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

High performance ac drive and adjustable frequency ac drive
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See also: Instruction and Installation Manual
700S High Performance
AC Drive
and
700H Adjustable Frequency
AC Drive
Frame 11
315-400KW / 400V
500-600HP / 480V
500-600HP / 600V
450-560KW / 690V
Hardware Service Manual

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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 11 315-400KW / 400V 500-600HP / 480V 500-600HP / 600V 450-560KW / 690V Hardware Service Manual...

  • Page 2: Important User Information

    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 Chapter 3 Torque Specifications........... . . 3-1 Understanding Torque Figures in Assembly Diagrams .
  • Page 5 Removing the W Phase (Right-Side) Rectifying Board, Rectifying Module and Output Power Module ............. . 3-36 Installation.

  • Page 7: Preface

    This manual does not contain in depth fault information for troubleshooting. Fault information is available in publications 20C-PM001, Programming Manual - PowerFlex 700H Adjustable Frequency AC Drive, PFLEX-IN006, Installation Instructions - PowerFlex 700S and 700H Adjustable Frequency AC Drive, and 20D-UM006, User Manual - PowerFlex 700S High...

  • Page 8: 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 9: Cross References

    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 10: 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 11 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 12: Chapter 1 Creating Fault Reports

    Troubleshooting and Error Codes Creating Fault Reports Complete fault reports are critical for analysis and repair of modules returned to the factory. At a minimum, perform and record the following: Record the contents of the fault queue (faults and times of occurrence) Make record of any burn marks on the rectifying module, DC-capacitors, inverter bridge, charging resistors, balancing/precharging resistors, printed circuit boards, bus bars, cabling and fiber-optic cabling...

  • Page 13: Addressing 700H Hardware Faults

    [Power Loss Time]. Enable/Disable interruption. with [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 14 Troubleshooting and Error Codes Name Description Action (if appropriate) OverVoltage DC bus voltage exceeded maximum Monitor the AC line for high line value. voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install and external dynamic brake option.

  • Page 15: 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 16: No Output Voltage

    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 17: No Him Display

    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 Specification? Module OK? Module...

  • Page 18: Over-Temperature Faults

    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 19: 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 20: 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 Viewing the 700S Diagnostic...
  • Page 21 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 22: Performing Visual Inspections

    Component Test Procedures Performing Visual Inspections Visually inspect the cooling tunnels and power structure before energizing the drive. Inspecting the Cooling Tunnels 1. Remove the main cooling fans from the bottom of the power structure. Refer to Removing the Main Fans on page 3-24.
  • Page 23 Component Test Procedures 1. Remove power from the drive. Refer to Removing Power from the Drive on page 3-3. 2. Disconnect the motor leads from the drive. 3. On ac input drives, conduct forward and reverse biased diode tests on the Rectifying module(s).
  • Page 24 Component Test Procedures Table 2.B Reverse Biased Diode Tests on Rectifying Module(s) Meter Leads Nominal meter reading Meter should display “.0L” (zero load) If the drive fails any of these measurements, replace all Rectifying modules. 4. Conduct forward and reverse biased diode tests on the Output Power modules.

  • Page 25: 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 26: Gate Interface Resistance

    Component Test Procedures Gate Interface Resistance There are three Gate Driver boards, one per output power module. Measure the gate interface resistance for each output power transistor. The resistance from each gate and collector pin to the branch emitter pin should be about 333 ohms.
  • Page 27 Component Test Procedures 1. Remove power from the drive. Refer to Removing Power from the Drive on page 3-3. 2. Remove the covers from the power structure. Refer to Removing the Covers from the Power Structure on page 3-13. 3. Disconnect the Main Fan Inverters power supply cables in order to prevent them from running during these tests.

  • Page 28: Checking The Opto-Couplers

    2-10 Component Test Procedures 9. Connect the High Voltage DC Test Power Supply DC+ to the DC+ on each Gate Driver board. ATTENTION: The sheet metal cover and mounting screws on the ASIC board located on the power structure are energized at (-) DC bus potential high voltage.
  • Page 29 Component Test Procedures 2-11 1. Locate the fiber optic receiver which transmits the signals for the U High (UH) gate interface and connector X10 on the Gate Driver board. X10 provides the gate interface for the UH output power transistor in the U Phase Output Power module.

