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pflex-tg003 - Rockwell Automation

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3. Q Table C G PowerFlex 700S High Power Fiber Optic Interface Board to ASIC Board Fiber Optic Connections 700SInterface Board ASIC Board Fiber Description Fiber Optic Connector Type to Type Connector UI Description Gate Enable J8 TX RX Hi Gate Enable U Post J9 TX RX H2 U Gate V Post J10 TX IRX H8 V Gate W Post J11 TX IRX H4 W Gate A D Convert J12 TX RX H5 A D Convert VBUS_TX J14 TX RX H6 VBUS_RX VBUS_RX J13 RX TX Hi 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 Voltage Feedback Description Fiber Optic Connector Type Type Board Connector Description TX J6 TX RX J5 RX RX J7 RX TX JJ TK Figure C 6 Fan Inverter Circuit Board Connectors Connector Descriptions C 7 X3 H E
4. 2 18 Checking the Main Fan Motors 2 19 Chapter 3 Torque Specifications IIIA 3 1 Understanding Torque Figures in Assembly Diagrams lesse es 3 3 Removing Power from the Drive 2 0 0 cece eee eens 3 3 Removing Power Sieve heey NAY A PER bs dg Eder ik oat wale pet 3 3 Removing the DPI HIM Assembly 3 4 Ena ONA i nepote beetle qr sb ma gute Re satan d tue edet bd 3 4 Installation eh nek NEEN Ree See E EE SUR RE SUPER 3 5 Removing the 700S Control Assembly 3 5 Kememak he nea can ashe UE Rip D pado NES ia AREA ace a d aw E RR edi 3 5 Installations uices a Gans hake EGRE od EM X dien 3 7 Removing the 700S High Power Fiber Optic Interface Circuit Board 3 7 Removal 2 ee Mee NEE EE Ute nea ede tedio e eye 3 7 Installation Geier dee e ER EEN EM e ERR Ret Mel ae 3 8 Removing the 700S Control Assembly 3 8 Removal Bag bs ste DES VUE OS Qa DATEI IPS eer RM E 3 8 Installation lee RUP IIR SEN EN Ee hea i 3 9 Removing the 700H I O Boards and Control Assembly n n nanuunnannanaran 3 9 Removals eg Seege RES eA eet exe nexo beet 3 9 Installateur aes EE LIRE ps 3 11 Removing the 700H Fiber Optic Adapter Board 3 11 Removal botes tete atu te tee ets ent ua E 3 11 Installations e iiu Se esu x ecu Remo RE
5. 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 eb sri eer ABER E Ie ei 2 18 Checking Fan Inverter Fuses 2 18 Isolating a Faulty Fan Inverter
6. X8 e Q e e e o FI Table C I ASIC Board to Main Cooling Fan Inverter Phase U Connections ASIC Board Fan Inverter Description Connector Pin Number Pin Number Connector Description 15V de powerto X11 2 2 X8 15V dc power from Fan Inverter boards ASIC board Fan Control 3 3 Fan Control Alarm from Fans 4 7 Fan Alarm to ASIC board II 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 X3 Fan Inverter Phase W Pin Number Pin Number Connector 2 2 X8 3 3 4 7 Table C L Main Cooling Fan Inverter Phase W Connections Description 15V dc power Fan Alarm Fan Inverter Phase W conector Phase W Zen Fan Inverter Description 15V dc power Next Fan Control Fan Alarm Description 15V dc power Fan Alarm C 8 Connector Descriptions
7. 3 16 Access Procedures Installation Install the Airflow Plate in reverse order of removal while referring to Torgue 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 Access Procedures 3 17 Installation Install the Protective Covers in reverse order of removal while referring to Torgue Specifications on page 3 1 Removing the 700S Voltage Removal Feedback Circuit Board 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 t
8. NS P X13 X6 X10 xi O xD DEE WEEN Eu Sp zo te Des X13 Pin1 X13 Pin5 24V de Common 24V de Power X10 Pin 1 X11 Pin 1 X12 Pin 1 X9 Table 2 G Rectifying Board Charge Relay Test Results No Power on X13 24V dc Power on X13 Meter Leads Meter Leads A Results A Results J3 X9 J3 X10 Pin 1 J7 X9 0C J7 X11 Pin 1 0 2 0V J11 X9 J11 X12 Pin 1 Checking the DC Bus Capacitors Component Test Procedures 2 17 Important This procedure reguires special eguipment and training Only gualified and trained personnel should perform these procedures These tests reguire 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 de for drives with 380 500V ac input or 775V de 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
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10. 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 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 X7 e Serial Port X2 X3 X4 X5 X6 Slot A SlotB SlotC SlotD Slot E Removing the 700H Fiber Optic Adapter Board 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 SNe 27 Ib 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 Removal
11. Hardware Connections Figure C 7 X50 Terminal Block Connectors Customer Connections Example External Precharge Circuitry CR1 Pilot Relay CR1 M Main DC Contactor CR2 Precharge For DC Input Only Do Not Install on AC Input Drives Terminal Block on Control Pan Drive Connections ASIC Board 24VDC isolated 0VDC Charge Relay Table C M X50 Terminal Block Precharge Circuit Connections ASIC Board Connector Terminal to X50 Terminal Block Description X9 25 1 Precharge Complete Signal 26 2 Precharge Complete Signal X15 21 3 Charge Relay Contact 23 4 Charge Relay Contact Appendix D Disassembly Assembly Diagrams For a Diagram on See Main Power Structure Assembly page D 2 Power Structure page D 3 Phase U Power Structure Components page D 4 Phase V and W Power Structure Components page D 5 Fan Inverter page D 6 ASIC Assembly page D 7 Main Fan Assembly page D 8 Disassembly Assembly Diagrams on the following pages illustrate disassembly and assembly of the Diagrams and Spare Parts drive and its sub systems and are followed by a list of spare part numbers Numbers where applicable 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 Mai
12. 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 X1 connects to Main Sockets for Control Fiber Optic cables 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 using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when 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 Removing the Covers from the Power Structure 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 EC Sec 8 Ib in 7 Remove the Fiber Optic Adapter Board from the Control Frame Installation Install the 700H Fiber Optic Adapter
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14. ASIC Assembly Cover NA 400 480V 590A SK H1ASICBD D590 400 480V 650A SK H1ASICBD D650 400 480V 730A SK H1ASICBD D730 600 690V 460A SK H1ASICBD E460 600 690V 502A SK H1ASICBD E502 600 690V 590A SK H1ASICBD E590 ASIC Board D 8 Disassembly Assembly Diagrams Figure D 7 Main Fan Assembly Main Fan Assembly Main Fan Housing L Fan Intake Cone Table D G Main Fan Assembly Part Numbers Part Name Spare Part No Main Fan Assembly 230W 20 PP01080 Main Fan Housing NA Main Fan Intake Cone NA www rockwellautomation com Power Conirol and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core E Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication PFLEX TG003A EN P March 2006 Copyright 2006 Rockwell Automation Inc All rights reserved Printed in USA Allen Bradley PowerFlex 700S amp 700H Drives Frame 11 Hardware Service Manual
