic cabling
• Make record of any liquid and condensation marks on printed circuit
boards, components and mechanical parts
• Make record of the amount of dust and other additional particles on drive
and drive components
• Make record of any mechanical damage to the drive and drive
components
• Record the size and type of main fuses
• Record any other important marks and damage
Addressing 700S Hardware
Faults
Fault
HiHp In PhaseLs
No.
65
HiHp Bus Com Dly
66
HiHp Bus Link LS
67
HiHp Bus CRC Er
68
HiHp Bus WtchDog
69
HiHp Fan Fdbk Ls
70
Description
AC Input Phase Loss - AC voltage is
not present on one or two input
phases.
Action (if appropriate)
1. Check for voltage on each
input phase.
2. Check the status of each
external input fuse.
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.
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.
Bus Communication CRC Error - too Check fiber-optic connections
many Cycling Ring Checksum (CRC) between the Power Interface
Circuit Board and Voltage
errors have occurred in the
Feedback Circuit Board.
communication bus.
Wait five minutes before
A fast power cycle may cause the
700S Main Control Board to attempt re-energizing the drive.
to communicate with the ASIC Board
before the ASIC Board is energized.
Bus Communication Watchdog Error - 1. Check fiber-optic
connections between the
communication has halted in 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.
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
Fault
HiHp Drv OvrLoad
No.
71
Description
Drive Overload - the circuit board on
the Power module has detected an
overload.
HiHp PwrBd PrcEr
72
Power Board Processor Error - a
microprocessor on the Power Board
has detected a communication error.
HiHp PrChrg Cntc
73
HiHp PwrEE Error
74
Precharge Contactor Fault - proper
contactor feedback has not occurred.
The precharge contactor has probably
failed to pick up or the feedback signal
has failed. This fault only applies to
DC input drives.
Power EEPROM Error - the rating of
the drive and data in the Power
EEPROM on the Power Board do not
match.
Check the main cooling fan and
Power Board Over-Temperature fan power supply, replace if
temperature of the Power Board on
necessary.
has exceeded 85° C.
HiHP PwrBd OTemp 75
Addressing 700H Hardware
Faults
1-3
Name
Auxiliary In
Power Loss
No.
2
3
UnderVoltage
4
Description
Auxiliary input interlock is open.
DC bus voltage remained below
[Power Loss Volts] for longer than
[Power Loss Time]. Enable/Disable
with [Fault Config 1]. For more
information refer to publication
20C-PM001, Programming Manual PowerFlex 700H.
DC bus voltage fell below the
minimum value of 333V for 400/480V
drives and 461V for 600/ 690V drives.
Enable/Disable with [Fault Config 1].
For more information refer to
publication 20C-PM001,
Programming Manual - PowerFlex
700H.
Action (if appropriate)
Measure output current of the
drive. If the level is ever greater
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.
1. Check fiber-optic
connections between the
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.
• Check precharge circuit
wiring.
• Check for loose connections
on X50 terminal block and/or
the X9 and X15 connectors
on the ASIC Board.
Replace output power module
or program a new power board.
Action (if appropriate)
Check remote wiring.
Monitor the incoming AC line for
low voltage or line power
interruption.
Monitor the incoming AC line for
low voltage or power
interruption.
1-4
Troubleshooting and Error Codes
Name
OverVoltage
No.
5
Input Phase
17
OutPhasMissng
21
Ground Fault
13
InverterFault
14
System Fault
10
Load Loss
15
HiHp Drv OvrLoad
31
Power Unit
70
Description
DC bus voltage exceeded maximum
value.
Action (if appropriate)
Monitor the AC line for high line
voltage or transient conditions.
Bus overvoltage can also be
caused by motor regeneration.
Extend the decel time or install
and external dynamic brake
option.
One input line phase missing.
Check user-supplied fuses
Check AC input line voltage.
Zero current in one output motor
Check motor wiring.
phase.
Check motor for open phase.
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
condition.
current rating. The current must
appear for 800ms before the drive will
fault.
Hardware problem in the power
Cycle power.
structure.
Replace drive.
Hardware problem exists in the power Cycle power.
structure.
Replace drive.
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.
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.
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
Diagnostic Procedures by
Symptom
1-5
The following charts list drive symptoms, symptom descriptions and
recommended actions.
Blown Input Fuses
Use this procedure when a drive clears any of its external circuit breaker or
power fuses:
Disconnect Motor
Leads
Perform Forward
Diode Tests on
Rectifying Module
Rectifying
Module
OK?
No
Replace
Rectifying
Module
Power
Modules
OK?
No
Replace
Power
Modules
Capacitors
OK?
No
Replace
Capacitors
Motor and
Lead Resistances
> 1 Mohm?
No
Remedy Motor
and Lead
Problems
Are There
Any Line to
Load Shorts?
Yes
Replace
AC
Choke
Yes
Perform Forward
Diode Tests on
Output Power
Modules
Yes
Examine Bus
Capacitors for
Charring and
Damaged Reliefs
Yes
Check Motor and
Lead Resistances
at 1000V
Yes
Disconnect AC
Choke from
Rectifying Module
No
Are There
Any Line to
Line Shorts?
No
Yes
Reconnect
AC
Choke
Reconnect
Motor
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
Voltage within
Specification?
Measure DC Bus
Voltage
Perform forward
diode tests on
Rectifying Module
No
Rectifying
Module OK?
No
Replace Rectifying
Module
No
Replace
Capacitors
Yes
Examine Bus
Capacitors for
Charring and
Damaged Reliefs
Yes
Capacitors
OK?
Yes
Measure Power
Supply Voltages
Voltages within
Specification?
Replace Power
Supply
No
Yes
Check Board
Connections
Does Drive
Run?
No
Does Drive
Run?
Replace Main
Control Board
No
Replace Power
Interface Board
(on 700S)
Does Drive
Run?
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
Connection
and Seating
Properly
Connected?
No
Reseat or
reconnect
HIM
No
Perform forward
diode tests on
Rectifying Module
Yes
Measure DC Bus
Voltage
DC Bus
Voltage within
Specification?
Rectifying
Module OK?
No
Replace Rectifying
Module
No
Replace
Capacitors
Yes
Examine Bus
Capacitors for
Charring and
Damaged Reliefs
Yes
Capacitors
OK?
Yes
Yes
Measure Power
Supply on X4 of
DPI Circuit Board
Voltage
= 12V dc?
Replace Power
Interface Board
(on 700S)
No
Yes
Replace Output
Power Module
(on 700H)
Check DPI and
Power Supply
Connections
Does HIM
Function?
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):
Check Surrounding
Air Temperature
Temperature
Exceeds
Specification?
Yes
Provide
Additional Airflow
or Air Conditioning
Current
Exceeds
Specification?
Yes
Reduce Load or
Procure a Drive
With a Higher
Rating
Frequency Too
High for Lead Length
and Surrounding
Temp?
Yes
Lower PWM
Frequency
Proper Space
At Inlet?
No
Remedy
Spacing at
Inlet
Yes
Remove
Air Flow
Blockages
No
Check Motor
Current and Load
Levels
No
Check PWM
Frequency
No
Check Fans and
Air Flow
Through the Drive
Yes
Airlflow
Blockages?
No
Fans
Running
Properly?
Yes
Power Voltage
Equals Bus
Voltage?
No
Check Fan Inverter
Fuses (F1 and F2)
Connection
Good?
No
Repair
Connection
Output Equals
50 Hz / 220V rms?
No
Replace
Fan Inverter(s)
Fan Motor has
Open or Short
Circuits?
Yes
Replace
Fan Motor(s)
No
Check Power
Voltage on Fan
Inverters
Yes
Check Connection
Between ASIC
Board and Fan
Inverters
Yes
Check Fan
Inverter Outputs
on X1, X4 and X5
Yes
Check Fan Motors
for Short and
Open 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.
!
Viewing the 700H Diagnostic
LED
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.
The Control Assembly on 700H drives contains a diagnostic LED which is
visible through the cover of the Control Assembly.
!
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
Steady
Flashing Quickly
Flashing Slowly
Viewing the 700S Diagnostic
LEDs
!
Indication
The drive is operational and has no faults
• Switching power supply overload
• Rectifier board fault
• Fan or fan inverter fault
• Brake Chopper fault
• Fiber Optic Adapter board Fault
Bad connection between circuit boards, check all connections
The PowerFlex 700S contains a Run LED, controller LEDs, and SynchLink
LEDs. These LEDs are only operational when the drive is energized and are
only visible when the drive door is open. The status of these LEDs can also
be viewed from the HIM or from an application program (e.g.,
DriveExplorer™) in parameter 554 [LED Status]. This feature is only
available with DriveLogix version 15.03 or later.
ATTENTION: The RUN LED and the controller LEDs are only operational when the drive is energized.
Servicing energized equipment can be hazardous. Severe injury or death can result from electrical shock, burn
or unintended actuation of controlled equipment. Follow Safety related practices of NFPA 70E, ELECTRICAL
SAFETY FOR EMPLOYEE WORKPLACES. DO NOT work alone on energized equipment!
Component Test Procedures
2-3
➊
➋
➌
Table C Drive Status Indicator Descriptions
#
Name
Color
State
Description
➊
PWR
(Power)
STS
(Status)
Green
Steady
Illuminates when power is applied to the drive.
Green
Flashing
Steady
Flashing
DRIVE
Control Assembly
Communications
Control
Power Structure
➋
➌
PORT
MOD
NET A
NET B
(1)
SYNCHLINK Green
ENABLE
(1)
Drive ready, but not running & no faults are present.
Drive running, no faults are present.
Yellow
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.
Refer to the
Status of DPI port internal communications (if present).
Communication
Status of communications module (when installed).
Adapter User Manual Status of network (if connected).
Status of secondary network (if connected).
Steady
Green
Red
Flashing
Flashing
Green
Green
On
Off
The module is configured as the time keeper.
or
The module is configured as a follower and
synchronization is complete.
The follower(s) are not synchronized with the time keeper.
The module is configured as a time master on SynchLink
and has received time information from another time
master on SynchLink.
The drive’s enable input is high.
The drive’s enable input is low.
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 structure before energizing
the drive.
Inspecting the Cooling Tunnels
1. Remove the main cooling fans from the bottom of the power structure.
Refer to Removing the Main Fans on page 3-24.
2. Inspect the tunnels. Clean the heatsinks and tunnels if necessary.
Inspecting the Power Structure
1. Remove the covers from the power structure. Refer to Removing the
Covers from the Power Structure on page 3-13.
2. Check components for burn marks, breakage or foil delamination on
circuit boards. Check all the boards on the power structure, including
those on the Output Power modules and the Rectifying module(s) (if
present).
Replace any of these components without further testing if they show
evidence of burn marks, breakage or foil delamination.
