Allen-Bradley PowerFlex 700H Hardware Service Manual
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Allen-Bradley PowerFlex 700H Hardware Service Manual

High performance/adjustable frequency ac drive
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See also: Service Manual , Instruction and Installation Manual
700S High Performance
AC Drive
and
700H Adjustable Frequency
AC Drive
Frame 12
450-560kW, 400V
700-900HP, 480V
630-800kW, 690V
700-900HP 600V
Hardware Service Manual
Table of Contents
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Summary of Contents for Allen-Bradley PowerFlex 700H

  • Page 1 700S High Performance AC Drive 700H Adjustable Frequency AC Drive Frame 12 450-560kW, 400V 700-900HP, 480V 630-800kW, 690V 700-900HP 600V Hardware Service Manual...
  • Page 2 Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at www.rockwellautomation.com/literature) describes some important differences between solid state equipment and hard-wired electromechanical devices.

  • Page 3: Table Of Contents

    Table of Contents Important User Information ..........1-2 Preface Who Should Use this Manual? .
  • Page 4 Appendix A Software Tools ............A-1 Service tools.

  • Page 5: Preface

    What is in this Manual This manual contains hardware service information for Frame 12 PowerFlex 700H and 700S drives only. Verify that you are working on a Frame 12 drive by checking the data nameplate on the Control Frame. The frame number is printed just above the serial number.

  • Page 6: Reference Materials

    Overview Reference Materials Allen-Bradley publications are available on the internet at www.rockwellautomation.com/literature. The following publications provide general drive information. Title Publication Wiring and Grounding Guide, (PWM) AC Drives DRIVES-IN001… Safety Guidelines for the Application, Installation and Maintenance of SGI-1.1 Solid State Control A Global Reference Guide for Reading Schematic Diagrams 0100-2.10...

  • Page 7: Additional Support Available On Internet

    Chapter 2. “Figure C.1 on page C-2” is a cross reference to figure C.1 on page 2 of Appendix C. Additional Support Additional troubleshooting information and software tools are available on the Allen-Bradley Drives Support Website (http://www.ab.com/support/ Available on Internet abdrives/).

  • Page 8: General Precautions

    Overview General Precautions Class 1 LED Product ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into module ports or fiber-optic cable connectors. ATTENTION: The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage.
  • Page 9 Chapter Troubleshooting and Error Codes ATTENTION: To avoid an electric shock hazard, ensure that all power to the drive has been removed before performing the following. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive.

  • Page 10: Chapter 1 Creating Fault Reports

    Troubleshooting and Error Codes Creating Fault Reports 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...
  • Page 11 Troubleshooting and Error Codes Fault Description Action (if appropriate) HiHp Drv OvrLoad Drive Overload - the circuit board on Measure output current of the the Power Module has detected an drive. If the level is ever greater overload. than the maximum drive rated output current level reduce the load.

  • Page 12: Addressing 700H Hardware Faults

    Loss Time]. Enable/Disable with parameter 238 [Fault Config 1]. For more information refer to publication 20C-PM001, Programming Manual - PowerFlex 700H. UnderVoltage DC bus voltage fell below the Monitor the incoming AC line for minimum value of 333V for 400/480V low voltage or power drives and 461V for 600/ 690V drives.

  • Page 13: Diagnostic Procedures By Symptom

    Troubleshooting and Error Codes Diagnostic Procedures by The following charts list drive symptoms, symptom descriptions and recommended actions. Symptom Blown Input Fuses Use this procedure when a drive clears any of its external circuit breaker or power fuses: Replace Perform Forward Disconnect Motor Rectifying Rectifying...
  • Page 14 Troubleshooting and Error Codes No Output Voltage Use this procedure when there is no voltage present at the drive output terminals, even though the drive indicates the motor is running: DC Bus Perform forward Measure DC Bus Rectifying Replace Rectifying Voltage within diode tests on Voltage...
  • Page 15 Troubleshooting and Error Codes No HIM Display Use this procedure when the HIM does not function: Check HIM Reseat or Properly Connection reconnect Connected? and Seating DC Bus Perform forward Rectifying Replace Rectifying Measure DC Bus Voltage within diode tests on Module OK? Module Voltage...
  • Page 16 Output Equals Replace Inverter Outputs 50 Hz / 220V rms? Fan Inverter(s) on X1, X4 and X5 Check Fan Motors Fan Motor has Replace for Short and Open or Short Fan Motor(s) Open Circuits Circuits? Contact Allen-Bradley Drives Technical Support...

