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Appendix A

Service Tools and Equipment

Software Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B

Schematics

List of Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Appendix C

Disassembly / Assembly Diagrams

Disassembly/Assembly Diagrams and Spare Parts Numbers . . . . . . . . . . . . . . . . . . . . . . C-1

Index

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Summary of Contents for powerflex 700h

Page 1: ...FRAME 10 HARDWARE SERVICE MANUAL 200 250 kW 400V 300 450 HP 480V 250 450 HP 600V 250 400 kW 690V PowerFlex 700S 700H Adjustable Frequency AC Drives ...

Page 2: ...e examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations I...

Page 3: ...cedures from Chapter 2 Updated the Checking the Rectifying Module procedures to include the new Series B Rectifying board 2 9 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 Change See Page Updated the 700S hardware faults 1 2 Remo...

Page 4: ...soc ii Summary of Changes Notes ...

Page 5: ...pter 1 Troubleshooting and Error Codes Creating Fault Reports 1 2 Addressing 700S Faults 1 2 Addressing 700H Faults 1 13 Common Drive Conditions and Corrective Actions 1 17 Technical Support Options 1 19 Chapter 2 Component Test Procedures Viewing the 700H Diagnostic LED 2 1 Performing Visual Inspections 2 2 Conducting Forward and Reverse Biased Diode Tests for Major Power Components 2 3 Conductin...

Page 6: ...cuit Board 3 21 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 3 28 Installing the Main Fans 3 28 Removing the ASIC Circuit Board 3 29 Installing the ASIC Circuit Board 3 30 Removing the Rec...

Page 7: ...ice Tools and Equipment Software Tools A 1 Service Tools A 1 Appendix B Schematics List of Schematic Diagrams B 1 Appendix C Disassembly Assembly Diagrams Disassembly Assembly Diagrams and Spare Parts Numbers C 1 Index ...

Page 8: ...4 ...

Page 9: ...kW Heavy Duty Power DC Voltage Range 462 594 350 583 713 350 Amps Input DC AC Voltage Range 0 400 50 Hz 0 460 60 Hz Base Hz default Output 3 Phase 0 320Hz Continuous Amps 300 245 330 368 300 245 330 368 1 Min Overload Amps 2 Sec Overload Amps 450 490 450 490 MFD in 1989 on Nov 9 Serial Number 2622381652 2622381652 MADE IN THE USA FAC 1B Series A Standard I O NONE Original Firmware No 2 04 UL US C ...

Page 10: ...rence Guide for Reading Schematic Diagrams 100 2 10 Guarding Against Electrostatic Damage 8000 4 5 2 Title Publication Programming Manual PowerFlex 700H AC Drive 20C PM001 User Manual PowerFlex 700S Drive with Phase I Control 20D UM001 User Manual PowerFlex 700S Drive with Phase II Control 20D UM006 Installation Instructions Hi Resolution Feedback Option Card for PowerFlex 700S Drives 20D IN001 In...

Page 11: ...eference to figure C 1 on page 2 of Appendix C Additional Support Available on Internet Additional troubleshooting information and software tools are available on the Allen Bradley Drives Support Website http www ab com support abdrives 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 ...

Page 12: ...ors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system ATTENTION Only qualified personnel familiar with high power PowerFlex 700S and 700H Drives and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury an...

Page 13: ...y 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 Bl...

Page 14: ... Speed Limit and 335 Abs OverSpd Lim Check to see if the encoder feedback polarity is correct 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 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 over...

Page 15: ...of the MDI feedback Option Card Reconnect encoder or replace encoder 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 user Informational only 8 SLink HW Fail A fault on loading SynchLink firmware into FPGA on Main Control Board at power up Replace Main Control Board 9...

Page 16: ... parameter 2 Motor NP FLA Configure with parameter 372 Mtr OL Pend Cnfg 13 Motor Stalled The motor has stalled These three 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 parame...

Page 17: ...ator 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 either the Motor Autotuning procedure or the Power Circuits Diagnostics test Parameters 463 MC Diag Error 1 464 MC Diag Error 2 and 465 MC Diag Error 3 display Motor Autotuning and Power Circuit Diagno...