Conducting Forward and
Reverse Biased Diode Tests
for Major Power Components
A forward biased diode test checks the semiconductor junctions between
the terminals and measures the voltage drop across those junctions. To pass
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).
Important: 600V ac input, 460A and 502A frame 11 drives only have one
Rectifying module. For all other drive configurations, you must
complete these procedures for both Rectifying modules.
-
+
~.0L
~0.5V
+
Forward biased test
on PN-junction
Reverse biased test
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 the motor leads from the drive.
3. On ac input drives, conduct forward and reverse biased diode tests on
the Rectifying module(s).
Figure 2.1 Measurement Points for Forward and Reverse Diode Tests
DC+
DC-
U/T1
1L1
V/T2
1L3
1L2
W/T3
2L1
2L3
2L2
Note: 600V ac input, 460A and 502A frame 11
drives only have one Rectifying module.
Table 2.A Forward Biased Diode Tests on Rectifying Module(s)
L1
L2
L3
DCDCDC-
Meter Leads
+
DC+
DC+
DC+
L1
L2
L3
Nominal meter reading
Value should gradually rise to about
0.5V
2-6
Component Test Procedures
Table 2.B Reverse Biased Diode Tests on Rectifying Module(s)
Meter Leads
+
L1
DCL2
DCL3
DCDC+
L1
DC+
L2
DC+
L3
Nominal meter reading
Meter should display “.0L” (zero load)
If the drive fails any of these measurements, replace all Rectifying modules.
4. Conduct forward and reverse biased diode tests on the Output Power
modules.
Table 2.C Forward Biased Diode Tests on Output Power Modules
DCDCDCT1
T2
T3
Meter Leads
+
T1
T2
T3
DC+
DC+
DC+
Nominal meter reading
Meter should display “.0L” (zero load)
Table 2.D Reverse Biased Diode Tests on Output Power Modules
Meter Leads
+
T1
DCT2
DCT3
DCDC+
T1
DC+
T2
DC+
T3
Nominal meter reading
Value should gradually rise to about
0.5V
If the drive fails any of these measurements, replace all three Output
Power modules.
Component Test Procedures
Checking Fiber Optic
Connections to the Gate
Driver Boards
2-7
Damaged or improperly connected fiber optic cables can cause apparent
Gate Driver board malfunctions.
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structure. Refer to Removing the
Covers from the Power Structure on page 3-13.
3. Locate the three Gate Driver boards on the front of the power structure.
H
W
X1
4. Verify the fiber optic cables are properly connected (refer to Figure
B.7 on page B-8, Figure B.8 on page B-9, Figure B.9 on page B-10, or
Figure B.10 on page B-11).
5. Disconnect the cables and inspect them for scratches and cracks.
6. Reconnect the cables, replacing any damaged cables.
Conducting Gate Driver
Board Measurements
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structure. Refer to Removing the
Covers from the Power Structure on page 3-13.
2-8
Component Test Procedures
Gate Interface Resistance
There are three Gate Driver boards, one per output power module. Measure
the gate interface resistance for each output power transistor. The resistance
from each gate and collector pin to the branch emitter pin should be about
333 ohms. If any of the gate interfaces fails this test, replace the appropriate
(left, middle, or right) output power module.
X10
+/- 15 V
Gate Interface for
U, V or W High (H)
H
~333 ohms
+/- 15 V
~333 ohms
Emitter
L
X1
X11
+/- 15 V
Gate Interface for
U, V or W Low (L)
~333 ohms
~333 ohms
+/- 15 V
Emitter
Preparing the Drive for Active Measurements on the Gate Driver Board
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
the Gate Driver board to determine if the board is
malfunctioning.
Important: A High Voltage DC Test Power Supply is required to perform
these tests.
Component Test Procedures
2-9
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structure. Refer to Removing the
Covers from the Power Structure on page 3-13.
3. Disconnect the Main Fan Inverters power supply cables 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.
4. Disconnect the fiber optic cables that connect the ASIC board to the
three Gate Driver boards at the Gate Driver board ends.
5. Disconnect the plug from the X6 connector on the ASIC board.
6. Make the following connections from a High Voltage DC Test Power
Supply to X6 on the ASIC board using a new connector plug.
From High Voltage DC Test
Power Supply
DC+
DC-
To this pin on the X6 on ASIC
Board
1
3
Jumper pin 1 to pin 2 on connector
7. Disconnect the DC+ wire from each of the three Gate Driver boards.
H
DC+
L
DC-
8. Connect the High Voltage DC Test Power Supply DC- to the DC- Bus
Bar.
2-10
Component Test Procedures
9. Connect the High Voltage DC Test Power Supply DC+ to the DC+ on
each Gate Driver board.
!
!
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. 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 board 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.
10. 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).
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.
Component Test Procedures
2-11
1. Locate the fiber optic receiver which transmits the signals for the U
High (UH) gate interface and connector X10 on the Gate Driver board.
X10 provides the gate interface for the UH output power transistor in
the U Phase Output Power module.
2. Measure the DC voltage at each UH gate pin and the emitter pin on X10
by placing the DC- common probe on the emitter pin and the voltage
probe on the gate pins.
X10
DC+ Voltage Probe
+15V DC
DC+ Voltage Probe
+15V DC
DC- Common Probe
3. While shining an intense light (like a flashlight) into the fiber optic
receiver for the UH cable, measure the DC voltage at each UH gate pin
and the emitter pin on X10 with respect to DC-. Each 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 2 and 3 with connector X11 and the UL cable. X11
provides the gate interface for the UL output power transistor in the U
Phase Output Power module. If the drive fails any of these tests, replace
the Gate Driver board.
X11
DC+ Voltage Probe
+15V DC
+15V DC
DC+ Voltage Probe
DC- Common Probe
5. Repeat steps 2 and 3 with connector X10 and the VH cable. X10
provides the gate interface for the VH output power transistor in the V
Phase Output Power module. If the drive fails any of these tests, replace
the Gate Driver board.
6. Repeat steps 2 and 3 with connector X11 and the VL cable. X11
provides the gate interface for the VL output power transistor in the V
Phase Output Power module. If the drive fails any of these tests, replace
the Gate Driver board.
7. Repeat steps 2 and 3 with connector X10 and the WH cable. X10
provides the gate interface for the WH output power transistor in the W
Phase Output Power module. If the drive fails any of these tests, replace
the Gate Driver board.
8. Repeat steps 2 and 3 with connector X11 and the WL cable. X11
provides the gate interface for the WL output power transistor in the W
2-12
Component Test Procedures
Phase Output Power module. If the drive fails any of these tests, replace
the Gate Driver board.
9. Connect the multi-meter (ohms) black test lead to the DC- Bus Bar and
the red test lead from the multi-meter to the output terminal on the U
Phase.
10. Shine an intense light into the UL fiber optic receiver on the Gate Driver
board. This should gate the IGBT and the multi-meter should indicate
that the IGBT is short-circuited. This will happen if the circuit from the
fiber optic receiver to the output terminal is functioning properly.
11. Connect the multi-meter red test lead to the DC+ Bus Bar and the black
test lead to the UH output terminal.
12. Shine an intense light into the UH fiber optic receiver on the Gate
Driver board. This should gate the IGBT and the multi-meter should
indicate that the IGBT is short-circuited. This will happen if the circuit
from the fiber optic receiver to the output terminal is functioning
properly.
13. Repeat steps 9 - 12 for VL and VH on the V Phase Gate Driver board.
14. Repeat steps 9 - 12 for WL and WH on the W Phase Gate Driver board.
Important: The test does not verify that both blocks are operating. If one
block is not operating, the drive will indicate an I2T hardware
fault.
Checking the Rectifying
Module(s) on AC Input
Drives
600V ac input, 460A and 502A frame 11 drives have only one Rectifying
module. Complete the “Testing 600V AC Input, 460A and 502A Drives”
procedure below only if you are checking the Rectifying module on a 600V
ac input, 460A and 502A drive. If you are checking the Rectifying module
on a 400V ac input, 590A, 650A or 730A, or 600V ac input, 590A drive
refer to Testing 400V AC Input, 590A, 650A or 730A, or 600V AC Input,
590A Drives on page 2-14.
Testing 600V AC Input, 460A and 502A Drives
Important: This procedure requires special equipment and training. 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 structure. Refer to Removing the
Covers from the Power Structure on page 3-13.
Component Test Procedures
2-13
3. Visually inspect the pre-charging resistors. If the pre-charging resistors
are damaged:
A. Replace all Rectifying modules (See Removing the W Phase
(Right-Side) Rectifying Board, Rectifying Module and Output
Power Module on page 3-36).
B. Check the capacitors, rectifier(s) 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).
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 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.E below. 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 W Phase (Right-Side) Rectifying Board, Rectifying Module and
Output Power Module on page 3-36).
Table 2.E Rectifying Module Resistance Measurements
Measurement points
X10: red to X10: black
X11: red to X11: black
X12: red to X12: black
Resistance
18Ω ± 1Ω
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
Table 2.G on page 2-16. If the Rectifying Module fails any of these
tests, replace it (See Removing the W Phase (Right-Side) Rectifying
Board, Rectifying Module and Output Power Module on page 3-36).
Important: Power supply polarity is critical during these tests. Reversing
the polarity will damage components on the circuit board.
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.
2-14
Component Test Procedures
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 Table 2.G on page 2-16 below. If the Rectifying Module fails
any of these tests, replace it (See Removing the W Phase (Right-Side)
Rectifying Board, Rectifying Module and Output Power Module on
page 3-36).
Testing 400V AC Input, 590A, 650A or 730A, or 600V AC Input, 590A
Drives
Important: This procedure requires special equipment and training. 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 structure. Refer to Removing the
Covers from the Power Structure on page 3-13.
3. Visually inspect the pre-charging resistors. If the pre-charging resistors
are damaged:
A. Replace all Rectifying modules (See Removing the V Phase
(Middle) Rectifying Board, Rectifying Module and Output Power
Module on page 3-33 and Removing the W Phase (Right-Side)
Rectifying Board, Rectifying Module and Output Power Module on
page 3-36).
B. Check the capacitors, rectifier(s) 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).
4. On the first converter, verify that the plugs on the cable that connects
X13 on the Rectifying board to X2 on the ASIC board are properly
seated.
5. On the first converter, remove the X50 jumper from the Rectifying
board.
6. Verify that the plugs on the cable that connects X6 on the Rectifying
board of the first converter to X13 on the Rectifying board of the second
converter are properly seated.
7. Verify that the jumper at X50 on the Rectifying board of the second
converter is in place.
Component Test Procedures
2-15
Taking Measurements on Rectifying Module
8. Disconnect connectors X13, X12, X11 and X10.
9. Perform resistance measurements, using a digital multimeter, on the
points listed in Table 2.F below. These points are on the back of the
X10, X11 and X12 plugs which you have disconnected from the board.