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

    2-12 Component Test Procedures Phase Output Power module. If the drive fails any of these tests, replace the Gate Driver board. 9. Connect the multi-meter (ohms) black test lead to the DC- Bus Bar and the red test lead from the multi-meter to the output terminal on the U Phase.

  • Page 31: Taking Measurements On Rectifying Module

    Component Test Procedures 2-13 3. Visually inspect the pre-charging resistors. If the pre-charging resistors are damaged: A. Replace all Rectifying modules (See Removing the W Phase (Right-Side) Rectifying Board, Rectifying Module and Output Power Module on page 3-36). B. Check the capacitors, rectifier(s) and external connections for short-circuits.

  • Page 32: Testing 400V Ac Input, 590A, 650A Or 730A, Or 600V Ac Input, 590A Drives

    2-14 Component Test Procedures 10.Verify that the voltage and resistance between the following points is zero: J3 and X10: Pin 1, J7 and X11: Pin 1, and J11 and X12: Pin 1. Refer to Table 2.G on page 2-16 below. If the Rectifying Module fails any of these tests, replace it (See Removing the W Phase (Right-Side) Rectifying Board, Rectifying Module and Output Power Module on...

  • Page 33: Taking Measurements On Rectifying Module

    Component Test Procedures 2-15 Taking Measurements on Rectifying Module 8. Disconnect connectors X13, X12, X11 and X10. 9. Perform resistance measurements, using a digital multimeter, on the points listed in Table 2.F below. These points are on the back of the X10, X11 and X12 plugs which you have disconnected from the board.
  • Page 34 2-16 Component Test Procedures Figure 2.2 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.G Rectifying Board Charge Relay Test Results No Power on X13 24V dc Power on X13 Meter Leads...

  • Page 35: 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 36: Checking The Main Fan Inverters And Fans

    2-18 Component Test Procedures Checking the Main Fan Checking Inverter LEDs Inverters and Fans A frame 11 drive has three fans and three fan inverters. Each fan inverter has a red and a green diagnostic LED. ATTENTION: The inverter LEDs are only operational when the drive is energized, and only visible with the covers removed from the power structure.

  • Page 37: Checking The Main Fan Motors

    Component Test Procedures 2-19 Checking the Main Fan Motors 1. Remove power from the drive. Refer to Removing Power from the Drive on page 3-3. 2. Remove the covers from the power structure. Refer to Removing the Covers from the Power Structure on page 3-13.
  • Page 38 2-20 Component Test Procedures Notes:...

  • Page 39: 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 40 Access Procedures Item Screw Final Torque 700H Fiber Optic Adapter 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...

  • Page 41: Understanding Torque Figures In Assembly Diagrams

    Access Procedures Understanding 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 42: Removing The Dpi / Him Assembly

    Access Procedures 3. Measure the DC bus voltage at the DC+ & DC- terminals on the Power Terminal Block. The voltage must be zero. Removing the DPI / HIM Removal Assembly 1. Remove power from the drive. Refer to Removing Power from the Drive on page 3-3.

  • Page 43: Installation

    Access Procedures 6. Remove the four mounting screws and the assembly from the Control Frame. Mounting Screws 0.9 N-m (8 lb.-in.) Installation Install the DPI / HIM Assembly in the reverse order of removal, while referring to Torque Specifications on page 3-1.
  • Page 44 Access Procedures 4. Loosen the captive screw on the Control Assembly mounting plate and swing the Control Assembly away from the drive. Phase II Control Shown Captive Screw 5. Carefully disconnect the ribbon cables from the sockets on the High Power Fiber Optic Interface Circuit Board on the back of the control mounting plate, and carefully set them aside.

  • Page 45: Installation

    Access Procedures 6. Loosen the two mounting screws on the front of the Control Assembly and slide the cassette control off the mounting bracket. Note: Ribbon cables not shown for clarity only. Installation Install the 700S Control Assembly in the reverse order of removal, while referring to Torque Specifications on page 3-1.

  • Page 46: Removing The 700S Control Assembly

    Access Procedures Important: Minimum inside bend radius for fiber-optic cable is 25.4 mm (1 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable. Signal attenuation increases with decreased inside bend radii. Ribbon Cables Phase II Control Shown Fiber-Optic Sockets Screws...

