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pflex-tg002 - Rockwell Automation

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2. e 0 9 N m J 8 Ib in 3 Open the panel that holds the DPI interface and HIM 4 Unplug the DPI cable from the X2 connector on the DPI Interface circuit board X2 X4 Back view of DPI circuit board which should remain mounted on the back of the assembly J f 5 On 7005 drives only unplug the cable from the X4 connector on the DPI circuit board 6 Remove the four mounting screws and the assembly from the Control Frame Mounting screws P1 _ 0 9 N m 8 Ib in e D NS Installing the DPI HIM Assembly Removing the 700S Phase I Control Assembly Access Procedures 3 5 Install the DPI HIM assembly in reverse order of removal while referring to Torque Specifications on page 3 2 1 Remove power from the drive Refer to Removing Power from Drive on page 3 3 Important Before removing connections and wires mark the connections and wires to avoid incorrect wiring during 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 fiber optic cable is 25 4 mm 1 in Any bends with a shorter inside radius ca
3. 3 14 Installing the 700H Fiber Optic Adapter Circuit Board 3 15 Removing the Covers from the Power 5 2 3 15 Installing the Protective 2 0 3 19 Removing the 7005 Voltage Feedback Circuit 3 20 Installing the 7005 Voltage Feedback Circuit Board 3 2 Removing the Gate Driver and Adapter Circuit Boards 3 22 Installing the Gate Driver and Adapter Circuit Boards 3 26 Removing the Power Structure from the Drive Enclosure 3 27 Installing the Power Structure in the Drive Enclosure 3 27 Removing the Main Fans lle 3 28 Installing the Main Fans sssseeeeeeeee RII II 3 28 Removing the ASIC Circuit Board eee 3 29 Installing the ASIC Circuit 2 0 3 30 Removing the Rectifying Circuit Board eee eee 3 31 Installing the Rectifying Circuit Board 3 31 Removing the Precharging Resistors from Series B Drives 3 32 Installing the Precharging Resistors on Series B Drives 3 33 Removing the Left Side Output Power Module 0 cee ee ee eee 3 34 Installing the Left Side Output Power 3 36 Removing the Right Side Output Power Module and Rectify
4. Access Procedures 3 21 5 Remove the five screws that secure the Voltage Feedback circuit board to the drive and remove the circuit board from the drive Ds N m 8 Ib in Y Y Screws 5 Installing the 7005 Voltage Install the 7005 Voltage Feedback circuit board in reverse order of removal Feedback Circuit Board while referring to Torque Specifications on page 3 2 3 22 Access Procedures Removing the Gate Driver 1 Remove power from the drive Refer to Removing Power from Drive on and Adapter Circuit Boards page 3 3 2 Remove the covers from the power structure Refer to Removing the Covers from the Power Structure on page 3 15 3 Disconnect the wires from the fuse block that holds the fuses for the Fan Inverters and remove the fuses 4 Remove the four screws that secure the fuse block to the bracket beneath it and remove the fuse block Remove fuse wires Remove fuses Remove screws and fuse block e wat Led ve a Access Procedures 3 23 5 Carefully disconnect the fiber optic cables from sockets along the top of the Gate Driver 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
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9. 3 Remove the power structure from the drive cabinet Refer to Removing the Power Structure from the Drive Enclosure on page 3 27 Access Procedures 3 41 4 Prepare the Power Structure for Inverter assembly removal Description Remove the cable ties that secure the cables with orange insulation on both left hand and right hand sides This will allow you to move the cables while removing the inverter assemblies Left hand Inverter Right hand Inverter Left hand Side View Front View on Left hand Side 3 42 Access Procedures 5 Remove the Inverter assemblies Task Description Remove the two M5 POZIDRIV screws that secure the front of the fan A inverter to the drive ES Disconnect the fan motor cable under the inverter B Remove the four M5 POZIDRIV screws that secure the bottom of the fan inverter to the drive Disconnect the cables at X2 X8 and X3 on left hand and center D inverters and X2 and X8 on right hand inverter Carefully remove the inverters by sliding them out towards the front of E the drive Bottom View of Power Structure Important Take care to not damage the output transformer when removing or installing the inverter Access Procedures 3 43 6 Remove the Inverter from the old Inverter assembly Description Disconnect the cables at connectors X4 Blue and X5 Black Right ha
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11. e Parameter 902 SL Error Status 904 SL Node Cnfg displays SynchLink errors 905 SL Rx CommFormat and 910 SL Tx CommFormat e Reconnect SynchLink communication fibers Configured with parameter 384 SL CommLoss Cnfg 10 Power Loss e DC Bus voltage has fallen below e Verify AC line power the minimum value e Parameter 306 DC Bus Voltage displays bus voltage e Parameter 330 Fault TP Data displays the minimum value when parameter 329 Fault TP Sel is set to five The drive must first complete precharge before this check is made 1 4 Troubleshooting and Error Codes No Description Action if appropriate 11 Motor OLoad Trip A motor overload trip has occurred e Reduce the mechanical load Parameter 308 Output Current iS e Enter the correct motor nameplate squared scaled and integrated over load amps in parameter 2 time When this integrated value Motor NP FLA du Configure with parameter 371 Mtr i OL Trip Cnfg The integrator s output can be viewed in parameter 330 Fault TP Data when parameter 329 Fault TP Sel is set to 13 Mtr OL Outpt The overload integration rate is affected by parameters 336 Motor OL Factor 337 Mtr 121 Curr Min 338 Mtr I2T Spd Min and 339 Mtr I2T Calibrat 12 Motor OLoad Pend motor overload is pending Reduce the mechanical load Parameter 308 Output Current iS Enter the correct motor nameplat
12. 8 Ib in mm hex standoff AC Input Terminals on Power Structure M10 nut 40 N m 354 Ib in ASIC Fan M4 x 16 POZIDRIV 0 4 N m 3 5 Ib in Block Mounting M10 12 hexagonal screw 20 N m 177 Ib in Capacitor M4 x 8 self tapping 1 N m 9 Ib in Capacitor Bus Bar M6 x 16 POZIDRIV 4 N m 35 Ib in Capacitor Bus Bar M6 x 20 POZIDRIV 4 N m 35 Ib in DC DC Terminals M6 x 20 POZIDRIV 5 N m 44 Ib in DPI HIM Assembly mounting M3 x 6 Phillips 0 9 N m 8 Ib in DPI HIM Assembly Door M3 x 6 Phillips 0 9 N m 8 Ib in Main Fan M4 x 8 POZIDRIV 1 7 N m 15 Ib in Main Fan Mounting M6 x 20 POZIDRIV 3 N m 27 Ib in Main Fan Inverter Assembly M5 x 10 POZIDRIV 4 N m 35 Ib in Motor Output Terminals on Power Structure M8 x 20 hexagonal screw 20 N m 177 Ib in Output Power Module Output Terminals U V W 8 x 20 hexagonal screw 14 N m 124 Ib in Rectifier board Mounting x 8 POZIDRIV 1 N m 9 Ib in Rectifying Module Input Terminals L1 L2 L3 M10 20 hexagonal screw 12 N m 106 Ib in Touch Cover Main Fan M5 x 16 3 N m 27 Ib in Y Bus Bar M10 nut 40 N m 354 Ib in POZIDRIV is a registered trademark of the Phillips Screw Company Phillips is a registered trademark of Phillips Screw Company Removing Power from Drive A Access Procedures 3 3 ATTENTION To avoid an electric shock hazard verify that the voltage on the
13. Check the motor nameplate data has failed 2 Check the motor connections 99 UserSet Timer User Set load or save was not Replace the Main Control board completed in less than 5 seconds 100 Param Chksum The checksum read from the Main 1 Restore the drive to the factory Control board does not match the defaults checksum calculated 2 Cycle the power 3 Reload User Set if used 104 PwrBrd Chksum The checksum read from the 1 Cycle the power EEPROM does not match the 2 Contact Technical Support See checksum calculated from the Technical Support Options on EEPROM data i page 1 19 for more information 3 If the problem persists replace the drive 106 MCB PB Config The drive rating information stored on 1 Reset the fault or cycle the power the power board is incompatible with 5 Replace the Main Control board the Main Control board 107 New IO Option New option board was added to the 1 Restore the drive to the factory Main Control board defaults 2 Reprogram parameters as necessary 113 Fatal App A Fatal Application error has 1 Replace the Main Control board occurred Common Drive Conditions and Corrective Actions No Name 114 AutoT Enable Description started Autotune is enabled but has not Troubleshooting and Error Codes 1 17 Action if appropriate Press the Start key within 20 seconds of enabling autotune 120 I O Change An option board has been re
14. Circuit Board removal Removing the 7005 High Power Fiber Optic Interface Circuit Board Access Procedures 3 11 1 Remove power from the drive Refer to Removing Power from Drive on page 3 3 2 Loosen the captive screw and swing the Control assembly away from drive 3 Carefully disconnect the ribbon cables from the sockets at the top of the High Power Fiber Optic Interface circuit board and carefully set them aside Ribbon cables _____ Fiber optic cables Screws 5 P a N m 8 Ib in J5 Connector 4 Carefully disconnect the fiber optic cables from sockets along the right side of the High Power Fiber Optic Interface circuit board and carefully set them aside ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors Important Minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Any bends with a shorter inside radius can permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii 3 12 Access Procedures 5 Disconnect the 24V power supply cable from connector J5 on the High Power Fiber Optic Interface circuit board 6 Remove the five screws that secure the High Power Fiber Optic Interface circuit board to the Control Frame and remove
15. Cycle the drive power SRAM memory e Ifthe fault remains replace the Main Control Board 20 DSP Device Error A DSP Velocity Position Loop e Cycle the drive power interrupt task has not been completed in the allotted time 3 a replace the 22 Over Frequency Encoderless algorithm fails to converge on correct speed Two possible causes 1 Velocity regulator is attempting to run below motor s slip speed 2 Frequency regulator pulls out and commanded motor frequency slows to maximum frequency limit 23 MC Commissn Fail The drive has failed to complete e Verify that motor nameplate data is either the Motor Autotuning entered correctly into the drive procedure or the Power Circuits Verify the motor is wired for the Diagnostics test Parameters 463 correction voltage entering into the MC Diag Error 1 464 MC Diag drive Error 2 and 465 MC Diag Error 3 display Motor Autotuning and Power i if e and Circuit Diagnostic faults IEG ides Parameter 465 MC Diag Error 3 Change tuning mode in to Drive current inductance voltage parameter 515 FVC Tune Config and speed are not within motor to 9 NoRotate Tune nameplate specifications This fault occur most frequently on low horsepower motors 24 DC Bus Overvolt Refer to Protection in Appendix A in e Verify the AC Line the PowerFlex 7005 Phase ll Drive Verify that either the brake or bus User Manual publication reg
16. Disconnect the wiring from connectors X21 and X31 X22 and X32 and X23 and X33 on the Rectifying board o o X9 X100 X12 x33 X23 Xll x32 x22 X10 0 X6 X13 X101 X8 x2 Xi X41 Access Procedures 3 33 5 Remove the two screws that secure each of the Precharging Resistors to the drive frame and remove the Precharging Resistors 6 Pulse Drive Pers Remove screws from resistors 12 Pulse Drive Remove screws from resistors Installing the Precharging Install the Precharging Resistors in reverse order of removal Resistors on Series B Drives 3 34 Access Procedures Removing the Left Side Important Do not attempt to disassemble the Output Power Module Output Power Module Important Always replace the Output Power Modules in pairs do not replace just one module 1 Remove power from the drive Refer to Removing Power from 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 15 w Remove the power structure from the drive cabinet Refer to Removing the Power Structure from the Drive Enclosure on page 3 27 4
17. Interface board and the ASIC board Fiber optic connections between the High Power Fiber Optic Interface board and Voltage Feedback board 69 HiHp Bus Bus Communication Watchdog Error Check the communication bus lines WichDog no message packets came 1 10 pin connector between the through in the communication bus Control board and High watchdog error was detected Power Fiber Optic Interface board 2 Fiber optic connections between the High Power Fiber Optic Interface board and Voltage Feedback board 3 Replace the Voltage Feedback board 4 Replace the High Power Fiber Optic Interface board 5 Replace the ASIC board 6 Replace the Main Control board 70 HiHp Fan Fdbk Ls Fan Feedback Loss an inverter 1 Check the 10 pin connector cooling fan did not send active between the Main Control board feedback or did not work and High Power Fiber Optic Interface board 2 Check the fiber optic connections between the High Power Fiber Optic Interface Circuit board and the ASIC board 3 Verify that the inverter cooling fans are running 71 HiHp Drv OvrLoad Drive Overload the drive s operating 1 Reduce the mechanical load point has exceeded the intermittent 2 it after reducing the load the output current rating and a foldback to the current levels are well below the continuous rating in parameter 400 drive rated levels replace the Rated Amps has occurred power module 72 HiHp PwrBd PrcEr A processor on t