If this test fails, replace both Rectifying modules (See Removing the
V Phase (Middle) Rectifying Board, Rectifying Module and Output
Power Module on page 3-33 and Removing the W Phase (Right-Side)
Rectifying Board, Rectifying Module and Output Power Module on
page 3-36).
Table 2.F Rectifying Module Resistance Measurements
Measurement points
X10: red to X10: black
X11: red to X11: black
X12: red to X12: black
Resistance
18Ω ± 1Ω
10. 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 Table 2.G on page 2-16. If this test fails, replace both
Rectifying modules (See Removing the V Phase (Middle) Rectifying
Board, Rectifying Module and Output Power Module on page 3-33 and
Removing the W Phase (Right-Side) Rectifying Board, Rectifying
Module and Output Power Module on page 3-36).
Important: Power supply polarity is critical during these tests. Reversing
the polarity will damage components on the circuit board.
11. 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.
12. 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 Table 2.G on page 2-16. If this test fails, replace both
Rectifying modules (See Removing the V Phase (Middle) Rectifying
Board, Rectifying Module and Output Power Module on page 3-33 and
Removing the W Phase (Right-Side) Rectifying Board, Rectifying
Module and Output Power Module on page 3-36).
2-16
Component Test Procedures
Figure 2.2 Rectifying board layout and measurement points
Precharging
Resistors
X4
X2
X1
X3
X41
J7
J3
J11
X8
X101
X13
X6
X10
X11
X100
X50
X13: Pin 1
(24V dc Common)
X9
X12
X13: Pin 5
(24V dc Power)
X10: Pin 1
X11: Pin 1
X12: Pin 1
Table 2.G Rectifying Board Charge Relay Test Results
J3
J7
J11
No Power on X13
Meter Leads
+
Results
X9
X9
0Ω
X9
J3
J7
J11
24V dc Power on X13
Meter Leads
+
Results
X10: Pin 1
X11: Pin 1
0Ω / 0V
X12: Pin 1
X9
Component Test Procedures
Checking the DC Bus
Capacitors
2-17
Important: This procedure requires special equipment and training. Only
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 structure. Refer to Removing the
Covers from the Power Structure on page 3-13.
3. Set the current limit of the DC power supply to less than 50mA.
4. 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. Leakage current should be less than
3mA when voltage has stabilized.
9. Abort test if current leakage is significantly higher when voltage has
stabilized.
10. 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.
11. 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.
12. If any capacitor has failed. Replace all the capacitors in the same series
connection (See Removing the DC Bus Capacitors on page 3-38).
2-18
Component Test Procedures
Checking the Main Fan
Inverters and Fans
Checking Inverter LEDs
A frame 11 drive has three fans and three fan inverters. Each fan inverter has
a red and a green diagnostic LED.
!
LED
Red
Steady
Off
Flashing
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!
Green
Steady
Flashing
Steady
Indication
Inverter Idle
Inverter Running
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. Locate
these fuses and, using a multi-meter, verify that they are not open.
Isolating a Faulty Fan Inverter
The ASIC board controls all three fan inverters. A cable connects X11 on
the ASIC board to X8 on the first inverter. Another cable connects X3 of the
first inverter to X8 on the second inverter. Another cable connects X3 of the
second inverter to X8 on the third inverter. A jumper terminates X3 on the
third inverter. Refer to Figure B.11 on page B-12. Use the following
procedure to isolate a faulty inverter if the main fans are not running:
1. Disconnect the cable from X3 of the second inverter.
2. Remove the jumper from X3 of the third inverter, and connect it to X3
of the second inverter.
3. Energize the drive. If only the fans on the first and second inverters run,
then the fan on the third inverter is faulty.
4. Disconnect the cable from X3 of the first inverter.
5. Remove the jumper from X3 of the third inverter, and connect it to X3
of the first inverter.
6. Energize the drive. If only the fans on the first and third inverters run,
then the fan on the second inverter is faulty. If none of the fans run, then
the first inverter is faulty.
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 structure. Refer to Removing the
Covers from the Power Structure on page 3-13.
3. Disconnect the first 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.H below, replace the
fan (See Removing the Main Fans on page 3-24).
Table 2.H Correct Fan Measurements
Connection Wires
Brown-Black
Blue-Black
Blue-Brown
Resistance to ground
Resistance ± 5%
60
26
34
∞ (infinity)
5. Reconnect the first fan motor to its inverter.
6. Repeat steps 3-4 for the second and third fan motor.
2-20
Notes:
Component Test Procedures
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: 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.
!
Torque Specifications
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.
The following table lists fastener torque specifications:
Item
DPI / HIM Assembly Door
Screw
M3 x 6 Phillips®
DPI / HIM Assembly (mounting)
M3 x 6 Phillips
700S Power Interface Circuit
Board (mounting)
700H I/O and Control Assembly
M3 x 6 Phillips
M4 x 8 self-tapping
Final Torque
0.9 N-m
(8 lb.-in.)
0.9 N-m
(8 lb.-in.)
0.9 N-m
(8 lb.-in.)
0.8 N-m
(7 lb.-in.)
3-2
Access Procedures
Item
Screw
700H Fiber Optic Adapter Board
M4 x 8 POZIDRIV ®
(mounting)
700S Voltage Feedback Circuit
M3 x 6 Phillips
Board (mounting)
AC Input Terminals on Power
M10 nut
Structure
Motor Output Terminals on Power
M8 x 20 hexagonal screw
Structure
Main Fan (Mounting)
M6 x 20 POZIDRIV
Main Fan
M4 x 8 POZIDRIV
Touch Cover (Main Fan)
M5 x 16
ASIC Fan
M4 x 16 POZIDRIV
Rectifier board (Mounting)
M4 x 8 POZIDRIV
Output Power Module Output
Terminals (U,V,W)
Rectifying Module Input
Terminals (L1,L2,L3)
Y-Bus Bar
M8 x 20 hexagonal screw
M10 nut
Capacitor
M4 x 8 self tapping
Capacitor Bus Bar
M6 x 16 POZIDRIV
Capacitor Bus Bar
M6 x 20 POZIDRIV
DC- / DC+ Terminals
M6 x 20 POZIDRIV
Block (Mounting)
M10 x 12 hexagonal screw
700S Voltage Feedback Circuit
Board (mounting)
M3 x 0.5 thread - 37 mm x
37 mm hex standoff
M10 x 20 hexagonal screw
POZIDRIV® is a registered trademark of the Phillips Screw Company
Phillips® is a registered trademark of Phillips Screw Company
Final Torque
0.9 N-m
(8 lb.-in.)
0.9 N-m
(8 lb.-in.)
40 N-m
(354 lb.-in.)
20 N-m
(177 lb.-in.)
3 N-m
(27 lb.-in.)
1.7 N-m
(15 lb.-in.)
3 N-m
(27 lb.-in.)
0.4 N-m
(3.5 lb.-in.)
1 N-m
(9 lb.-in.)
14 N-m
(124 lb.-in.)
12 N-m
(106 lb.-in.)
40 N-m
(354 lb.-in.)
1 N-m
(9 lb.-in.)
4 N-m
(35 lb.-in.)
4 N-m
(35 lb.-in.)
5 N-m
(44 lb.-in.)
20 N-m
(177 lb.-in.)
0.9 N-m
(8 lb.-in.)
Access Procedures
3-3
Understanding Torque Figures in Assembly Diagrams
Icons and numbers in the assembly diagrams indicate how to tighten
hardware:
Fastener Type
POZIDRIV Screw
Tool Type and Size
PZ indicates POZIDRIV screwdriver bit
P indicates Phillips screwdriver bit
Phillips Screw
Hexagonal Bolt
or Standoff
Hexagonal
Screw
Hexagonal Nut
PZ2
4 N-m
(35 lb.-in.)
Tightening Torque
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:
• sending an erroneous signal to your system’s field devices,
causing unintended machine motion
• causing an explosion in a hazardous environment
Electrical arcing causes excessive wear to contacts on both the
module and its mating connector. Worn contacts may create
electrical resistance.
Removing 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.
3-4
Access Procedures
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
Removing the DPI / HIM
Assembly
Removal
1. Remove power from the drive. Refer to 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 the front of the 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 the 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 the X4 connector on the
circuit board.
Access Procedures
3-5
6. Remove the four mounting screws and the assembly from the Control
Frame.
Mounting Screws
P1
0.9 N-m
(8 lb.-in.)
Installation
Install the DPI / HIM Assembly in the reverse order of removal, while
referring to Torque Specifications on page 3-1.
Removing the 700S Control
Assembly
Removal
1. Remove power from the drive. Refer to 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.
3-6
Access Procedures
4. Loosen the captive screw on the Control Assembly mounting plate and
swing the Control Assembly away from the drive.
Phase II Control Shown
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.
Access Procedures
3-7
6. Loosen the two mounting screws on the front of the Control Assembly
and slide the cassette control off the mounting bracket.
Note: Ribbon cables not shown
for clarity only.
Installation
Install the 700S Control Assembly in the reverse order of removal, while
referring to Torque Specifications on page 3-1.
Removing the 700S High
Power Fiber Optic Interface
Circuit Board
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the 700S Control Assembly. Refer to (Removing the 700S
Control Assembly on page 3-5.
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.
3-8
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.
Ribbon Cables
Phase II Control Shown
Fiber-Optic
Sockets
J5
Screws
(5)
P1
0.9 N-m
(8 lb.-in.)
4. Remove the five screws which secure the High Power Fiber Optic
Interface Circuit Board to the Control Frame.
5. 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.
Removing the 700S Control
Assembly
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the 700S Main Control Assembly. Refer to Removing the 700S
Control Assembly on page 3-5.
Access Procedures
3-9
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 3-7.
4. Lift the Control Assembly up and off of the hinge.
Installation
Install the 700S Control Assembly in reverse order of removal.
Removing the 700H I/O
Boards and Control
Assembly
Removal
1. Remove power from the drive. Refer to Removing Power from the
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.
3-10
Access Procedures
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
the 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
(Slot A)
X3
(Slot B)
X4
(Slot C)
X5
(Slot D)
X6
(Slot E)
Access Procedures
3-11
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.
Removing the 700H Fiber
Optic Adapter Board
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the I/O boards and Control Assembly. Refer to Removing the
700H I/O Boards and Control Assembly on page 3-9.
3. Move the Control Frame to expose its back, while referring to
Removing the Covers from the Power Structure on page 3-13.
3-12
Access Procedures
4. Disconnect the control power cable from X2 of the Fiber Optic Adapter
Board.