  • Page 47: Removing The 700S High Power Fiber Optic Interface Circuit Board

    Access Procedures 3. Remove the 700S High Power Fiber Optic Interface Circuit Board. Refer to Removing the 700S High Power Fiber Optic Interface Circuit Board on page 3-7. 4. Lift the Control Assembly up and off of the hinge. Installation Install the 700S Control Assembly in reverse order of removal.
  • Page 48 3-10 Access Procedures 3. Remove the I/O Boards from the Control Board and enclosure. Note the order of the boards and the keys which prevent placement of boards in the incorrect slots. Do not remove enclosure cover. Enclosure is illustrated without the cover for clarity.

  • Page 49: Installation

    Access Procedures 3-11 5. Remove the three screws which secure the Control Assembly to the drive. Do not remove enclosure cover. Enclosure is illustrated without the cover for clarity. 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 50 3-12 Access Procedures 4. Disconnect the control power cable from X2 of the Fiber Optic Adapter Board. X1 connects Sockets for to Main Fiber-Optic Control cables X2 connects to 24V dc power 5. Carefully disconnect the fiber-optic cables from the right side of the circuit board, and carefully set them aside.

  • Page 51: Removing The Covers From The Power Structure

    Access Procedures 3-13 6. Remove the four screws which secure the Fiber Optic Adapter board to the stand-offs on the back of the Control Frame. 0.9 N-m (8 lb.-in.) 7. Remove the Fiber Optic Adapter Board from the Control Frame. Installation Install the 700H Fiber Optic Adapter Board in reverse order of removal, while referring to...
  • Page 52 3-14 Access Procedures 2. If moving the control frame from a DC input drive with precharge interlock, disconnect the wiring from terminal strip X50. X50 Terminal Block 3. Loosen the T8 Torx-head screws, which secure the Control Frame to the drive enclosure.

  • Page 53: Removing The Airflow Plate

    Access Procedures 3-15 Removing the Airflow Plate The drive is equipped with a plate, just above the Control Frame, that manages airflow through the drive. You must remove this plate in order to access the protective covers. Removal 1. Remove power from the drive. Refer to Removing Power from the Drive on page 3-3.

  • Page 54: Removing The Protective Covers From Power Structure

    3-16 Access Procedures Installation Install the Airflow Plate in reverse order of removal, while referring to Torque Specifications on page 3-1. Removing the Protective Covers from Power Structure You must remove the protective covers to gain access to the power structure. Removal 1.

  • Page 55: Removal

    Access Procedures 3-17 Installation Install the Protective Covers in reverse order of removal, while referring to Torque Specifications on page 3-1. Removing the 700S Voltage Removal Feedback Circuit Board 1. Remove power from the drive. Refer to Removing Power from the Drive on page 3-3.

  • Page 56: Installation

    3-18 Access Procedures 6. Remove the five screws which secure the Voltage Feedback Circuit Board to the drive. 7. Remove the circuit board from the drive. 0.9 N-m (8 lb.-in.) 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: Installation

    Access Procedures 3-19 4. Carefully disconnect the fiber-optic cables from sockets along the top of the Gate Driver Board, and carefully set them aside. ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation.

  • Page 58: Removing The Asic Board

    3-20 Access Procedures Removing the ASIC Board Removal ATTENTION: The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage. Risk of electrical shock, injury, or death exists if someone comes into contact with the assembly.

  • Page 59: Installation

    Access Procedures 3-21 6. Disconnect the other cables from sockets on the front of the ASIC Board, and set them aside. 7. Remove the fan from the ASIC Board. 8. Slide the ASIC Board out of the assembly chassis. 9. Remove the ASIC assembly chassis from the mounting plate. 10.
  • Page 60 3-22 Access Procedures 5. Remove the input (AC or DC) and brake wiring (if equipped) from the incoming terminals at the top of the power structure. Motor Connection Terminals U/T1 V/T2 W/T3 AC Power Terminals Ground Connection...
  • Page 61 Access Procedures 3-23 6. Remove the six screws that secure the Power Structure to the enclosure frame. Remove screws Remove screws 7. Follow the instructions in publication PFLEX-IN014, Installation Instructions - PowerFlex 700S /700H High Power Maintenance Stand, to install the Maintenance Stand. Remove the power structure by sliding it onto the rails of the Maintenance Stand.

  • Page 62: Installation

    3-24 Access Procedures Installation Install the power structure in reverse order of removal, while referring to Torque Specifications on page 3-1. Refer to the publication PFLEX-IN006 , Installation Instructions - PowerFlex 700S and 700H High Power Drives, for tightening torques of motor terminations. Removing the Main Fans Removal There are three main fans on the drive.