18. Socket extension 230mm 12 Wrench 7mm 8mm 10mm 13mm 17mm 19mm 22mm 13 Wire cutter 14 Nose pliers 15 Crimping tools For cable terminals 1 5 240 16 Angle wrench 17 Screw driver 18 Flat nose 7 2 mm 19 POZIDRIV 1 2 3 20 Phillips 1 2 3 21 Torx 25 22 Hexagonal wrench 4 5 6 23 ESD protected place of work Working surface Floor covering seat and ground connections 24 ESD protective clothing Wrist wrap shoes overall clothing coat 25 20 MAINSTND maintenance stand Maintenance stand for removing power structure from drive cabinet 26 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 A 2 Service Tools and Equipment Notes List of Schematic Diagrams Appendix B Schematics For a Schematic Diagram on See Power Circuitry for Drives with AC Input page B 2 Power Circuitry for Drives with DC Input page B 3 Circuit Board Connections for 7005 Drives with Phase Control page B 4 Circuit Board Connections for 700S Drives with Phase II Control page B 5 Circuit Board Connections for 700H Drives page B 6 Fan Power Supply Connections page B 7 Schematics B 2 9v 104 no AN ig
19. X101 J11 e 5 1 x Component Test Procedures Table 2 K Rectifying Board Charge Relay Test Results No Power on X13 Meter Leads Results J3 X9 J7 X9 009 J11 X9 2 11 2 12 Component Test Procedures Checking the Fan Inverters and Main Fans Gate Driver board Fan Inverter Fuses Checking the Fan Inverter LEDs frame 10 drive has two fans and two fan inverters Each fan inverter has a red and a green diagnostic LED AN ATTENTION The inverter LEDs are only operational when the drive is energized and only visible with the covers removed from the power structure Servicing energized equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Follow Safety related practices of NFPA 70E ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES DO NOT work alone on energized equipment LED Red Green Indication Steady Steady Inverter Idle Off Flashing Inverter Running Flashing Steady Inverter Faulted or No Control from ASIC Board Checking the Fan Inverter Fuses A pair of fuses F1 and F2 are included in the circuit to feed DC Bus power to the fan inverters The fuses are located on the left front of the drive next to the Gate Driver board Locate these fuses and using a multi meter verify that they are no
20. above the maximum limit or temperature sensor has failed shorted or open See parameter 346 Drive OL Status bit 0 NTC Shorted and bit 1 NTC Open e Lower the ambient temperature e Verify that the cooling fan s and fan inverter s are running and functioning properly e Check the heatsink for blockage or excessive dirt and clear clean as necessary Check the air filters if present for blockage and replace as necessary Troubleshooting and Error Codes 1 5 No Description Action if appropriate 16 InvOLoad Pend drive s operating point is e Reduce the load on the drive approaching the intermittent current e Configured with parameter 376 rating limitation If output current Inv OL Pend Cnfg remains at or above present levels an inverter overload condition will occur 17 Inv OLoad Trip The drive s operating point has e Reduce the mechanical load exceeded the intermittent current Configured with parameter 377 rating and a foldback to the Inv OL continuous rating in parameter 400 Rated Amps has occurred 18 Ext Fault Input A digital input has detected an Configured with parameter 379 Ext external fault Enter a value of 3 Ext Fault or 38 ExtFault Inv in one of the Digin x Sel parameters to configure an input to detect an external fault Fit Alm Cnfg 19 DSP Memory Error Flash memory does not match the e
21. and Common Mode Filter circuit board Updated the Spare Parts Lists for the Disassembly Assembly Drawings C4 Added an Index Index 1 soc ii Summary of Changes Notes Summary of Changes Preface Chapter 1 Chapter 2 Table of Contents Important User Information ssseeeeeeeeee 1 2 Manual Updates Current vC eA pede d e e CS IRR pte tied 5 1 Previous REVISION 255 Ed E st Mes act ER AA 5 1 Overview Who Should Use this 177 P 1 Whatisan this Manual rens ee EDIDI dea ua p P 1 What is Not in this Manual eeeeeeeee 2 Reference Matetials ive tp as Ra 2 Understanding Manual 2 ee 3 Additional Support Available on 2 0 3 General Precautions ced e er e RA ER SPA P 4 Troubleshooting and Error Codes Creating Fault Reports 02 4 cs eis he Dem D ERGO DRY e ts 1 2 Addressing 7005 Faults llle ne eee eee tesso 1 2 Addressing 700H I n E 1 13 Common Drive Conditions and Corrective 2 2 1 17 Technical Support Options 2 1 19 Component Test Procedures Viewing the 700H Diagnostic LED sslsseeeeee eee 2 1 Performing Visual Inspections 2 I 2 2 Conducting F
22. bus capacitors has discharged completely before servicing Check the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by 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 Turn off and lock out input power Wait five minutes Check the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements 3 4 Access Procedures Removing the DPI HIM 1 Remove power from the drive Refer to Removing Power from Drive on Assembly page 3 3 Important Before removing connections and wires mark the connections and wires to avoid incorrect wiring during assembly 2 Remove the two screws from front of DPI HIM assembly Screws
23. can permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii Access Procedures 3 15 6 Remove the four screws which secure the Fiber Optic Adapter bracket to the stand offs on the back of the Control Frame Remove 4 screws ends 8 Ib in 7 Remove the Fiber Optic Adapter Board from the Control Frame Installing the 700H Fiber Install the 700H Fiber Optic Adapter circuit board in reverse order of Optic Adapter Circuit Board removal while referring to Torque Specifications on page 3 2 Removing the Covers from You must remove the protective covers to gain access to the power structure the Power Structure Moving the Control Frame You must first move the Control Frame in order to remove the protective covers from the drive 1 Remove power from the drive Refer to Removing Power from Drive on page 3 3 2 Loosen the T8 Torx head screws that secure the Control Frame to the drive enclosure remove screws on early frame 10 drives 3 Swing the Control Frame out and away from the power structure 3 16 Access Procedures Frame 10 drives from early production runs have holes instead of slots for these screws You must completely remove the screws from these drives in order to swing open the control frame Access Procedures 3 17 Removing the Airflow Plate The drive is equipped with a plate
24. circuit board The tests you can perform and the results of those tests vary depending on which series of board is in your drive Rectifying Circuit Board Catalog String Voltage Class Series A Series B 400 480V AC 20 VB00459 20 VB00461 600 690V AC 20 VB00460 20 VB00462 1 Remove power from the drive Refer to Removing Power from 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 15 3 Remove the Power Structure from the enclosure Refer to Removing the Power Structure from the Drive Enclosure on page 3 27 4 Visually inspect the pre charging resistors If the pre charging resistors are damaged A Replace the Rectifying Module Refer to Removing the Right Side Output Power Module and Rectifying Module on page 3 36 B Check the rectifiers and external connections for short circuits C Check the Output Power Modules Refer to Conducting Forward and Reverse Biased Diode Tests for Major Power Components on page 2 3 5 Verify that the plugs on the cable that connects X13 on the Rectifying Board to X2 on the ASIC Board are properly seated 6 Verify that the jumper at X50 on the Rectifying board is in place Taking Measurements on Rectifying Module 7 Disconnect connectors X13 X12 X11 and X10 8 Perform resistance measurements using a digital multimeter on the points listed in Table 2 I on page 2 10 or Table 2 J on
25. drive Refer to Removing Power from 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 15 3 Remove the power structure from the drive cabinet Refer to Removing the Power Structure from the Drive Enclosure on page 3 27 Access Procedures 3 37 4 Carefully disconnect the fiber optic cables from 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 cables from X13 X14 and X15 sockets on the Gate Driver board and carefully set them aside 6 Disconnect the DC Bus wiring from the Gate Driver board 7 Remove the cable tie that secures the Power Module circuit board to the Adapter board 8 Disconnect the output leads from the bottom of the Output Power Module 9 Remove the Y bus bars Y Bus Bars 3 38 Access Procedures 10 Remove the balancing resistor wires from the bus bars Balancing Resistors AC Input Terminals L1 L2 L3 Balancing Resistor Wires 11 Dis
26. has Informational only been cleared 131 Alarm Cleared Indicates that all alarms have been _ Informational only cleared 132 Alarm Cleared indicates that the alarm queue has _ Informational only been cleared Addressing 700H Faults Troubleshooting and Error Codes 1 13 Name Description Action if appropriate 2 Auxiliary In The auxiliary input interlock is open Check all remote wiring 3 Power Loss The DC bus voltage remained below Monitor the incoming AC line for low the value set in parameter Power _ voltage or line power interruption Loss Volts for longer than the time specified in parameter Power Loss Time You can enable disable this fault with parameter 238 Fault Config 1 4 UnderVoltage The DC bus voltage fell below the Monitor the incoming AC line for low minimum value of 333V for 400 480V voltage or power interruption drives and 461V for 600 690V drives You can enable disable this fault with parameter 238 Fault Config 1 5 OverVoltage The DC bus voltage exceeded the Monitor the AC line for high line maximum value voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install a dynamic brake option 6 Motor Stall The motor is operating at high current 1 Run an Autotune and low frequency and is not 2 Reduce the Load accelerating 7 MotorOverl
27. incoming line potential To avoid electric shock hazard or damage to equipment only qualified service personnel should perform the following procedure Thoroughly read and understand the procedure before beginning If an event does not occur while performing this procedure Do Not Proceed Remove Power including user supplied control voltages User supplied voltages may exist even when main AC power is not applied to then drive Correct the malfunction before continuing ATTENTION Power must be applied to the drive to perform Loading the 700H EEPROM If you replace the Output Power Modules or Control Board in a 700H drive you must load information about the Power Modules or Control Board into the Power EEPROM Contact Allen Bradley Drives Technical Support for instructions and software tools for performing this operation 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 Avww ab com Click on Support http support rockwellautomation com Under Contact Customer Support click on Phone Support Internet Go to http www ab com support abdrives E mail support drives ra rockwell com Be prepared to provide the following information when you contact technical support e Product Catalog Number e Product Serial Number e Firmware Revision Level 4 2 Start Up Aft
28. just above the Control Frame that manages airflow through the drive You must remove this plate in order to remove the protective covers 1 Remove power from the drive Refer to Removing Power from 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 15 Screws ES M 3 Remove the T8 Torx head screws that secure the airflow plate to the drive and remove the air flow plate from the drive enclosure 3 18 Access Procedures Removing the Protective Covers from Power Structure 1 Remove power from the drive Refer to Removing Power from Drive on page 3 3 Move the Control Frame away from the power structure Refer to Removing the Covers from the Power Structure on page 3 15 Remove the Airflow Plate Refer to Removing the Airflow Plate on page 3 17 Remove the four M5 POZIDRIV screws that 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 covers Remove the four M5 POZIDRIV screws that secure the main front protective cover to the drive then remove the protective cover Access Procedures 3 19 6 Remove the side pr
29. missed the mating connectors Install the brackets and install and tighten the mounting screws Connect all of the cables on the Gate Driver board Removing the Power Structure from the Drive Enclosure Installing the Power Structure in the Drive Enclosure Access Procedures 3 27 1 Remove power from the drive Refer to Removing Power from 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 15 AC Power Connection Terminals r1 i T AA oiam SOSA T Ground Motor Connection Connection Terminals 3 Remove the motor wiring from the power structure at the front of the power structure 4 Remove the ground connection from the lower right rear corner of the power structure 5 Remove the AC power wiring from the incoming terminals at the top of the power structure 6 Follow the instructions in publication PFLEX INO14 Installation Instructions PowerFlex 7005 700H High Power Maintenance Stand to install the Maintenance Stand Remove the power structure by sliding it onto the rails of the Maintenance Stand Install the power structure in reverse order of removal while referring to Torque Specifications on page 3 2 Refer to the publication PFLEX INOO6 Installation Instructions PowerFlex 7008 and 700H High Power Drives for tightening torques of motor terminations 3 28 Access Procedures Rem