H7
H6
X1 connects
to Main
Control
H5
H4
Sockets for
Fiber-Optic
cables
H3
H2
H1
X2 connects
to 24V dc
power
5. Carefully disconnect the fiber-optic cables from the right side of the
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.
Access Procedures
3-13
6. Remove the four screws which secure the Fiber Optic Adapter board to
the stand-offs on the back of the Control Frame.
PZ2
0.9 N-m
(8 lb.-in.)
7. Remove the Fiber Optic Adapter Board from the Control Frame.
Installation
Install the 700H Fiber Optic Adapter Board in reverse order of removal,
while referring to Torque Specifications on page 3-1.
Removing the Covers from
the Power Structure
Moving the Control Frame
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
3-14
Access Procedures
2. If moving the control frame from a DC input drive with precharge
interlock, disconnect the wiring from terminal strip X50.
X50 Terminal Block
3. Loosen the T8 Torx-head screws, which secure the Control Frame to the
drive enclosure.
4. Swing the Control Frame out and away from the power structure.
Loosen T8 Torx-head
screws
Installation
Install the Control Frame in reverse order of removal, while referring to
Torque Specifications on page 3-1.
Access Procedures
3-15
Removing the Airflow Plate
The drive is equipped with a plate, just above the Control Frame, that
manages airflow through the drive. You must remove this plate in order to
access the protective covers.
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Move the Control Frame away from the power structure. Refer to
Removing the Covers from the Power Structure on page 3-13.
3. Remove the T8 Torx-head screws which secure the airflow plate to the
drive.
4. Slide the airflow plate off of drive.
Screws
3-16
Access Procedures
Installation
Install the Airflow Plate in reverse order of removal, while referring to
Torque Specifications on page 3-1.
Removing the Protective Covers from Power Structure
You must remove the protective covers to gain access to the power structure.
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Move the Control Frame away from the power structure. Refer to
Removing the Covers from the Power Structure on page 3-13.
3. Remove the Airflow Plate. Refer to Removing the Airflow Plate on
page 3-15.
4. Remove the four M5 POZIDRIV 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 POZIDRIV screws, which secure the main front
protective cover to the drive, then remove the protective cover.
!
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Foll DC power, ck and
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Access Procedures
3-17
Installation
Install the Protective Covers in reverse order of removal, while referring to
Torque Specifications on page 3-1.
Removing the 700S Voltage
Feedback Circuit Board
Removal
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 Structure on page 3-13.
3. Carefully disconnect the fiber-optic cables from J4 and J5 sockets at 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 DC bus connection cable from the J2 socket and the
motor feedback connection cable from the J3 socket at the top of the
Voltage Feedback Circuit Board.
5. Disconnect the cable from J8 socket of the Voltage Feedback Circuit
Board, and set it aside.
J2
J3
J4 J5
J8
3-18
Access Procedures
6. Remove the five screws which secure the Voltage Feedback Circuit
Board to the drive.
7. Remove the circuit board from the drive.
P1
0.9 N-m
(8 lb.-in.)
Screws
(5)
Installation
Install the 700S Voltage Feedback Circuit Board in reverse order of
removal, while referring to Torque Specifications on page 3-1.
Removing the Gate Driver
Board
Removal
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 Structure on page 3-13.
3. Disconnect the DC +/- supply from X1 of the Gate Driver Board.
Access Procedures
3-19
4. 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.
5. Remove the two screws on the right side of the Gate Driver Board that
secure the clear plastic cover.
6. Disconnect the other cables from sockets of the Gate Driver Board, and
set them aside.
7. Remove the remaining two screws that secure the Gate Driver Board to
the Power module.
8. Carefully remove the board.
Installation
1. Install the Gate Driver Board in the reverse order of removal.
3-20
Access Procedures
Removing the ASIC Board
Removal
!
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.
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 Structure on page 3-13.
3. Remove the cover from the ASIC assembly and the -DC bus connection
from the cover.
4. Unplug the fan, which mounts on the cover, from connector X1 of the
ASIC board.
5. 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.
Access Procedures
3-21
6. Disconnect the other cables from sockets on the front of the ASIC
Board, and set them aside.
7. Remove the fan from the ASIC Board.
8. Slide the ASIC Board out of the assembly chassis.
9. Remove the ASIC assembly chassis from the mounting plate.
10. Remove the plastic board holder.
Installation
Install the ASIC Board in reverse order of removal, while referring to
Torque Specifications on page 3-1. Reconnect cables to ASIC Board, while
referring to Figure B.10 on page B-11 or Figure B.7 on page B-8).
Removing the Power
Structure from the Drive
Cabinet
Removal
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 Structure on page 3-13.
3. Remove the motor wiring from the power structure at the front of the
power structure.
4. Remove the ground connection from the lower right corner of the power
structure.
3-22
Access Procedures
5. Remove the input (AC or DC) and brake wiring (if equipped) from the
incoming terminals at the top of the power structure.
Motor Connection
Terminals
U/T1
1L1
V/T2
1L3
1L2
W/T3
2L1
2L3
2L2
AC Power
Terminals
Ground
Connection
PE
Access Procedures
3-23
6. Remove the six screws that secure the Power Structure to the enclosure
frame.
Remove screws
Remove screws
7. 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.
3-24
Access Procedures
Installation
Install the power structure 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
There are three main fans on the drive.
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the bottom protective cover from the power structure. Refer to
Removing the Covers from the Power Structure on page 3-13.
3. Disconnect the fan cable connectors under the power structure.
4. Remove the two screws which secure each fan to the drive. Then
remove the fans.
Disconnect Fan Cables (3)
Remove Screws (6)
Access Procedures
3-25
Installation
Install the fans in reverse order of removal, while referring to Torque
Specifications on page 3-1.
Removing the Fan Inverters
Removal
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 Structure on page 3-13.
3. Remove the power structure from the drive cabinet. Refer to Removing
the Power Structure from the Drive Cabinet on page 3-21.
4. Verify the following default DIP switch settings.
Switch
S1
S2
S3
S4
Setting
Off
Off
On
Off
To indicate the following:
50 Hz fan motor frequency
220 V ac motor voltage
230 V ac motor voltage
Frame size 9 - 13
ON
S1
S2
S3
OFF
S4
3-26
Access Procedures
5. Remove the cable-ties that secure the cables with black insulation to the
fan inverter assemblies. This will allow you to move the cables and
remove the inverter assemblies.
Fan Inverter Locations
Remove cable-ties
6. Disconnect the fan motor cable under the inverter.
7. Remove the four M5 POZIDRIV screws, which secure the bottom of
the fan inverter to the drive. Proper tightening torque for reassembly is 4
N-m (35 lb.-in.).
8. Disconnect the cables at X2, X8 and X3 (on left-hand and center
inverters); and X2 and X8 (on right-hand inverter).
Access Procedures
3-27
9. Carefully remove the inverters by sliding them out toward the front of
the drive.
Bottom View
of Power Structure
Remove Screws
Disconnect fan
motor cable
Remove Screws
Important: Do not damage the output transformer when removing or
installing the inverter.
3-28
Access Procedures
10. To remove the inverter from the old inverter assembly, disconnect the
cables at connectors X4 (Blue) and X5 (Black).
Disconnect X4 and X5
=
Right-hand Inverter Shown
11. Remove two M5 POZIDRIV screws, which secure the inverter board
and its heatsink to the assembly carriage. Proper tightening torque for
reassembly is 4 N-m (35 lb.-in.).
12. Carefully remove the inverter board and its heatsink from the assembly
carriage.
Remove two screws and remove inverter
board and heatsink
=
Right-hand Inverter Shown
Installation
Install the fan inverters in reverse order of removal, while referring to
Torque Specifications on page 3-1.
Access Procedures
Removing the U Phase
(Left-Side) Output Power
Module
3-29
Removal
Important: Do not attempt to disassemble the Output Power Module.
Important: Always replace all three Output Power Modules (do not replace
just one module).
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 Structure on page 3-13.
3. Remove the power structure from the drive cabinet. Refer to Removing
the Power Structure from the Drive Cabinet on page 3-21.
4. Disconnect the output leads from the bottom of the Output Power
Module.
5. Remove the screws that secure the DC Bus Bars connecting the Input
Power Terminals to the Main DC Bus Bars and remove the Bus Bars.
DC Bus Bars
6. Disconnect the rectifying circuit wiring from the Main DC Bus Bars.
3-30
Access Procedures
7. Remove the screws that secure the Main DC Bus Bars to the Power
Structure and remove the Main Bus Bars.
DC Bus Bars
Insulator
8. Remove the screws that secure the Input Power Terminal assembly to
the Power Structure and remove the Input Power Terminal assembly.
9. Remove the screws that secure the Air Flow Guide to the Power
Structure and remove the Air Flow Guide.
Input Power Terminal Assembly
Air Flow Guide
Access Procedures
3-31
10. Remove the screws that secure the U Phase (left side) Power assembly
to the drive and remove the Power assembly.
11. Remove the screws that secure the motor connection leads to the Power
Module assembly and remove the motor connection leads.
Motor
Connection
Leads
12. Remove the screws that secure the Snubber Capacitors and remove the
Snubber Capacitors.
13. Remove the screws that secure the DC Bus Bars to the U Phase (left
side) power module and remove the DC Bus Bars.
Snubber
Capacitors
DC Bus Bars
Insulator
3-32
Access Procedures
14. Remove the screws which secure the Output Power Module to the drive.
15. Disconnect the Power Module Circuit Board from the Adapter Board.
16. Remove the Output Power Module from the drive.
Installation
Install the Output Power Module in reverse order of removal, while
referring to Torque Specifications on page 3-1.
Access Procedures
Removing the V Phase
(Middle) Rectifying Board,
Rectifying Module and
Output Power Module
3-33
Removal
Important: Do not attempt to disassemble the Output Power Module.
Important: Always replace all three Output Power Modules (do not replace
just one module).
Important: 600V ac input, 460A and 502A frame 11 drives only have one
Rectifying module. The Rectifying module is contained in the
W Phase (right) Power assembly.
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 Structure on page 3-13.
3. Remove the power structure from the drive cabinet. Refer to Removing
the Power Structure from the Drive Cabinet on page 3-21.
4. Disconnect the output leads from the bottom of the Output Power
Module.
5. Remove the screws that secure the V Phase (middle) Power assembly to
the drive and remove the Power assembly.
6. Disconnect all the wiring from the Rectifying Board and carefully set it
aside.
Important: For 690V 460A and 502A units, the X50 Jumper must be
removed from the Rectifying Board.
7. Remove the balancing resistor wires from bus bars.
8. Disconnect the cables from the AC input terminals on the Rectifying
Module.
Balancing Resistors
Balancing Resistor Wires
3-34
Access Procedures
9. Remove the five screws that secure the Rectifying Circuit Board to the
drive and remove the Rectifying Circuit Board.