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17. while referring to Torgue Specifications on page 3 1 Removing the V Phase Middle Rectifying Board Rectifying Module and Output Power Module Access Procedures 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 Remove power from the drive Refer to Removing Power from the Drive on page 3 3 Remove the covers from the power structures Refer to Removing the Covers from the Power Structure on page 3 13 Remove the power structure from the drive cabinet Refer to Removing the Power Structure from the Drive Cabinet on page 3 21 Disconnect the output leads from the bottom of the Output Power Module Remove the screws that secure the V Phase middle Power assembly to the drive and remove the Power assembly 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 Remove the balancing resistor wires from bus bars Disconnect the cables from the AC input terminals on the Rectifying Module Balancing Resistors alancing Resistor Wires 3 34 Access Procedures 9 Remove the five screws that secure the Rectif
18. Damage or any other applicable ESD protection handbook 1 2 Troubleshooting and Error Codes Creating Fault Reports Addressing 700S Hardware Faults Complete fault reports are critical for analysis and repair of modules returned to the factory At a minimum perform and record the following e 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 e Make record of any liquid and condensation marks on printed circuit boards components and mechanical parts e Make record of the amount of dust and other additional particles on drive and drive components e 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 Fault No Description Action if appropriate HiHp In PhaseLs 65 AC Input Phase Loss AC voltage is 1 Check for voltage on each not present on one or two input input phase phases 2 Check the status of each external input fuse Hp Bus Com Dly 66 Bus Communication Time Delay the Check fiber optic connections processor has not received proper _ between the Power Interface periodic feedback information Circuit Board and Voltage Feedback Circuit Board Hp Bu
19. HIM assembly Screws P a N m U 8 Ib 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 4 d o Da C Back view of DPI S 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 Ib 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 Removal Assembly 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 using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when Important Minimum inside bend radius for SynchLink and ControlNet fiber optic cab
20. NE ag UNE E 3 13 Removing the Covers from the Power Structure 3 13 Moving the Control Frame re nieres ere oaa cee eee nee 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 saat Pete ege be oak tags peat ae S e Gnas DURS perma 3 17 Installation EEN RR SE Re SE AEN ET e Pe eae ES 3 18 Removing the Gate Driver Board 3 18 Remoyv l 2025 hAd hoe bi ee be ee a eee ee iru er iate 3 18 Installation e aeania anaren iana eat aa Eege dee Gd 3 19 Removing the ASIC Board 3 20 Removal A ne eRe Se Ge ety ee UR tea tele EE en a bet E 3 20 Installation AA heal ce ea m e emo Key hes age ae a ae 3 21 Removing the Power Structure from the Drive Cabinet 3 21 Removal shel e Ea tapered AE en Ges setae aoa S 3 21 Installati hz LARES Eee hey Bee Sy Ee ee RS 3 24 Removing the Main Fans lees hm 3 24 Removals ees Reese TS ee dE NEE de ee ERE EMI 3 24 Installation 4 LbsrpeehesrweveDertewebspubpee4 nV pee VP ET ec ETE RII 3 25 Removing the Fan Inverters 3 25 Removals anenee ged Nee Re e de nde p tete ees a 3 25 Installation 2 celis hieu Ru eI RU en EN ved EE nU tU RS 3 28 Removing the U Phase Left Side Output Po
21. 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 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 Meter Leads Nominal meter reading L1 DC L2 DC L3 DC Value should gradually rise to about DC L1 0 5V DC L2 DC L3 2 6 Component Test Procedures Table 2 B Reverse Biased Diode Tests on Rectifying Module s Meter Leads Nominal meter reading L1 DC L2 DC L3 DC DC L1 DC L2 DC L3 Meter should display 7 OU 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 Meter Leads Nominal meter reading DC T1 DC T2 DC T3 T1 DC T2 DC T3 DC Meter should display 0L zero load Table 2 D Reverse Biased Diode Tests on Output Power Modules Meter Leads Nominal meter reading Ti DC T2 DC T3 DC DC T1 DC T2 DC
22. 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 Software Tools Service Tools Appendix A Service Tools and Equipment DriveTools SP DriveExecutive DriveExplorer and DriveObserver are software tools for uploading downloading and monitoring system parameters This list of basic service tools which will cover needs of tools for repair and maintenance measurements Item Description Details 1 Oscilloscope Portable digitizing dual channel scope with isolation 2 Current clamp 1000A ac rms signal output 3 Soldering station Soldering de soldering 4 Adjustable power supply 0 1300Vdc 1A adjustable current limit Efore LPS 750 HV or equivalent 5 Adjustable power supply 0 690Vac 1096 10A three phase galvanic isolation 6 Multi meter Digital multi meter capable of ac and dc voltage c
23. T3 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 2 7 Checking Fiber Optic Damaged or improperly connected fiber optic cables can cause apparent Connections to the Gate Gate Driver board malfunctions Driver Boards 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 3 2 Remove the covers from the power 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 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 1 Remove power from the drive Refer to Removing Power from the Board Measurements Drive on page 3 3 2 Remove the covers from the power 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 fr
24. cooling fan and temperature of the Power Board on fan power supply replace if has exceeded 85 C necessary Name No Description Action if appropriate Auxiliary In 2 Auxiliary input interlock is open Check remote wiring Power Loss 3 DC bus voltage remained below Monitor the incoming AC line for Power Loss Volts for longer than low voltage or line power Power Loss Time Enable Disable interruption with Fault Config 1 For more information refer to publication 20C PMO001 Programming Manual PowerFlex 700H UnderVoltage 4 DC bus voltage fell below the Monitor the incoming AC line for minimum value of 333V for 400 480V drives and 461V for 600 690V drives Enable Disable with Fault Config 1 For more information refer to publication 20C PMOO1 Programming Manual PowerFlex 700H low voltage or power interruption 1 4 Troubleshooting and Error Codes Name No Description Action if appropriate OverVoltage 5 DC bus voltage exceeded maximum Monitor the AC line for high line value voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install and external dynamic brake option Input Phase 17 Oneinputline phase missing Check user supplied fuses Check AC input line voltage OutPhasMissng 21 Zero current in one output motor Check motor wiring phase Check motor for open phase Ground Fault 13 A current path