  • Page 17: Chapter 2 Viewing The 700H Diagnostic Led

    Chapter Component Test Procedures ATTENTION: To avoid an electric shock hazard, ensure that all power to the drive has been removed before performing the following. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive.

  • Page 18: Viewing The 700S Diagnostic Leds

    Component Test Procedures LED visible through this hole Indication Steady The drive is operational and has no faults Flashing Quickly 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...
  • Page 19 Component Test Procedures ➊ ➋ ➌ Table C Drive Status Indicator Descriptions Name Color State Description ➊ Green Steady Illuminates when power is applied to the drive. (Power) ➋ Green Flashing Drive ready, but not running & no faults are present. (Status) Steady Drive running, no faults are present.

  • Page 20: Performing Visual Inspections

    Component Test Procedures Performing Visual Inspections Visually inspect the cooling tunnels and power structures before energizing the drive. Inspecting the Cooling Tunnels 1. Remove the main cooling fans from the bottom of the power structures. Refer to Removing the Main Fans on page 3-26.
  • Page 21 Component Test Procedures 1. Remove power from the drive. Refer to Removing Power from the Drive on page 3-3. 2. Disconnect all motor leads from the drive. 3. Conduct forward and reverse biased diode tests on the Rectifying Modules (if present). Figure 2.1 Measurement Points for Forward and Reverse Diode Tests DC- DC+ DC- DC+...
  • Page 22 Component Test Procedures Table 2.B Forward Biased Diode Tests on Rectifying Module for Power Structure #2 Meter Leads Nominal meter reading DC+/R+ DC+/R+ DC+/R+ Meter should beep once and value should gradually rise to about 0.5V If the drive does not contain the brake chopper option, the DC+/R+ terminal will be labeled DC+.
  • Page 23 Component Test Procedures Table 2.F Forward Biased Diode Tests on Output Power Modules for Power Structure Meter Leads Nominal meter reading 2U/T1 2V/T2 2W/T3 Meter should display “.0L” (zero load) 2U/T1 DC+/R+ 2V/T2 DC+/R+ 2W/T3 DC+/R+ If the drive does not contain the brake chopper option, the DC+/R+ terminal will be labeled DC+.

  • Page 24: Checking Fiber Optic Connections To The Gate Driver Boards

    Component Test Procedures Checking Fiber Optic Damaged or improperly connected fiber optic cables can cause apparent Gate Driver Board malfunctions. Connections to the Gate Driver Boards 1. Remove power from the drive. Refer to Removing Power from the Drive on page 3-3.
  • Page 25 Component Test Procedures Gate Interface Resistance 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 the appropriate (left or right) Output Power Module per Power Structure.
  • Page 26 2-10 Component Test Procedures Preparing the Drive for Active Measurements on the Gate Driver Boards Important: This procedure requires special equipment and training. Only qualified and trained personnel should perform these procedures. If you do not have the special equipment, replace each Gate Driver Board to determine if the boards are malfunctioning.
  • Page 27 Component Test Procedures 2-11 6. Connect the minus (-) probe of the multimeter to the DC- wire. Make sure these DC+ and DC- connections are insulated from all objects. 7. Connect the High Voltage DC Test Power Supply to these wires. ATTENTION: The sheet metal cover and mounting screws on the ASIC Boards located on the power structures are energized at (-) DC bus potential high voltage.
  • Page 28 2-12 Component Test Procedures Checking the Opto-Couplers Class 1 LED Product ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into module ports or fiber-optic cable connectors. 1.
  • Page 29 Component Test Procedures 2-13 Output Power Module. If the drive fails any of these tests, replace the Gate Driver Board. 8. Repeat steps 3 and 4 with connector X9 and the VH cable. X9 provides the gate interface for the VH output power transistor in the right-hand Output Power Module.