10. Remove the screws that secure the Snubber Capacitors and remove the
Snubber Capacitors.
11. Remove the screws that secure DC Bus Bars to right side of power
structure, and remove the DC Bus Bars.
Snubber Capacitors
DC Bus Bars
Insulator
Access Procedures
3-35
12. Remove the screws that secure the Rectifying Module to the power
structure and remove the Rectifying Module.
13. Remove the screws that secure the Output Power Module to the power
structure, and remove the Output Power Module.
Rectifying Module
Output Power Module
Installation
Install the Output Power Module in reverse order of removal, while
referring to Torque Specifications on page 3-1.
3-36
Access Procedures
Removing the W Phase
(Right-Side) Rectifying
Board, Rectifying Module
and Output Power Module
Important: Do not attempt to disassemble the Output Power Module.
Important: Always replace all three Output Power Modules (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 Structure on page 3-13.
3. Remove the power structure from the drive cabinet (Removing the
Power Structure from the Drive Cabinet on page 3-21).
4. Disconnect the output leads from the bottom of the Output Power
Module.
5. Remove the screws that secure the W Phase (right-side) Power
assembly to the drive and remove the Power assembly.
Important: For 690V 460A and 502A units, the W Phase (right-side)
Power assembly does not have a Rectifying Module.
6. Disconnect all the wiring from the Rectifying Board and carefully set it
aside.
7. Remove the balancing resistor wires from bus bars.
8. Disconnect the cables from the AC input terminals on the Rectifying
Module.
Balancing Resistors
Balancing Resistor Wires
Access Procedures
3-37
9. Remove the five screws that secure the Rectifying Circuit Board to the
drive and remove the Rectifying Circuit Board.
10. Remove the screws that secure the Snubber Capacitors and remove the
Snubber Capacitors.
11. Remove the screws that secure DC Bus Bars to right side of power
structure, and remove the DC Bus Bars.
Snubber Capacitors
DC Bus Bars
Insulator
3-38
Access Procedures
12. Remove the screws that secure the Rectifying Module to the power
structure and remove the Rectifying Module.
13. Remove the screws that secure the Output Power Module to the power
structure, and remove the Output Power Module.
Rectifying Module
Output Power Module
Installation
Install the Output Power Module in reverse order of removal, while
referring to Torque Specifications on page 3-1.
Removing the DC Bus
Capacitors
Removal
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 Structure on page 3-13.
3. Remove the power structure from the drive cabinet. Refer to Removing
the Power Structure from the Drive Cabinet on page 3-21.
4. Remove the Rectifying Module and Output Power Module. Refer to
Removing the U Phase (Left-Side) Output Power Module on page 3-29,
Removing the V Phase (Middle) Rectifying Board, Rectifying Module
and Output Power Module on page 3-33, and Removing the W Phase
(Right-Side) Rectifying Board, Rectifying Module and Output Power
Module on page 3-36.
Important: It is not necessary to remove the Rectifying Board, Rectifying
Module, or Output Power Module in order to remove the DC
Bus Capacitors.
Access Procedures
3-39
5. Remove the four screws that secure the capacitor to the power structure,
and remove the capacitor.
Installation
Install the capacitors in reverse order of removal, while referring to Torque
Specifications on page 3-1.
3-40
Notes:
Access Procedures
Chapter
4
Start-Up After Repair
!
Phone
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.
United States/
Canada
1.262.512.8176 (7 AM - 6 PM CST)
1.440.646.5800 (24 hour support)
Outside United
States/Canada
You can access the phone number for your country via
the Internet:
Go to http://www.ab.com
Click on Support (http://
support.rockwellautomation.com/)
Under Contact Customer Support, click on Phone
Support
Internet
⇒
Go to http://www.ab.com/support/abdrives/
E-mail
⇒
[email protected]
Be prepared to provide the following information when you contact
support:
• Product Catalog Number
• Product Serial Number
• Firmware Revision Level
Before Applying Power to
the Drive
1. Check for zero volts between DC+ and DC-.
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
Supply.
(Optional)
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
Testing Without a Motor
4-3
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
Circuit Diagnostic Test on a
700S
The Power Circuit Diagnostic Test, on the 700S, allow you to diagnose
problems in the drive’s power structure without applying large amounts of
power.
1. Verify that input power wiring and grounding is connected.
2. Verify that the motor cables are connected.
3. Energize the drive.
4. From the Monitor menu on the HIM press
navigate to the Main menu.
Esc
(the escape button) to
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.
Service Tools
This list of basic service tools which will cover needs of tools for repair and
maintenance measurements.
Item
1
2
3
4
Description
Oscilloscope
Current clamp
Soldering station
Adjustable power supply
5
Adjustable power supply
6
Multi meter
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Insulation tester
Torque wrench
Torque wrench
box wrench
socket extension
Wrench
Wire cutter
Nose pliers
Crimping tools
Angle wrench
Screw driver
*Flat nose
*POZIDRIV
*Phillips
*Torx
Hexagonal wrench
ESD-protected place of work
24
ESD-protective clothing
Details
Portable, digitizing, dual channel scope, with isolation
1000A(ac, rms), signal output
Soldering / de soldering
0...1300Vdc, 1A, adjustable current limit. Efore LPS
750-HV or equivalent.
0...690Vac (+10%), 10A, three phase, galvanic
isolation
Digital multi meter, capable of ac and dc voltage,
continuity, resistance, capacitance measurements,
and forward diode bias tests. Fluke model 87 III or
equivalent.
1000Vdc
1...12Nm
6...50Nm
7mm, 8mm, 10mm, 13mm, 17mm, 19mm, 22mm
230mm
7mm, 8mm, 10mm, 13mm, 17mm, 19mm, 22mm
For cable terminals 1,5...240
7*2(mm)
1, 2, 3
1, 2, 3
25
4, 5, 6
Working surface, Floor covering, seat and ground
connections
Wrist wrap, shoes, overall clothing (coat)
A-2
Service Tools and Equipment
Item
25
26
Description
Power supply (service)
20-MAINSTD maintenance stand
27
Fiber-optic repair kit
Details
Capacity of three phase service 400/500/690Vac, 30A
Maintenance stand for removing power structure from
drive cabinet
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
Schematics
List of Schematic Diagrams
For a Schematic Diagram on…
Phase U Power Circuitry for Drives with AC Input
Phase V Power Circuitry for Drives with AC Input
Phase W Power Circuitry for Drives with AC Input
Phase U Power Circuitry for Drives with DC Input
Phase V Power Circuitry for Drives with DC Input
Phase W Power Circuitry for Drives with DC Input
Circuit Board Connections for 700H Drives with AC Input
Circuit Board Connections for 700H Drives with DC Input
Circuit Board Connections for 700S Drives - Phase II Control with AC Input
Circuit Board Connections for 700S Drives - Phase II Control with DC Input
Fan Inverter and Main Fan Connections
See...
page B-2
page B-3
page B-4
page B-5
page B-6
page B-7
page B-8
page B-9
page B-10
page B-11
page B-12
B
From ASIC Board X3
From ASIC Board H9
From ASIC Board H8
TERM 1
To 80W Power Supply J2
U_HI
Fiber Optic Cables
X6
Driver Board
H16
X11
X10
H15
I1
X7
TERM 2
X6
V_HI
10
U_LO
Power Board
5
X12
X8
I2
X1
See Note 1
Note 1 - 400V/600V Capacitor Configuration
400V - 3 Caps in Series, 2 Caps in Parallel
600V - 2 Caps in Series, 3 Caps in Parallel
5
I3
W_LO
Figure B.1 Phase U Power Circuitry for
Drives with AC Input
5
To Voltage
Feedback J1
U/T1
Power Wiring Diagrams
To ASIC Board X6
DC- DC+
From Phase V
B-2
Schematics
Phase U Power Circuitry for Drives with AC Input
W_HI
TERM 3
V_LO
*
X2
X2
X2
*
X3
X3
X3
X2 is 400/480 V Tap
X3 is 500 V Tap
