700S and 700H Frame 11 Replacement Power Structures
Contents
1. ofl H O J5 Power Supply Voltage Feedback Board l V TT 1 E J4 J5 O o O uL xz 1 5 OOO Mode Filter Board d J1 J5 INO AL 11 J8 12 PowerFlex 700S and 700H Frame 11 Replacement Power Structures Connections to the 700H Control Frame When installing a power structure in a PowerFlex 700H drive you must make eight connections between the ASIC and Fiber Optic Adapter and Rectifier boards Connect this component termination point in this component termination point the the Power Structure to Control Frame ASIC Board H1 fiber optic connector Fiber Optic Adapter Board H1 fiber optic connector ASIC Board H2 fiber optic connector Fiber Optic Adapter Board H2 fiber optic connector ASIC Board H3 fiber optic connector Fiber Optic Adapter Board H3 fiber optic connector ASIC Board H4 fiber optic connector Fiber Optic Adapter Board H4 fiber optic connector ASIC Board H5 fiber optic connector Fiber Optic Adapter Board H5 fiber optic connector ASIC Board H6 fiber optic connector Fiber Optic2. gt ENS PowerFlex 700S and 700H Frame 11 Replacement Power Structures 7 Insulate Terminal X4 on the Rectifier Circuit Board 1 Follow the lettered steps below to insulate terminal X4 on the Rectifier circuit board refer to Figure 3 on page 5 for jumper location Task Description amp Remove the screw from the X4 connection on the Rectifier circuit board Insulate the top and bottom of the X4 connection on the Rectifier circuit board Important Do not install the screw and washer that was removed from this connection Side View of Power Structure 1 X41 Circuit Board Jie 8 PowerFlex 700S and 700H Frame 11 Replacement Power Structures Step 2 Removing Power From the Existing Drive Step 3 Removing the Old Power Structure Step 4 Installing the New Power Structure the voltage on the bus capacitors has discharged before servicing the drive Check the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION To avoid an electric shock hazard verify that Remove power before making or breaking cable connections When you remove or in
3. CRI M F2 R2 CR Main DC Contactor gt M CR2 Precharge Important For DC Input Only Charge Relay Refer to the ASIC Board Charge Pelay Contact Rati gs table below Do Not Install on AC Input Drives ASIC Board Charge Relay Contact Ratings Load Resistance load cos 1 Rated load 8 A at 250 VAC 5 A at 30 VDC Rated carry current 8A Max switching voltage 250 VAC 30 VDC 400 VAC Max switching current AC8A DC5A Max switching power 2 000 VA 150 W Failure rate reference value 5 VDC 10 mA for gold plating 0 35 min PowerFlex 700S and 700H Frame 11 Replacement Power Structures 15 Step 6 Installing the All frame 11 replacement power structures are shipped from the factory Product Identification Label without a product identification label on the drive If you are installing the power structure in a 700S drive you should label it with the accompanying PowerFlex 700 label If you are installing the power structure in a 700H drive you should label it with the accompanying PowerFlex 700H label on New Power Structure Step 7 Starting the Drive 1 Install the protective covers on the drive Refer to publication PFLEX INOOG6 Installation Instructions PowerFlex 700S and 700H High Power Drives for assistance in installing these covers 2 Start up the drive
4. Digial Digtal Digtal WO Inputs Outputs Outputs 700H Control Assembly PowerFlex 700S and 700H Frame 11 Replacement Power Structures 13 Figure 8 Termination Points on Fiber Optic Adapter Board 700H Drives Back View Heb 14 PowerFlex 700S and 700H Frame 11 Replacement Power Structures Pre Charge Connections on Drives with DC Input You must connect the ASIC board connectors X9 and X15 to the X50 terminal block for the pre charge circuit The X50 terminal block is located on the Control Frame Refer to the Installation Instructions PowerFlex 700 and 700H High Power Drives publication PFLEX INOOG for information regarding the pre charge circuit X50 Terminal Block Connections ASIC Board Connector Terminal 50 Terminal Pre Charge Circuit Connection Description X9 25 1 Pre charge Complete Signal 24V DC 26 2 Pre charge Complete Signal Common X15 21 3 Charge Relay Contact 23 4 Charge Relay Contact Figure 9 Sample Pre charge Wiring Diagram Customer Connections External precharge circuitry is shown as dashed lines Drive Connections Terminal Block ASIC Board Precharge Complete M DC 4 C9HH F1 R1 CR2 ME T DC Source E I pr M ene CRI Pilot Relay M DC J r9 JF 1