  • Page 30: Checking Rectifying Module (On Ac Input Drives Only)

    2-14 Component Test Procedures Figure 2.3 Opto-Coupler Checks for Right-Hand Output Power Module Should measure -15V dc with respect to DC- with no light in WH cable Should measure +15V dc with respect to DC- with light in WH cable Should measure -15V dc with respect to DC- with no light in WH cable Should measure +15V dc with respect to DC- with light in WH cable Should measure -15V dc with respect to DC- with no light in VH cable...
  • Page 31 Component Test Procedures 2-15 4. Verify that the plugs on the cable that connects X13 on the Rectifying Board to X2 on the ASIC Board are properly seated. 5. Verify that the jumper at X50 on the Rectifying board is in place. Taking Measurements on the Rectifying Module 6.
  • Page 32 2-16 Component Test Procedures Figure 2.4 Rectifying Board Layout and Measurement Points Precharging Resistors X101 X100 X13: Pin 5 X13: Pin 1 (24V dc Power) (24V dc Common) X10: Pin 1 X11: Pin 1 X12: Pin 1 Table 2.J Rectifying Board Charge Relay Test Results No Power on X13 24V dc Power on X13 Meter Leads...

  • Page 33: Checking The Dc Bus Capacitors

    Component Test Procedures 2-17 Checking the DC Bus Important: This procedure requires special equipment and training. Only qualified and trained personnel should perform these Capacitors procedures. These tests require the recommended high voltage DC-power supply. 1. Remove power from the drive. Refer to Removing Power from the Drive on page 3-3.
  • Page 34 2-18 Component Test Procedures Checking the Main Fan Checking Inverter LEDs Inverters and Fans A frame 12 drive has four fans and four fan inverters; two fans and two fan inverters per Power Structure. Each fan inverter has a red and a green diagnostic LED.
  • Page 35 Component Test Procedures 2-19 Checking the Main Fan Motors 1. Remove power from the drive. Refer to Removing Power from the Drive on page 3-3. 2. Remove the covers from the power structures. Refer to Removing the Covers from the Power Structures on page 3-15.
  • Page 36 2-20 Component Test Procedures Notes:...

  • Page 37: Chapter 3 Torque Specifications

    Chapter Access Procedures ATTENTION: To avoid an electric shock hazard, ensure that all power to the drive has been removed before performing the following. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive.
  • Page 38 Access Procedures Item Screw Final Torque 700H Star Coupler Board M4 x 8 POZIDRIV ® 0.9 N-m (mounting) (8 lb.-in.) 700S Voltage Feedback Circuit M3 x 6 Phillips 0.9 N-m Board (mounting) (8 lb.-in.) AC Input Terminals on Power M10 nut 40 N-m Structure (354 lb.-in.)

  • Page 39: Removing Power From The Drive

    Access Procedures Understanding the Torque Figures in Assembly Diagrams Icons and numbers in the assembly diagrams indicate how to tighten hardware: Tool Type and Size Fastener Type PZ indicates POZIDRIV screwdriver bit POZIDRIV Screw P indicates Phillips screwdriver bit Phillips Screw Hexagonal Bolt or Standoff Hexagonal...
  • Page 40 Access Procedures Removing Power 1. Turn off and lock out input power. Wait five minutes. 2. Verify that there is no voltage at the drive’s input power terminals. 3. Measure the DC bus voltage at the DC+ & DC- terminals on the Power Terminal Block.
  • Page 41 Access Procedures Removing the DPI / HIM Removal Assembly 1. Remove power from the drive (Removing Power from the Drive on page 3-3). Important: Before removing connections and wires, mark the connections and wires to avoid incorrect wiring during assembly. 2.
  • Page 42 Access Procedures Frame. Mounting Screws 0.9 N-m (8 lb.-in.) Installation Install the DPI / HIM Assembly in reverse order of removal, while referring Torque Specifications on page 3-1. Removing the 700S Phase II Removal Control Assembly 1. Remove power from the drive (Removing Power from the Drive on page 3-3).
  • Page 43 Access Procedures 4. Loosen the captive screw on the Control Assembly mounting plate and swing the Control Assembly away from drive. Captive Screw 5. Carefully disconnect the ribbon cables from the sockets on the High Power Fiber Optic Interface Circuit Board on the back of the control mounting plate, and carefully set them aside.
  • Page 44 Access Procedures 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. Installation Install the 700S Phase II Control Assembly in reverse order of removal, while referring to Torque Specifications on page 3-1.
  • Page 45 Access Procedures Important: Minimum inside bend radius for fiber-optic cable is 25.4 mm (1 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable. Signal attenuation increases with decreased inside bend radii. 4. Disconnect the other cables from the sockets on the High Power Fiber Optic Interface Circuit Board and set them aside.