25. the 700S Diagnostic The PowerFlex 700S contains a Run LED controller LEDs and SynchLink LEDs LEDs These LEDs are only operational when the drive is energized and are only visible when the drive door is open The status of these LEDs can also be viewed from the HIM or from an application program e g DriveExplorer in parameter 554 LED Status This feature is only available with DriveLogix version 15 03 or later 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 The RUN LED and the controller LEDs are only operational when the drive is energized DRIVE Component Test Procedures 2 3 Table C Drive Status Indicator Descriptions Name Color State Description PWR Green Steady llluminates when power is applied to the drive Power STS Green Flashing Drive ready but not running amp no faults are present Status Steady Drive running no faults are present 3 Yellow Flashing When running a type 2 non configurable alarm condition S exists drive continues to run When stopped a start inhibit a exists and the drive c
26. 11 and the WL cable X11 provides the gate interface for the WL output power transistor in the W 2 12 Component Test Procedures Checking the Rectifying Module s on AC Input Drives 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 PT hardware fault 600V ac input 460A and 502A frame 11 d
27. 2 9 Verify that the DC Test Power Supply is de energized Connect the power supply s DC to the drive s DC terminal and the power supply s DC to the drive s DC terminal Set the power supply voltage setting to zero Switch on the external DC Test Power Supply 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 TT5N dc for drives with 600 690V ac input 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 Make configuration changes which allow the HIM to issue start and speed commands Make configuration changes which allow operation without an encoder and motor 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 Testing Without a Motor Performing the Power Circuit Diagnostic Test on a 700S Start Up After Repair 4 3 This test allows you to measure several operating parameters and diagnose problems without connecting the motor 1 Verify that input powe
28. 2 on the ASIC board are properly seated Verify that the jumper at X50 on the Rectifying board is in place Taking Measurements on Rectifying Module 6 7 Disconnect connectors X13 X12 X11 and X10 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 Resistance X10 red to X10 black X11 red to X11 black 180 10 X12 red to X12 black 8 Without applying power to X13 verify that there is no resistance between the following points J3 and X9 J7 and X9 and J11 and X9 Refer to 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 9 the polarity will damage components on the circuit board 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 vol
29. 7 LEX peog DISV wold Appendix C Connector Descriptions For Information on See ASIC Board to Gate Driver Board Phase U Connections page C 3 ASIC Board to Gate Driver Board Phase V Connections page C 3 ASIC Board to Gate Driver Board Phase W Connections page C 3 ASIC Board to Rectifier Precharge Circuit Board Phase V Connections page C 4 Rectifier Precharge Circuit Board Phase V to Rectifier Precharge Circuit Board Phase W_ page C 4 Connections PowerFlex 700H Fiber Optic Adapter Circuit Board to ASIC Board Fiber Optic page C 5 Connections PowerFlex 700S High Power Fiber Optic Interface Board to ASIC Board Fiber Optic page C 6 Connections PowerFlex 700S High Power Fiber Optic Interface Board to Voltage Feedback Board page C 6 Fiber Optic Connections ASIC Board to Main Cooling Fan Inverter Phase U Connections page C 7 Main Cooling Fan Inverter Phase U to Main Cooling Fan Inverter Phase V Connections page C 7 Main Cooling Fan Inverter Phase V to Main Cooling Fan Inverter Phase W Connections page C 7 Main Cooling Fan Inverter Phase W Connections page C 7 X50 Terminal Block Precharge Circuit Connections page C 8 Circuit Board Connections 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
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31. Board in reverse order of removal while referring to Torque Specifications on page 3 1 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 Loosenthe 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
32. C I V TEMP V_DC T H15 fiber optic VH or Gate Top H16 fiber optic VL or Gate Bottom olol N OD Oo A OJN CO CO NI GD Oo AI C P e e bs e H10 fiber optic H11 fiber optic zr a bass TI cxx O Table C C ASIC Board to Gate Driver Board Phase W Connections ASIC Board Gate Driver Board Connector Pin Number to Pin Number Connector Description X5 1 pia 1 X6 W Feedback 2 2 W Power OK 3 3 W DTR 4 4 W_ETR 5 5 W_ITR 6 6 W_DC 7 7 WI 8 8 W DC I 9 9 W TEMP 10 Ex 10 W_DC T H12 fiber optic H12 H15 H15 fiber optic WH or Gate Top H13 fiber optic H13 bs H16 H16 fiber optic WL or Gate Bottom 1 DTR N Desat 0 ETR Phase 12T 3 TR Phase Overcurrent C4 Connector Descriptions Figure C 3 Rectifier Precharge Circuit Board Connectors x Xi X2 X3 x41 Co lt Ss em XB oun wl X13 X6 sb WW X100 X9 Q VJ oeoooo ooooo 9 X12 O Table C D ASIC Board to Rectifier Prec
33. C 1 ASIC Board Connectors X9 X6 X2 X11 H8 H9 H10 H11 H12 H13 OQ U Uu ji L WE L L L L X15 Ht He H3 H4 H5 H6 H7 O O X3 X4 X5 V M Y IN Y iN Y If Figure C 2 Gate Driver Board Connectors Connector Descriptions C 3 Table C A ASIC Board to Gate Driver Board Phase U Connections Gate Driver ASIC Board Board Connector Pin Number to Pin Number Connector Description X3 1 Lx 1 X6 U Feedback 2 M 2 U Power OK 3 m 3 U prn See Note Below 4 e 4 U_ETR 5 7 5 U_ITR 6 ae 6 U_DC 7 SE 7 UI 8 A 8 U DC I 9 m 9 U TEMP 10 E 10 U_DC T H8 fiber optic H8 H15 H15 fiber optic UH or Gate Top H9 fiber optic H9 H16 H16 fiber optic 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 Gate Driver Board Connector Pin Number to Pin Number Connector Description X4 1 ER 1 X6 V Feedback V Power OK V DTR V ETR V_ITR V DC VI V D
34. D 4 Disassembly Assembly Diagrams DC Link Bus Bar Kit 500V Cover Plate Rectifying Module Electrolytic Capacitor Figure D 3 Phase U Power Structure Components Snubber Capacitor Assembly ii Table DC Phase U Power Structure Components Part Numbers 480V Shown Part Name Spare Part No Cover Plate NA DC Link Bus Bar Kit 500V NA 690V NA Electrolytic Capacitor ELKO 3300 jf 420V Bus Capacitor 400 480V 20 PP01005 ELKO 5600uf 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 IW Capacitor Assembly Precharge Rectifying Board 480V Shown DC Link Bus Bar Kit 500V Bus Bar Bridge DC De 4 T oe d s EN C Bus Bar Bridge DC Si 7 eg e ER Output Power Module Gate Driver Board Rectifying Module Electrolytic Fs Capacitor Table D D Phase V and W Power Structure Components Part Numbers Part Name Spare Part No Cover Plate NA DC Link Bus Bar Kit 500V NA 690V NA Electrolyti