5. make the following connections between the ASIC and Fiber Optic Interface Power Supply Voltage Feedback Common Mode Filter and Rectifier boards Connect this component termination point in the Power Structure to ASIC Board H1 fiber optic connector this component terminatio Control Frame n point on the iber Optic Interface Board J8 fiber optic connector ASIC Board H2 fiber optic connector iber Optic Interface Board J9 fiber optic connector F F ASIC Board H3 fiber optic connector Fiber Optic Interface Board J10 fiber optic connector ASIC Board H4 fiber optic connector Fiber Optic Interface Board J11 fiber optic connector ASIC Board H5 fiber optic connector Fiber Optic Interface Board J12 fiber optic connector ASIC Board H6 fiber optic connector Fiber Optic Interface Board J14 fiber optic connector ASIC Board H7 fiber optic connector Fiber Optic Interface Board J13 fiber optic connector ASIC Board X10 Insulate and do not connect ASIC Board X2 Rectifier Board X13 AC input drives only Power Supply Voltage Feedback Board J8 Common Mode Filter Board J5 Power Supply Voltage Feedback Board J5 fiber optic connector Fiber Optic Interface Board J6 Power Supply Voltage Feedback Board J4 fiber optic connector Fiber Optic Interface Board J7 Figure 4 Connections for 7005 Drives with Phase Il Control Make and veri
6. Adapter Board H6 fiber optic connector ASIC Board H7 fiber optic connector Fiber Optic Adapter Board H7 fiber optic connector ASIC Board X10 Fiber Optic Adapter Board X2 ASIC Board X2 Rectifier Board X13 Figure 7 Connections Between the Power Structure and Control Frame 700H Drives Make and verify these connections X10 Ht ASIC H3 Board H5 H6 H7 To X13 Connector for Rectifier Board AC Input Drives Only 2 i Fiber Optic Cables Inside Power Structure Lr LHHH CHG X2 Hi H2 H3 H4 H5 H6 H7 xa Fiber Optic Adapter Board ese 1 37 7 E ES xi 2 DPI Interface HIM 700H Control Board a Hle KH RS 232 1 x x x5 Programming n Slot A Slot B Slot C Slot D Slot E Port m C3 70 20C DAT A x 20 E on 24V de Digital Input 20c DPIt w Analog VO Digital Output pun DPI Communications xi PORT or Option Option DPI ti MOD Po COMM ji 118V ac Digital Input Option E HM w Analog VO x a i qo eno P P DPI Assembly Analog
7. Gommnon Mode Fiter Board 2 30 91 4 2 d h n 4 Ji J5 Fiber Optic EP s 5 interface J6Tk um Power Supply Board 4 m Fiber re Voltage x Feedback d S 5 EE 10 9 xe 20 vBo0601 J4 DPI on 2 i dy Interface yp Bezel OX d Board DOOR DiveLogix 2 20 PWR ee aay 60077 9 SIS NE 1224V HIM M6 4 cont G oe Pan Fan Option 2 Xi NETB HIM T DPI Assembly EXTERNAL DPI 10 PowerFlex 700S and 700H Frame 11 Replacement Power Structures Figure 5 Termination Points on the ASIC Board Fiber Optic connections to the Fiber Optic Interface board Connect to Pre charge circuitry on DC input drives Connects to X13 connector for the Rectifier boards on the center and Q right side power stacks on C AC input drives X3 X5 Connects to fan ASIC assembly cover PowerFlex 700S and 700H Frame 11 Replacement Power Structures Figure 6 Termination Points on 700S Boards Fiber Optic Interface Board vm
8. of the drive s power structure Common Mode jumper Front View of Assembly PowerFlex L 7008 J Hp rad Rectifier Circuit Board 2 9 30 Io ge 9 PowerFlex 700S and 700H Frame 11 Replacement Power Structures Move the Common Mode Jumper to the Disconnected Position 1 Follow the lettered steps below to move the common mode jumper to the disconnected position refer to Figure 3 on page 5 for jumper location Task Description Loosen the upper screw Remove the lower screw Move the jumper to the horizontal position D Install and tighten the screws amp Front View of Power Structure D D R g gt j 44 amp 1 Rectifying Circuit Board