  • Page 46: Removing The 700S Phase Ii Control Assembly

    3-10 Access Procedures Removing the 700S Control Removal Assembly Mounting Plate 1. Remove power from the drive. Refer to Removing Power from the Drive on page 3-3. 2. Remove the 700S Phase II Control Assembly. Refer to Removing the 700S Phase II Control Assembly on page 3-6.

  • Page 47: Removing The 700H I/O Boards And Control Assembly

    Access Procedures 3-11 Removing the 700H I/O Removal Boards and Control 1. Remove power from the drive. Refer to Removing Power from the Assembly Drive on page 3-3. 2. Open the enclosure that contains the Control and I/O Boards and carefully unplug the DPI cable and any I/O cables.
  • Page 48 3-12 Access Procedures 5. Remove the three screws which secure the Control Assembly to the drive. Do not remove enclosure cover. Enclosure is illustrated without the cover for clarity. 3 N-m (27 lb.-in.) 6. Remove the Control Assembly. Installation Install the 700H Control and I/O Boards in reverse order of removal, while referring to Torque Specifications on page 3-1.

  • Page 49: Removing The 700H Star Coupler Board

    Access Procedures 3-13 Removing the 700H Star Removal Coupler Board 1. Remove power from the drive. Refer to Removing Power from the Drive on page 3-3. 2. Referring to Removing the 700H I/O Boards and Control Assembly on page 3-11, remove the I/O boards and Control Assembly. 3.
  • Page 50 3-14 Access Procedures Important: Minimum inside bend radius for fiber-optic cable is 25.4 mm (1 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable. Signal attenuation increases with decreased inside bend radii. 6. Remove the six screws which secure the Star Coupler Board to the stand-offs on the back of the Control Frame.

  • Page 51: Removing The Covers From The Power Structures

    Access Procedures 3-15 Removing the Covers from Moving the Control Frame the Power Structures Removal 1. Remove power from the drive (Removing Power from the Drive on page 3-3). 2. Loosen the T8 Torx-head screws, which secure the Control Frame to the drive enclosure.
  • Page 52 3-16 Access Procedures Removing the Airflow Plates The drive is equipped with metal plates, at the top of both enclosures, that manage airflow through the drive. You must remove these plates in order to access the protective covers. Removal 1. Remove power from the drive (Removing Power from the Drive on page 3-3).
  • Page 53 Access Procedures 3-17 Installation Install the Airflow Plates in reverse order of removal, while referring to Torque Specifications on page 3-1. Removing the Protective Covers from the Power Structures You must remove the protective covers to gain access to the power structures.
  • Page 54 3-18 Access Procedures 7. Repeat step 4 - 6 to remove the protective covers from Power Structure Installation Install the Protective Covers in reverse order of removal, while referring to Torque Specifications on page 3-1.

  • Page 55: Removing The 700S Voltage Feedback Circuit Board

    Access Procedures 3-19 Removing the 700S Voltage Removal Feedback Circuit Board 1. Remove power from the drive (Removing Power from the Drive on page 3-3). 2. Remove the covers from the power structures. Refer to Removing the Covers from the Power Structures on page 3-15.
  • Page 56 3-20 Access Procedures 0.9 N-m (8 lb.-in.) Remove five screws Installation Install the 700S Voltage Feedback Circuit Board in reverse order of removal, while referring to Torque Specifications on page 3-1.

  • Page 57: Removing The Gate Driver And Adapter Boards

    Access Procedures 3-21 Removing the Gate Driver Removal and Adapter Boards 1. Remove power from the drive (Removing Power from the Drive on page 3-3). 2. Remove the covers from the power structures. Refer to Removing the Covers from the Power Structures on page 3-15.
  • Page 58 3-22 Access Procedures 7. Remove the six screws which secure the brackets to the drive. Then remove the brackets. 8. Remove eight of the stacker connectors from the Gate Driver Board, leaving the two connectors that are third from the top. Do Not remove this Do Not remove this stacker connector...
  • Page 59 Access Procedures 3-23 9. Carefully remove the 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. 11. Repeat steps 3 - 10 to remove the Gate Driver and Adapter Boards from Power Structure 2.
  • Page 60 3-24 Access Procedures Installation 1. On Power Structure 1, replace the Adapter Board and install the cable ties, which secure it to the circuit boards on the Output Power Modules. 2. 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.