35. N m 15 Ib in Touch Cover Main Fan M5 x 16 3 N m 27 Ib in ASIC Fan M4 x 16 POZIDRIV 0 4 N m 3 5 Ib in Rectifier board Mounting M4 x 8 POZIDRIV 1 N m 9 Ib in Output Power Module Output M8 x 20 hexagonal screw 14 N m Terminals U V W 124 Ib in Rectifying Module Input M10 x 20 hexagonal screw 12 N m Terminals L1 L2 L3 106 Ib in Y Bus Bar M10 nut 40 N m 354 Ib in Capacitor M4 x 8 self tapping 1 N m 9 Ib in Capacitor Bus Bar M6 x 16 POZIDRIV 4 N m 85 Ib in Capacitor Bus Bar M6 x 20 POZIDRIV 4 N m 85 Ib in DC DC Terminals M6 x 20 POZIDRIV 5 N m 44 Ib in Block Mounting M10 x 12 hexagonal screw 20 N m 177 Ib in 700S Voltage Feedback Circuit Board mounting OO 5 OO amp amp d d amp O D XD 6 M3 x 0 5 thread 37 mm x 37 mm hex standoff POZIDRIV is a registered trademark of the Phillips Screw Company Phillips is a registered trademark of Phillips Screw Company 0 9 N m 8 Ib in Removing Power from the Drive Access Procedures 3 3 Understanding Torgue Figures in Assembly Diagrams Icons and numbers in the assembly diagrams indicate how to tighten hardware Tool Type and Size Fastener T idi e PZ indicates POZIDRIV screwdriver bit POZIDRIV Screw P indicates Phillips screwdriver bit Phillips Screw Hexagonal Bolt or Standoff P72 Hexagonal gt GEI Nm Screw 35 Ib
36. No Description Action if appropriate Hp Drv OvrLoad 71 Drive Overload the circuit board on Measure output current of the the Power module has detected an drive If the level is ever greater overload than the maximum drive rated output current level reduce the load If the levels are always well below the drive rated levels then replace the power module HiHp PwrBd PrcEr 72 Power Board Processor Error a 1 Check fiber optic microprocessor on the Power Board connections between the has detected a communication error Power Interface Circuit Board and Voltage Feedback Circuit Board 2 Check connections between the Main Control Board and the Power Interface Circuit Board 3 Replace the Voltage Feedback Circuit Board 4 Replace the Power Interface Circuit Board 5 Replace the Main Control Board HiHp PrChrg Cntc 73 Precharge Contactor Fault proper e Check precharge circuit contactor feedback has not occurred wiring The precharge contactor has probably e Check for loose connections failed to pick up or the feedback signal op X50 terminal block and or has failed This fault only applies to the X9 and X15 connectors DC input drives on the ASIC Board HiHp PwrEE Error 74 Power EEPROM Error the rating of Replace output power module the drive and data in the Power or program a new power board EEPROM on the Power Board do not match HiHP PwrBd OTemp 75 Power Board Over Temperature Check the main
37. 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 gt 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 e identify a hazard e avoid the hazard e 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 gt e E 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 Ta
38. TENTION 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 A 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 eieleleieleieigelei CO DC Voltage Probe DC Voltage Probe T 15V DC 15V DC 1 DC Common Probe ejejejej6jeje o e gt lt 3 While shin
39. TENTION Running the drive without the Main Fan 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 To this pin on the X6 on ASIC Power Supply Board DC 1 DC 3 Jumper pin 1 to pin 2 on connector 7 Disconnect the DC wire from each of the three Gate Driver boards 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 AN A 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 AT
40. alling 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 3 29 Removing the U Phase Removal Left Side 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 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 Terminal
41. annot be started D Steady A type 1 user configurable alarm condition exists but 3 drive continues to run e 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 PORT Refer to the Status of DPI port internal communications if present S MOD Communication Status of communications module when installed S NET A Adapter User Manual Status of network if connected E NET B Status of secondary network if connected Gel oO t 0 SYNCHLINK Green Steady The module is configured as the time keeper o or E The module is configured as a follower and g synchronization is complete 8 Green Flashing The follower s are not synchronized with the time keeper 8 Red Flashing The module is configured asa time master on SynchLink and has received time information from another time master on SynchLink ENABLE Green On The drive s enable input is high Green Off The drive s enable input is low 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 Conducting Forward and Reverse Biased Diode Tests for Major Power Components the drive Inspecting the Cooling Tunnels 1 Remove the main co
42. ation User Manual DriveLogix System 20D UM002 Installation Instructions DriveLogix Controller 20D INO02 Installation Instructions Memory Expansion for DriveLogix Controller 20D INO07 ControlNet Daughtercard Installation Instructions 1788 INO002 ControlNet Daughtercard Installation Instructions 1788 INO005 Terms The following words are used throughout the manual to describe an action Word Meaning Can Possible able to do something Cannot Not possible not able to do something May Permitted allowed Must Unavoidable you must do this Shall Required and necessary Should Recommended Should Not Not recommended Additional Support Available on Internet 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 on page C 2 is a cross reference to figure C 1 on page 2 of Appendix C 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 gt gt D GE P P 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 l
43. 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 ATTENTION Power must be applied to the drive to perform Phone United States 1 262 512 8176 7 AM 6 PM CST Canada 1 440 646 5800 24 hour support Outside United You can access the phone number for your country via States Canada the Internet Go to http www ab com Click on Support http support rockwellautomation com Under Contact Customer Support click on Phone Support Internet Go to http Avww ab com support abdrives E mail gt support drives ra rockwell com Be prepared to provide the following information when you contact support Product Catalog Number Product Serial Number Firmware Revision Level Before Applying Power to 1 Check for zero volts between DC and DC the Drive 2 Perform forward and reverse biased diode tests using a digital multimeter Refer to Conducting Forward and Reverse Biased Diode Tests for Major Power Components on page 2 4 4 2 Start Up After Repair Testing with the External DC This is a low current low risk test for the Output Power Module and drive Power Supply Without Load Control board It requires the recommended High Voltage DC Test Power Supply Optional 1
44. ble of Contents Important User Information 1 2 Preface Who Should Use this Manual P 1 What isin this Manual 4 NEE EE X ei ei eae Ce eat RU Pa Rue P 1 What is Not in this Manual P 1 Reference Materials iebeserenere pe EES eae PR E Us P 2 Understanding Manual Conventions P 2 Terms ai iber eege AA ek care As Me AN re LAN dad P 2 Cross References AI EE dE AA P 3 Additional Support Available on Internet P 3 General Precautions P 4 Glass 1 LED Product coe ote RI Eee ee tede etre Me tet P 4 Chapter 1 Creating Fault A cerato o Eos o EEN pea eas pu gtt Vea dps 1 2 Addressing 700S Hardware Faults 1 2 Addressing 700H Hardware Faults 1 3 Diagnostic Procedures by Symptom 1 5 Blown Input Fuses eech ine Ae ie Ee oie Es 1 5 No Qutput Voltage leote re RR RM MET S NER Se Sg 1 6 No HIM Display er upveeneve ee pep eae ea PATE ENEE e 1 7 Over Temperature Faults 1 8 Chapter 2 Viewing the 700H Diagnostic EBD 2 1 Viewing the 700S Diagnostic LEDS
