Professional Documents
Culture Documents
AC Drive
and
700H Adjustable Frequency
AC Drive
Frame 11
315-400KW / 400V
500-600HP / 480V
500-600HP / 600V
450-560KW / 690V
Important: Identifies information that is critical for successful application and understanding of the product.
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Preface
P-1
P-1
P-1
P-2
P-2
P-2
P-3
P-3
P-4
P-4
Chapter 1
1-2
1-2
1-3
1-5
1-5
1-6
1-7
1-8
Chapter 2
Chapter 3
Removing the W Phase (Right-Side) Rectifying Board, Rectifying Module and Output Power
Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Removing the DC Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Chapter 4
Appendix A
Appendix B
Appendix C
Appendix D
4-1
4-2
4-3
4-3
4-4
Preface
Overview
Cat No.
20D
500 N 0 NNNBNNNN
UL Open Type/IP00
540V
250 kW
Normal Duty Power
200 kW
Heavy Duty Power
Input: DC,
462 - 594
DC Voltage Range
Amps
350
Output: 3 Phase, 0 - 320Hz
AC Voltage Range
0 - 400
50 Hz
Base Hz (default)
Continuous Amps
420/500
630/550
1 Min Overload Amps
840/630
2 Sec Overload Amps
MFD. in 1989 on Nov 9
Cat No.
20D
300 N 0 NNNBNNNN
UL Open Type/IP00
540V
650V
Normal Duty Power
160 kW
250 kW
Heavy Duty Power
132 kW
200 kW
Input: DC,
DC Voltage Range
462 - 594 583 - 713
Amps
350
350
Output: 3 Phase, 0 - 320Hz
AC Voltage Range
0 - 400
0 - 460
50 Hz
60 Hz
Base Hz (default)
Continuous Amps
300/245
300/245
1 Min Overload Amps
330/368
330/368
2 Sec Overload Amps
450/490
450/490
Series: A
Standard I/O: NONE
Original Firmware No. 2.04
UL
US
LISTED
IND CONT EQ
2622381652
Series: A
650V
450 kW
500 kW
C
583 - 713
350
UL
US
LISTED
IND CONT EQ
9D42
0 - 460
60 Hz
420/500
630/550
840/630
Frame #: 11
2622381652
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
Performance AC Drive Phase II Control.
p-2
Overview
Reference Materials
Publication
DRIVES-IN001...
SGI-1.1
0100-2.10
8000-4.5.2
Publication
20C-PM001...
20D-UM006...
20D-IN001...
20D-IN004...
20D-IN005...
20D-IN006...
20D-IN014...
PFLEX-IN006...
PFLEX-RM003...
Understanding Manual
Conventions
Publication
20D-UM002...
20D-IN002...
20D-IN007...
1788-IN002...
1788-IN005...
Terms
The following words are used throughout the manual to describe an action:
Word
Can
Cannot
May
Must
Shall
Should
Should Not
Meaning
Possible, able to do something
Not possible, not able to do something
Permitted, allowed
Unavoidable, you must do this
Required and necessary
Recommended
Not recommended
Overview
p-3
Cross References
Figure 2.2 on page 2-6 is a cross reference to figure 2.2 on page 5 of
Chapter 2.
Figure C.1 on page C-2 is a cross reference to figure C.1 on page 2 of
Appendix C.
Additional Support
Available on Internet
p-4
Overview
General Precautions
!
!
Chapter
1-2
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
Make record of any liquid and condensation marks on printed circuit
boards, components and mechanical parts
Make record of the amount of dust and other additional particles on drive
and drive components
Make record of any mechanical damage to the drive and drive
components
Record the size and type of main fuses
Record any other important marks and damage
Fault
HiHp In PhaseLs
No.
65
66
67
68
69
70
Description
AC Input Phase Loss - AC voltage is
not present on one or two input
phases.
Fault
HiHp Drv OvrLoad
No.
71
Description
Drive Overload - the circuit board on
the Power module has detected an
overload.
72
73
74
1-3
Name
Auxiliary In
Power Loss
No.
2
3
UnderVoltage
Description
Auxiliary input interlock is open.
DC bus voltage remained below
[Power Loss Volts] for longer than
[Power Loss Time]. Enable/Disable
with [Fault Config 1]. For more
information refer to publication
20C-PM001, Programming Manual PowerFlex 700H.
DC bus voltage fell below the
minimum value of 333V for 400/480V
drives and 461V for 600/ 690V drives.
Enable/Disable with [Fault Config 1].
For more information refer to
publication 20C-PM001,
Programming Manual - PowerFlex
700H.
1-4
Name
OverVoltage
No.
5
Input Phase
17
OutPhasMissng
21
Ground Fault
13
InverterFault
14
System Fault
10
Load Loss
15
31
Power Unit
70
Description
DC bus voltage exceeded maximum
value.