Page 18: ...he 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 Illegal Interrupt Self Diagnostic Fault Data Error Cycle power Reflash firmware Replace Main Control Board 31 Precharge Error The precharge function has failed to complete within 30 seconds default of the precharge requ...

Page 19: ...parameter 390 SL MultErr Cnfg 41 Ridethru Timeout The drive has been in a bus loss ride through condition for more than two seconds default The ride through timeout can be configured in parameter 407 Power Loss Time Verify the AC Line Verify the value in Power Loss Time 42 DC Bus Undervolt Bus voltage has fallen below the level configured in parameter 409 Line Undervolts Verify the AC Line In fram...

Page 20: ...rt 4 Configured with parameter 391 DPI CommLoss Cfg 53 DPI Loss Port 5 The device at DPI port 5 has stopped communicating with the drive A SCANport device is connected to a drive operating DPI devices at 500k Baud Verify DPI device is present and functional at port 5 Configured with parameter 391 DPI CommLoss Cfg 54 DPI Loss Port 6 The device at DPI port 6 has stopped communicating with the drive ...

Page 21: ...nfg 65 HiHp In PhaseLs AC Input Phase Loss the AC input phase voltage has fallen 1 Check for voltage on each AC 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 Bus Communication Time Delay the communication bus has dela...

Page 22: ...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 cooling fan did not send active feedback or did not work 1 Check the 10 pin connector between the Main Control board and High Power Fiber Optic Interface board 2 Check the fiber optic connections between the High Power Fiber Optic Interface Circuit board and the A...

Page 23: ...nd fan power supply replace if necessary Replace the Power modules if the ambient temperature is within specification and the cooling fans are operating properly 81 Soft Over Trvl Motion Only Position feedback exceeds the maximum positive travel setting parameter 694 Motn Mx Pos Trvl Configured with parameter 395 Sft OvrTrvlCnfg 82 Soft Over Trvl Motion Only Position feedback exceeds the maximum n...

Page 24: ...nel 1 Change configuration for Anlg In1LossCnfg 95 Analog In 2 Loss Analog Input channel 2 is lost For configuration of Analog Input channel 2 see parameter 1094 Anlg In2LossCnfg Check condition of Analog Input channel 2 Change configuration for Anlg In2LossCnfg 96 Analog In 3 Loss Analog Input channel 3 is lost For configuration of Analog Input channel 3 see parameter 1095 Anlg In3LossCnfg Check ...

Page 25: ... settings of parameters 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 exceeded the maximum allowable value 85 degrees C Alarm 90 degrees C Fault 1 Verify that the maximum ambient temperature has not been exceeded 2 Check the fan s 3 Ch...

Page 26: ...stem 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 Compensation or Bus Regulation have attempted to add an output frequency adjustment greater than the value programmed in parameter 83 Overspeed Limit Remove the excessive load or overhauling conditions...

Page 27: ... nameplate data and verify the proper entry in the Motor Data parameters 54 Zero Divide This event occurred because a mathematical function had a dividend of zero 1 Cycle the power 2 Replace the main control board 59 Gate Disable Both of the digital gate disable inputs SD 1 and SD 2 are not enabled on the 20C DG1 option board 1 Check the motor 2 Verify that the option board is properly wired 3 Rep...

Page 28: ...magnetizing current rotate test has failed 1 Check the motor nameplate data 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 has failed 1 Check the motor nameplate data 2 Check the motor connections 99 UserSet Timer A User Set load or save was not completed in less than 5 seconds Replace the Main Control...

Page 29: ...00S 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 o...

Page 30: ...ings 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 Verify that the line to line is open Verify that the line to ground is open 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...

Page 31: ...ems 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 butt...

Page 32: ...ime 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 Capt...

Page 33: ...s 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 C...

Page 34: ...s 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 LED 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 be...

Page 35: ...ode test should find an open circuit and the meter should display a value close to zero Ex 0L 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...