45. c Capacitor ELKO 3300 jf 420V Bus Capacitor 400 480V 20 PP01005 ELKO 5600yf 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 Spare Part No 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 Figure D 5 Fan Inverter am Fan Inverter Board e Output Transformer Fan Capacitor Table D E Fan Inverter Part Numbers Part Name Fan Capacitor 7uf 450V ac Assembly for Fan Inverter Spare Part No 20 PP00060 Fan Inverter Board 20 VB00299 Output Transformer Assembly for Fan Inverter 20 FR10845 Disassembly Assembly Diagrams D 7 Figure D 6 ASIC Assembly 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 The sheet metal cover and mounting screws on ASIC Board ASIC Assembly Bracket ASIC Assembly a Bracket E Ke kg ASIC Assembly Bracket Table DE ASIC Assembly Part Numbers Part Name Spare Part No ASIC Assembly Bracket NA ASIC Assembly Bracket NA ASIC Assembly Bracket NA
46. ck Fans and Air Flow Through the Drive Proper Space At Inlet Yes Airlflow Blockages No Fans Running Properly No Check Power Power Voltage Voltage on Fan Equals Bus Inverters Voltage Yes Check Connection Between ASIC Board and Fan Connection Inverters Good Check Fan Inverter Outputs on X1 X4 and X5 Output Equals 50 Hz 220V rms Yes Check Fan Motors Fan Motor has for Short and Open or Short Open Circuits Circuits No Contact Allen Bradley Drives Technical Support Yes Provide Additional Airflow or Air Conditioning Reduce Load or Procure a Drive With a Higher Rating Lower PWM Frequency Remedy Spacing at Inlet Remove Air Flow Blockages Check Fan Inverter Fuses F1 and F2 Repair Connection Replace Fan Inverter s Replace Fan Motor s Chapter 2 Component Test Procedures gt gt PP 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 amp 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 t
47. 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 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 ATTENTION The inverter LEDs are only operational when LED Red Green Indication Steady Steady Inverter Idle Off Flashing Inverter Running Flashing Steady Inverter Faulted or No Control from ASIC board Checking Fan Inverter Fuses A pair of fuses F1 and F2 feed DC Bus power to both inverters Locat
48. e 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
49. e 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 11 12 the polarity will damage components on the circuit board 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 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 7 Xi X2 X3 X41 a
50. es Drive Control Board Run Replace Power Does Drive Interface Board Run on 700S No Replace Voltage Feedback Board on 700S Troubleshooting and Error Codes 1 7 No HIM Display Use this procedure when the HIM does not function Check HIM Connection and Seating Reseat or Properly Connected No reconnect HIM Yes DC Bus Measure DC Bus Voltage within Voltage Specification Perform forward No diode tests on Rectifying Module Rectifying Module OK Replace Rectifying Module Examine Bus Capacitors for Capacitors Charring and OK Damaged Reliefs Replace Yes Capacitors Yes Measure Power Replace Power Supply on X4 of E s No Interface Board DPI Circuit Board u i on 700S Yes Replace Output Power Module on 700H it Check DPI and Power Supply Connections Does HIM Function No Replace HIM Troubleshooting and Error Codes Over Temperature Faults Use this procedure to troubleshoot drive over temperature faults 14 Inv Otemp Pend and 15 Inv Otemp Trip in 700S or 8 Heatsink OvrTemp and 9 Trnsistr OvrTemp in 700H Temperature Exceeds Specification Check Surrounding Air Temperature Check Motor Current Current and Load adum Levels peci ication Frequency Too High for Lead Length and Surrounding Temp Check PWM Frequency No Che
51. 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 gt gt PP 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 amp 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
52. 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 Resistance 5 Brown Black 60 Blue Black 26 Blue Brown 34 Resistance to ground oo infinity 5 Reconnect the first fan motor to its inverter 6 Repeat steps 3 4 for the second and third fan motor 2 20 Component Test Procedures Notes Chapter 3 Access Procedures ATTENTION To avoid an electric shock hazard ensure that all power to the drive has been removed before performing the following ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged before performing any work on the drive Measure the DC bus voltage at the DC amp DC terminals The voltage must be zero ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION HOT surfaces can cause severe burns Do not touch the heatsink surface during operation of the drive After disconnecting power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emi
53. ge B 2 Phase V Power Circuitry for Drives with AC Input page B 3 Phase W Power Circuitry for Drives with AC Input page B 4 Phase U Power Circuitry for Drives with DC Input page B 5 Phase V Power Circuitry for Drives with DC Input page B 6 Phase W Power Circuitry for Drives with DC Input page B 7 Circuit Board Connections for 700H Drives with AC Input page B 8 Circuit Board Connections for 700H Drives with DC Input page B 9 Circuit Board Connections for 700S Drives Phase II Control with AC Input page B 10 Circuit Board Connections for 700S Drives Phase H Control with DC Input page B 11 Fan Inverter and Main Fan Connections page B 12 Schematics B 2 Power Wiring Diagrams indu Oy UU seAug 10 Mindi 4aMod fi eseud L N l4 9X peog DISV OL mmi Sa ge9 200 On 6H pJeog DISV WO4 8H P Rog DISV Wo Z Alddns mod M08 OL Z EX DEEN WOH EH peog au x 8x X 9x pJeog JoMOd TA TY m TA UE E TA T EI E PAM S A7 g z a E 3 E Se L LI GL TTT III ty RI kA 1 peqpes4 Fd Er SON OL j Nj j Ii E Je ee I 1 Ji til Wi di db jis i LI Lin KE IW l I ji Hi Uh 4 Kc L 1 l H ign iV T Af
54. harge Circuit Board Phase V Connections ASIC Board Connector X2 1 Pin Number to oae IN Rectifier Board Phase Pin Number V Connector Description 1 X13 SWTS_DRV 2 SWTS_FB 3 DC 4 Mains Fault 5 24V Table C E Rectifier Precharge Circuit Board Phase V to Rectifier Precharge Circuit Board Phase W Connections Rectifier Board Phase V Connector X6 Rectifier Board Pin Number to Pin Number Phase W Connector Description 1 1 X13 SWTS_DRV 2 2 SWTS_FB 3 3 DC 4 4 Mains Fault 5 5 24V Connector Descriptions C 5 Figure CA PowerFlex 700H Fiber Optic Adapter Circuit Board Connectors Table C F PowerFlex 700H Fiber Optic Adapter Circuit Board to ASIC Board Fiber Optic Connections 700H Interface Board Fiber ASIC Board Fiber Description Optic Connector Type jto Type Connector 1 Description ENA Out H1 TX RX H Gate_Enable UH H2 TX RX H2 U Gate VH H3 TX RX H3 V Gate WH H4 TX RX H4 W Gate A D Convert H5 TX RX H5 A D Convert VBUS TX H6 TX RX H6 VBUS RX VBUS DN Hi RX IX H7 VBUS_TX 1 Refer to Figure C 1 on page C 2 for ASIC board fiber optic connectors C 6 Connector Descriptions Figure C 5 PowerFlex 700S High Power Fiber Interface Circuit Board Connectors CS Zeg A eier utomation AL bei