30. page 2 10 on AC Three Phase drives These points are on the back of the X10 X11 and X12 plugs which you have disconnected from the board If the Rectifying Module fails any of these tests replace it Refer to Removing the Right Side Output Power Module and Rectifying Module on page 3 36 2 10 Component Test Procedures Table 21 Series A Rectifying Circuit Board Resistance Measurements Measurement points Resistance X10 red to X10 black X11 red to X11 black 180 10 X12 red to X12 black Table 2 Series Rectifying Circuit Board Resistance Measurements Measurement points Resistance X10 red to X10 black X11 red to X11 black 470 4 7Q X12 red to X12 black Drives with Series A Rectifying Circuit Boards Only 9 Without applying power to X13 verify that there is no resistance between the following points J3 and X9 J7 and X9 and J11 and X9 Refer to Rectifying Board Charge Relay Test Results on page 2 11 If the Rectifying Module fails any of these tests replace it Refer to Removing the Right Side Output Power Module and Module on page 3 36 Figure 2 2 Rectifying Board Layout and Measurement Points X9 Jumpers for the Precharging Resistors amp EL LET VEN ESTE m AM x12 xi X10 X6 X13
31. 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 Remove fiber optic cables 6 Disconnect the other cables from the sockets of the Gate Driver board and set them aside 3 24 Access Procedures 7 Remove the six screws that secure the brackets to the drive and remove the brackets Access Procedures 3 25 8 Remove eight of the stacker connectors from the Gate Driver board leaving the two smaller ones which are third from the top 9 Carefully remove the Gate Driver board and the remaining connectors 10 Remove the cable ties that secure the Adapter board to the circuit boards on the Output Power Modules and remove the Adapter board 3 26 Access Procedures Installing the Gate Driver and Adapter Circuit Boards Replace the Adapter board and install the cable ties that secure it to the circuit boards on the Output Power Modules Plug the old stacker connectors into the new Gate Driver board so the pins do not protrude through the connectors on the back of the board Align the Gate Driver board so that its connectors align with the mating connectors on the Adapter board While supporting the Adapter board from behind press the Gate Driver board onto it Verify the proper alignment of the mounting with a mirror Verify that none of the pins in the stacker connectors have
32. terminology procedures required troubleshooting equipment equipment protection procedures and methods and safety precautions This manual contains hardware service information for Frame 10 PowerFlex 7005 and 700H drives only Verify that you are working on a Frame 10 drive by checking the data nameplate on the Control Frame The frame number is printed just above the serial number Cat No 20D J 500 0 NNNBNNNN 540V 650V Series A Standard NONE Normal Duty Power 250kW 450kW Original Firmware No 2 04 Heavy Duty Power 200kW 500kW Input DC C US LISTED DC Voltage Range 462 594 583 713 Amps 350 UL Open Type IP00 350 IND CONT EQ 9D42 Output 3 Phase 0 320Hz AC Voltage Range 0 400 0 460 C Base Hz defaul 50 Hz 60 Hz Continuous Amps 420 500 420 500 1 Min Overload Amps 630 550 630 550 2 Sec Overload Amps 840 630 840 630 MFD in 1989 on Nov 9 Frame 10 Serial Number 2622381652 AB p 2 Overview What is Not in this Manual Reference Materials This manual does not contain in depth installation and fault information for troubleshooting Troubleshooting information is available in publications 20C PMOOI Programming Manual PowerFlex 700H Adjustable Frequency AC Drive 20D UMO001 User Manual PowerFlex 7005 Drive with Phase I Control or 20D UMO006 User Manual PowerFlex 7005 Drive with Phase II Control Complete installation information is available i
33. 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 identify a hazard avoid a hazard and 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 PP PowerFlex DriveExplorer DriveExecutive DPI and SCANport are either trademarks or registered trademarks of Rockwell Automation Inc Current Revision Previous Revision Summary of Changes Manual Updates This information summarizes the changes made to the PowerF lex 7008 and 700
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36. 329 Fault TP Select is set to value 15 or 16 Cycle power e Reflash firmware Replace Main Control Board 29 PWM Signal Short This fault is detected when ever the actual IGBT gate is different than the commanded IGBT states This fault is detected by the Motor Control MC processor 30 MC Firmware One of the following Motor Control MC firmware errors has occurred MC Task Over Run e Illegal Interrupt e Self Diagnostic Fault e Data Error Cycle power e Reflash firmware Replace Main Control Board 31 Precharge Error The precharge function has failed to complete within 30 seconds default of the precharge request The precharge time out can be configured in parameter 410 PreChrg TimeOut A precharge request is initiated when the DC Bus voltage is above the Undervoltage Trip level and the precharge input is high the requirement for the precharge being high can be bypassed by setting parameter 411 PreChrg Control bit 01 PreChrg Enable off e Verify the value in parameter 410 PreChrg TimeOut e Verify the bit value in parameter 411 PreChrg Control 1 Enbl PrChrg e Configured with parameter 381 PreChrg Err Cnfg 32 PWM Asynch The Motor Control Processor is not synchronized with SynchLink 33 15volt Power The12V DC control voltage is outside the tolerance range The positive voltage power must be within the band from 17 00 t
37. 8 0 9 ainpow 1ndino 1M MoT M10 LEX 29 009 suu 005 J8MOg UI 2 N n 10 o eotepelu 9jeo einpojN T 1 M0d 397 ul Sio swyo 009 JA MoT 00 ainpoy P SWYO 009 suyo 00s JeMOg 437 ul 9x M 20 9jeo ss a qj 7 E nn 1ndino 1u61 000000 ejnpojy 1ndjno 387 ul HN N 20 eren HN UBIH 20 ere Jeu ee o Jen 00S ss alle pin se 009 009 908055 a suluo 008 cB 0 910799 INDO 3ndino YBIY 3 180550 1ndinQ JeMog 4427 ul HA YBIH A 10 aveau ere cda o9 Fa HA UBIH A 40 eret Jeniu3 gt ISH ZH 6H rH oH 1 _ Suyo 00S EC 008 009 ex x SWYO 009 1ndinQ 437 ut HM YBIH M 20 eyeo HM YBIH M 20 eje g NE SWYO p suyo gog 9041909 x ox 008 Checking the Rectifying Module on AC Input Drives Only Component Test Procedures 2 9 Important This procedure requires special equipment and training Only qualified and trained personnel should perform these procedures There is a series A and series B Rectifying
38. ASICBD E416 ASIC Assembly Upgrade Kit without the ASIC Board 20 FR10850 ASIC Assembly Bracket ASIC Assembly Bracket 8 ASIC Assembly Bracket Included in 20 FR10850 ASIC Assembly Cover Disassembly Assembly Diagrams C 9 Figure C 6 Main Fan Assembly Right Side Fan Main Fan 230W ain Fan Housing Intake Cone Zl Left Side Fan Main Fan 230W Main Fan Housing Intake Cone Table C F Main Fan Assembly Part Numbers Part Name Part Number Intake Cone NA Main Fan Housing NA Main Fan 230W 20 PP01080 C 10 Disassembly Assembly Diagrams Notes Numerics 700H Fiber Optic Adapter Circuit Board Installing 3 15 Removing 3 14 700H I O Circuit Boards and Control Assembly Installing 3 13 Removing 3 12 7008 High Power Fiber Optic Interface Circuit Board Installing 3 12 Removing 3 11 7008 Phase Control Assembly Installing 3 6 Removing 3 5 7005 Phase II Control Assembly Installing 3 8 Removing 3 6 7005 Voltage Feedback Circuit Board Installing 3 21 Removing 3 20 A Airflow Plate Removing 3 17 ASIC Circuit Board Installing 3 30 Removing 3 29 C Checking Fan Inverter Fuses 2 12 Fan Inverter LEDs 2 12 Main Fan Inverters and Fans 2 12 Main Fan Motors 2 13 Rectifying Module 2 9 Common Mode Filter Circuit Board Installing 3 10 Removing 3 9 Component Test Procedures 2 1 Conducting Forward and Reverse Biased Diode Tests for Major Power Components 2 3 Control Frame
39. Control bit14 Find Home or bit 27 Return Home automatically 1 12 Troubleshooting and Error Codes No 88 Name Stahl Optics Description Linear Stahl Encoder detected a fault Parameter 291 Lin1 Stahl Status shows the details of the fault Action if appropriate e Reconnect encoder or replace encoder e Reconnect option feedback card 93 12volt Power The12V DC control voltage is outside e Check the power supply on the Alarm the tolerance range Alarm The High Power Fiber Optic Interface positive voltage power exceeds and Voltage Feedback boards 15 50 V DC The negative voltage power exceeds 15 50V DC 94 AnalogIn 1 Loss Analog Input channel 1 is lost For e Check condition of Analog Input configuration of Analog Input channel channel 1 vee k S 1093 Ang e Change configuration for Anlg In1LossCnfg 95 In 2 Loss Analog Input channel 2 is lost For e Check condition of Analog Input configuration of Analog Input channel channel 2 ep i 1094 An ig e Change configuration for Anlg In2LossCnfg 96 3 055 Analog Input channel 3 is lost For e Check condition of Analog Input configuration of Analog Input channel channel 3 aa 3095 Anlg e Change configuration for Anlg In3LossCnfg 129 Faults Cleared Indicates that all faults have been Informational only cleared 130 Fault Q Cleared Indicates that the fault queue
40. D460 500 Amp SK H1 QOUT D500 600V Class 261 Amp SK H1 QOUT E261 325 Amp SK H1 QOUT E325 385 Amp SK H1 QOUT E385 416 Amp SK H1 QOUT E416 Rectifying Module 400V Class 20 FR10820 600V Class 20 FR10821 C 5 C 6 Disassembly Assembly Diagrams Figure C 3 Left Hand Side of Power Structure DC Bus Potential Contact may cause electric shock injury or death Disconnect all sources of power before touching any metal parts ASIC Assembly Ey Snubber Capacitor Assembly ATTENTION ASIC Sheet Metal and Mounting Screws are at DC Bus Bar Rm ua apum fe gt s s DC Bus Bar Insulator p ccm E E DC Bus Bar DC Bus Bar Insulator DC Bus Bar DC Bus Bar Insulator Cover Plate Output Power Module Insulation Support Electrolytic Capacitor ELKO 3300mf 420V Frame Disassembly Assembly Diagrams C 7 Table Left Hand Side of Power Structure Part Numbers Part Name Part Number Cover Plate NA Frame NA DC Bus Bar Insulator 20 FR10026 DC Bus Bar Insulator 20 FR10028 DC Bus Bar 20 FR10048 DC Bus Bar 20 FR10052 DC Bus Bar Insulator 20 FR100143 Insulation Support NA DC Bus Bar 20 FR10191 ASIC Assembly Upgrade Kit without the ASIC Board 20 FR10850 Series A Drive Discharging Resistor 2x16k 20 PP00056 Series B Drive Discharging Resistor 2x16k 20 PP13027 Electrolytic Capacitor EL
41. H Drives Frame 10 Hardware Service Manual publication PFLEX TG002 since the April 2007 release Change See Page Updated the 7008 and 700H faults 12 Removed the Diagnostic Procedures by Symptom diagrams and replaced them with 1 17 the new Common Drive Conditions and Corrective Actions tables Added the Technical Support Options section 1 19 Removed the Active Gate Driver Board measurements procedures from Chapter 2 Updated the Checking the Rectifying Module procedures to include the new Series B 2 9 Rectifying board Added procedure for removing the precharging resistors on series B rectifiers 3 32 Updated the Start Up After Repair procedures 4 1 Updated the Right Hand Side and Left Hand Side Power Structure spare parts lists C 4 This information summarizes the changes made to the PowerF lex 7008 and 700H Drives Frame 10 Hardware Service Manual publication PFLEX TG002 since the July 2005 release Change See Page Updated the 700S hardware faults 1 2 Removed references to brake option in the Conducting Forward and Reverse Biased 2 3 Diode Tests for Major Power Components brake option not available on PowerFlex 700H S Frame 10 drives Added Removal of PowerFlex 700S Phase II Control 3 6 Added the Removal of the Common Mode Filter Board 3 9 Updated the Circuit Board Connections Schematics to include the X50 Terminal Block B 1
42. KO 3300uf 420V 20 PP01005 Snubber Capacitor Assembly 20 PP10019 Output Power Module 400V Class 385 Amp SK H1 QOUT D385 460 Amp SK H1 QOUT D460 500 Amp SK H1 QOUT D500 600V Class 261 Amp SK H1 QOUT E261 325 Amp SK H1 QOUT E325 385 Amp SK H1 QOUT E385 416 Amp SK H1 QOUT E416 Figure C 4 Fan Inverter Assembly Capacitor 7uf 450V ac Fan Inverter Circuit Board Output Transformer Assembly Output Transformer Assembly for Fan Inverter Left for Fan Inverter Right Table C D Fan Inverter Assembly Part Numbers Part Name Part Number Output Transformer Assembly for Fan Inverter Left 20 FR10844 Output Transformer Assembly for Fan Inverter Right 20 FR10845 Capacitor 7uf 450V ac 20 PP0001 1 Fan Inverter Circuit Board 20 VB00299 C 8 Disassembly Assembly Diagrams Figure C 5 ASIC Assembly DC Bus Potential Contact may cause electric shock injury or death Disconnect all sources of power before touching any metal parts ATTENTION ASIC Sheet Metal and Mounting Screws are at ASIC Assembly Cover ASIC Board ASIC Assembly Bracket ASIC Assembly Bracket ASIC Assembly Bracket Table ASIC Assembly Part Numbers Part Name Part Number ASIC Board 400V Class 385 Amps SK H1 ASICBD D385 460 Amps SK H1 ASICBD D460 500 Amps SK H1 ASICBD D500 600V Class 261 Amps SK H1 ASICBD E261 325 Amps SK H1 ASICBD E325 385 Amps SK H1 ASICBD E385 416 Amps SK H1
43. Moving 3 15 Creating Fault Reports 1 2 Index D DC Bus Capacitors Installing 3 45 Removing 3 44 De energizing the Drive 3 3 DPI HIM Assembly Installing 3 5 Removing 3 4 F Fan Inverters Diagnostic LED 2 12 Fuses 2 12 Installing 3 43 Removing 3 40 Tests 2 12 Fault Reports 1 2 Forward Biased Diode Tests 2 3 G Gate Driver and Adapter Circuit Boards Installing 3 26 Removing 3 22 Gate Driver Board Measurements Gate Interface Resistance 2 7 Gate Interface Resistance 2 7 2 8 Inspecting Cooling Tunnels 2 2 Power Structure 2 3 Isolating a Faulty Fan Inverter 2 13 L Left Side Output Power Module Installing 3 36 Removing 3 34 M Main Fan Motors Tests 2 13 Index 2 Main Fans Installing 3 28 Removing 3 28 Tests 2 12 Moving the Control Frame 3 15 Output Power Modules Forward Biased Diode Tests on 2 5 2 6 Reverse Biased Diode Tests on 2 5 2 6 Output Power Transistor Gate Resistance 2 8 P Performing Visual Inspections 2 2 Power Structure Installing 3 27 Removing 3 27 Powering Down 3 3 Protective Covers Installing 3 19 Removing 3 18 R Rectifying Circuit Board Installing 3 31 Layout 2 10 Measurement Points 2 10 Removing 3 31 Rectifying Module 2 9 Forward Biased Diode Tests on 2 4 2 5 Installing 3 40 Removing 3 36 Reverse Biased Diode Tests on 2 4 2 5 Removing Power from the Drive 3 3 Resistance Measurements 2 9 Reverse Biased Diode Tests 2 3 Right Side Output Power Modu