  • Page 61: Removing The Power Structures From The Drive Enclosure

    Access Procedures 3-25 Removing the Power Removal Structures from the Drive 1. Remove power from the drive (Removing Power from the Drive on Enclosure page 3-3). 2. Remove the covers from the power structures. Refer to Removing the Covers from the Power Structures on page 3-15.

  • Page 62: Removing The Main Fans

    3-26 Access Procedures Installation Install the power structures in reverse order of removal, while referring to Torque Specifications on page 3-1. Refer to the publication PFLEX-IN006 , Installation Instructions - PowerFlex 700S and 700H High Power Drives, for tightening torques of motor terminations. Removing the Main Fans Removal 1.

  • Page 63: Removing The Asic Boards

    Access Procedures 3-27 Installation Install the fans in reverse order of removal, while referring to Torque Specifications on page 3-1. Removing the ASIC Boards Removal ATTENTION: The sheet metal cover and mounting screws on the ASIC Boards located on the power structures are energized at (-) DC bus potential high voltage.
  • Page 64 3-28 Access Procedures 6. Carefully disconnect the fiber-optic cables from sockets of the ASIC Board, and carefully set them aside. ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into fiber-optic ports or fiber-optic cable connectors.

  • Page 65: Removing The Rectifying Boards

    Access Procedures 3-29 Removing the Rectifying Removal Boards 1. Remove power from the drive (Removing Power from the Drive on page 3-3). 2. Remove the covers from the power structures. Refer to Removing the Covers from the Power Structures on page 3-15.

  • Page 66: Removing The Left-Side Output Power Modules

    3-30 Access Procedures Removing the Left-Side Removal Output Power Modules Important: Do not attempt to disassemble the Output Power Modules. Important: Always replace the Output Power Modules in pairs (do not replace just one module). 1. Remove power from the drive (Removing Power from the Drive on page 3-3).
  • Page 67 Access Procedures 3-31 7. Remove the balancing resistor wires from bus bars. Balancing Resistors Balancing Resistor Wires Snubber Capacitors Snubber Capacitor Fastening Screws 8. Remove the screws that secure the Snubber Capacitors, and remove the Snubber Capacitors. 9. Remove the screws that secure the DC Bus Bars to the left side of the power structure, and remove the DC Bus Bars.
  • Page 68 3-32 Access Procedures 12. Remove the Output Power Module from the drive. 13. Repeat steps 4 - 12 to remove the left-side Output Power Module from Power Structure 2. Installation Install the Output Power Modules in reverse order of removal, while referring to Torque Specifications on page 3-1.

  • Page 69: Removing The Right-Side Output Power Modules And Rectifying Modules

    Access Procedures 3-33 Removing the Right-Side Removal Output Power Modules and Important: Do not attempt to disassemble the Output Power Modules. Rectifying Modules Important: Always replace the Output Power Modules in pairs (do not replace just one module). 1. Remove power from the drive (Removing Power from the Drive on page 3-3).
  • Page 70 3-34 Access Procedures 8. Loosen, but do not remove, the screws that secure the Y Bus Bars to the drive. Y Bus Bars 9. Remove the balancing resistor wires from bus bars. Balancing Resistors AC Input Terminals Balancing Resistor Wires (L1, L2, L3) 10.
  • Page 71 Access Procedures 3-35 13. Remove the screws that secure the Snubber Capacitors, and remove the Snubber Capacitors. Snubber Capacitors Snubber Capacitor Fastening Screws 14. Remove the screws that secure DC Bus Bars to right side of power structure, and remove the DC Bus Bars.
  • Page 72 3-36 Access Procedures 15. Remove the screws that secure the Rectifying Module to the power structure, and remove the Rectifying Module. 16. Remove the screws that secure the Output Power Module to the power structure, and remove the Output Power Module. 17.