55. hat 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 9 Disconnect connectors X13 X12 X11 and X10 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 Resistance X10 red to X10 black X11 red to X11 black 180 10 X12 red to X12 black 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 Se
56. he 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 Removing the Main Fans Installation Install the power structure in reverse order of removal while referring to Torgue Specifications on page 3 1 Refer to the publication PFLEX INO06 Installation Instructions PowerFlex 7008 and 700H High Power Drives for tightening torques of motor terminations 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 PowerFlex L 7008 j 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 Cover
57. i iza dr tt aia ee mI i F ME i L m B i f s d Allen Bradley 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 Automation 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
58. i Annan emod U1 9x amp um Dem eu axeo MaLyd OL zH TH Ani MOd ul 9TH UH DO anug a9 Aug OL Ani MOd UISTH peog aua a9 Aeseud OL Va x w ue4preog JSV z ARDUD MOJ U19X x peog JNU 9189 A eseud OL 009X pass SX msn ue OL An Mog UISTH ai d DE aya 93 9 1 9seud OL AnrOu Mod ul TH ei DE aya 93 9 1 9seud OL Anman sms utgx e He piog swugexo nasydo 7771 AepyaBiey six Y z D 9 DECH Annon amod ug 30 WA dm wao s d H ex 2EV m E 11 Schematics ynduj 20 YHM j01 u09 eseug seu S004 10 suon2euuo peog linda OL g anbi ida kwapa r AT8IABSSV Ida WIH l
59. ime for cooling ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook Viewing the 700H Diagnostic The Control Assembly on 700H drives contains a diagnostic LED which is LED visible through the cover of the Control Assembly A ATTENTION The Control Assembly LED is only operational when the drive is energized and only visible with the door of the drive enclosure is open Servicing energized equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Follow Safety related practices of NFPA 70E ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES DO NOT work alone on energized equipment 2 2 Component Test Procedures LED visible through this hole LED Indication Steady The drive is operational and has no faults Flashing Guickly e Switching power supply overload e Rectifier board fault e Fan or fan inverter fault e Brake Chopper fault e Fiber Optic Adapter board Fault Flashing Slowly Bad connection between circuit boards check all connections Viewing
60. in lt at Tightening Torque Hexagonal Nut Torx Head Screw OOOO voltage on the bus capacitors has discharged before performing any work on the drive Measure the DC bus voltage at the DC amp DC terminals The voltage must be zero ATTENTION To avoid an electric shock hazard verify that the 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 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 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 amp DC terminals on the Power Terminal Block The voltage must be zero Removing the DPI HIM Removal Assembly 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
61. ing 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 elei gt lt elele DC Voltage Probe DC Voltage Probe 15V DC D 15V DC 1 DC Common Probe elelelele elelelelele 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 X
62. le 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 Il 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 Removing the 700S High Power Fiber Optic Interface Circuit Board 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 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 f
63. n Power Structure Assembly 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 The sheet metal cover and mounting screws on the Main Terminal Cover Intervening DC Bus Bar Intervening DC Bus Bar ME 1 Bi ASIC tel ec Assembly NE il E Upgrade Kit ges cmi eg ZA Output Transformer without ASIC M OR H GI 4 Assembly for Fan Inverter Board CEN age Ss ain Fan Assembly 230W Table D A Main Power Structure Assembly Part Numbers Part Name Spare Part No ASIC Assembly Upgrade Kit without the ASIC Board NA Capacitor 7uf 450V ac 20 PP00060 Connection Cover Bottom NA Connection Cover Top NA Intervening DC Bus Bar NA Intervening DC Bus Bar NA Main Fan Assembly 230W 20 PP01080 Main Terminal Cover NA Output Transformer Assembly for Fan Inverter 20 FR10845 Figure D 2 Power Structure TS Disassembly Assembly Diagrams Za ze Reng Table D B Power Structure Part Numbers Part Name Power Structure Rating 400 480V 590A Spare Part No SK H1 PWRMOD D590 400 480V 650A SK H1 PWRMOD D650 400 480V 730A SK H1 PWRMOD D730 600 690V 460A SK H1 PWRMOD E460 600 690V 502A SK H1 PWRMOD E502 600 690V 590A SK H1 PWRMOD E590 Power Structure D 3
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65. o 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 using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when 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 T T J4 J5 O 40 O Rockwell Automation Lt as COO O 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 Ib in Installation Install the 700S Voltage Feedback Circuit Boa
66. o en ida r1 _ peog jonu zag EE WIH ex IX L ET TX ajoo a peog dt I Aber 1H 9H SH tH H ZH TH EN ando SO n n z4 No DCH SEI 200 ql 14H I 9H ex SH Agno Mod UI 9TH ei i peog ayq 89 M 9seud OL I EH Am Mod UI GTH em peog aaya SEA eseud OL cH AQI DO ul 9x TH pueog Jaruga 39 M 9seud OL Ee J MOd AvC OLX iaceat ek x w ae e ANIOI Mod UI STH an seu indu 9y uo resu JON oq Au duj 20 104 Dro ad SEA 1 wai npnip ewog Ul 9X m 9ex pueog aruq oO 9seud oL aun OX URN m 009X ja3uo ue TTX 8X Japanu ue oL H iro4D emod ue et t DOEN peog anyud 93e9 1 aseud OL C Ammup Jod UI STH a v pJeog Jeng SEO N aseud OL nmm rj 2 Fd BILUD STX NE ADIDI eMod ui ox ex z pJeog aug 9389 f 9Sseud OL no ajdwer3 e6euoeiq an EE pueog ti Aginoip mod ursng oa wan z 9x wao d E 25v E ji Ab L4 i i Schematics B 10 1ndu 2v YM 04WUOd eseud SANA S004 10 suonoauuo pJeog n3119 E n l4 iga reus im ui ee
67. ocated 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 amp DC terminals The voltage must be zero ATTENTION Potentially
68. 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 alancing 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 ersessos a LLL PM 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 WW 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 vi Rectifying Module Output Power Module Installation Install the Output Power Module in reverse order of removal while referring to Torgue Specifications on page 3 1 Removing the DC Bus Removal Capacito
69. oling 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 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 OL zero load A reverse biased diode test should find an open circuit and the meter should display OL 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 Forward biased test Reverse biased test on PN junction on PN junction Component Test Procedures 2 5 1