  • Page 63: Installation

    Access Procedures 3-25 Installation Install the fans in reverse order of removal, while referring to Torque Specifications on page 3-1. Removing the Fan Inverters Removal 1. Remove power from the drive. Refer to Removing Power from the Drive on page 3-3.
  • Page 64 3-26 Access Procedures 5. Remove the cable-ties that secure the cables with black insulation to the fan inverter assemblies. This will allow you to move the cables and remove the inverter assemblies. Fan Inverter Locations Remove cable-ties 6. Disconnect the fan motor cable under the inverter. 7.
  • Page 65 Access Procedures 3-27 9. Carefully remove the inverters by sliding them out toward the front of the drive. Bottom View of Power Structure Remove Screws Disconnect fan motor cable Remove Screws Important: Do not damage the output transformer when removing or installing the inverter.
  • Page 66 3-28 Access Procedures 10. To remove the inverter from the old inverter assembly, disconnect the cables at connectors X4 (Blue) and X5 (Black). Disconnect X4 and X5 Right-hand Inverter Shown 11. Remove two M5 POZIDRIV screws, which secure the inverter board and its heatsink to the assembly carriage.

  • Page 67: Removing The U Phase (Left-Side) Output Power Module

    Access Procedures 3-29 Removing the U Phase Removal (Left-Side) Output Power Important: Do not attempt to disassemble the Output Power Module. Module Important: Always replace all three Output Power Modules (do not replace just one module). 1. Remove power from the drive. Refer to Removing Power from the Drive on page 3-3.
  • Page 68 3-30 Access Procedures 7. Remove the screws that secure the Main DC Bus Bars to the Power Structure and remove the Main Bus Bars. DC Bus Bars Insulator 8. Remove the screws that secure the Input Power Terminal assembly to the Power Structure and remove the Input Power Terminal assembly.
  • Page 69 Access Procedures 3-31 10. Remove the screws that secure the U Phase (left side) Power assembly to the drive and remove the Power assembly. 11. Remove the screws that secure the motor connection leads to the Power Module assembly and remove the motor connection leads. Motor Connection Leads...

  • Page 70: Installation

    3-32 Access Procedures 14. Remove the screws which secure the Output Power Module to the drive. 15. Disconnect the Power Module Circuit Board from the Adapter Board. 16. Remove the Output Power Module from the drive. Installation Install the Output Power Module in reverse order of removal, while referring to Torque Specifications on page 3-1.

  • Page 71: Module

    Access Procedures 3-33 Removing the V Phase Removal (Middle) Rectifying Board, Important: Do not attempt to disassemble the Output Power Module. Rectifying Module and Output Power Module Important: Always replace all three Output Power Modules (do not replace just one module). Important: 600V ac input, 460A and 502A frame 11 drives only have one Rectifying module.
  • Page 72 3-34 Access Procedures 9. Remove the five screws that secure the Rectifying Circuit Board to the drive and remove the Rectifying Circuit Board. 10. Remove the screws that secure the Snubber Capacitors and remove the Snubber Capacitors. 11. Remove the screws that secure DC Bus Bars to right side of power structure, and remove the DC Bus Bars.

  • Page 73: Installation

    Access Procedures 3-35 12. Remove the screws that secure the Rectifying Module to the power structure and remove the Rectifying Module. 13. Remove the screws that secure the Output Power Module to the power structure, and remove the Output Power Module. Rectifying Module Output Power Module Installation...

  • Page 74: Module

    3-36 Access Procedures Removing the W Phase Important: Do not attempt to disassemble the Output Power Module. (Right-Side) Rectifying Important: Always replace all three Output Power Modules (do not replace Board, Rectifying Module just one module). and Output Power Module 1.
  • Page 75 Access Procedures 3-37 9. Remove the five screws that secure the Rectifying Circuit Board to the drive and remove the Rectifying Circuit Board. 10. Remove the screws that secure the Snubber Capacitors and remove the Snubber Capacitors. 11. Remove the screws that secure DC Bus Bars to right side of power structure, and remove the DC Bus Bars.
  • Page 76 3-38 Access Procedures 12. Remove the screws that secure the Rectifying Module to the power structure and remove the Rectifying Module. 13. Remove the screws that secure the Output Power Module to the power structure, and remove the Output Power Module. Rectifying Module Output Power Module Installation...