Page 36: ...t 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 DC L2 DC L3 L1 DC L2 DC L3 DC Table 2 B Reverse Biased Diode Tests on Rectifying Module Meter Leads Nominal meter reading L1 DC Meter should display 0L zero load L2 DC L3 DC DC L1 DC L2 DC L3 DANGER DANGER DC BUS CONDUCTORS AND CAPACITORS OPERATE AT HIGH...

Page 37: ...ipment 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 L2 DC L3 DC Table 2 D Reverse Biased Diode Tests on Rectifying Module Meter Leads Nominal meter reading L1 DC Meter should display 0L zero load and rises to the meter battery voltage L2 DC L3 DC DC L1 DC L2 DC L3 Table 2 E Forward Biased Diode Test...

Page 38: ...ear 1 0V verify that the actual voltage measured is consistent for the Rectifying module and the Output Power modules DC T2 DC T3 T1 DC The value should gradually rise to about 0 35V 2 2 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 T2...

Page 39: ...om 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 Locate the Gate Driver Board on the front of the power structure H5 H7 H9 H4 H6 H8 X3 X4 X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 X1 ahw1009 eps ...

Page 40: ...ace for U High UH in Left Power Output Module X6 500 ohms 500 ohms 500 ohms 500 ohms 500 ohms 500 ohms Gate Interface for W Low WL in Left Power Output Module Gate Interface for U Low UL in Left Power Output Module Gate Interface for V Low VL in Left Power Output Module X8 500 ohms 500 ohms Emitter Gate Interface for W High WH in Right Power Output Module X9 500 ohms 500 ohms Emitter Gate Interfac...

Page 41: ...wer 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 o...

Page 42: ...fying 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 Rectifying Module on page 3 36 Figure 2 2 Rectifying Board Layout and Measurement Points Measurement points Resistance X10 red to X10 black 18Ω 1Ω X11 red to X11 black X12 red to X12 black Measurement points Resistance X10 red to X...

Page 43: ...Component Test Procedures 2 11 Table 2 K Rectifying Board Charge Relay Test Results No Power on X13 Meter Leads Results J3 X9 0Ω J7 X9 J11 X9 ...

Page 44: ...a multi meter verify that they are not open 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 SA...

Page 45: ...er 3 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 2 Remove the covers from the power structure Refer to Removing the Covers from the Power Structure on page 3 15 3 Disconnect the left hand fan motor from its inverter 4 Measure the resistance of the fa...

Page 46: ...2 14 Component Test Procedures ...

Page 47: ...l 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 int...

Page 48: ...l screw 20 N m 177 lb in Capacitor M4 x 8 self tapping 1 N m 9 lb in Capacitor Bus Bar M6 x 16 POZIDRIV 4 N m 35 lb in Capacitor Bus Bar M6 x 20 POZIDRIV 4 N m 35 lb in DC DC Terminals M6 x 20 POZIDRIV 5 N m 44 lb in DPI HIM Assembly mounting M3 x 6 Phillips 0 9 N m 8 lb in DPI HIM Assembly Door M3 x 6 Phillips 0 9 N m 8 lb in Main Fan M4 x 8 POZIDRIV 1 7 N m 15 lb in Main Fan Mounting M6 x 20 POZ...

Page 49: ...minal 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 dam...

Page 50: ...IM assembly 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 5 On 700S 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 Screws P1 0 9 N m 8 lb in ahw0664 eps X4 X2 ahw0665 eps Back view of DPI circuit board which s...

Page 51: ...nal attenuation increases with decreased inside bend radii 1 Loosen the captive screw and swing the Control assembly away from drive 2 On the 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 M...

Page 52: ...fore removing connections and wires mark the connections and wires to avoid incorrect wiring during assembly 2 Unplug any fiber optic ControlNet and SynchLink cables from the Control Assembly if present 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 attenu...

Page 53: ...Unplug any remaining I O and communications cables from the Control assembly and set them aside 4 Loosen the captive screw on the Control assembly mounting plate and swing the Control assembly away from the drive Captive screw ...