70. om 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 Gate Interface for 333 ohms U V or W High H 333 ohms Z e D j AL 15V e Gate Interface for oen uS I 15V U V or W Low L 333 ohms Ge kl Preparing the Drive for Active Measurements on the Gate Driver Board Important This procedure reguires special eguipment and training Only gualified and trained personnel should perform these procedures f 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 Inverters could cause the drive to overheat or fault Possible equipment damage could occur You must replace the fuses before running the drive AT
71. ontinuity resistance capacitance measurements and forward diode bias tests Fluke model 87 III or equivalent 7 Insulation tester 1000Vdc 8 Torque wrench 1 12Nm 9 Torque wrench 6 50Nm 10 box wrench 7mm 8mm 10mm 13mm 17mm 19mm 22mm 11 Socket extension 230mm 12 Wrench 7mm 8mm 10mm 13mm 17mm 19mm 22mm 13 Wire cutter 14 Nose pliers 15 Crimping tools For cable terminals 1 5 240 16 Angle wrench 17 Screw driver 18 Flat nose 7 2 mm 19 POZIDRIV 1 2 3 20 Phillips 1 2 3 21 Torx 25 22 Hexagonal wrench 4 5 6 23 ESD protected place of work Working surface Floor covering seat and ground connections 24 ESD protective clothing Wrist wrap shoes overall clothing coat A 2 Service Tools and Equipment Item Description Details 25 Power supply service Capacity of three phase service 400 500 690Vac 30A 26 20 MAINSTD maintenance stand Maintenance stand for removing power structure from drive cabinet 27 Fiber optic repair kit Agilent HFBR 4593 Polishing Kit consisting of a Polishing Fixture 600 grit abrasive paper and 3 mm pink lapping film 3M Company OC3 14 For Agilent HFBR 4532 latching connectors and HFBR RL cable Refer to Agilent publications 5988 9777EN and 5988 3625EN Appendix B Schematics List of Schematic Diagrams For a Schematic Diagram on See Phase U Power Circuitry for Drives with AC Input pa
72. out of the assembly chassis Remove the ASIC assembly chassis from the mounting plate 10 Remove the plastic board holder A o 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 Removal 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 3 Remove the covers from the power structures Refer to Removing the Covers from the Power Structure on page 3 13 Remove the motor wiring from the power structure at the front of the power structure 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 eguipped from the incoming terminals at the top of the power structure Motor Connection Terminals o o o o o o ILI 1L3 217 213 AC Power 212 Terminals Ground Connection PE Access Procedures 3 23 6 Remove the six screws that secure the Power Structure to the enclosure frame Remove screws PowerFlex L 700S J 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 t
73. r 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 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 the escape button to navigate to the Main menu 5 Use GD 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 e 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
74. rd in reverse order of removal while referring to Torque Specifications on page 3 1 Removing the Gate Driver Removal Board 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 using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when 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
75. rives 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 5 board to X
76. rom 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 using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when 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 Il Control Shown Co K LL My 2 L Fiber Optic Sockets PU UL ILL A Screws 5 P1 0 9 N m 8 Ib 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 Removal Assembly 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 Removing the 700H I O Boards and Control Assembly Access Procedures 3 9
77. rs 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 Yt j d Installation Install the capacitors in reverse order of removal while referring to Torgue Specifications on page 3 1 3 40 Access Procedures Notes Chapter 4 Start Up After Repair the following start up procedure Some of the voltages present are at incoming line potential To avoid electric shock hazard or damage to eguipment only gualified service personnel should perform the following procedure Thoroughly read and understand the procedure
78. s LinkLS 67 Bus Communication Link Loss bus Check fiber optic connections communication between the Power between the Power Interface Interface Circuit Board and Voltage Circuit Board and Voltage Feedback Circuit Board has halted Feedback Circuit Board Hp Bus CRC Er 68 Bus Communication CRC Error too Check fiber optic connections many Cycling Ring Checksum CRC between the Power Interface errors have occurred in the Circuit Board and Voltage communication bus Feedback Circuit Board A fast power cycle may cause the Wait five minutes before 700S Main Control Board to attempt re energizing the drive to communicate with the ASIC Board before the ASIC Board is energized Hp Bus WtchDog 69 Bus Communication Watchdog Error 1 Check fiber optic communication has halted in the connections between the communication bus causing the Power Interface Circuit Board watch dog timer to expire and Voltage Feedback Circuit Board 2 Check connections between the Main Control Board and the Power Interface Circuit Board 3 Replace the Voltage Feedback Circuit Board 4 Replace the Power Interface Circuit Board 5 Replace the Main Control Board HiHp Fan FdbkLs 70 Fan Feedback Loss a fan feedback 1 Check the main cooling fan signal has been lost 2 Check the Main Control Board cooling fan Addressing 700H Hardware Faults Troubleshooting and Error Codes 1 3 Fault
79. s 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 Setting To indicate the following 1 Off 50 Hz fan motor frequency 2 Off 220 V ac motor voltage S3 On 230 V ac motor voltage S4 Off Frame size 9 13 ON S S S3 S4 OFF 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 BA A T amp Remove Screws Disconnect fan motor cable Remove Screws c1 eee a t OT A Important Do not damage the output transformer when removing or inst
80. s to the Main DC Bus Bars and remove the Bus Bars DC Bus Bars fer 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 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 Se 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 ee A 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
81. ssembly Diagrams and Spare Parts Numbers D 1 Who Should Use this Manual Whatis in this Manual What is Not in this Manual Preface Overview 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 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 0 460 60 Hz 420 500 630 550 840 630 Frame 11 Serial Number 2622381652 This manual does not contain in depth fault information for troubleshooting Fault information is available in publications 20C PMO001 Programming Manual PowerFlex 700H Adjustable Frequency AC Drive PFLEX INOO06 Installation Instructions PowerFlex 700S and 700H Adjustable Frequency AC Drive and 20D UM006 User Manual PowerFlex 7008 High Performance AC Drive Phase II Control p 2 Overview Reference Materials Understanding Manual Conventions Allen Bradley publications are available on the in
82. tage 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 t