Line Reactor
X1
X1
X1
5
X6
To Rectifier Board X13
X13
X50
TO FAN
SEE SHEET 3
From ASIC X4
From ASIC H10
From ASIC H11
X6
H15
Gate Driver Board
X10
X6
I1
5
H16
X11
X7
V_LO
Fiber Optic Cables
10
X1
Power Board
See Note 1
U_LO
From ASIC X2
Mains Voltage
Suppression
X12
DC+
W_HI
W_LO
TERM 3
I3
5
To Voltage
Feedback J1
V/T2
Figure B.2 Phase V Power Circuitry for
Drives with AC Input
X12
X8
I2
5
Note 1 - 400V/600V Capacitor Configuration
400V - 3 Caps in Series, 2 Caps in Parallel
600V - 2 Caps in Series, 3 Caps in Parallel
TERM 1
Rectifier Board
X8
X11
DC-
To DC Bus Phase U and W
U_HI
X4
X4i
X3
X2
X1
X10
K3
V_HI
Remove Jumper For:
Non-CE Listed Units, DC Units on
Regenerative Front Ends, Grounded
Delta Connected Inputs
PE
L3/T
L2/S
LI/R
X9
K1
K2
Schematics
B-3
Phase V Power Circuitry for Drives with AC Input
TERM 2
X2 X3
X2 X3
X2 X3
* X2 is 400/480 V Tap
X3 is 500 V Tap
Line Reactor
X1
X1
X1
5
X6
From ASIC X5
From ASIC H12
From ASIC H13
DC-
X6
H15
Gate Driver Board
X10
X6
I1
5
H16
X11
X7
X12
X8
I2
5
W_LO
W_HI
TERM 3
I3
5
To Voltage Feedback J1
W/T3
Figure B.3 Phase W Power Circuitry
for Drives with AC Input
V_LO
Fiber Optic Cables
10
X1
Power Board
See Note 1
TERM 1
Jumper
X50
X12
Note 1 - 400V/600V Capacitor Configuration
400V - 3 Caps in Series, 2 Caps in Parallel
600V - 2 Caps in Series, 3 Caps in Parallel
U_HI
X13
X11
Mains Voltage
Suppression
Rectifier Board
X8
X10
DC+
From Phase V
U_LO
X4i
X4
X3
X2
X1
K1
K3
V_HI
From Rectifier Board X6
Remove Jumper For:
Non-CE Listed Units, DC Units on
Regenerative Front Ends,
Grounded Delta Connected Inputs
L3/T
L2/S
LI/R
*
X9
K2
B-4
Schematics
Phase W Power Circuitry for Drives with AC Input
TERM 2
R1 CR2
R2 CR2
PE
To 80W Power
Supply Connection
J2
DC-
DC+
From ASIC X3
From ASIC H8
From ASIC H9
10
U_HI
TERM 1
U_LO
Fiber Optic Cables
X6
H15
H16
X11
X10
Gate Driver Board
X7
TERM 2
X6
I1
5
V_HI
X1
Power Board
See Note 1
V_LO
To ASIC Board
Connection X6
EXTERNAL WIRING
SHOWN DASHED
F2
M
DC Source
F1
M
X12
X8
I2
5
Note 1 - 400V/600V Capacitor Configuration
400V - 3 Caps In Series, 2 Caps In Parallel
600V - 2 Caps In Series, 3 Caps In Parallel
W_LO
W_HI
DC- To Phase
V and W
Figure B.4 Phase U Power Circuitry for
Drives with DC Input
I3
5
To Voltage Feedback
Connection J1
U/T1
DC+ To Phase
V and W
Schematics
TERM 3
B-5
Phase U Power Circuitry for Drives with DC Input
DC-
DC+
To Fan
From ASIC X4
From ASIC X10
From ASIC H11
DC+
DC-
10
U_HI
TERM 1
Fiber Optic Cables
H15
H16
X11
X10
V_LO
X6
Driver Board
U_LO
X1
X7
TERM 2
X6
I1
5
X12
X8
I2
5
Note 1 - 400V/600V Capacitor Configuration
400V - 3 Caps In Series, 2 Caps In Parallel
600V - 2 Caps In Series, 3 Caps In Parallel
V_HI
Power Board
See Note 1
To U and
W Phase
W_LO
W_HI
Figure B.5 Phase V Power Circuitry for
Drives with DC Input
I3
5
To Voltage Feedback
Connaction J1
V/T2
B-6
Schematics
Phase V Power Circuitry for Drives with DC Input
TERM 3
DC-
From V Phase
DC+
From ASIC X5
From ASIC H12
From ASIC H13
10
U_HI
TERM 1
Fiber Optic Cables
H16
V_LO
X6
H15
X11
X10
Gate Driver Board
U_LO
X1
X7
TERM 2
X6
I1
5
V_HI
Power Board
See Note 1
W_LO
W_HI
TERM 3
I3
5
Figure B.6 Phase W Power Circuitry for
Drives with DC Input
Note 1 - 400V/600V Capacitor Configuration
400V - 3 Caps In Series, 2 Caps In Parallel
600V - 2 Caps In Series, 3 Caps In Parallel
X12
X8
I2
5
To Voltage Feedback
Connection J1
W/T3
Schematics
B-7
Phase W Power Circuitry for Drives with DC Input
frm11_circuit_bd_conns_700H_AC.eps
Analog
I/O
(10)
Digital
Inputs
(8/10)
20C-DA1-AB
(115V ac Digital
Input w/ Analog I/O)
3
3
20C-D01
(Digital Output
Option)
(Slot B)
(Slot A)
20C-DA1-A
(24V dc Digital
Input w/ Analog I/O)
X3
X2
Control Board
Fiber Optics
Adapter Board
X4
X2
2
Option
Board
(Slot C)
+24V
X1
X1
H1 H2
37
H6
Option
Board
(Slot D)
X5
H3 H4 H5
M
H7
X3
X1
(Slot E)
X6
X3
X2
X15 Charge Relay
0EVA
+24V
24V POWER
9
RS-232
Programming
Port
X7
H7
H6
H5
H4
H3
H2
H1
X10
X1
X26
X11 (Fan Control)
20C-DPI1
(DPI Communcations
Option)
1
GND 2
+24V
Fiber Optic Cables
2
23
22
21
X9
ASIC
Board
X29
X2
H13
H12
X5
H11
H10
X4
X600
5
20
20C-DPI1
DPI
Comm
Option
X3
J3
DPI Assembly
PORT
MOD
NET A
NET B
PWR
J2
HIM
Bezel
9
J1
HIM
EXTERNAL DPI
HIM
EXAMPLE:
20-HIM-A3
DOOR
Figure B.7 Circuit Board Connections for
700H Drives with AC Input
9
To Phase V Rectifier Board
X13 in Power Circuitry
To Phase W Gate Driver Board
H16 in Power Circuitry
To Phase W Gate Driver Board
H15 in Power Circuitry
To Phase W Gate Driver Board
X6 in Power Circuitry
To Phase V Gate Driver Board
H16 in Power Circuitry
To Phase V Gate Driver Board
H15 in Power Circuitry
To Phase V Gate Driver Board
X6 in Power Cirucitry
To Phase U Gate Driver Board
H16 in Power Circuitry
To Phase U Gate Driver Board
X6 in Power Circuitry
From DC Bus in Power Circuitry
H9
DC-
DC+
To Phase U Gate Driver Board
H15 in Power Circuitry
3
20-VB00601
DPI
Interface X1
X4
Board
X2
1
2
H8
X3
X6
Control Wiring Diagrams
ASIC Board Fan
To Fan Inverter X8
3
25
26
B-8
Schematics
Circuit Board Connections for 700H Drives with AC Input
M
CR2
M
frm11_circuit_bd_conns_700H.eps
Analog
I/O
(10)
Digital
Inputs
(8/10)
20C-DA1-AB
(115V ac Digital
Input w/ Analog I/O)
20C-DA1-A
(24V dc Digital
Input w/ Analog I/O)
3
3
20C-D01
(Digital Output
Option)
X3
(Slot B)
X2
(Slot A)
Control Board
Fiber Optics
Adapter Board
X4
X3
2
X1
X1
H1 H2
M
37
X5
H5
H6
Option
Board
(Slot D)
H3 H4
To Fan Inverter X8
ASIC Board Fan
Option
Board
(Slot C)
+24V
For DC Input Only (Do Not Install on AC Input Drives)
Precharge
Main DC Contactor
CR1
Pilot Relay
CR1
External Precharge Example Circuitry
M
H7
2
3
4
3
2
1
X2
25
X1
(Slot E)
X6
23
22
21
26
X15 Charge Relay
X3
0EVA
+24V
H7
H6
H5
H4
H3
H2
H1
X2
9
RS-232
Programming
Port
X7
X10 24V Power
X1
X26
X11 (Fan Control)
X9
20C-DPI1
(DPI Communcations
Option)
1
GND 2
+24V
Fiber Optic Cables
X50
ASIC
Board
1
20
20C-DPI1
DPI
Comm
Option
X3
20-VB00601
DPI
Interface X1
X4
Board
X2
X29
X2
H13
H12
X5
J3
DPI Assembly
PORT
MOD
NET A
NET B
PWR
J2
HIM
Bezel
9
J1
9
HIM
EXTERNAL DPI
HIM
EXAMPLE:
20-HIM-A3
DOOR
Figure B.8 Circuit Board Connections for
700H Drives with DC Input
To Phase W Gate Driver Board
H16 in Power Circuitry
To Phase W Gate Driver Board
H15 in Power Circuitry
To Phase W Gate Driver Board
X6 in Power Circuitry
To Phase V Gate Driver Board
H16 in Power Circuitry
To Phase V Gate Driver Board
H15 in Power Circuitry
H10
H11
To Phase V Gate Driver Board
X6 in Power Cirucitry
X4
X600
To Phase U Gate Driver Board
H16 in Power Circuitry
To Phase U Gate Driver Board
X6 in Power Circuitry
From DC Bus in Power Circuitry
H9
DC-
DC+
To Phase U Gate Driver Board
H15 in Power Circuitry
3
2
H8
X3
X6
Schematics
B-9
Circuit Board Connections for 700H Drives with DC Input
COM
INPUT
COMM
OPTION
COMPACT
FLASH OPTION
COMPACT
I/O OPTION
P1
80
50
16
TX
RX
P1
P3
P4
LEOB
OPTIONAL
P2
SYNC
LINK P1
OPTION
P2
ENET
OPTION
P1
FDBK
OPTION
BOARD
SECOND ENCODER
SAFE OFF OPTION
FDBK
INPUTS
120
7
80
P2
P3
P2
16
34
34
RS-232
PORT
TB1
P13
P12
P4
P11
P10
P3
PHASE II
CONTROL
BOARD
WITH ALL
OPTIONS
SHOWN
P7
P5
P21
P1
P2
P6
P9
TB2
2
40
30
10
ELC
BATTERY
J2
J1
J17
J3
J13
J14
J11 J12
J18
2
External
24 V DC
1=24V
3=Common
(75W min)
J15
+5V
-12 V
+12 V
+24 V Iso
2
3
Fiber Optic Cables
Fiber Optic Cables
HiHP Fiber Optic
Interface Board
J9 J10
J8
(Gate Enable)
P1
(W Gate)
RJ45
CONNECTOR
(V Gate)
(U Gate)
M
(Vbus Tx)
(ADconv)
ASIC Board Fan
To Fan Inverter X8
(Vbus Rx)
25
J6
J7
X15 Charge Relay
0EVA
+24V
J4
9
8
2
9
Fiber
2
9
8
X29
X2
H13
H12
20
DPI
Comm
Option
X3
5
DPI ASSEMBLY
PORT
MOD
NET A
NET B
PWR
STS
J3
9
DPI
Bezel
J1
J2
-U
-V
-W
J2
-DC+
J1
9
External DPI
HIM
Example:
20-HIM-A3
DOOR
HIM
To Phase V Rectifier Board
X13 in Power Circuitry
To Phase W Gate Driver Board
H16 in Power Circuitry
To Phase W Gate Driver Board
H15 in Power Circuitry
To Phase W Gate Driver Board
X6 in Power Circuitry
To Phase V Gate Driver Board
H16 in Power Circuitry
H11
X5
To Phase V Gate Driver Board
H15 in Power Circuitry
To Phase V Gate Driver Board