9. AB Installation Instructions Wy PowerFlex 700S and 700H Frame 11 Replacement Power Structures Introduction Use this document to install a replacement power structure on a PowerFlex 700S or 700H frame 11 drive This document covers the following replacement power structures Spare Module Catalog PowerFlex 700H PowerFlex 700H PowerFlex 700 PowerFlex 700 String AC Input DC Input AC Input DC Input SK H1 PWRMOD E460 20CE460 20CK460 20DE460 20DK460 20CF460 20CM460 20DF460 20DM460 SK H1 PWRMOD E502 20CE502 20CK502 20DE502 20DK502 20CF502 20CM502 20DF502 20DM502 SK H1 PWRMOD E590 20CE590 20CK590 20DE590 20DK590 20CF590 20CM590 20DF590 20DM590 SK H1 PWRMOD D590 20CC590 20CH590 20DC590 20DH590 20CD590 20CJ590 20DD590 20DJ590 SK H1 PWRMOD D650 20CC650 20CH650 20DC650 20DH650 20CD650 20CJ650 20DD650 20DJ650 SK H1 PWRMOD D730 20CC730 20CH730 20DC730 20DH730 20CD730 20CJ730 20DD730 20DJ730 What You Need to Do Step 1 Configure new power structure Step 2 Remove power from existing drive Step 3 Remove old power structure Step 4 Install new power structure Step 5 Connect new power structure to components in drive Step 6 Install product identification label on new power structure Step 7 Start drive 2 PowerFlex 700S and 700H Frame 11 Replacement Power Structures Step 1 Configuring the New Power Structure Before configuring the power structure you must rem
10. Refer to the Start Up procedures in the appropriate publication User Manual PowerFlex 700 Drives with Phase II Control 20D UMO06 Programming Manual PowerFlex 700H Drives 20C PMO001 Reference Materials www rockwellautomation com literature Allen Bradley publications are available on the internet at The following manuals are recommended for general drive information Title Publication Wiring and Grounding Guidelines for Pulse Width Modulated Drives DRIVES INO01 Industrial Automation Wiring and Grounding Guidelines 1770 4 1 Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES TD001 Safety Guidelines for the Application Installation and Maintenance of Solid SGI 1 1 State Control A Global Reference Guide for Reading Schematic Diagrams 0100 2 10 Guarding Against Electrostatic Damage 8000 4 5 2 The following manuals are recommended for detailed PowerFlex 700H and 700 information Title Publication Reference Manual PowerFlex 700S Drives with Phase II Control PFLEX RMO03 User Manual PowerFlex 700S Drives with Phase II Control 20D UMO06 Programming Manual PowerFlex 700H Drives 20C PM001 Installation Instructions PowerFlex 700S and 700H High Power Drives PFLEX INOOG6 Hardware Service Manual PowerFlex 700S and 700H Frame 11 Drives PFLEX TG003 For Allen Bradley Drives Technical Support Title Online at Allen Bra
11. dley Drives Technical Support www tockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core E Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication PFLEX INO11C EN P August 2008 Supersedes PFLEX INO11B EN P March 2006 www ab com support abdrives 360399 P03 Copyright 2008 Rockwell Automation All rights reserved Printed in the U S A
12. fy these connections To X13 Connector for Rectifier Board AC Input Drives Only J42 4 Eu ma Embedded P2 RJ45 P1 EtherNet I P Connector Option Board TX RX SynchLink Option Board Te x Hi Gate Enable P3 P2 Logix py po Expansion Board P3 CompactFlash Memory P10 Compact llo 80 NetLinx 1 Daughtercard Comm Input P2 Pt Feedback i Main Feedback Option Inputs Board e Control P Board M Second Encoder 16 or PS Safe Off Option Board P6 Pat Fiber Optic Cables H2 U Gate H3 V Gate H4 W Gate H5 ADcom H6 Vbus Tx H7 Vbus Rx ASIC Board TB 7005 Control Assembly Phase II 49 Ji Jt2 J14 J13 E
13. he Rectifier Circuit Board on page 7 Installation on a Grounded B Phase Delta System If you are installing a drive on a grounded B phase Delta system you e Must move the common mode jumper to the disconnected position refer to Move the Common Mode Jumper to the Disconnected Position on page 6 e Must insulate terminal X4 on the Rectifier circuit board refer to Insulate Terminal X4 on the Rectifier Circuit Board on page 7 Note Refer to Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives Installation Instructions publication DRIVES INO01 for additional information on an ungrounded distribution system or high resistive ground installation PowerFlex 700S and 700H Frame 11 Replacement Power Structures 5 The jumper is located on the Rectifying Module s For drives with one Rectifying Module it is located on the upper right side of the middle power stack V Phase For drives with two Rectifying Modules they are located on the upper right side of the middle V Phase and right side W Phase power stacks Voltage Class 400 480V AC Amps 590 Number of Rectifying Modules 650 730 600 690V AC 460 502 590 Figure 3 Mode Jumper and Rectifier Circuit Board Location There is one jumper located on each Rectifying Module The Rectifying Modules are located on the upper right side of the center and right side power stack