83. ternet at www rockwellautomation conmliterature The following publications provide general drive information Title Publication Wiring and Grounding Guide PWM AC Drives DRIVES INO001 Safety Guidelines for the Application Installation and Maintenance of SGI 1 1 Solid State Control A Global Reference Guide for Reading Schematic Diagrams 0100 2 10 Guarding Against Electrostatic Damage 8000 4 5 2 The following publications provide specific PowerFlex drive information Title Publication Programming Manual PowerFlex 700H AC Drive 20C PM001 User Manual PowerFlex 700S High Performance Drive Phase Il 20D UMO06 Control Installation Instructions Hi Resolution Feedback Option Card for 20D INO001 PowerFlex 700S Drives Installation Instructions Multi Device Interface Option for PowerFlex 20D IN004 7008 Drives Installation Instructions Main Control Board PowerFlex 700S Drives 20D IN005 Installation Instructions Control Assembly Cover for PowerFlex 700S 20D INOO6 Drives Installation Instructions PowerFlex 700S 700H High Power 20D INO014 Maintenance Stand Installation Instructions PowerFlex 700S and 700H Drives PFLEX INOOG Reference Manual PowerFlex 700S Adjustable Frequency Drive PFLEX RMO003 Phase II Control The following publications provide information that applying the DriveLogix Controller is necessary when Title Public
84. the ASIC Board Removal 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 The sheet metal cover and mounting screws on 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 using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when 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 Removing the Power Structure from the Drive Cabinet Access Procedures 3 21 Disconnect the other cables from sockets on the front of the ASIC Board and set them aside Remove the fan from the ASIC Board Slide the ASIC Board
85. to earth ground greater Check the motor and external than 2596 of drive rating Ground fault wiring to the drive output level is 50 of the drive s heavy duty terminals for a grounded current rating The current must condition appear for 800ms before the drive will fault InverterFault 14 Hardware problem in the power Cycle power structure Replace drive System Fault 10 Hardware problem exists in the power Cycle power structure Replace drive Load Loss 15 Do not use this fault in 700H Check that parameter 238 applications Fault Config 1 bit 0 Power Loss and parameter 259 Alarm Config 1 bit 13 Load Loss are set to zero Hp Drv OvrLoad 31 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 Power Unit 70 One or more of the output transistors Clear fault were operating in the active region instead of desaturation This can be caused by excessive transistor current or insufficient base drive voltage Diagnostic Procedures by Symptom Disconnect Motor Leads Troubleshooting and Error Codes 1 5 The following charts list drive symptoms symptom descriptions and recommended actions Blown Input Fuses Use this proced
86. ts intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook GPP PPP Torgue Specifications The following table lists fastener torgue specifications Item Screw Final Torque DPI HIM Assembly Door M3 x 6 Phillips 0 9 N m 8 Ib in DPI HIM Assembly mounting M3 x 6 Phillips 0 9 N m 8 Ib in 7008 Power Interface Circuit M3 x 6 Phillips 0 9 N m Board mounting 8 Ib in 700H I O and Control Assembly M4 x 8 self tapping 0 8 N m 7 lb in 3 2 Access Procedures Item Screw Final Torgue 700H Fiber Optic Adapter Board M4 x 8 POZIDRIV 0 9 N m mounting 8 Ib in 700S Voltage Feedback Circuit M3 x 6 Phillips 0 9 N m Board mounting 8 Ib in AC Input Terminals on Power M10 nut 40 N m Structure 354 Ib in Motor Output Terminals on Power M8 x 20 hexagonal screw 20 N m Structure 177 lb in Main Fan Mounting M6 x 20 POZIDRIV 3 N m 27 Ib in Main Fan M4 x 8 POZIDRIV 1 7
87. ueog JeAug ueJj OL LX pyeog Jamod Lf UOIOGUUOH xXoeqpee eDeyoA oL CL A TONS 171 iL d pleted USCH seues uj sde Z A009 PIER uj sde Z seues ul sded ACO uONeINHIJUOD 103pedep AQOY AOOP T 2ION eseud M pue N oL 90 od Od B 7 Schematics indu JA Ui seAug 10 uinou1 JOMOd MWaspud og N iJ LH OISV W04 CLH OlSV WOl4 SX OISV WO4 Soe ondo Jadi 9JJeJed uj sde seues uj sde Z A009 9JJeJed uj SdeD z seues uj sde AOL uoneunbyuo 10719edeD AQ09 AOOF T SION OL 9IH PO 9x pieog Jang ejec iX eux LLX OLX J Lf uonoeuuo xoeqpeeJ eBejoA OL d T JON 935 eseug A UoJJ 9q Schematics B 8 Control Wiring Diagrams ynduj JV ui seAug HOOL 10 suonaeuuo pJeog hindi g an ig
88. ure when a drive clears any of its external circuit breaker or power fuses Replace No Rectifying Module Perform Forward Diode Tests on Rectifying Module Rectifying Module OK Yes Replace No Power Modules Perform Forward Power Diode Tests on Modules Output Power OK Modules Examine Bus Capacitors for Capacitors Charring and OK Damaged Reliefs Replace No Capacitors Yes Remedy Motor No and Lead Problems Check Motor and Motor and Lead Resistances Lead Resistances at 1000V gt 1 Mohm Yes Disconnect AC Are There Choke from Any Line to Rectifying Module Load Shorts Yes No Are There Any Line to Line Shorts Reconnect Reconnect Motor Choke Leads 1 6 Troubleshooting and Error Codes No Output Voltage Use this procedure when there is no voltage present at the drive output terminals even though the drive indicates the motor is running DC Bus Measure DC Bus Voltage within Voltage Specification Perform forward No diode tests on Rectifying Module Rectifying Module OK Replace Rectifying Module Examine Bus Capacitors for Capacitors Charring and OK Damaged Reliefs Yes Replace Capacitors Measure Power Voltages within Replace Power Supply Voltages Specification ne Supply Check Board Does Drive Connections Run No Replace Main Do
89. wer Module 3 29 Removal uui Ei emere Ex n Eet ete xo extera 3 29 Installations 3 5 4 ret SS Silsbee dee nthe ere er te eR 3 32 Removing the V Phase Middle Rectifying Board Rectifying Module and Output Power Module 22 26 dee je eee Gee Obs sti ced 3 33 Removal ee to oea miea SE E EE 3 33 Chapter 4 Appendix A Appendix B Appendix C Appendix D Removing the W Phase Right Side Rectifying Board Rectifying Module and Output Power Te UE 3 36 Installation uere AA AAA Gan eds Ga TE A 3 38 Removing the DC Bus Capacitors 3 38 ue EE 3 38 Install tiOT celi eo AA UAE AA AAA Rua t ace WA 3 39 Before Applying Power to the Drive 0 0 eee eee eee eens 4 1 Testing with the External DC Power Supply Without Load Optional 4 2 Testing WithoutaMotor 4 3 Performing the Power Circuit Diagnostic Test on a 700S 4 3 Testing With the Motor 4 4 Software Tools essi 4p pL D EPPLORP IE RIT aes UDIN PEE ADS A 1 Service Toolsi IA Ae KA E Eeer BE eer Beete ht A 1 List of Schematic Diagrams B 1 Power Wiring Diagrams e sia essa 2 0 0 nuana cnet E Daa ET B 2 Control Wiring Diagrams AA r iia ande iaaii B 8 Circuit Board Connections eer aa n a E aa aa C 1 Hardware Connections C 8 Disassembly A
90. ying Circuit Board to the drive and remove the Rectifying Circuit Board E Frspeerses see ad 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 WW 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 LE 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 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

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