  • Page 73: Removing The Fan Inverters

    Access Procedures 3-37 Removing the Fan Inverters Removal 1. Remove power from the drive (Removing Power from the Drive on page 3-3). 2. Remove the covers from the power structures. Refer to Removing the Covers from the Power Structures on page 3-15.
  • Page 74 3-38 Access Procedures 5. Remove the Inverter Assemblies. Task Description Remove the two M5 Pozi-drive screws, which secure the front of the fan inverter to the drive. Proper tightening torque for reassembly is 4 N-m (35 lb.-in.). Disconnect the fan motor cable under the inverter. Remove the four M5 Pozi-drive screws, which secure the bottom of the fan inverter to the drive.
  • Page 75 Access Procedures 3-39 6. Remove the Inverter from the old Inverter Assembly. Task Description Disconnect the cables at connectors X4 (Blue) and X5 (Black). Right-hand Inverter Shown Task Description Remove two M5 Pozi-drive screws, which secure the inverter board and its heatsink to the assembly carriage. Proper tightening torque for reassembly is 4 N-m (35 lb.-in.).
  • Page 76 3-40 Access Procedures Removing the DC Bus Removal Capacitors 1. Remove power from the drive (Removing Power from the Drive on page 3-3). 2. Remove the covers from the power structures. Refer to Removing the Covers from the Power Structures on page 3-15.
  • Page 77 Access Procedures 3-41 5. Remove the screws that secure DC Bus Bars to right side of power structure, and remove the DC Bus Bars. 6. Remove the four (4) screws that secure the capacitor to the power structure, and remove the capacitor. 7.
  • Page 78 3-42 Access Procedures Installation Install the capacitors in reverse order of removal, while referring to Torque Specifications on page 3-1.

  • Page 79: Before Applying Power To The Drive

    Chapter Start-Up After Repair ATTENTION: Power must be applied to the drive to perform the following start-up procedure. Some of the voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, only qualified service personnel should perform the following procedure.

  • Page 80: Testing With The External Dc Power Supply Without Load (Optional)

    Start-Up After Repair Testing with the External DC This is a low current - low risk test for the Output Power Module and drive Control board. It requires the recommended High Voltage DC Test Power Power Supply Without Load Supply. (Optional) 1.

  • Page 81: Testing Without A Motor

    Start-Up After Repair Testing Without a Motor This test allows you to measure several operating parameters and diagnose problems without connecting the motor. 1. Verify that input power wiring and grounding is connected. 1. Verify that the motor cables are disconnected. 2.

  • Page 82: Testing With The Motor

    Start-Up After Repair Testing With the Motor This test allows you to measure several operating parameters and diagnose problems without connecting the motor to its mechanical load. 1. Verify that input power wiring and grounding is connected. 2. Verify that the motor cables are connected. 3.

  • Page 83: Appendix A Software Tools

    Appendix Service Tools and Equipment ™ ™ ™ Software Tools DriveTools SP, DriveExecutive, DriveExplorer and DriveObserver software tools for uploading, downloading and monitoring system parameters.

  • Page 84: Service Tools

    Service Tools and Equipment Service tools This list of basic service tools which will cover needs of tools for repair and maintenance measurements. Item Description Details Oscilloscope Portable, digitizing, dual channel scope, with isolation Current clamp 1000A(ac, rms), signal output Soldering station Soldering / de soldering Adjustable power supply...
  • Page 85 Appendix Schematics List of Schematic Diagrams For a Schematic Diagram on… See... Circuit Board Connections for 700S Drives with Phase II Control page B-2 Circuit Board Connections for 700H Drives page B-3 ASIC Circuit Board Connections page B-4 Power Circuitry for Drives with AC Input (Power Structure #1) page B-5 Power Circuitry for Drives with AC Input (Power Structure #2) page B-6...
  • Page 86 Schematics Circuit Board Connections for 700S Drives with Phase II Control RS-232 Port ENet Option RJ45 Phase II Connector Control Synchlink Board Option with all Options Compact I/O Option Fdbk Fdbk Option Compact Inputs Board Flash Option LEOB (Optional) Elect. Comm.

  • Page 87: Circuit Board Connections For 700H Drives

    Schematics Circuit Board Connections for 700H Drives...