Page 54: ...late 6 Loosen the two mounting screws on the front of the Control assembly and slide the control cassette off the mounting bracket Installing the 700S Phase II Control Assembly Install the 700S Phase II Control assembly in reverse order of removal Disconnect ribbon cables Note Control mounting plate not shown for clarity only Note Ribbon cables not shown for clarity only ...

Page 55: ... 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 24VSupply cable...

Page 56: ...Mode Filter circuit board to the four standoffs on the control assembly mounting plate and remove the Common Mode Filter circuit board Installing the Common Mode Filter Circuit Board Install the Common Mode Filter Circuit Board in the reverse order of removal Remove screws ...

Page 57: ... from sockets along the right side of the High Power Fiber Optic Interface circuit board and carefully set them aside 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 ATTENTION Hazard of permanent eye damage exists when using op...

Page 58: ...uit board in reverse order of removal while referring to Torque Specifications on page 3 2 Removing the 700H I O Circuit Boards and Control Assembly 1 Remove power from the drive Refer to Removing Power from Drive on page 3 3 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 B...

Page 59: ...Control circuit board in a 700H drive you must load information about the Control circuit board into the Power EEPROM Refer 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 ahw0704 eps X7 X2 Slot A Serial Port X3 Slot B X4 Slot C X5 Slot D X6 Slot E ahw0708 eps Do not remove enclo...

Page 60: ...cables from right side of the circuit board and carefully set them aside 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 ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emi...

Page 61: ...cations on page 3 2 Removing the Covers from the Power Structure You must remove the protective covers to gain access to 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 ...

Page 62: ...ocedures ahw0730 eps 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 or Screws ...

Page 63: ...rder 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 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 ahw0731 eps Screws ...

Page 64: ... to Removing the Airflow Plate on page 3 17 4 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 5 Remove the four ...

Page 65: ... 3 19 6 Remove the side protective covers Installing the Protective Covers Install the Protective Covers in reverse order of removal while referring to Torque Specifications on page 3 2 ahw0732 eps 4 4 4 4 5 5 5 5 6 6 5 ...

Page 66: ...rd and carefully set them aside 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 ATTENTION Hazard of permanent eye damage exists wh...

Page 67: ...uit board to the drive and remove the circuit board from the drive Installing the 700S Voltage Feedback Circuit Board Install the 700S Voltage Feedback circuit board in reverse order of removal while referring to Torque Specifications on page 3 2 Screws 5 P1 0 9 N m 8 lb in ahw0731 eps ...

Page 68: ...overs 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 ...

Page 69: ...ter inside radius can permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii 6 Disconnect the other cables from the sockets of the Gate Driver board and 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...

Page 70: ...3 24 Access Procedures 7 Remove the six screws that secure the brackets to the drive and remove the brackets gate_driver_bracket01 jpg gate_driver_bracket02 jpg ...

Page 71: ...r 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 gate_driver jpg ...

Page 72: ...the connectors on the back of the board 3 Align the Gate Driver board so that its connectors align with the mating connectors on the Adapter board 4 While supporting the Adapter board from behind press the Gate Driver board onto it 5 Verify the proper alignment of the mounting with a mirror Verify that none of the pins in the stacker connectors have missed the mating connectors 6 Install the brack...

Page 73: ...erminals at the top of the power structure 6 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 Installing the Power Structure in the Drive Enclosure Install the power structure in reverse order of removal while...

Page 74: ...rs 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 Installing the Main Fans Install the fans in reverse order of removal while referring to Torque Specifications on page 3 2 Disconnect connectors from fan inverters Remove screws ...

Page 75: ...de 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 ATTENTION The sheet metal cover and mounting screws on the ASIC circuit board located on t...

Page 76: ...of the ASIC board and carefully set them aside 11 Disconnect the other cables from sockets on the ASIC board and set them aside Installing the ASIC Circuit Board 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 ...

Page 77: ...e 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 Installing the Rectifying Circuit Board Install the Rectifying circuit board in reverse order of removal while referring to Torque Specifica...