14. ons Connect cable to X2 connector 3 O X1 X1 connector E X4 X5 Figure 2 Rectifier Board Connectors Cable connected to X2 on ASIC board X13 connectors for Rectifier boards PowerFlex 700S and 700H Frame 11 Replacement Power Structures Configuring the EMC Filter Frame 11 size drives are equipped with common mode capacitors To guard against drive damage these capacitors should be disconnected depending upon the type of ground system on which the drive is installed Installation on an Ungrounded Distribution System or High Resistive Ground If you are installing a 400 480V AC input drive on an ungrounded distribution system or high resistive ground you e Must move the common mode jumper to the disconnected position refer to Move the Common Mode Jumper to the Disconnected Position on page 6 e Should insulate terminal X4 on the Rectifier circuit board refer to Insulate Terminal X4 on the Rectifier Circuit Board on page 7 If you are installing a 600 690V AC input drive on an ungrounded distribution system or high resistive ground you e Must move the common mode jumper to the disconnected position refer to Move the Common Mode Jumper to the Disconnected Position on page 6 e Must insulate terminal X4 on the Rectifier circuit board refer to Insulate Terminal X4 on t
15. ove the protective covers from the drive Refer to publication PFLEX INOO6 Installation Instructions PowerFlex 7005 and 700H High Power Drives for assistance in removing these covers Configuring a DC Input Drive Power structures are shipped from the factory pre configured for DC input operation Connecting an AC Input Drive Power structures are shipped from the factory pre configured for DC input operation When installing a replacement power structure on a drive with AC input you must remove the X2 plug from it s protective sleeve and plug the cable into the ASIC and Rectifier board s Task Description Remove the cover from the ASIC board assembly Disconnect the ASIC fan from the assembly by unplugging the cable from X1 on the ASIC board see Figure 1 on page 3 for location Remove the cover from the connector on the loose cable bundled with the flat gate driver board cables and connect the cable to the X2 connector on the ASIC board see Figure 1 on page 3 for location Connect the other end of the cable connected to X2 on the ASIC board to the X13 connector for the Rectifier board s on the V Phase and W Phase if present power stack see Figure 2 on page 3 for location Connect the fan cable to the X1 connector on the ASIC board Install the cover on the ASIC board assembly PowerFlex 700S and 700H Frame 11 Replacement Power Structures Figure 1 ASIC Board Connecti
16. sert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by e sending an erroneous signal to your system s field devices causing unintended machine motion e causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance 1 Turn off and lock out input power Wait five minutes 2 Verify that there is no voltage at the drive s input power terminals 3 Measure between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements Refer to the PowerFlex 700H S Frame 11 Hardware Service Manual publication PFLEX TG003 for information about removing the power structure Refer to the PowerFlex 700H S Frame 11 Hardware Service Manual publication PFLEX TG003 for information about installing the power structure Step 5 Connecting the Power Structure to Components in the Drive PowerFlex 700S and 700H Frame 11 Replacement Power Structures 9 You must connect the power structure to control components on the control frame If the drive has DC input you must also connect the precharge circuit Connections to the 700S Control Frame When installing a power structure in a PowerFlex 700S drive you must
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