44. MultErr Cnfg State displays SynchLink multiplier overflow errors 41 Ridethru Timeout The drive has been in a bus loss e Verify the AC Line ride through condition for more than Verify the value in Power Loss two seconds default The Time ride through timeout can be configured in parameter 407 Power Loss Time 42 DC Bus Undervolt Bus voltage has fallen below the level e Verify the AC Line configured in parameter 409 Line In frames 1 4 and 9 13 verify Undervolts the precharge resistor is present With power off there should be a resistance between DC BR e In frames 5 4 6 check the precharge board for errors See the precharge board LED for fault sequence Configured with parameter 393 BusUndervoltCnfg 43 VoltageFdbk Loss Loss of Motor or DC Bus Voltage e Check the communication line Feedback has occurred because of a between Motor Control MC and communication failure between Motor Voltage Feedback board Control and Voltage Feedback board Replace the Voltage Feedback board Configured with parameter 394 VoltFdbkLossCnfg 44 Runtime Data Rst Runtime data hours energy has 45 Enable Health Safety circuit is active Check input signal to the Safety circuit 46 Interp Out Synch Interpolator for position feedback lost Configured with parameter 378 synchronization with Velocity Position Interp Fit Cnfg Loop VPL 1 8 Troublesh
45. N The Control Assembly LED is only operational when the drive is energized and only visible with the covers removed from the power structure Servicing energized equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Follow Safety related practices of NFPA 70E ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES DO NOT work alone on energized equipment 2 2 Component Test Procedures LED visible through this hole LED Indication Steady The drive is operational and has no faults Flashing Quickly e e Switching power supply overload Rectifier Board fault Fan or fan inverter fault Brake Chopper fault Fiber Optic Adapter Board Fault Flashing Slowly Bad connection between circuit boards check all connections Performing Visual Inspections Visually inspect the cooling tunnels and power structure before energizing the drive Inspecting the Cooling Tunnels 1 Remove power from the drive Refer to Removing Power from Drive on page 3 3 2 Remove the main cooling fans from the bottom of the power structure Refer to Removing the Main Fans on page 3 28 3 Inspect the tunnels Clean the heatsinks and tunnels if necessary Conducting Forward and Reverse Biased Diode Tests for Major Power Components Component Test Procedures 2 3 Inspecting the Power Structure 1 Remove power from the drive Refer to Removing Pow
46. PowerFlex 7005 700H Adjustable Frequency AC Drives FRAME 10 HARDWARE SERVICE MANUAL 200 250 kW 400V 300 450 HP 480V 250 450 HP 600V 250 400 kW 690V ALLEN BRADLEY ROCKWELL SOFTWARE 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 http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect
47. Remove the cable tie that secures the Power Module circuit board to the Adapter board 5 Disconnect the output leads from the bottom of the Output Power Module 6 Remove the Y bus bars Y Bus Bars Access Procedures 3 35 7 Remove the balancing resistor wires from the bus bars Balancing Resistor Wires Snubber Capacitors 2 Snubber Fastening Screws 8 Remove the screws that secure the Snubber Capacitors and remove the Snubber Capacitors from the power structure 9 Remove the screws that secure the DC bus bars to the left side of the power structure and remove the DC bus bars 10 Remove the screws that secure the Output Power Module to the drive 11 Disconnect the Power Module circuit board from the Adapter board 3 36 Access Procedures 12 Remove the Output Power Module from the drive Installing the Left Side Important If you replace the Output Power Modules in a 700H drive you Output Power Module must load information about the Power Modules into the Power EEPROM refer to Loading the 700H EEPROM on page 4 1 Install the Output Power Module in reverse order of removal while referring to Torque Specifications on page 3 2 Removing the Right Side Important Do not attempt to disassemble the Output Power Module Output Power Module and Rectifying Module Important Always replace the Output Power Modules in pairs do not replace just one module 1 Remove power from the
48. ameters 54 Zero Divide This event occurred because a 1 Cycle the power mathematical function had a dividend 2 Replace the main control board of zero 59 Gate Disable Both of the digital gate disable inputs 1 Check the motor SD 1 and 50 2 not enabled 2 Verify that the option board is the 20C DG1 option board properly wired 3 Replace the option board Refer to Appendix E Instructions for ATEX Approved PowerFlex 700H Drives in Group II Category 2 Applications with ATEX Approved Motors in the PowerFlex 700H S High Power Drives Installation Manual publication PFLEX INOOG for information on installing this option board 60 Hrdwr Therm The thermistor input is activated 1 Check the motor gt 4kQ on the 20C DG1 option 2 The resistance of the thermistor board input must go below 2kQ before the drive can be reset 63 Shear Pin The value programmed in parameter Check the load requirements and the 148 Current Lmt Val has been value in Current Lmt Val exceeded You can enable disable this fault with parameter 238 Fault Config 1 65 Removed An I O option board has been Clear the fault removed 70 Power Unit One or more of the output transistors Clear the fault were operating in the active region instead of desaturation This can be caused by excessive transistor current or insufficient base drive voltage 1 16 Troubleshooting and Error Codes No Name Descript
49. ance 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 completely before servicing Check the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION Potentially fatal voltages may result from improper usage of an oscilloscope and other test equipment The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded If an oscilloscope is used to measure high voltage waveforms use only a dual channel oscilloscope in the differential mode with X 100 probes It is recommended that the oscilloscope be used in the A minus B Quasi differential mode with the oscilloscope chassis correctly grounded to an earth ground Chapter 1 Troubleshooting and Error Codes gt ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into module ports or fiber optic cable connectors ATTENTION The sheet metal cover and mounting screws on the ASIC board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if some
50. at 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 completely before servicing Check the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION 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 This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook The Control Assembly on 700H drives contains a diagnostic LED which is visible through the cover of the Control Assembly ATTENTIO
51. ation Troubleshooting and Error Codes 1 15 No Name Description Action if appropriate 32 Fan Cooling Fan is not energized at start 1 Check the status LEDs on the fan command inverter s 2 Verify that the fan s and fan inverter s are running 33 AutoResetLim The drive unsuccessfully attempted Correct the cause and manually clear to reset a fault and resumed running for the programmed number of Flt RstRun Tries you can enable disable this fault with parameter 238 Fault Config 1 the fault 34 CAN Bus Fit A sent message was not 1 Cycle the power acknowledged 2 Replace the Main Control board 37 HeatsinkUndTp ambient temperature is too low Raise the ambient temperature 44 Device Change The new power unit or option board Clear the fault and reset the drive to installed is a different type the factory defaults 45 Device Add A new option board was added Clear the fault 47 NvsReadChksum There was an error reading 1 Cycle the power parameters 9 Elapsed MWh and 10 2 Replace the Main Control board Elapsed Run Time from EEPROM 48 ParamsDefault The drive was commanded to write 1 Clear the fault or cycle power to default values to EEPROM the drive 2 Program the drive parameters as needed 50 MotorCalcData The motor nameplate data is Check the motor nameplate data and incorrect verify the proper entry in the Motor Data par
52. autions Class 1 LED Product A gt gt ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into module ports or fiber optic cable connectors ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference 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 7005 and 700H Drives and associated machinery should plan or implement the installation start up and subsequent mainten
53. board If there are loose or missing connections or a board has been damaged replace the loose or missing connections or repair or replace any of the boards as needed Otherwise Replace the HIM Technical Support Options Troubleshooting and Error Codes 1 19 Technical Support Wizards If you are connected to a drive via DriveExplorer or DriveExecutive you can run a Tech Support wizard to gather information that will help diagnose problems with your drive and or peripheral device The information gathered by the wizard is saved as a text file and can be emailed to your remote technical support contact See What You Need When You Call Tech Support on page 1 20 for more information To run a Tech Support wizard in DriveExplorer select Wizards from the Actions menu In DriveExecutive select Wizards from the Tools menu Or click the button Follow the prompts to complete the wizard 1 20 Troubleshooting and Error Codes What You Need When You Call Tech Support When you contact Technical Support please be prepared to provide the following information Order number Product catalog number and drives series number if applicable Product serial number Firmware revision level Most recent fault code Your application The data contained in the following parameters will help in initial troubleshooting of a faulted PowerFlex 700H drive You can use the table below to record the data provided in each paramet
54. connect all wiring from the circuit board on the Rectifying Module 12 Disconnect the cables from the AC input terminals on the Rectifying Module 13 Remove the circuit board from the Rectifying Module refer to Removing the Rectifying Circuit Board on page 3 31 14 Remove the screws that secure the Snubber Capacitors and remove the Snubber Capacitors md Snubber Capacitors Snubber Capacitor Fastening Screws Access Procedures 3 39 15 Remove the screws that secure DC bus bars to right side of power structure and remove the DC bus bars 16 Remove the screws that secure the Rectifying Module to the power structure and remove the Rectifying Module n E 000 3 40 Access Procedures 17 Remove the screws that secure the Output Power Module to the power structure and remove the Output Power Module Installing the Right Side Important If you replace the Output Power Modules in a 700H drive you Output Power Module and must load information about the Power Modules into the Power Rectifying Module Refer to Loading the 700H EEPROM on page 4 1 Install the Output Power Module in reverse order of removal while referring to Torque Specifications on page 3 2 Removing the Fan Inverters 1 Remove power from the drive Refer to Removing Power from 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 15
55. d Power Board Over Temperature the e Verify that the ambient Otemp temperature of the High Power Fiber temperature is within the Optic Interface circuit board has specification Check the main cooling fan and fan power supply replace if necessary e Replace the Power modules if the ambient temperature is within specification and the cooling fans are operating properly 81 Soft Over Motion Only Configured with parameter 395 Sft Position feedback exceeds the OvrTrviCnfg maximum positive travel setting parameter 694 Motn Mx Pos 82 Soft Over Trvl Motion Only Configured with parameter 396 Sft Position feedback exceeds the OvrTrviCnfg maximum negative travel setting parameter 695 Motn Mx Neg 83 Over Trvl Motion Only Configured with parameter 397 Hrd Signal for the hardware positive over OvrTrvlCnfg travel appears on a digital input 84 Over Trvl Motion Only Configured with parameter 398 Hrd Signal for the hardware negative over OvrTrvlCnfg travel appears on a digital input 85 Position Error Motion Only e Verify the value in Motn PositErrTol Configured with parameter 399 Position ErrCnfg 86 Drive Homing When the drive is in Drive Homing mode parameter 740 Position Control bit 24 or bit 27 is On the Drive Homing Alarm triggers and the drive moves to a home position Check parameter 740 Position