Page 78: ... 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 the wiring from connectors X21 and X31 X22 and X32 and X23 and X33 on the Rectifying board X13 X6 X10 X11 X12 X9 X100 X3 X2 X1 X4 X41 X8 X101 X50 X33 X23 X32 X22 X31 X21 ...

Page 79: ...arging Resistors to the drive frame and remove the Precharging Resistors Installing the Precharging Resistors on Series B Drives Install the Precharging Resistors in reverse order of removal Remove screws from resistors 6 Pulse Drive 12 Pulse Drive Remove screws from resistors ...

Page 80: ...ng 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 4 Remove the cable tie that secures the Power Module circuit board to the Adapter board 5 Disconnect the output leads from the b...

Page 81: ...m 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 Balancing Resistors Balancing Resistor Wires Snubber Capacitors Snubber Capacitor Fastening Screws ...

Page 82: ...g to Torque Specifications on page 3 2 Removing the Right Side Output Power Module and Rectifying Module Important Do not attempt to disassemble the 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 t...

Page 83: ...e 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 ATTENTION Hazard of permanent eye damage exists when using optica...

Page 84: ...inals 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 right_modules01 jpg AC Input Terminals L1 L2 L3 Balancing Resistors Balancing Resistor Wires right_modules02 jpg Snubber Capacitors Snubber Capacitor Fastening Scre...

Page 85: ...crews 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 right_modules03 jpg right_modules04 jpg ...

Page 86: ...ower 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 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 3 Remove the p...

Page 87: ...le 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 A Left hand Side View Left hand Inverter Front View on Left hand Side fm10_front jpg prepare_left jpg prepare_right jpg A A A Right hand Inverter ...

Page 88: ...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 inverters and X2 and X8 on right hand inverter Carefully remove the inverters by sliding them out towards the front of the drive A B C D E Important Take care to not damage the output transformer when removing or installing the inverter Bottom View of Power Structur...

Page 89: ...ue Specifications on page 3 2 Task Description Disconnect the cables at connectors X4 Blue and X5 Black A Task Description Remove two M5 POZIDRIV screws that secure the inverter board and heatsink to the assembly carriage Carefully remove the inverter board and heatsink from the assembly carriage B C Right hand Inverter Shown right_assy_upright jpg right_assy_underside jpg A A B B ...

Page 90: ... 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 5 Remove the screws that secure DC bus bars to right side of power structure and remove the DC bus bars right_modules01 jpg AC Input Terminals L1 L2 L3 Balancing Resistors Balancing Resistor Wires...

Page 91: ...screws that secure the capacitor to the power structure and remove the capacitor Installing the DC Bus Capacitors Install the DC bus capacitors in reverse order of removal while referring to Torque Specifications on page 3 2 removing_caps jpg ...

Page 92: ...3 46 Access Procedures Notes ...

Page 93: ...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 C...

Page 94: ...ting the motor to the drive 1 Verify that the input power wiring and grounding is connected 2 Verify that the motor cables are disconnected 3 Energize the drive 4 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 5 Make configuration changes that allow the HIM to issue start and speed commands 6 Make configurati...

Page 95: ... bus voltage and verify that the value is reflected in parameter 306 DC Bus Voltage 5 From the Monitor menu on the HIM press the escape button to navigate to the Main menu 6 Use the down button to move the cursor to the Start Up selection and press to select Start Up Then press again to verify your intention to continue with the Start Up menu 7 Use the down button to move the cursor to Power Circu...

Page 96: ...Verify that the motor cables are connected 3 Verify that the motor load is disconnected 4 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 5 Energize the drive 6 Start the drive and increase the speed from zero to base speed 7 Measure the drive output current and verify that the value is reflected in parameter ...

Page 97: ...ward diode bias tests Fluke model 87 III or equivalent 7 Insulation tester 1000Vdc 8 Torque wrench 1 12Nm 9 Torque wrench 6 50Nm 10 Box wrench 7mm 8mm 10mm 13mm 17mm 19mm 22mm 11 Socket extension 230mm 12 Wrench 7mm 8mm 10mm 13mm 17mm 19mm 22mm 13 Wire cutter 14 Nose pliers 15 Crimping tools For cable terminals 1 5 240 16 Angle wrench 17 Screw driver 18 Flat nose 7 2 mm 19 POZIDRIV 1 2 3 20 Philli...