  • Page 88: Asic Circuit Board Connections

    Schematics ASIC Circuit Board Connections To 700S HiHP Fiber Note: External Wiring Shown as Optic Dashed Lines. For DC Input Only Interface (Do Not Install on AC Input Drives). Feedback Board J28 Board #1 ASIC H903 700H Star Board X900 From DC Bus H900 Coupler...
  • Page 89 Schematics Power Circuitry for Drives with AC Input (Power Structure #1) W_LO W_LO W_HI W_HI TERM W TERM W V_LO V_LO V_HI V_HI TERM V TERM V U_LO U_LO U_HI U_HI TERM U TERM U Adapter Board To ASIC Board #1...
  • Page 90 Schematics Power Circuitry for Drives with AC Input (Power Structure #2) W_LO W_LO W_HI W_HI TERM W TERM W V_LO V_LO V_HI V_HI TERM V TERM V U_LO U_LO U_HI U_HI TERM U TERM U Adapter Board To ASIC Board #2...
  • Page 91 Schematics Power Circuitry for Drives with DC Input (Power Structure #1) W_LO W_LO W_HI W_HI TERM W TERM W V_LO V_LO V_HI V_HI TERM V TERM V U_LO U_LO U_HI U_HI TERM U TERM U Adapter Board To ASIC Board #1...
  • Page 92 Schematics Power Circuitry for Drives with DC Input (Power Structure #2) W_LO W_LO W_HI W_HI TERM W TERM W V_LO V_LO V_HI V_HI TERM V TERM V U_LO U_LO U_HI U_HI TERM U TERM U Adapter Board To ASIC Board #2...

  • Page 93: Fan Power Supply Connections

    Schematics Fan Power Supply Connections From DC Bus in Power Structure From ASIC Board #2 - X11 BLUE X2-3 X4-1 BLK 2 2.2uf 10Meg Main Fan 300VAC X2-1 Y/GRN DC/AC Left Side 230V AC X5-1 2.2uf 50 Hz 10Meg 300VAC BLACK Setup Switch Fan Frequency Converter...

  • Page 94: Ac Input Motor Connections

    B-10 Schematics AC Input Motor Connections...

  • Page 95: Dc Input Motor Connections

    Schematics B-11 DC Input Motor Connections...
  • Page 96 B-12 Schematics Notes:...

  • Page 97: Appendix C Circuit Board Connections

    ASIC Board on Power Structure #2 to Rectifier/Precharge Circuit page C-6 Board on Power Structure #2 Connections PowerFlex 700H and 700S Interface Board to ASIC Board on Power page C-8 Structure #1 Fiber Optic Connections PowerFlex 700H and 700S Interface Board to ASIC Board on Power...
  • Page 98 Connector Descriptions Figure C.1 ASIC Board Connectors Figure C.2 Gate Driver Board Connectors...
  • Page 99 Connector Descriptions Table C.A ASIC Board on Power Structure #1 to Gate Driver Board on Power Structure #1 - Phase U Connections Gate Driver ASIC Board Board Connector Pin Number to Pin Number Connector Description . . . U_Feedback . . . U_Power_OK (1) See Note Below .
  • Page 100 Connector Descriptions Table C.C ASIC Board on Power Structure #1 to Gate Driver Board on Power Structure #1 - Phase W Connections ASIC Board Gate Driver Board Connector Pin Number to Pin Number Connector Description . . . W_Feedback . . . W_Power_OK .
  • Page 101 Connector Descriptions Table C.E ASIC Board on Power Structure #2 to Gate Driver Board on Power Structure #2 - Phase V Connections ASIC Board Gate Driver Board Connector Pin Number to Pin Number Connector Description . . . V_Feedback . . . V_Power_OK .
  • Page 102 Connector Descriptions Figure C.3 Rectifier/Precharge Circuit Board Connectors X101 X100 Table C.G ASIC Board on Power Structure #1 to Rectifier/Precharge Circuit Board on Power Structure #1 Connections ASIC Board Rectifier Board Connector Pin Number to Pin Number Connector Description . . . 1 SWTS_DRV .
  • Page 103 Connector Descriptions Figure C.4 PowerFlex 700S High Power Star Interface Circuit Board Connectors...
  • Page 104 Connector Descriptions Figure C.5 PowerFlex 700H Star Coupler Circuit Board Connectors Table C.I PowerFlex 700H and 700S Interface Board to ASIC Board on Power Structure #1 Fiber Optic Connections Interface Board Fiber ASIC Board Optic Connector Fiber Connector Description: Reference to ASIC...
  • Page 105 Connector Descriptions Table C.J PowerFlex 700H and 700S Interface Board to ASIC Board on Power Structure #2 Fiber Optic Connections Interface Board Fiber ASIC Board Optic Connector Fiber Connector Description: Reference to ASIC 700H 700S Type to Type Board . . . RX Gate_Enable .