56. e squared scaled and integrated over full load amps in parameter 2 time When this integrated value Motor NP FLA iin e Configure with parameter 372 Mtr OL Pend Cnfg The integrator s output can be viewed in parameter 330 Fault TP Data when parameter 329 Fault TP Sel is set to 13 Mtr OL Outpt The overload integration rate is affected by parameters 336 Motor OL Factor 337 Mtr 121 Curr Min 338 Mtr I2T Spd Min and 339 Mtr 12T Calibrat 13 Motor Stalled The motor has stalled These three e Increase torque limit conditions have occurred at the same time for the amount of time specified in parameter 373 Motor Stall Time 1 Drive is not stopped parameter 150 Logic State Mach not equal to zero 2 Drive is on limit parameter 304 Limit Status not equal to zero 3 Drive is at zero speed parameter 155 Logic Status bit 13 At Zero Spd is set e Reduce mechanical load Configured with parameter 374 Motor Stall Cnfg 14 Inv Pend Parameter 313 Heatsink Temp is e Reduce the mechanical load within 10 C of the maximum value Lower the ambient temperature View the maximum heat sink Configured with parameter 375 temperature in parameter 348 Drive Inv OT Pend Cnfg OL TP Data when parameter 347 Drive OL TP Sel is set to 30 15 Inv OTemp Trip Parameter 313 Heatsink Temp is e Reduce the mechanical load
57. ecified limits limiting 2 Verify that the system ground impedance follows the proper grounding techniques 3 Disable bus regulation and or add a dynamic brake resistor and or extend the deceleration time 25 OverSpd Limit Functions such as Slip Remove the excessive load or Compensation or Bus Regulation overhauling conditions or increase have attempted to add an output the value in parameter 83 frequency adjustment greater than Overspeed Limit the value programmed in parameter 83 Overspeed Limit 28 BrakResMissing brake resistor has been detected 1 Program parameter Bus Reg Mode x to not use the brake option 2 Install a brake resistor 29 Anlg In Loss An analog input is configured to fault 1 Check parameter settings on a signal loss A signal loss has 5 Check for broken loose occurred Configure this fault with connections at the inputs Anlg In x Loss 30 MicroWatchdog A microprocessor watchdog timeout 1 Cycle the power has occurred 2 Replace the Main Control board 31 IGBT Temp HW The drive output current has 1 Check for an excess load 2 exceeded the instantaneous current limit Raise the value set in Accel Time x 3 Parameter 53 Motor Cntl Sel may need to be set to Custom V Hz 4 Verify the values set in parameters 62 IR Voltage Drop and 63 Flux Current Ref 5 Contact Technical Support See Technical Support Options on page 1 19 for more inform
58. eed Limit and 335 Abs OverSpd Lim Action if appropriate Check to see if the encoder feedback polarity is correct e Check to see if the drive is in torque mode selected in parameter 110 Speed TorqueMode value 2 Torque Ref If the drive is in torque mode verify that there is a load present e Verify min max settings in parameters 75 Rev Speed Lim and Par 76 Fwd Speed Lim Check to see if the load is overhauling If it is overhauling turn the bus regulator off using parameter 414 Brake Bus Cnfg bit 2 BusRef High 2 Vref Decel Fail The value of parameter 301 Motor Spd Ref has failed to decrease during a ramp to zero speed stop This may be due to a speed trim from parameters 21 Speed Trim 1 22 Speed Trim 2 or 23 Speed Trim 3 3 Encoder 0 Loss One of the following has occurred on encoder 0 missing encoder broken wire quadrature error phase loss Reconnect encoder or replace encoder e Configured with parameters 365 Fdbk LsCnfg Pri 366 Fdbk LsCnfg Alt and 367 Fdbk LsCnfgPosit 4 Encoder 1 Loss One of the following has occurred on encoder 1 missing encoder broken wire quadrature error phase loss Reconnect encoder or replace encoder e Configured with parameters 365 Fdbk LsCnfg Pri 366 Fdbk LsCnfg Alt and 367 Fdbk LsCnfgPosit Troubleshooting and Error Codes 1 3 No Description Acti
59. electrical shock injury or death exists if ATTENTION The sheet metal cover and mounting screws on the someone comes into contact with the assembly 4 Complete the Conducting Forward and Reverse Biased Diode Tests for Major Power Components on page 2 3 for the Output Power modules If the test is not completed successfully replace the Output Power modules Otherwise continue with step 5 5 Check the motor windings and motor cables with a high resistance DVM megger Repair or replace the motor as needed 1 18 Troubleshooting and Error Codes Blown Input Fuse If the drive causes the AC input line fuse to open complete the following tests to verify that the power structure is functioning properly before replacing the AC input line fuse and reapplying power to the drive Diagnostic Procedure 1 Disconnect the motor leads Corrective Action Continue with step 2 2 Complete the Conducting Forward and Reverse Biased Diode Tests for Major Power Components on page 2 3 for the Rectifier module If the test is not completed successfully replace the Rectifying module Continue with step 3 3 Complete the Conducting Forward and Reverse Biased Diode Tests for Major Power Components on page 2 3 for the Output Power modules If the test is not completed successfully replace the Output Power modules Continue with step 4 4 Examine the DC bus capacitors If t
60. er Repair Before Applying Power to the Drive Testing Without the Motor 1 Check the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements Perform the 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 3 This test allows you to measure several operating parameters and diagnose problems without connecting the motor to the drive 1 2 Verify that the input power wiring and grounding is connected Verify that the motor cables are disconnected Energize the drive 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 that allow the HIM to issue start and speed commands Make configuration changes that allow operation without an encoder and motor Start the drive by pressing a the start button Increase the speed command from zero to base speed by pressing the up button Measure the output voltage on each phase and verify that it is balanced If it is unbalanced troubleshoot the drive 10 Stop the drive by pressing the stop button 11 Re configure the drive to suit the application Perf
61. er from Drive on page 3 3 Remove the covers from the power structure Refer to Removing the Covers from the Power Structure on page 3 15 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 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 A reverse biased diode test should find an open circuit and the meter should display a value close to zero Ex OL zero load Important The actual voltage readings may vary depending upon your equipment If your readings are not near the indicated values in the tables below verify that the actual voltage measured is consistent for the Rectifying module and Output Power modules There is a series A and series B Rectifying circuit board The tests you can perform and the results of those tests vary depending on which series of board is in your drive Rectifying Circuit Board Catalog String Voltage Class Series A Series B 400 480V AC 20 VB00459 20 VB00461 600 690V AC 20 VB00460 20 VB00462 1 Remove power from the drive Refer to Removing Power from Drive on page 3 3 Remove the covers from
62. er listed Name Description Parameter Data 224 Fault Frequency Captures and displays the output speed of drive at time of last fault 225 Fault Amps Captures and displays motor amps at time of last fault 226 Fault Bus Volts Captures and displays the DC bus voltage of drive at time of last fault 227 Status 1 Fault Captures and displays Drive Status 1 bit pattern at time of last fault 228 Status 2 Fault Captures and displays Drive Status 2 bit pattern at time of last fault 229 Alarm 1 Fault Captures and displays Drive Alarm 1 bit pattern at time of last fault 230 Alarm 2 Fault Captures and displays Drive Alarm 2 bit pattern at time of last fault 243 Fault 1 Code A code that represents the fault that tripped 245 Fault2 Code drive 247 Fault 3 Code 249 Fault 4 Code 251 Fault 5 Code 253 Fault 6 Code 255 Fault 7 Code 257 Fault 8 Code 244 Fault 1 Time Time stamp of the fault occurrence 246 Fault 2 Time 248 Fault 3 Time 250 Fault 4 Time 252 Fault 5 Time 254 Fault 6 Time 256 Fault 7 Time 258 Fault 8 Time 262 269 Alarm Code 1 8 A code that represents a drive alarm No time stamp available Viewing the 700H Diagnostic LED Chapter 2 Component Test Procedures gt gt gt bb ATTENTION To avoid an electric shock hazard ensure th
63. eter should display 0L zero load DC T2 DC T3 2 6 Component Test Procedures Series B Rectifying Circuit Board Output Power Module Tests Table 2 G Forward Biased Diode Tests on Output Power Modules Meter Leads Nominal meter reading DC T1 DC T2 The value should gradually rise to about 1 0v 0 DC T3 T1 DC T2 DC The value should gradually rise to about 0 350 T3 DC 07 The actual voltage reading may vary depending upon your equipment If your readings are not near 1 0V verify that the actual voltage measured is consistent for the Rectifying module and the Output Power modules The actual voltage reading may vary depending upon your equipment If your readings are not near 0 35V verify that the actual voltage measured is consistent for the Rectifying module and the Output Power modules Table 2 H Reverse Biased Diode Tests on Output Power Modules Meter Leads Nominal meter reading Ti DC T2 DC T3 DC DC z Meter should display 00 zero load and rises to the meter battery voltage DC T2 DC T3 If the drive fails any of these measurements replace both Output Power Modules Component Test Procedures 2 7 Conducting Gate Driver 1 Remove power from the drive Refer to Removing Power from Drive on Board Gate Interface page 3 3 Resistance Measurements 2 Remove the covers from the power structure Refer to Removing the Covers fro
64. he High Power Fiber Check the communication bus Optic Interface circuit board has detected a self diagnostic problem lines 1 10 pin connector between the Main Control board and High Power Fiber Optic Interface board 2 Fiber optic connections between the High Power Fiber Optic Interface board and ASIC board 3 Replace the High Power Fiber Optic Interface board Troubleshooting and Error Codes 1 11 Parameter 769 Position Error exceeded parameter 696 Motn PositErrTol No Name Description Action if appropriate 73 HiHp PrChrg Cntc Precharge Contactor Fault the On drives with DC input precharge contactor did not send Check for loose or incorrect back the active feedback connections from the external precharge circuit to the X50 terminal block and to the ASIC board X9 and X15 On drives with AC input e Check the precharge resistors and relays on the Rectifier board 74 HiHp PwrEE Error Power EEPROM Error the CRC of 1 Cycle power the data stored in the High Power 2 Check the communication bus Fiber Optic Interface circuit board lines EEPROM does not match the stored 10 connector between the Main Control board and High Power Fiber Optic Interface board e Fiber optic connections between the High Power Fiber Optic Interface board and ASIC board 3 Replace the High Power Fiber Optic Interface board 4 Replace the ASIC board 75 HiHP PwrB
65. he Power EEPROM Refer Assembly to Loading the 700H EEPROM on page 4 1 Install the 700H Control and I O circuit boards in reverse order of removal while referring to Torque Specifications on page 3 2 3 14 Access Procedures Removing the 700H Fiber Optic Adapter Circuit Board Remove power from the drive Refer to Removing Power from Drive on page 3 3 Remove the I O circuit boards and Control assembly Refer to Removing the 700H I O Circuit Boards and Control Assembly on page 3 12 Move the Control Frame to expose its back Refer to Removing the Covers from the Power Structure on page 3 15 Disconnect the control power cable from X2 on the Fiber Optic Adapter circuit board o 7 t 6 5 X7 connects to Main F H1 through H7 sockets Control circuit board 5 for Fiber Optic cables Note Disconnects 2 when you remove 2 the circuit board from A 1 the control frame r n O X2 connects to 24V dc power Carefully disconnect the fiber optic cables from right side of the circuit board and carefully set them aside using optical transmission equipment This product emits intense ATTENTION Hazard of permanent eye damage exists when light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors Important Minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Any bends with a shorter inside radius
66. here is evidence of charring and damaged reliefs replace the DC bus capacitors Otherwise continue with step 5 5 Check the motor windings and motor cables with a high resistance DVM megger Repair or replace the motor as needed Otherwise continue with step 6 6 Disconnect and check the AC choke with a high resistance DVM megger e Verify that the line to line is open e Verify that the line to ground is open e Verify that the input to output is low resistance but not shorted Repair or replace the AC choke as needed Continue with step 7 7 Reconnect the AC choke and motor leads No HIM Display If the HIM does not display complete the following procedure to verify that power is available Diagnostic Procedure 1 Measure the DC bus voltage Corrective Action If the DC bus is not within specification repair or replace the Rectifying module as needed Otherwise continue with step 2 2 Measure the DC voltage supply at connector X4 on the DPI circuit board on the back of the HIM cradle The voltage should be approximately 12V DC If the DC voltage is incorrect PowerFlex 7005 drives Replace the High Power Fiber Optic Interface circuit board e PowerFlex 700H drives Replace the output power modules Otherwise continue with step 3 3 Check for loose or missing connections between the DPI circuit board and the High Power Fiber Optic Interface circuit