Page 98: ...A 2 Service Tools and Equipment Notes ...

Page 99: ... with AC Input page B 2 Power Circuitry for Drives with DC Input page B 3 Circuit Board Connections for 700S Drives with Phase I 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 ...

Page 100: ... Cables H4 UH H5 UL H6 VH H7 VL H8 WH H9 WL From ASIC Board H8 From ASIC Board H9 From ASIC Board H10 From ASIC Board H11 From ASIC Board H12 From ASIC Board H13 X8 X9 X10 X11 X12 X3 X4 X5 X6 X7 Driver Board X11 X12 X13 X17 X19 X1 X2 X3 X7 X9 X6 From ASIC Board X2 DC DC To ASIC Board X6 5 X1 X2 X3 X1 X2 X3 X1 X2 X3 Line Reactor L1 R L2 S L3 T X50 T1 U T2 V T3 W DC DC To Voltage Feedback Board J2 O...

Page 101: ...L H8 WH H9 WL From ASIC Board H8 From ASIC Board H9 From ASIC Board H10 From ASIC Board H11 From ASIC Board H12 From ASIC Board H13 X8 X9 X10 X11 X12 X3 X4 X5 X6 X7 Driver Board X11 X12 X13 X17 X19 X1 X2 X3 X7 X9 DC DC To ASIC Board X6 T1 U T2 V T3 W DC DC To Voltage Feedback Board J2 On 700S Only To Voltage Feedback Board J1 On 700S Only PE F1 R1 CR2 M F1 R1 CR2 M External Circuitry DC Source X1 ...

Page 102: ...To Rectifying Board X13 in Power Circuitry X3 To Gate Driver Board X13 in Power Circuitry X4 To Gate Driver Board X14 in Power Circuitry X5 To Gate Driver Board X15 in Power Circuitry UH H8 To Gate Driver Board H4 in Power Circuitry UL H9 To Gate Driver Board H5 in Power Circuitry VH H10 To Gate Driver Board H6 in Power Circuitry VL H11 To Gate Driver Board H7 in Power Circuitry WH H12 To Gate Dri...

Page 103: ... WL H13 To Gate Driver Board H9 in Power Circuitry Fiber Optic Cables ASIC Board H1 Gate Enable H2 U Gate H3 V Gate H4 W Gate H5 ADconv H6 Vbus Tx H7 Vbus Rx X10 X11 Fan Control X1 M ASIC Board Fan 2 2 To Left Hand Main Fan Inverter X8 X1 1 2 21 22 23 X9 25 26 X15 DC Bus Precharge Control CR1 Pilot Relay CR1 M Main DC Contactor M CR2 Precharge M External Precharge Example Circuitry For DC Input On...

Page 104: ...ower Circuitry X3 To Gate Driver Board X13 in Power Circuitry X4 To Gate Driver Board X14 in Power Circuitry X5 To Gate Driver Board X15 in Power Circuitry UH H8 To Gate Driver Board H4 in Power Circuitry UL H9 To Gate Driver Board H5 in Power Circuitry VH H10 To Gate Driver Board H6 in Power Circuitry VL H11 To Gate Driver Board H7 in Power Circuitry WH H12 To Gate Driver Board H8 in Power Circui...

Page 105: ...k 5 Black 4 Black 3 Black 2 Black 1 X4 X5 2 2 μf 10 MΩ 2 2 μf 10 MΩ Brown 7 μf F2 6A F1 6A From DC Bus in Power Structure X8 X2 4 Fan Frequency Converter Off S1 1 Off S1 2 On S1 3 Off S1 4 S1 Setup Switch M2 Black Yellow Green Blue Main Fan Right Side 230V ac 50 Hz M Black 6 Black 5 Black 4 Black 3 Black 2 Black 1 X4 X5 2 2 μf 10 MΩ 2 2 μf 10 MΩ Brown 7 μf X3 X3 2 4 Jumper Figure B 6 Fan Inverter ...