  • Page 77: Installation

    Access Procedures 3-39 5. Remove the four screws that secure the capacitor to the power structure, and remove the capacitor. Installation Install the capacitors in reverse order of removal, while referring to Torque Specifications on page 3-1.
  • Page 78 3-40 Access Procedures Notes:...

  • 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. Service Tools This list of basic service tools which will cover needs of tools for repair and maintenance measurements.
  • Page 84 Service Tools and Equipment Item Description Details Power supply (service) Capacity of three phase service 400/500/690Vac, 30A 20-MAINSTD maintenance stand Maintenance stand for removing power structure from drive cabinet 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).
  • Page 85 Appendix Schematics List of Schematic Diagrams For a Schematic Diagram on… See... Phase U Power Circuitry for Drives with AC Input page B-2 Phase V Power Circuitry for Drives with AC Input page B-3 Phase W Power Circuitry for Drives with AC Input page B-4 Phase U Power Circuitry for Drives with DC Input page B-5...

  • Page 86: Power Wiring Diagrams

    Schematics Power Wiring Diagrams Phase U Power Circuitry for Drives with AC Input W_LO W_HI TERM 3 V_LO V_HI TERM 2 U_LO U_HI TERM 1...

  • Page 87: Phase V Power Circuitry For Drives With Ac Input

    Schematics Phase V Power Circuitry for Drives with AC Input W_LO W_HI TERM 3 V_LO V_HI TERM 2 U_LO U_HI TERM 1...

  • Page 88: Phase W Power Circuitry For Drives With Ac Input

    Schematics Phase W Power Circuitry for Drives with AC Input W_LO W_HI TERM 3 V_LO V_HI TERM 2 U_LO U_HI TERM 1...

  • Page 89: Phase U Power Circuitry For Drives With Dc Input

    Schematics Phase U Power Circuitry for Drives with DC Input W_LO W_HI TERM 3 V_LO V_HI TERM 2 U_LO U_HI TERM 1...

  • Page 90: Phase V Power Circuitry For Drives With Dc Input

    Schematics Phase V Power Circuitry for Drives with DC Input W_LO W_HI TERM 3 V_LO V_HI TERM 2 U_LO U_HI TERM 1...

  • Page 91: Phase W Power Circuitry For Drives With Dc Input

    Schematics Phase W Power Circuitry for Drives with DC Input W_LO W_HI TERM 3 V_LO V_HI TERM 2 U_LO U_HI TERM 1...

  • Page 92: Control Wiring Diagrams

    Schematics Control Wiring Diagrams Circuit Board Connections for 700H Drives with AC Input frm11_circuit_bd_conns_700H_AC.eps...

  • Page 93: Circuit Board Connections For 700H Drives With Dc Input

    Schematics Circuit Board Connections for 700H Drives with DC Input frm11_circuit_bd_conns_700H.eps...

  • Page 94: Circuit Board Connections For 700S Drives - Phase Ii Control With Ac Input

    B-10 Schematics Circuit Board Connections for 700S Drives - Phase II Control with AC Input...

  • Page 95: Circuit Board Connections For 700S Drives - Phase Ii Control With Dc Input

    Schematics B-11 Circuit Board Connections for 700S Drives - Phase II Control with DC Input...