67. ice is connected to a drive operating DPI devices at 500k 9 Baud 54 DPI Loss Port6 The device at DPI port 6 has stopped e Verify DPI device is present and communicating with the drive functional at port 6 A SCANport device is connected to a B eee 331 drive operating DPI devices at 500k 9 Baud 55 NetLoss DPI P1 A communications fault has occurred e Verify network connection between the communication adapter at DPI port 1 and the network b UL Configured with parameter 392 NetLoss DPI Cnfg 56 NetLoss DPI P2 A communications fault has occurred e Verify network connection between the communication adapter at DPI port 2 and the network S Nery netiork e Configured with parameter 392 NetLoss DPI Cnfg 57 NetLoss DPI P3 A communications fault has occurred e Verify network connection between the communication adapter at DPI port 3 and the network e Mery netivork Configured with parameter 392 NetLoss DPI Cnfg 58 NetLoss DPI P4 A communications fault has occurred e Verify network connection between the communication adapter at DPI port 4 and the network e Verify status of network Configured with parameter 392 NetLoss DPI Cnfg 59 Net Loss DPI P5 Troubleshooting and Error Codes Description communications fault has occurred between the communication adapter at DPI port 5 and the network 1 9 Action if appropriate Verify
68. in parameter 306 DC Bus Voltage 700S parameter 012 DC Bus Voltage 700H Energize the drive Start the drive and increase the speed from zero to base speed Measure the drive output current and verify that the value is reflected in parameter 308 Output Current 7005 parameter 003 Output Current 700H 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 continuity resistance capacitance measurements and forward diode bias tests Fluke model 87 Ill or equivalent 7 Insulation tester 1000Vdc 8 Torque wrench 1 12 9 Torque wrench 6 50Nm 10 Box wrench 7mm 8mm 10mm 13mm 17mm 19mm 22mm 11
69. ing Module 3 36 Installing the Right Side Output Power Module and Rectifying Module 3 40 Removing the Fan Inverters 2 lees 3 40 Installing the Fan Inverters 2 2 RII 3 43 Removing the DC Bus Capacitors 0 0 cee ccc eee enna 3 44 Installing the DC Bus Capacitors 0 0 eee cc ee eens 3 45 Start Up After Repair Loading the 700H EEPROM 2 2 0 4 1 Before Applying Power to the 2 eh 4 2 Testing Without the s coroa na e e RII II 4 2 Performing the Power Circuit Diagnostic Test a 7005 4 3 Testing With the Motor Without a Mechanical Load 4 4 Appendix A Appendix B Appendix C Index Service Tools and Equipment Software Tools inc tarte ette bod etes ui sep st a a ie exi qu A 1 Service TOOS tn r t aves eate E aec A 1 Schematics List of Schematic Diagrams eee e nes B 1 Disassembly Assembly Diagrams Disassembly Assembly Diagrams and Spare Parts Numbers C 1 Who Should Use this Manual What is 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
70. ion Action if appropriate 71 Periph Loss The communications card has a fault 1 Check the DPI device event queue on the network side and corresponding fault information for the device 81 Port DPI Loss The DPI port has stopped 1 If the adapter was not intentionally communicating A SCANport device was connected to a drive operating DPI devices at 500k baud disconnected check the wiring to the port Replace the wiring port expander adapters Main control board or complete drive as required 2 Check the HIM connection 3 If an adapter was intentionally disconnected and the bit for that adapter in parameter 276 Logic Mask is set to 1 this fault will occur To disable this fault set the Logic Mask bit for the adapter to E 95 AutoT Rs Stat The Autotune Rs Static Test has 1 Verify that the motor is not rotating failed when autotune is enabled 2 Check the motor connections 96 AutoT Lm Rot The Autotune Lm rotate test has 1 Check the motor nameplate data failed 2 Check the motor connections 3 Verify that the Accel Time Base Speed 40 x 33 sec Note 33 sec time limit to bring motor to 40 Hz 97 AutoT MagRot The Autotune magnetizing current 1 Check the motor nameplate data rotate test has failed 2 Check the motor connections 3 Verify that the Accel Time Base Speed 40 x 33 sec see above 98 AutoT Saturat The Autotune saturation curve test 1
71. ise to about 0 35V L3 DC 07 The actual voltage reading may vary depending upon your equipment If your readings are not near 1 0V verify that the actual voltage measured is consistent for the Rectifying module and the Output Power modules 9 The actual voltage reading may vary depending upon your equipment If your readings are not near 0 35V verify that the actual voltage measured is consistent for the Rectifying module and the Output Power modules Table 2 D Reverse Biased Diode Tests on Rectifying Module Meter Leads Nominal meter reading L1 DC L2 DC L3 DC DC Meter should display 00 zero load and rises to the meter battery voltage DC L2 DC L3 Important If the drive fails any of these measurements replace the Rectifying Module Series A Rectifying Circuit Board Output Power Module Tests Table 2 E Forward Biased Diode Tests on Output Power Modules Meter Leads Nominal meter reading DC T1 DC T2 26 The value should gradually rise to about 0 50 T2 DC T3 DC 07 The actual voltage reading may vary depending upon your equipment If your readings are not near 0 5V verify that the actual voltage measured is consistent for the Rectifying module and the Output Power modules Table 2 F Reverse Biased Diode Tests on Output Power Modules Meter Leads Nominal meter reading Ti DC T2 DC KS 2 M
72. le Installing 3 40 Removing 3 36 S Series B Drives Precharging Resistors Installing 3 33 Removing 3 32 Service Tools and Equipment A 1 Software Tools A 1 Spare Part Numbers ASIC Assembly C 8 Fan Inverter Assembly C 7 Left Hand Side of Power Structure C 7 Main Fan Assembly C 9 Main Power Structure Assembly C 3 Right Hand Side of Power Structure C 5 T Taking Measurements on Rectifying Module 2 9 Technical Support Options 1 19 What You Need When Calling 1 20 Wizards 1 19 Torque Figures 3 2 Torque Specifications 3 2 Turning the Drive Off 3 3 V Viewing the 700H Diagnostic LED 2 1 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core E Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication PFLEX TG002B EN P December 2007 Supersedes PFLEX TG002A EN P July 2005 Copyright O 2007 Rockwell Automation Inc All rights reserved Printed in USA
73. ly Left 20 FR10844 Fan Inverter Assembly Right 20 FR10845 ASIC Assembly 20 FR10850 Upgrade Kit without the ASIC Board Motor Connector Assembly NA Capacitor 7uf 450V 20 PP00011 Fuse Base DC 20 PP01094 Adapter Board 20 VB00330 Gate Driver Board SK H1 GDB1 F10D 4 Disassembly Assembly Diagrams Figure 2 Right Hand Side of Power Structure DC Bus Bar DC Bus Bar Insulator DC Bus Bar E DC Bus Bar Insulator Output Power Module Rectifying Module Discharging Resistor x s Electrolytic Capacitor ELKO 3300mf 420V Disassembly Assembly Diagrams Table C B Right Hand Side of Power Structure Part Numbers Part Name Part Number Frame NA DC Bus Bar Insulator 20 FR10027 DC Bus Bar Insulator 20 FR10028 DC Bus Bar 20 FR100044 DC Bus Bar 20 FR10052 DC Bus Bar Insulator 20 FR100143 Air Flow Guide Right NA DC Bus Bar 20 FR10190 Series A Drive Discharging Resistor 2x16k 20 PP00056 Series B Drive Discharging Resistor 2x16k 20 PP13027 Series B Drive Precharging Resistors not shown 20 PP00066 Electrolytic Capacitor ELKO 3300uf 420V 20 PP01005 Snubber Capacitor Assembly 20 PP10019 Series A Rectifying Board 400 480V AC 20 VB00459 600 690V 20 VB00460 Series B Rectifying Board 400 480V AC 20 VB00461 600 690V AC 20 VB00462 Output Power Module 400V Class 385 Amp SK H1 QOUT D385 460 Amp SK H1 QOUT
74. m the Power Structure on page 3 15 3 Locate the Gate Driver Board on the front of the power structure Component Test Procedures 2 8 4 Measure the gate interface resistance for each output power transistor The resistance from each gate and collector pin to the branch emitter pin should be about 500 ohms If any of the gate interfaces fails this test replace both Output Power modules ajnpow fiy ul 006 10 no 5249008 p aveau 99 DC ejnpojy 1ndino z swyo 009 1 M0d uir enpoy 1ndino 8040 009 gt 74 A 40 006 aye Jamod UHU Z uo 00
75. moving Power from 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 15 3 Remove the power structure for the drive Refer to Removing the Power Structure from the Drive Enclosure on page 3 27 4 Disconnect all the wiring from connectors X10 X11 X12 X13 the Rectifying board and carefully set it aside 5 Remove the screws that secure the circuit board to the Rectifying Module and remove the board Series A Rectifying Board Shown X11 X10 X101 0 J3 gt X3 amp 9 X41 Installing the Rectifying Circuit Board Install the Rectifying circuit board in reverse order of removal while referring to Torque Specifications on page 3 2 3 32 Access Procedures Removing the Precharging Resistors from Series B Drives 1 Remove power from the drive Refer to Removing Power from 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 15 3 Remove the power structure for the drive Refer to Removing the Power Structure from the Drive Enclosure on page 3 27 4
76. n permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii 1 Loosen the captive screw and swing the Control assembly away from drive 2 Onthe Control assembly Unplug the I O and SynchLink cables from the Main Control circuit board Unplug the feedback wiring from Feedback Option card Unplug communication cables from DriveLogix controller if present 3 Unplug the ribbon cables from J2 and J7 on the Main Control circuit board Note If the DriveLogix option is installed the J2 and J7 connections for the ribbon cables will be located behind the DriveLogix controller 3 6 Access Procedures Installing the 700S Phase I Control Assembly Removing the 7005 Phase II Control Assembly 4 Remove the three screws that hold the control bracket and Phase I Main Control circuit board to the control frame nd H 8 B5 E m hr Ie Remove Three screws aura golle 9 0 8 O9 Loosen captive Screw 5 Remove the control bracket and Phase I Main Control circuit board Install the 700S Phase I Control assembly in reverse order of removal while referring to Torque Specifications on page 3 2 1 Remove power from the drive Refer to Removing Power from Drive on page 3 3 Important Before removing connectio
77. n publication PFLEX INOOG Installation Instructions PowerFlex 7005 and 700H Adjustable Frequency AC Drive Allen Bradley publications are available on the internet at www rockwellautomation comliterature The following publications provide general drive information Title Publication Wiring and Grounding Guide PWM AC Drives DRIVES INOO 1 Safety Guidelines for the Application Installation and Maintenance of SGI 1 1 Solid State Control A Global Reference Guide for Reading Schematic Diagrams 100 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 7005 Drive with Phase Control 20D UMO001 User Manual PowerFlex 7005 Drive with Phase Il Control 200 0 006 Installation Instructions Hi Resolution Feedback Option Card for 20D INO001 PowerFlex 7005 Drives Installation Instructions Multi Device Interface Option for PowerFlex 20D INO04 7008 Drives Installation Instructions Main Control Board PowerFlex 7005 Drives 20D INO05 Installation Instructions PowerFlex 7005 700H High Power 20D IN014 Maintenance Stand Installation Instructions PowerFlex 700S and 700H Drives PFLEX INOOG Reference Manual PowerFlex Adjustable Frequency Drive with PFLEX RMO002 Phase Control Reference Man
78. nd pee Uf Hood ae NIH e X cir 817 peog ar 525 a aoeuaqu d 6 jezeg pagu Ida Idd 109008407 ZX 6 eoejieju aur __ 120 ainjong peog aar 8 xa Lf lt A EGPCS 218 gt Ast wog t eDeyoA Oo 9 d TRENT m empnas og o Jaod Z n Aet er god Ae AAA mP osi Ave ar 75 SEI clr vin 8 preog T T OOOO mu xy sng ZH Ny 6H peog seni a 1M 9H PIT EE ruooqv SH PEE ESI HHA M YH T UHR eons OUS 10 ereo n zH NUS ate SH Hn eeu iH 52102 ondo 1994 9157 E x ox ue4 pJeog pix pod nia QS ol wx JN E pow ue LLX 8X ue OL LX preog enii ateg eng resur ON Auo indu 90 104 Lr exped e IX ou v sac JeMog UL eco Uez wo MOSQ usd 9 e 9x esL ris 1 0 SIX x 189 8X 0sx ejdurex3 tE 54 peog udo Xoeqpee4 d 9d 4 pA sndu yoeqpee4 ndul Id 08 O X34 22098 B 5 Schematics 10
79. nd Inverter Shown Remove two M5 POZIDRIV screws that secure the inverter board and B heatsink to the assembly carriage Carefully remove the inverter board and heatsink from the assembly c carriage Installing the Fan Inverters Install the fan inverters in reverse order of removal while referring to Torque Specifications on page 3 2 3 44 Access Procedures Removing the DC Bus 1 Remove power from the drive Refer to Removing Power from Drive on Capacitors page 3 3 2 Remove the covers from the power structure Refer to Removing the Covers from the Power Structure on page 3 15 3 Remove the power structure from the drive cabinet Refer to Removing the Power Structure from the Drive Enclosure on page 3 27 4 Remove the balancing resistor wires from bus bars Balancing Resistors AC Input Terminals L1 L2 L3 Balancing Resistor Wires 5 Remove the screws that secure DC bus bars to right side of power structure and remove the DC bus bars Access Procedures 3 45 6 Remove the four screws that secure the capacitor to the power structure and remove the capacitor 7 T Installing the DC Bus Install the DC bus capacitors in reverse order of removal while referring to Capacitors Torque Specifications on page 3 2 3 46 Access Procedures Notes Chapter 4 Start Up After Repair the following start up procedure Some of the voltages present are at