  • Page 106: Hardware Connections

    . . . J28 Trip_P1 H903 on Power Structure #2 . . . J27 Trip_P2 Table C.N ASIC Feedback Board to PowerFlex 700H Star Coupler Board Connections ASIC Feedback Board Description: Reference to Connector Star Coupler Board Connector Star Coupler Board H900 on Power Structure #1 .
  • Page 107 Connector Descriptions C-11 Table C.Q Right Side Main Cooling Fan Inverter Connections Fan Inverter Fan Inverter Description Connector Pin Number Pin Number Connector Description +15V dc power +15V dc power Fan Alarm Fan Alarm Figure C.8 X50 Terminal Block Connectors Terminal Blocks Customer Connections Drive Connections...
  • Page 108 C-12 Connector Descriptions Notes:...

  • Page 109: Appendix D Disassembly/Assembly Diagrams And Spare Parts Numbers

    MFD. in 2005 on Feb 29 Serial Number: 2622381652 2622381652 MADE IN THE USA (FAC 1B) MADE IN THE USA (FAC 1B) A complete list of spare parts for PowerFlex 700H/S drives is available on the Allen-Bradley web site at: http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf...
  • Page 110 Disassembly / Assembly Diagrams Figure D.1 Main Power Structure Assembly ATTENTION: The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage. Risk of electrical shock, injury, or death exists if someone comes into contact with the assembly.
  • Page 111 Disassembly / Assembly Diagrams Table D.A Main Power Structure Assembly Part Numbers Part Name Part No. Adapter Board 20-VB00330 Air Flow Guide Right ASIC Assembly Upgrade Kit (without ASIC Board) 20-FR10850 Bus Bar Fan Inverter Assembly, Left 20-FR10844 Fan Inverter Assembly, Right 20-FR10845 Fan Inverter Capacitor 7 f 450V ac 20-PP00060...
  • Page 112 Disassembly / Assembly Diagrams Figure D.2 Right Side of Power Structure Air Flow Guide, Right Snubber Capacitor Assembly Rectifying Board DC Bus Bar DC Bus Bar Insulator DC Bus Bar DC Bus Bar Insulator DC Bus Bar Rectifying Module DC Bus Bar Insulator Discharging Resistor Output Power Module Frame...
  • Page 113 Disassembly / Assembly Diagrams Part Name Part No. Output Power Module 400/480V 600/690V Rectifying Board 400/480V 20-VB00459 600/690V 20-VB00460 Rectifying Module 400/480V 20-FR10820 600/690V 20-FR10821 Snubber Capacitor Assembly 20-PP10019...
  • Page 114 Disassembly / Assembly Diagrams Figure D.3 Left Side of Power Structure 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.
  • Page 115 Disassembly / Assembly Diagrams Table D.C Left Side of Power Structure Part Numbers Part Name Part No. ASIC Assembly (without ASIC Board) Cover Plate DC Bus Bar 20-FR10048 20-FR10052 20-FR10191 DC Bus Bar Insulator 20-FR10026 20-FR10028 20-FR10143 Discharging Resistor 2x16k 20-PP00056 Electrolytic Capacitor ELKO 3300 f 420V for 400/480V Drives...
  • Page 116 Disassembly / Assembly Diagrams Figure D.5 ASIC Assembly ATTENTION: The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage. Risk of electrical shock, injury, or death exists if someone comes into contact with the assembly.
  • Page 117 Disassembly / Assembly Diagrams Figure D.6 Main Fan Assembly Main Fan Main Fan Housing, Left and Right Intake Cone Table D.F Main Fan Assembly Part Numbers Part Name Part No. Intake Cone Main Fan 230W 20-PP01080 Main Fan Housing, Left and Right...
  • Page 118 D-10 Disassembly / Assembly Diagrams Notes:...
  • Page 120 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 F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846 Publication PFLEX-TG004A-EN-P –...

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