X6 in Power Cirucitry
H10
X4
X600
To Phase U Gate Driver Board
H16 in Power Circuitry
H9
U/T1 PHASE FROM SHEET 2
V/T2 PHASE FROM SHEET 3
W/T3 PHASE FROM SHEET 4
DC- FROM SHEET 2
DC+ FROM SHEET 2
From DC Bus in Power Circuitry
To Phase U Gate Driver Board
H15 in Power Circuitry
DC-
DC+
H8
-DC-
3
To Phase U Gate Driver Board
X6 in Power Circuitry
Voltage
Feedback
Board
20-VB00601
1
2
X3
X6
80 W
Power
Supply
DPI
Interface
X4 Board X1
X2
Tx J4
Rx J5
+24V
J8
ASIC
Board
Figure B.9 Circuit Board Connections for 700S
Drives - Phase II Control with AC Input
Rx
Tx
J5
H7
H6
H5
H4
H3
H2
H1
X1
X11 (Fan Control)
X9
LED J16
Status
DPI
23
22
21
26
B-10
Schematics
Circuit Board Connections for 700S Drives - Phase II Control with AC Input
COM
INPUT
COMM
OPTION
COMPACT
FLASH OPTION
COMPACT
I/O OPTION
P1
RJ45
CONNECTOR
80
50
16
TX
RX
P1
P3
P4
LEOB
OPTIONAL
P2
SYNC
LINK P1
OPTION
P2
ENET
OPTION
P1
P1
FDBK
OPTION
BOARD
SECOND ENCODER
SAFE OFF OPTION
FDBK
INPUTS
120
7
80
P2
P3
P2
16
34
34
RS-232
PORT
TB1
P13
P12
P11
P10
P4
P3
CR2
M
Precharge
P5
P21
P1
P2
P6
P9
TB2
2
40
30
10
ELC
BATTERY
J2
J1
J17
J3
For DC Input Only (Do Not Install on AC Input Drives)
PHASE II
CONTROL
BOARD
WITH ALL
OPTIONS
SHOWN
P7
M
Main DC Contactor
CR1
J13
J14
J11 J12
M
J18
2
External
24 V DC
1=24V
3=Common
(75W min)
J15
+5V
-12 V
+12 V
+24 V Iso
2
3
Fiber Optic Cables
Fiber Optic Cables
HiHP Fiber Optic
Interface Board
J10
J9
J8
ASIC Board Fan
To Fan Inverter X8
(Gate Enable)
CR1
(V Gate)
(U Gate)
Pilot Relay
(W Gate)
External Precharge Example Circuitry
(Vbus Tx)
(ADconv)
M
(Vbus Rx)
X50
4
3
2
1
25
J6
J7
X15 Charge Relay
0EVA
+24V
J4
Rx
Tx
J5
H7
H6
H5
H4
H3
H2
H1
X1
X26
2
9
Fiber
9
8
X4
20
DPI
Comm
Option
X3
J2
To Phase U Gate Driver Board
X6 in Power Circuitry
X29
X2
H13
-U
-V
-W
J3
9
DPI
Bezel
J1
DPI ASSEMBLY
PORT
MOD
NET A
NET B
PWR
STS
J2
-DC+
J1
9
External DPI
HIM
Example:
20-HIM-A3
DOOR
HIM
To Phase W Gate Driver Board
H16 in Power Circuitry
To Phase W Gate Driver Board
H15 in Power Circuitry
To Phase W Gate Driver Board
X6 in Power Circuitry
X5
H12
To Phase V Gate Driver Board
H16 in Power Circuitry
To Phase V Gate Driver Board
H15 in Power Circuitry
To Phase V Gate Driver Board
X6 in Power Cirucitry
H11
H10
X4
X600
U/T1 PHASE FROM SHEET 2
V/T2 PHASE FROM SHEET 3
W/T3 PHASE FROM SHEET 4
DC- FROM SHEET 2
DC+ FROM SHEET 2
From DC Bus in Power Circuitry
To Phase U Gate Driver Board
H16 in Power Circuitry
DC-
DC+
H9
-DC-
3
To Phase U Gate Driver Board
H15 in Power Circuitry
Voltage
Feedback
Board
20-VB00601
1
2
H8
X3
X6
80 W
Power
Supply
DPI
Interface
Board X1
X2
Tx J4
Rx J5
+24V
J8
ASIC
Board
Figure B.10 Circuit Board Connections for 700S
Drives - Phase II Control with DC Input
9
8
2
X11 (Fan Control)
X9
LED J16
Status
DPI
23
22
21
26
Schematics
B-11
Circuit Board Connections for 700S Drives - Phase II Control with DC Input
DC-
DC+
From DC Bus in
Power Structure
6A
F1
(-)
DC- X2-1
(-)
(+)
On Off
On Off
S1 Setup Switch
Off Off
S1-1 S1-2 S1-3 S1-4
(-)
X2-1
DC-
(+)
DC+ X2-3
S1 Setup Switch
Off Off
S1-1 S1-2 S1-3 S1-4
DC- X2-1
DC+ X2-3
On Off
S1 Setup Switch
Off Off
S1-1 S1-2 S1-3 S1-4
(+)
DC+ X2-3
V1
X8
V1
V1
X8
X3
X8
X5-1
X4-1
X5-1
X4-1
4
X5-1
X4-1
Jumper
Fan Frequency Converter X3
DC/AC
U1
4
Fan Frequency Converter
DC/AC
U1
4
2
Fan Frequency Converter X3
DC/AC
U1
3
Black 1
Black 2
Black 1
Black 2
Black 1
Black 2
From ASIC Board X11
3
Black
5
Black
4
Black
6
Black
3
Black
5
Black
4
Black
6
Black
3
Black
5
Black
4
Black
6
Black
2.2uf
2.2uf
2.2uf
300Vac
2.2uf
300Vac
2.2uf
300VAC
2.2uf
300VAC
1
3
2
1
3
2
1
3
Brown
Black
4
Yellow/Green
Blue
Brown
Black
4
Yellow/Green
Blue
Brown
Black
4
Yellow/Green
Blue
Main Fan
W Phase
230Vac
50Hz
M
Main Fan
V Phase
230Vac
50Hz
M
Main Fan
U Phase
230Vac
50Hz
M
Figure B.11 Fan Inverter and Main Fan
Connections
7uf
10 MΩ
10 MΩ
7uf
10 MΩ
10 MΩ
7uf
10 MΩ
10 MΩ
2
B-12
Schematics
Fan Inverter and Main Fan Connections
Appendix
C
Connector Descriptions
For Information on…
ASIC Board to Gate Driver Board Phase U Connections
ASIC Board to Gate Driver Board Phase V Connections
ASIC Board to Gate Driver Board Phase W Connections
ASIC Board to Rectifier/Precharge Circuit Board Phase V Connections
Rectifier/Precharge Circuit Board Phase V to Rectifier/Precharge Circuit Board Phase W
Connections
PowerFlex 700H Fiber Optic Adapter Circuit Board to ASIC Board Fiber Optic
Connections
PowerFlex 700S High Power Fiber Optic Interface Board to ASIC Board Fiber Optic
Connections
PowerFlex 700S High Power Fiber Optic Interface Board to Voltage Feedback Board
Fiber Optic Connections
ASIC Board to Main Cooling Fan Inverter Phase U Connections
Main Cooling Fan Inverter Phase U to Main Cooling Fan Inverter Phase V Connections
Main Cooling Fan Inverter Phase V to Main Cooling Fan Inverter Phase W Connections
Main Cooling Fan Inverter Phase W Connections
X50 Terminal Block Precharge Circuit Connections
Circuit Board Connections
See...
page C-3
page C-3
page C-3
page C-4
page C-4
page C-5
page C-6
page C-6
page C-7
page C-7
page C-7
page C-7
page C-8
The following tables detail the connection points for the frame 11
PowerFlex 700S and 700H ac input drives circuit boards and components.
C-2
Connector Descriptions
Figure C.1 ASIC Board Connectors
X6
X9
X15
H1 H2 H3 H4 H5 H6 H7
X2
X11
H8 H9 H10 H11 H12 H13
X3
X4
X5
Figure C.2 Gate Driver Board Connectors
H15
H16
X6
X1
Connector Descriptions
Table C.A ASIC Board to Gate Driver Board Phase U Connections
ASIC Board
Connector
X3
Pin Number
1
2
3
4
5
6
7
8
9
10
H8 (fiber optic)
H8
H9 (fiber optic)
H9
to
...
...
...
...
...
...
...
...
...
...
...
...
Gate Driver
Board
Pin Number Connector
1
X6
2
3
4
5
6
7
8
9
10
H15
H15 (fiber optic)
H16
H16 (fiber optic)
Description
U_Feedback
U_Power_OK
U_DTR(1) See Note Below
U_ETR(2)
U_ITR(3)
U_DCUI
U_DC-_I
U_TEMP
U_DC-T
UH or Gate Top
UL or Gate Bottom
Note: See page C-3 for footnotes.
Table C.B ASIC Board to Gate Driver Board Phase V Connections
ASIC Board
Connector
X4
H10 (fiber optic)
H11 (fiber optic)
Pin Number
1
2
3
4
5
6
7
8
9
10
H10
H11
to Pin Number
...
1
...
2
...
3
...
4
...
5
...
6
...
7
...
8
...
9
...
10
...
H15
...
H16
Gate Driver Board
Connector
Description
X6
V_Feedback
V_Power_OK
V_DTR(1)
V_ETR(2)
V_ITR(3)
V_DCVI
V_DC-_I
V_TEMP
V_DC-T
H15 (fiber optic)
VH or Gate Top
H16 (fiber optic)
VL or Gate Bottom
Table C.C ASIC Board to Gate Driver Board Phase W Connections
ASIC Board
Connector
X5
Pin Number
1
2
3
4
5
6
7
8
9
10
H12 (fiber optic)
H12
H13 (fiber optic)
H13
(1)
DTR = N Desat
(2)
ETR = Phase I2T
(3)
ITR = Phase Overcurrent
to Pin Number
...
1
...
2
...
3
...
4
...
5
...
6
...
7
...
8
...
9
...
10
...
H15
...
H16
Gate Driver Board
Connector
Description
X6
W_Feedback
W_Power_OK
W_DTR(1)
W_ETR(2)
W_ITR(3)
W_DCWI
W_DC-_I
W_TEMP
W_DC-T
H15 (fiber optic)
WH or Gate Top
H16 (fiber optic)
WL or Gate Bottom
C-3
C-4
Connector Descriptions
Figure C.3 Rectifier/Precharge Circuit Board Connectors
X4
X2
X1
X3
X41
J9
J5
J1
J7
J3
J11
J11
X8
X101
X13
X6
X10
X11
X100
X50
X9
X12
Table C.D ASIC Board to Rectifier/Precharge Circuit Board Phase V Connections
ASIC Board
Connector
X2
Pin Number
1
2
3
4
5
Rectifier Board Phase
to Pin Number V Connector
...
1
X13
...
2
...
3
...
4
...
5
Description
SWTS_DRV
SWTS_FB
DC Mains Fault
+24V
Table C.E Rectifier/Precharge Circuit Board Phase V to Rectifier/Precharge Circuit
Board Phase W Connections
Rectifier Board
Phase V Connector Pin Number
X6
1
2
3
4
5
Rectifier Board
to Pin Number Phase W Connector
...
1
X13
...
2
...
3
...
4
...
5
Description
SWTS_DRV
SWTS_FB
DC Mains Fault
+24V
Connector Descriptions
C-5
Figure C.4 PowerFlex 700H Fiber Optic Adapter Circuit Board Connectors
H7
H6
H5
H4
H3
H2
H1
Table C.F PowerFlex 700H Fiber Optic Adapter Circuit Board to ASIC Board Fiber
Optic Connections
Description
ENA Out
UH
VH
WH
A/D Convert
VBUS_TX
VBUS_RX
(1)
700H Interface Board Fiber
Optic Connector
H1
H2
H3
H4
H5
H6
H7
Type
TX
TX
TX
TX
TX
TX
RX
to
...