80. network connection e Verify status of network Configured with parameter 392 NetLoss DPI Cnfg 60 NetLoss DPIP6 A communications fault has occurred e Verify network connection between the communication adapter at DPI port 6 and the network s Yom Sallis of network Configured with parameter 392 NetLoss DPI Cnfg 61 Logix Out of Run The DriveLogix controller is in a Clear fault Non Run mode Non Run modes 7 include program remote program Mts and faulted modes 9 9 62 Logix Timeout The communication connection to the Configured with parameter 387 Lgx DriveLogix controller has timed out Timeout Onfg 63 Logix Closed The DriveLogix controller has closed e Verify drive is present in the Controller to Configured with parameter 388 Drive connection Lox Closed Cnfg 64 LogixLink Chng A required link in the Controller to e Clear fault d ND Formatnas e Configured with parameter 389 i Lgx LinkChngCnfg 65 HiHpIn PhaseLs AC Input Phase Loss the AC input 1 Check for voltage on each AC phase voltage has fallen input phase 2 Check the status of each external AC input fuse 3 Check the Rectifying board and Rectifying Modules for each AC input phase 4 Configured with parameter 370 HiHp InPhsLs Cfg 66 HiHp Bus Com Dly High Horse Power Only Check the communication bus lines Bus Communication Time Delay the pin connector bet
81. ns 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 if present 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 cable is 25 4 mm 1 in Any bends with a shorter inside radius can permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii Access Procedures 3 7 Unplug any remaining I O and communications cables from the Control assembly and set them aside Loosen the captive screw on the Control assembly mounting plate and swing the Control assembly away from the drive Captive screw 3 8 Access Procedures 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 Disconnect ribbon cables LA Note Control mounting plate not shown for clarity only 6 Loosen the two mounting screws on the front of the Control assembly and slide the control cassette off the mounting bracket Note Ribbon cables not shown for clarity only Installing
82. o 11 61V DC The negative voltage power must be within the band from 17 00 to 11 61V DC e Replace switch mode power supply For smaller frames replace drive Troubleshooting and Error Codes 1 7 been zero due to a checksum error No Description Action if appropriate 35 Parameter The checksum read from the Cycle power Chksum EEPROM does not match the Replace Main Control Board checksum calculated 38 OL Trip The calculated temperature of the e Verify actual temperature of dynamic braking resistor is too high brake The temperature is calculated f hot wait for brake to cool If the resistor is internal the model If cold cycle power to the drive uses resistor characteristic stored in e If cold verify Brake PulseWatts the power structure EEPROM and Brake Watts are correct memory If the resistor is external the model Configured with parameter 369 uses values of parameters 416 Brake OL Brake PulseWatts and 417 Brake Watts 39 PowerEE CRC Fail The CRC of the data stored inthe e Cycle power kik oe does not e n High Horse Power units check f communication bus lines 10 pin connector in Main Control Board High Horse Power interface board and fiber optic cable connections 40 SLink Mult Oflow A SynchLink Multiplier Overflow has Configured with parameter 390 SL occurred Parameter 927 SL Mult
83. oad Internal electronic overload trip You 1 Run an Autotune can enable disable this with 2 Verify the settings of parameters parameter 238 Fault Config 1 48 Motor OL Factor and 47 Motor OL Hertz 3 Reduce the load so that the drive output current does not exceed the current set by the value in parameter 42 Motor NP FLA 8 HeatsinkOvrTp The heatsink temperature has 1 Verify that the maximum ambient exceeded the maximum allowable temperature has not been value exceeded 85 degrees C Alarm 2 Check the fan s S0 degrees C Srat 3 Check for an excess load 4 Check the carrier frequency 9 IGBT OverTemp The output transistors have exceeded 1 Verify that the maximum ambient their maximum operating temperature has not been temperature due to an excessive exceeded load 2 Check the fan s 3 Check for an excess load 10 System Fault A hardware problem exists in the 1 Cycle the power power structure 2 Verify the fiber optic connections 3 Contact Technical Support See Technical Support Options on page 1 19 for more information 4 If the problem persists replace the drive 12 OverCurrent The drive output current has Check programming for an excess exceeded the hardware current limit load improper DC boost setting DC brake voltage set too high or other causes of excess current Check for shorted motor leads or a shorted motor 13 Ground Fault A current path to earth ground exists Check the mo
84. on if appropriate 5 OptPortOLoss A fault on port 0 of the Hi Resolution e Reconnect encoder or replace Encoder Feedback Option Card MDI encoder Option Card Heidenhain or Resolver Reconnect option feedback card Feedback Option Card has occurred e Configured with parameters 365 e Parameter 260 StegmannO Fdbk LsCnfg Pri 366 Fdbk Status displays the fault status for LsCnig Alt and 367 Fdbk port 0 of the Hi Resolution LsCnfgPosit Encoder Feedback Option Card e Parameter 264 HeidenhainO Stat displays the fault status for port 0 of the Heidenhain Feedback Option Card e Parameter 269 Resolver0 Status displays the fault status for port 0 of the Resolver Feedback Option Card 6 jOptPort1Loss The Linear sensor portion of the MDI e Reconnect encoder or replace feedback option card has detected a fault condition e Parameter 286 Linear1 Status displays the fault status for linear portion of the MDI feedback Option Card encoder e Reconnect option feedback card Configured with parameters 365 Fdbk LsCnfg Pri 366 Fdbk LsCnfg Alt and 367 Fdbk LsCnfgPosit 7 Params Defaulted All parameters are reset to default by Informational only user 8 SLink HW Fail A fault on loading SynchLink e Replace Main Control Board firmware into FPGA on Main Control Board at power up 9 SLink Comm Fail A SynchLink communication fault has e Verify the SynchLink configuration occurred in parameters
85. one 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 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 all input power has been removed from the drive and the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION Potentially fatal voltages may result from improper usage of an oscilloscope and other test equipment The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded If an oscilloscope is used to measure high voltage wa
86. onnectors 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 gt bb Torque Specifications Access Procedures Understanding Torque Figures in Assembly Diagrams Icons and numbers in the assembly diagrams indicate how to tighten hardware Fastener Type POZIDRIV Screw Phillips Screw Hexagonal Nut O Hexagonal Bolt or Torx Head Screw The following table lists fastener torque specifications Tool Type and Size PZ indicates POZIDRIV screwdriver bit P indicates Phillips screwdriver bit Standoff P79 ee Hexagonal Screw n 44 Tightening Torque Item Fastener Final Torque 700H Fiber Optic Adapter Board mounting M4 x 8 POZIDRIV 0 9 N m 8 Ib in 700H I O and Control Assembly M4X8 self tapping 0 8 N m 7 Ib in 7005 Power Interface Circuit Board mounting M3 x6 Phillips 0 9 N m 8 Ib in 7005 Voltage Feedback Circuit Board mounting M3 x 6 Phillips 0 9 N m 8 Ib in 7005 Voltage Feedback Circuit Board mounting M3 x 0 5 thread 37 mm x 37 0 9 N m
87. ooting and Error Codes No Description Action if appropriate 47 MC CML Task Fail Current Minor Loop CML task has e Cycle power been delayed or run with incorrect interval 48 No Ctrl Device The controlling device HIM or e Reconnect the controlling device controller has been disconnected while the drive was running 49 DPI Loss Port 1 The device at DPI port 1 has stopped e Verify DPI device is present and communicating with the drive functional at port 1 A SCANport device is connected to a 2 d drive operating DPI devices at 500k 9 Baud 50 DPlLossPort2 The device at DPI port 2 has stopped e Verify DPI device is present and communicating with the drive functional at port 2 A SCANport device is connected to a Jj eee 391 drive operating DPI devices at 500k 9 Baud 51 DPlLossPort3 The device at DPI port 3 has stopped e Verify DPI device is present and communicating with the drive functional at port 3 A SCANport device is connected to a ara 2 drive operating DPI devices at 500k 9 Baud 52 DPI Loss Port4 The device at DPI port 4 has stopped e Verify DPI device is present and communicating with the drive functional at port 4 A SCANport device is connected to a nee 2 drive operating DPI devices at 500k 9 Baud 53 DPlLossPort5 The device at DPI port 5 has stopped e Verify DPI device is present and communicating with the drive functional at port 5 A SCANport dev
88. orming the Power Circuit Diagnostic Test on a 700S Drive Start Up After Repair 4 3 The Power Circuit Diagnostic Test on the 7005 drive allows you to diagnose problems in the drive s power structure without applying large amounts of power 1 2 Verify that input power wiring and grounding is connected Verify that the motor cables are connected Energize the drive Measure the DC bus voltage and verify that the value is reflected in parameter 306 DC Bus Voltage From the Monitor menu on the HIM press the escape button to navigate to the Main menu Use 62 the down button to move the cursor to the Start Up selection and press e to select Start Up Then press e again to verify your intention to continue with the Start Up menu Use amp 2 the down button to move the cursor to Power Circuit Diagnostics Pwr Circuit Diag and press to select Power Circuit Diagnostics Press a to begin the Power Circuit Diagnostic routine Follow the indications and instructions on the HIM 4 4 Start Up After Repair Testing With the Motor Without a Mechanical Load This test allows you to measure several operating parameters and diagnose problems without connecting the motor to its mechanical load 1 2 e Verify that input power wiring and grounding is connected Verify that the motor cables are connected Verify that the motor load is disconnected Measure the DC bus voltage and verify that the value is reflected
89. orward and Reverse Biased Diode Tests for Major Power Components 2 3 Conducting Gate Driver Board Gate Interface Resistance Measurements 2 7 Checking the Rectifying Module on AC Input Drives Only 2 9 Checking the Fan Inverters and Main Fans 0 0 0 2 12 Chapter 3 Chapter 4 Access Procedures Torque Specifications eter 3 2 Removing Power from 2 3 3 Removing the DPI HIM Assembly 2 3 4 Installing the DPI HIM 2 3 5 Removing the 7005 Phase I Control Assembly 3 5 Installing the 7005 Phase I Control Assembly 3 6 Removing the 7005 Phase II Control Assembly 3 6 Installing the 7005 Phase II Control Assembly 3 8 Removing the Common Mode Filter Circuit Board 2 2 3 9 Installing the Common Mode Filter Circuit Board 3 10 Removing 7005 High Power Fiber Optic Interface Circuit Board 3 11 Installing the 7005 High Power Fiber Optic Interface Circuit Board 3 12 Removing the 700H Circuit Boards and Control 3 12 Installing the 700H I O Circuit Boards and Control Assembly 3 13 Removing the 700H Fiber Optic Adapter Circuit Board
90. otective covers ZO Installing the Protective Install the Protective Covers in reverse order of removal while referring to Covers Torque Specifications on page 3 2 3 20 Access Procedures Removing the 700S Voltage 1 Remove power from the drive Refer to Removing Power from Drive on Feedback Circuit Board page 3 3 2 Remove the covers from the power structure Refer to Removing the Covers from the Power Structure on page 3 15 3 Carefully disconnect the fiber optic cables from the J4 and J5 sockets along 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 cable from the J8 socket of the Voltage Feedback circuit board and set it aside 4o O Rockwell Automation ia Q Q O
91. oving the Main Fans 1 Remove power from the drive Refer to Removing Power from 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 15 3 Disconnect the fan cable connectors under the power structure 4 Remove the two screws that secure each fan to the drive there are two fans and four screws Then remove the fans Remove screws Disconnect connectors from fan inverters Installing the Main Fans Install the fans in reverse order of removal while referring to Torque Specifications on page 3 2 Removing the ASIC Circuit Board Access Procedures 3 29 the ASIC circuit 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 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 15 3 Remove the power structure for the drive Refer to Removing the Power Structure from the Drive Enclosure on page 3 27 4 Carefully disconnect the fiber optic cables from sockets H1 H7 along the front of the ASIC board and carefully set them aside using optical transmission equipment This p
92. parts for PowerFlex 700S drives is available on the Allen Bradley web site at http www ab com support abdrives powerflex70 PF7ReleasedParts pdf Disassembly Assembly Diagrams Figure C 1 Main Power Structure 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 Main Terminal Cover e d Touch Cover Front ATTENTION The sheet metal cover and mounting screws on Touch Cover Side Plate Input Terminal Cable MEE 7 Input Terminal Assembly Bus Bar Insulator ee eee Connection Assembly Bus Bar Gate Drive Board Fuse Base dc angie Left Side Board m o a Side Board Bracket ter B ASIC Assembly d ee er Board d s n 7uf 450V q 2 Fan Inverter Assembly Left Plastic Cover Base Top Left Plastic Cover Base Top Right Fan Inverter Assembly Right Disassembly Assembly Diagrams C 3 Table C A Main Power Structure Assembly Part Numbers Part Name Part Number Bus Bar NA Insulator For Bus Bar NA Input Terminal Cable Insulator NA Input Terminal Assembly NA Plastic Cover Base Top Left NA Plastic Cover Base Top Right NA Left Side Board Bracket NA Right Side Board Bracket NA Touch Cover Front NA Touch Cover Side Plate NA Main Terminal Cover NA Fan Inverter Assemb