Page 106: ...B 8 Schematics Notes ...

Page 107: ...8 Main Fan Assembly page C 9 Cat No 20D J 500 N 0 NNNBNNNN UL Open Type IP00 540V Normal Duty Power 250 kW 200 kW 450 kW 500 kW Heavy Duty Power DC Voltage Range 462 594 350 583 713 350 Amps Input DC AC Voltage Range 0 400 50 Hz 0 460 60 Hz Base Hz default Output 3 Phase 0 320Hz Continuous Amps 420 500 630 550 420 500 630 550 1 Min Overload Amps 2 Sec Overload Amps 840 630 840 630 MFD in 1989 on N...

Page 108: ...f someone comes into contact with the assembly main_assembly jpg Main Terminal Cover Touch Cover Front Touch Cover Side Plate Input Terminal Cable Insulator Input Terminal Assembly Bus Bar Insulator Bus Bar Left Side Board Bracket Motor Connection Assembly Gate Drive Board Adapter Board Capacitor 7μf 450V ac Fan Inverter Assembly Left ASIC Assembly Plastic Cover Base Top Left Plastic Cover Base To...

Page 109: ... 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 Assembly Left 20 FR10844 Fan Inverter Assembly Right 20 FR10845 ASIC Assembly Upgrade Kit without the ASIC Board 20 FR10850 Motor Connector Assembly NA Capacitor 7μf 450V ac 20 PP00011 Fuse Base DC 20 PP01094 Adapter Board 20 VB0...

Page 110: ...t_assembly jpg 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 DC Bus Bar Insulator Output Power Module Frame Rectifying Module Discharging Resistor 2x16k Electrolytic Capacitor ELKO 3300mf 420V ...

Page 111: ...g Resistor 2x16k 20 PP13027 Series B Drive Precharging Resistors not shown 20 PP00066 Electrolytic Capacitor ELKO 3300μf 420V 20 PP01005 Snubber Capacitor Assembly 20 PP10019 Series A Rectifying Board 400 480V AC 20 VB00459 600 690V AC 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 D460 50...

Page 112: ...ectric shock injury or death Disconnect all sources of power before touching any metal parts left_assembly jpg Snubber Capacitor Assembly DC Bus Bar DC Bus Bar Insulator Output Power Module Frame Discharging Resistor 2x16k Electrolytic Capacitor ELKO 3300mf 420V Insulation Support Cover Plate DC Bus Bar DC Bus Bar Insulator DC Bus Bar DC Bus Bar Insulator ASIC Assembly ...

Page 113: ... Discharging Resistor 2x16k 20 PP13027 Electrolytic Capacitor ELKO 3300μf 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 fan_inverter_assembly jpg Fan Inverter Circuit Board Output Tr...

Page 114: ...ly Cover ASIC Board ASIC Assembly Bracket ASIC Assembly Bracket ASIC Assembly Bracket 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 ASICBD E416 ASIC Assembly Upgrade Kit without the ASIC Board 20 FR10850 ASIC Assem...

Page 115: ...mbly Table C F Main Fan Assembly Part Numbers fan_assembly jpg Main Fan 230W Right Side Fan Left Side Fan Main Fan Housing Intake Cone Main Fan 230W Main Fan Housing Intake Cone Part Name Part Number Intake Cone NA Main Fan Housing NA Main Fan 230W 20 PP01080 ...

Page 116: ...C 10 Disassembly Assembly Diagrams Notes ...

Page 117: ... 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 Moving 3 15 Creating Fault Reports 1 2 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 I...

Page 118: ...moving 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 Module 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 Si...

Page 119: ......

Page 120: ...rd 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 Power Control and Information Solutions Headquarters Publication PFLEX TG002B EN P December 2007 Supersedes PFLEX TG002A EN P July 2005 Copyright 2007 Rockwell Automation Inc All rights reserved Pr...

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