...
...
...
...
...
...
Type
RX
RX
RX
RX
RX
RX
TX
Refer to Figure C.1 on page C-2 for ASIC board fiber-optic connectors.
ASIC Board Fiber
Connector (1)
H1
H2
H3
H4
H5
H6
H7
Description
Gate_Enable
U_Gate
V_Gate
W_Gate
A/D Convert
VBUS_RX
VBUS_TX
C-6
Connector Descriptions
Figure C.5 PowerFlex 700S High Power Fiber Interface Circuit Board Connectors
J8
J9
J10
J11
J12
J14
J13
J6
J7
Table C.G PowerFlex 700S High Power Fiber Optic Interface Board to ASIC Board
Fiber Optic Connections
Description
Gate_Enable
U_Post
V_Post
W_Post
A/D Convert
VBUS_TX
VBUS_RX
(1)
700SInterface Board
Fiber Optic Connector
J8
J9
J10
J11
J12
J14
J13
Type
TX
TX
TX
TX
TX
TX
RX
to
...
...
...
...
...
...
...
Type
RX
RX
RX
RX
RX
RX
TX
ASIC Board Fiber
Connector (1)
H1
H2
H3
H4
H5
H6
H7
Description
Gate_Enable
U_Gate
V_Gate
W_Gate
A/D Convert
VBUS_RX
VBUS_TX
Refer to Figure C.1 on page C-2 for ASIC board fiber-optic connectors.
Table C.H PowerFlex 700S High Power Fiber Optic Interface Board to Voltage
Feedback Board Fiber Optic Connections
700SInterface Board
Description Fiber Optic Connector
TX
J6
RX
J7
Voltage Feedback
Type to Type Board Connector
TX
. . . RX
J5
RX
. . . TX
J4
Description
RX
TX
Connector Descriptions
C-7
Figure C.6 Fan Inverter Circuit Board Connectors
X3
X8
Table C.I ASIC Board to Main Cooling Fan Inverter Phase U Connections
Description
+15V dc power to
Fan Inverter boards
Fan Control
Alarm from Fans
(1)
ASIC Board
Fan Inverter
Connector(1) Pin Number Pin Number Connector Description
X11
2
2
X8
+15V dc power from
ASIC board
3
3
Fan Control
4
7
Fan Alarm to ASIC
board
Refer to Figure C.1 on page C-2 for ASIC board fiber-optic connectors.
Table C.J Main Cooling Fan Inverter Phase U to Main Cooling Fan Inverter Phase V
Connections
Description
+15V dc power
Fan Control
Fan Alarm
Fan Inverter
Phase U
Connector Pin Number Pin Number
X3
2
2
3
3
4
7
Fan Inverter
Phase V
Connector
X8
Description
+15V dc power
Next Fan Control
Fan Alarm
Table C.K Main Cooling Fan Inverter Phase V to Main Cooling Fan Inverter Phase W
Connections
Description
+15V dc power
Fan Control
Fan Alarm
Fan Inverter
Phase V
Connector
Pin Number Pin Number
X3
2
2
3
3
4
7
Fan Inverter
Phase W
Connector
Description
X8
+15V dc power
Next Fan Control
Fan Alarm
Table C.L Main Cooling Fan Inverter Phase W Connections
Description
+15V dc power
Fan Alarm
Fan Inverter
Phase W
Connector
X3
Fan Inverter
Phase W
Pin Number Pin Number Connector Description
2
4
X3
+15V dc power
4
2
Fan Alarm
C-8
Connector Descriptions
Hardware Connections
Figure C.7 X50 Terminal Block Connectors
Customer Connections
Terminal Block on Control Pan
Example External Precharge Circuitry
Drive Connections
X50
ASIC Board
X9
1
25
+24V DC
2
26
0V DC
3
21
M
4
23
Charge
Relay
X15
CR1
Pilot Relay
CR1
M
Main DC Contactor
M
CR2
Precharge
For DC Input Only
(Do Not Install on AC Input Drives)
Table C.M X50 Terminal Block Precharge Circuit Connections
ASIC Board
Connector Terminal
X9
25
26
X15
21
23
to X50 Terminal Block
...
1
...
2
...
3
...
4
Description
Precharge Complete Signal
Precharge Complete Signal
Charge Relay Contact
Charge Relay Contact
Isolated
Appendix
D
Disassembly / Assembly Diagrams
For a Diagram on…
Main Power Structure Assembly
Power Structure
Phase U Power Structure Components
Phase V and W Power Structure Components
Fan Inverter
ASIC Assembly
Main Fan Assembly
Disassembly/Assembly
Diagrams and Spare Parts
Numbers
See...
page D-2
page D-3
page D-4
page D-5
page D-6
page D-7
page D-8
Diagrams on the following pages illustrate disassembly and assembly of the
drive and its sub-systems and are followed by a list of spare part numbers
where applicable.
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.
Connection Cover, Top
Connection Cover, Bottom
Main Terminal
Cover
Intervening
DC+ Bus
Bar
Capacitor 7µf 450V ac
Intervening
DC- Bus
Bar
ASIC
Assembly
Upgrade Kit
(without ASIC
Board)
Output Transformer
Assembly for Fan Inverter
Main Fan Assembly 230W
Table D.A Main Power Structure Assembly Part Numbers
Part Name
ASIC Assembly Upgrade Kit (without the ASIC Board)
Capacitor 7µf 450V ac
Connection Cover, Bottom
Connection Cover, Top
Intervening DC+ Bus Bar
Intervening DC- Bus Bar
Main Fan Assembly 230W
Main Terminal Cover
Output Transformer Assembly for Fan Inverter
Spare Part No.
NA
20-PP00060
NA
NA
NA
NA
20-PP01080
NA
20-FR10845
Disassembly / Assembly Diagrams
Figure D.2 Power Structure
Power Structure
Table D.B Power Structure Part Numbers
Part Name
Power Structure
Rating
400/480V, 590A
400/480V, 650A
400/480V, 730A
600/690V, 460A
600/690V, 502A
600/690V, 590A
Spare Part No.
SK-H1-PWRMOD-D590
SK-H1-PWRMOD-D650
SK-H1-PWRMOD-D730
SK-H1-PWRMOD-E460
SK-H1-PWRMOD-E502
SK-H1-PWRMOD-E590
D-3
D-4
Disassembly / Assembly Diagrams
Figure D.3 Phase U Power Structure Components
480V Shown
Snubber Capacitor Assembly
DC Link Bus Bar Kit - 500V
Output Power Module
Cover Plate
Gate Driver Board
Rectifying Module
Electrolytic Capacitor
Table D.C Phase U Power Structure Components Part Numbers
Part Name
Cover Plate
DC Link Bus Bar Kit
Spare Part No.
NA
500V
NA
690V
NA
Electrolytic Capacitor
ELKO 3300µf 420V Bus Capacitor - 400/480V 20-PP01005
ELKO 5600µf 420V Bus Capacitor - 600/690V 20-PP01099
Snubber Capacitor Assembly
20-PP10019
Gate Driver Board 480V
SK-H1-GDB1-F11D
690V
SK-H1-GDB1-F11E
Output Power Module
400/480V
SK-H1-QOUT-D590
400/480V
SK-H1-QOUT-D650
400/480V
SK-H1-QOUT-D730
600/690V
SK-H1-QOUT-E460
600/690V
SK-H1-QOUT-E502
600/690V
SK-H1-QOUT-E590
Rectifying Module
400/480V
20-FR10820
600/690V
20-FR10821
Disassembly / Assembly Diagrams
D-5
Figure D.4 Phase V and W Power Structure Components
480V Shown
Snubber Capacitor Assembly
Precharge (Rectifying) Board
DC Link Bus Bar Kit - 500V
Bus Bar Bridge DCBus Bar Bridge DC+
Output Power Module
Gate Driver Board
Rectifying Module
Electrolytic
Capacitor
Table D.D Phase V and W Power Structure Components Part Numbers
Part Name
Cover Plate
DC Link Bus Bar Kit
Spare Part No.
NA
500V
NA
690V
NA
Electrolytic Capacitor
ELKO 3300µf 420V Bus Capacitor - 400/480V 20-PP01005
ELKO 5600µf 420V Bus Capacitor - 600/690V 20-PP01099
Snubber Capacitor Assembly
20-PP10019
Gate Driver Board 480V
SK-H1-GDB1-F11D
690V
SK-H1-GDB1-F11E
D-6
Disassembly / Assembly Diagrams
Part Name
Output Power Module
Rectifying Module
Spare Part No.
SK-H1-QOUT-D590
SK-H1-QOUT-D650
SK-H1-QOUT-D730
SK-H1-QOUT-E460
SK-H1-QOUT-E502
SK-H1-QOUT-E590
20-FR10820
20-FR10821
400/480V
400/480V
400/480V
600/690V
600/690V
600/690V
400/480V
600/690V
Figure D.5 Fan Inverter
Fan Inverter Board
Output Transformer
Assembly for Fan
Inverter
Fan Capacitor
Table D.E Fan Inverter Part Numbers
Part Name
Fan Capacitor 7µf 450V ac
Fan Inverter Board
Output Transformer Assembly for Fan Inverter
Spare Part No.
20-PP00060
20-VB00299
20-FR10845
Disassembly / Assembly Diagrams
D-7
Figure D.6 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
Table D.F ASIC Assembly Part Numbers
Part Name
ASIC Assembly Bracket
ASIC Assembly Bracket
ASIC Assembly Bracket
ASIC Assembly Cover
400/480V, 590A
400/480V, 650A
400/480V, 730A
ASIC Board
600/690V, 460A
600/690V, 502A
600/690V, 590A
Spare Part No.
NA
NA
NA
NA
SK-H1ASICBD-D590
SK-H1ASICBD-D650
SK-H1ASICBD-D730
SK-H1ASICBD-E460
SK-H1ASICBD-E502
SK-H1ASICBD-E590
D-8
Disassembly / Assembly Diagrams
Figure D.7 Main Fan Assembly
Main Fan Assembly
Main Fan Housing
Main Fan Intake Cone
Table D.G Main Fan Assembly Part Numbers
Part Name
Main Fan Assembly 230W
Main Fan Housing
Main Fan Intake Cone
Spare Part No.
20-PP01080
NA
NA
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Publication PFLEX-TG003A-EN-P – March 2006
Copyright © 2006 Rockwell Automation, Inc. All rights reserved. Printed in USA.
Allen-Bradley
PowerFlex 700S & 700H Drives (Frame 11)
Hardware Service Manual