  • Page 96: Fan Inverter And Main Fan Connections

    B-12 Schematics Fan Inverter and Main Fan Connections...
  • Page 97 Rectifier/Precharge Circuit Board Phase V to Rectifier/Precharge Circuit Board Phase W page C-4 Connections PowerFlex 700H Fiber Optic Adapter Circuit Board to ASIC Board Fiber Optic page C-5 Connections PowerFlex 700S High Power Fiber Optic Interface Board to ASIC Board Fiber Optic...
  • Page 98 Connector Descriptions Figure C.1 ASIC Board Connectors H1 H2 H3 H4 H5 H6 H8 H9 H10 H11 H12 H13 Figure C.2 Gate Driver Board Connectors...
  • Page 99 Connector Descriptions Table C.A ASIC Board to Gate Driver Board Phase U Connections Gate Driver ASIC Board Board Connector Pin Number to Pin Number Connector Description . . . U_Feedback . . . U_Power_OK (1) See Note Below . . . U_DTR .
  • Page 100 Connector Descriptions Figure C.3 Rectifier/Precharge Circuit Board Connectors X101 X100 Table C.D ASIC Board to Rectifier/Precharge Circuit Board Phase V Connections ASIC Board Rectifier Board Phase Connector Pin Number to Pin Number V Connector Description . . . SWTS_DRV . . . SWTS_FB .
  • Page 101 Connector Descriptions Figure C.4 PowerFlex 700H Fiber Optic Adapter Circuit Board Connectors Table C.F PowerFlex 700H Fiber Optic Adapter Circuit Board to ASIC Board Fiber Optic Connections 700H Interface Board Fiber ASIC Board Fiber Description Optic Connector Type to Type...
  • Page 102 Connector Descriptions Figure C.5 PowerFlex 700S High Power Fiber Interface Circuit Board Connectors Table C.G PowerFlex 700S High Power Fiber Optic Interface Board to ASIC Board Fiber Optic Connections 700SInterface Board ASIC Board Fiber Description Fiber Optic Connector Type to Type Connector Description...
  • Page 103 Connector Descriptions Figure C.6 Fan Inverter Circuit Board Connectors Table C.I ASIC Board to Main Cooling Fan Inverter Phase U Connections ASIC Board Fan Inverter Description Connector Pin Number Pin Number Connector Description +15V dc power to +15V dc power from Fan Inverter boards ASIC board Fan Control...

  • Page 104: Hardware Connections

    Connector Descriptions Hardware Connections Figure C.7 X50 Terminal Block Connectors Terminal Block on Control Pan Customer Connections Drive Connections ASIC Board Example External Precharge Circuitry +24V DC Isolated 0V DC Charge Relay Pilot Relay Main DC Contactor Precharge For DC Input Only (Do Not Install on AC Input Drives) Table C.M X50 Terminal Block Precharge Circuit Connections ASIC Board...

  • Page 105: Appendix D Disassembly/Assembly Diagrams And Spare Parts Numbers

    Diagrams and Spare Parts where applicable. Numbers 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 106 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 107 Disassembly / Assembly Diagrams Figure D.2 Power Structure Power Structure Table D.B Power Structure Part Numbers Part Name Rating Spare Part No. Power Structure 400/480V, 590A SK-H1-PWRMOD-D590 400/480V, 650A SK-H1-PWRMOD-D650 400/480V, 730A SK-H1-PWRMOD-D730 600/690V, 460A SK-H1-PWRMOD-E460 600/690V, 502A SK-H1-PWRMOD-E502 600/690V, 590A SK-H1-PWRMOD-E590...
  • Page 108 Disassembly / Assembly Diagrams Figure D.3 Phase U Power Structure Components 480V Shown Snubber Capacitor Assembly DC Link Bus Bar Kit - 500V Output Power Module Cover Plate Gate Driver Board Rectifying Module Electrolytic Capacitor Table D.C Phase U Power Structure Components Part Numbers Part Name Spare Part No.
  • Page 109 Disassembly / Assembly Diagrams Figure D.4 Phase V and W Power Structure Components 480V Shown Snubber Capacitor Assembly Precharge (Rectifying) Board DC Link Bus Bar Kit - 500V Bus Bar Bridge DC- Bus Bar Bridge DC+ Output Power Module Gate Driver Board Rectifying Module Electrolytic Capacitor...
  • Page 110 Disassembly / Assembly Diagrams Part Name Spare Part No. Output Power Module 400/480V SK-H1-QOUT-D590 400/480V SK-H1-QOUT-D650 400/480V SK-H1-QOUT-D730 600/690V SK-H1-QOUT-E460 600/690V SK-H1-QOUT-E502 600/690V SK-H1-QOUT-E590 Rectifying Module 400/480V 20-FR10820 600/690V 20-FR10821 Figure D.5 Fan Inverter Fan Inverter Board Output Transformer Assembly for Fan Fan Capacitor Inverter Table D.E Fan Inverter Part Numbers...
  • Page 111 Disassembly / Assembly Diagrams Figure D.6 ASIC Assembly ATTENTION: The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at (-) DC bus potential high voltage. Risk of electrical shock, injury, or death exists if someone comes into contact with the assembly.
  • Page 112 Disassembly / Assembly Diagrams Figure D.7 Main Fan Assembly Main Fan Assembly Main Fan Housing Main Fan Intake Cone Table D.G Main Fan Assembly Part Numbers Part Name Spare Part No. Main Fan Assembly 230W 20-PP01080 Main Fan Housing Main Fan Intake Cone...
  • Page 114 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-TG003A-EN-P –...

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