93. placed Reset the fault 121 Comm Loss No Output Voltage An I O Board lost communications with the Main Control board 1 Check the connector 2 Check for induced noise 3 Replace I O board or Main Control board The drive has no output voltage to the motor even though the drive indicates that the motor is running Diagnostic Procedure 1 Measure the DC bus voltage Corrective Action If the DC bus is not within specification repair or replace the Rectifying module as needed Otherwise continue with step 2 2 Measure the AC output voltage at the motor terminals using a VAC RMS meter and compare the measurement to the AC output voltage displayed on the HIM Par 307 Output Voltage for 7005 drives Par 6 Output Voltage for 700H drives If the AC output voltage at the motor terminals does not match the output voltage displayed on the HIM repair or replace the Output Power modules as needed Otherwise continue with step 3 3 Verify that there are no loose or missing connections between the Gate Driver board and ASIC board and the Gate Driver board and Adapter board If there are loose or missing connections or a board has been damaged replace the loose or missing connections or repair or replace any of the boards as needed Otherwise continue with step 4 ASIC board located on the power structure are energized at DC bus potential high voltage Risk of
94. roduct 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 Disconnect the other cables from sockets on the front of the ASIC board and set them aside 6 Disconnect the wire connected to the cover of the ASIC board 7 Remove the fan from the ASIC board 3 30 Access Procedures Installing the ASIC Circuit Board 8 Slide the ASIC board assembly out of its chassis 9 Remove the plastic board holder 10 Carefully disconnect the fiber optic cables from sockets H8 H13 along the back of the ASIC board and carefully set them aside 11 Disconnect the other cables from sockets on the ASIC board and set them aside Install the ASIC board in reverse order of removal while referring to Torque Specifications on page 3 2 Reconnect the cables to ASIC board while referring to Figure B 3 on page B 4 Figure B 4 on page B 5 or Figure B 5 on page B 6 Removing the Rectifying Circuit Board X9 X100 x12 a om e x0 o X6 X13 J7 Access Procedures 3 31 1 Remove power from the drive Refer to Re
95. rrect Fan Measurements Connection Wires Resistance 5 Black Brown 60 Brown Blue 26 Blue Black 34 Resistance to ground OL Zero Load 5 Reconnect the left hand fan motor to its inverter 6 Repeat steps 3 5 for the right hand fan motor 2 14 Component Test Procedures Chapter 3 Access Procedures ATTENTION To avoid an electric shock hazard ensure that all power to the drive has been removed before performing the following ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION HOT surfaces can cause severe burns Do not touch the heatsink surface during operation of the drive After disconnecting power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable c
96. t open pos pon pun pon pou p pou pus we qa kite ne OL n T1310 1 gt asa AAA EL ve 31111 E Component Test Procedures 2 13 Isolating a Faulty Fan Inverter The ASIC Board controls both fan inverters A cable connects X11 on the ASIC Board to X8 on the left hand inverter Another cable connects X3 of the left hand inverter to X8 on the right hand inverter A jumper terminates X3 on the right hand inverter Refer to Figure B 6 on page B 7 Use the following procedure to isolate a faulty inverter if the fans are not running 1 2 Disconnect the cable from X3 of the left hand inverter Remove the jumper from X3 of the right hand inverter and connect it to X3 of the left hand inverter Energize the drive If the left hand fan runs then the right hand fan inverter is faulty Checking the Main Fan Motors 1 Remove power from the drive Refer to Removing Power from Drive on page 3 3 Remove the covers from the power structure Refer to Removing the Covers from the Power Structure on page 3 15 Disconnect the left hand fan motor from its inverter Measure the resistance of the fan windings If the resulting measurements are not similar to those in Table 2 L below replace the fan Refer to Removing the Main Fans on page 3 28 Table 2 L Co
97. the 700S Phase ll Install the 700S Phase II Control assembly in reverse order of removal Control Assembly Access Procedures 3 9 Removing the Common 1 Remove power from the drive Refer to Removing Power from Drive on Mode Filter Circuit Board page 3 3 2 Loosen the captive screw on the control assembly mounting plate and swing the control assembly away from the drive Important Before removing connections and wires mark the connections and wires to avoid incorrect wiring during assembly 3 Disconnect the 24V power supply cable from connector J5 on the Common Mode Filter circuit board 4 Disconnect the twisted pair wires from connector J5 on the High Power Fiber Optic Interface circuit board 3 10 Access Procedures 5 Remove the four screws that secure the Common Mode Filter circuit board to the four standoffs on the control assembly mounting plate and remove the Common Mode Filter circuit board O J Remove screws Installing the Common Install the Common Mode Filter Circuit Board in the reverse order of Mode Filter
98. the circuit board from the Control Frame Installing the 700S High Install the 700S High Power Fiber Optic Interface circuit board in reverse Power Fiber Optic Interface order of removal while referring to Torque Specifications on page 3 2 Circuit Board Removing the 700H 1 Remove power from the drive Refer to Removing Power from Drive on Circuit Boards and Control page 3 3 Assembly 2 Open the enclosure that contains the Control and I O circuit boards and carefully unplug the DPI cable and any I O cables 3 Remove the I O circuit boards from the Control Board and enclosure Note the order of the boards and the keys which prevent placement of the boards in incorrect slots Do not remove enclosure cover Enclosure is illustrated without the cover for clarity Access Procedures 3 13 4 Unplug the serial connection from X7 on the Control circuit board X7 C Serial Port x2 X3 X4 X5 X6 Slot A SlotB SlotC SlotD Slot E o 5 Remove the three screws that secure the Control assembly to the control frame and remove the control assembly Do not remove enclosure cover Enclosure is illustrated without the cover for clarity SNe 27 Ib in Installing the 700H I O If you replace the Control circuit board in a 700H drive you must load Circuit Boards and Control information about the Control circuit board into t
99. the power structure Refer to Removing the Covers from the Power Structure on page 3 15 Disconnect the motor leads from the drive Conduct forward and reverse biased diode tests on the Rectifying Module if present and the Output Power Modules 2 4 Component Test Procedures Figure 2 1 Measurement Points for Forward and Reverse Diode Tests U T1 W T3 Series A Rectifying Circuit Board Rectifying Module Tests Table 2 A Forward Biased Diode Tests on Rectifying Module Meter Leads Nominal meter reading DC L1 DC L2 The value should gradually rise to about 0 5v L2 DC L3 DC 07 The actual voltage reading may vary depending upon your equipment If your readings are not near 0 5V verify that the actual voltage measured is consistent for the Rectifying module and the Output Power modules Table 2 B Reverse Biased Diode Tests on Rectifying Module Meter Leads Nominal meter reading L1 DC L2 DC 2 Meter should display 00 zero load DC L2 DC L3 Component Test Procedures 2 5 Series B Rectifying Circuit Board Rectifying Module Tests Table 2 C Forward Biased Diode Tests on Rectifying Module Meter Leads Nominal meter reading DC L1 DC L2 The value should gradually rise to about 1 0V DC L3 L1 DC L2 DC The value should gradually r
100. tor and external wiring that is greater than 25 of the drive to the drive output terminals for a rating The current must appear for grounded condition 800ms before the drive will fault 1 14 Troubleshooting and Error Codes No Name Description Action if appropriate 14 nverterFault hardware problem exists in the 1 Cycle the power power structure 2 Contact Technical Support See Technical Support Options on page 1 19 for more information 3 If the problem persists replace the drive 15 Load Loss Do not use this fault in 700H Check that parameter 238 Fault applications Config 1 bit 0 Power Loss and parameter 259 Alarm Config 1 bit 13 Load Loss are set to zero 16 Motor Therm The option board thermistor input is 1 Check to ensure that the motor is greater than the limit cooling properly 2 Check for an excess load 3 Verify the thermistor connection If the thermistor connection on the option board is not used it must be shorted 17 Input Phase One input line phase is missing 1 Check all user supplied fuses Configured in parameter 238 Fault 2 Check the AC input line voltage Config 1 21 OutPhasMissng There is zero current in one of the 1 Check the motor wiring output motor phases 2 Check the motor for an open phase 24 Decel Inhibit The drive cannot follow the 1 Verify that the input voltage is commanded decel due to bus within the sp
101. ual PowerFlex Adjustable Frequency Drive with PFLEX RMO003 Phase Control The following publications provide information that is necessary when applying the DriveLogix Controller Title Publication User Manual DriveLogix System 20D UM002 Installation Instructions DriveLogix Controller 20D INO02 Installation Instructions Memory Expansion for DriveLogix Controller 200 1 007 ControlNet Daughtercard Installation Instructions Catalog Numbers 1788 IN002 1788 CNC and 1788 CNCR ControlNet Daughtercard Installation Instructions Catalog Numbers 1788 005 1788 CNF and 1788 CNFR Understanding Manual Conventions Additional Support Available on Internet Overview p 3 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 Cross References Figure 2 2 on page 2 6 is a cross reference to figure 2 2 on page 5 of Chapter 2 Figure C 1 on page C 2 is a cross reference to figure C 1 on page 2 of Appendix C Additional troubleshooting information and software tools are available on the Allen Bradley Drives Support Website http www ab com support abdrives p 4 Overview General Prec
102. ulator is enabled parameter 20D UMO06 for DC Bus 414 Brake Bus Cnfg bit 0 Brake Overvoltage Trip levels Enable or bit 3 Bus Reg Enable respectively e Verify that parameter 128 Regen Power Lim is set properly e f Brake Bus bit 0 Brake Enable is set verify braking resistor is properly sized 25 Inv Trans Desat The IGBT detects a transistor failure Desat 1 6 Troubleshooting and Error Codes No 26 Name Ground Fault Description current to earth exceeds 3596 of the peak drive rating Action if appropriate Checkthe motor and external wiring to the drive output terminals for a grounded condition 27 Inst Overcurrent Instantaneous motor current exceeds 214 of rating e Reduce mechanical load Check the motor and external wiring to the motor 28 VPL MC Comm Fail A communication failure has occurred between the Velocity Position Loop VPL processor and the Motor Control MC processor on the main control board Possible Causes are e VPL is flashing MC firmware into the MC processor when HIM indicates Loading Config MC has failed to complete or pass diagnostic tests e MC has not detected VPL handshake activity for over 32 ms e VPL has not detected MC handshake activity for over 32 ms This is indicated when Fault Test Point 15 or 16 equals 1 This test point is viewed in parameter 330 Fault TP Data when parameter
103. veforms use only a dual channel oscilloscope in the differential mode with X 100 isolated 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 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 1 2 Troubleshooting and Error Codes Creating Fault Reports Addressing 700S Faults Clear and complete fault reports are critical for analysis and repair of modules returned to the factory At a minimum perform and record the following 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 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 No Name 1 Ovespd Det Description Motor speed has exceeded the limits set in parameters 75 Rev Speed Limit 76 Fwd Sp
104. ween the communication bus has delayed Main Control board and High feedback or bad communication Power Fiber Optic Interface board quality e Fiber optic connections between the High Power Fiber Optic Interface Circuit board and the ASIC board Fiber optic connections between the High Power Fiber Optic Interface board and Voltage Feedback board 67 HiHp Bus Link Ls Bus Communication Link Loss bus Check the communication bus lines communication between the High Power Fiber Optic Interface circuit board and the Voltage Feedback circuit board has stopped Fiber optic connections between the High Power Fiber Optic Interface board and Voltage Feedback board 10 pin connector between the Main Control board and High Power Fiber Optic Interface board Fiber optic connections between the High Power Fiber Optic Interface Circuit board and the ASIC board 1 10 Troubleshooting and Error Codes No Description Action if appropriate 68 HiHp Bus CRC Er Bus Communication CRC Error too Check the communication bus lines many CRC errors have occurred in 10 pin connector between the the communication bus Main Control board and High Power Fiber Optic Interface board A fast power cycle may cause the 7005 Main Control Board to attempt Fiber optic connections between to communicate with the ASIC Board the High Power Fiber Optic before the ASIC Board is energized

pflex-tg002 - Rockwell Automation

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