Diagnostic Procedures by
Symptom
1-5
Disconnect Motor
Leads
Perform Forward
Diode Tests on
Rectifying Module
Rectifying
Module
OK?
No
Replace
Rectifying
Module
Power
Modules
OK?
No
Replace
Power
Modules
Capacitors
OK?
No
Replace
Capacitors
Motor and
Lead Resistances
> 1 Mohm?
No
Remedy Motor
and Lead
Problems
Are There
Any Line to
Load Shorts?
Yes
Replace
AC
Choke
Yes
Perform Forward
Diode Tests on
Output Power
Modules
Yes
Examine Bus
Capacitors for
Charring and
Damaged Reliefs
Yes
Yes
Disconnect AC
Choke from
Rectifying Module
No
Are There
Any Line to
Line Shorts?
No
Yes
Reconnect
AC
Choke
Reconnect
Motor
Leads
1-6
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
Voltage within
Specification?
Measure DC Bus
Voltage
Perform forward
diode tests on
Rectifying Module
No
Rectifying
Module OK?
No
Replace Rectifying
Module
No
Replace
Capacitors
Yes
Examine Bus
Capacitors for
Charring and
Damaged Reliefs
Yes
Capacitors
OK?
Yes
Measure Power
Supply Voltages
Voltages within
Specification?
Replace Power
Supply
No
Yes
Check Board
Connections
Does Drive
Run?
No
Does Drive
Run?
Replace Main
Control Board
No
Replace Power
Interface Board
(on 700S)
Does Drive
Run?
No
Replace Voltage
Feedback Board
(on 700S)
1-7
No HIM Display
Use this procedure when the HIM does not function:
Check HIM
Connection
and Seating
Properly
Connected?
No
Reseat or
reconnect
HIM
No
Perform forward
diode tests on
Rectifying Module
Yes
Measure DC Bus
Voltage
DC Bus
Voltage within
Specification?
Rectifying
Module OK?
No
Replace Rectifying
Module
No
Replace
Capacitors
Yes
Examine Bus
Capacitors for
Charring and
Damaged Reliefs
Yes
Capacitors
OK?
Yes
Yes
Measure Power
Supply on X4 of
DPI Circuit Board
Voltage
= 12V dc?
Replace Power
Interface Board
(on 700S)
No
Yes
Replace Output
Power Module
(on 700H)
Does HIM
Function?
No
Replace HIM
1-8
Over-Temperature Faults
Use this procedure to troubleshoot drive over-temperature faults (14 - Inv
Otemp Pend and 15 - Inv Otemp Trip in 700S or 8 - Heatsink OvrTemp and
9 - Trnsistr OvrTemp in 700H):
Check Surrounding
Air Temperature
Temperature
Exceeds
Specification?
Yes
Provide
Additional Airflow
or Air Conditioning
Current
Exceeds
Specification?
Yes
Reduce Load or
Procure a Drive
With a Higher
Rating
Frequency Too
High for Lead Length
and Surrounding
Temp?
Yes
Lower PWM
Frequency
Proper Space
At Inlet?
No
Remedy
Spacing at
Inlet
Yes
Remove
Air Flow
Blockages
No
Check Motor
Current and Load
Levels
No
Check PWM
Frequency
No
Yes
Airlflow
Blockages?
No
Fans
Running
Properly?
Yes
Power Voltage
Equals Bus
Voltage?
No
Connection
Good?
No
Repair
Connection
Output Equals
50 Hz / 220V rms?
No
Replace
Fan Inverter(s)
Yes
Replace
Fan Motor(s)
No
Check Power
Voltage on Fan
Inverters
Yes
Check Connection
Between ASIC
Board and Fan
Inverters
Yes
Check Fan
Inverter Outputs
on X1, X4 and X5
Yes
Check Fan Motors
for Short and
Open Circuits
No
Contact
Allen-Bradley
Drives
Technical
Support
Chapter
2-2
LED
Steady
Flashing Quickly
Flashing Slowly
Indication
The drive is operational and has no faults
Switching power supply overload
Rectifier board fault
Fan or fan inverter fault
Brake Chopper fault
Fiber Optic Adapter board Fault
Bad connection between circuit boards, check all connections
The PowerFlex 700S contains a Run LED, controller LEDs, and SynchLink
LEDs. These LEDs are only operational when the drive is energized and are
only visible when the drive door is open. The status of these LEDs can also
be viewed from the HIM or from an application program (e.g.,
DriveExplorer) in parameter 554 [LED Status]. This feature is only
available with DriveLogix version 15.03 or later.
ATTENTION: The RUN LED and the controller LEDs are only operational when the drive is energized.
Servicing energized equipment can be hazardous. Severe injury or death can result from electrical shock, burn
or unintended actuation of controlled equipment. Follow Safety related practices of NFPA 70E, ELECTRICAL
SAFETY FOR EMPLOYEE WORKPLACES. DO NOT work alone on energized equipment!
2-3
Name
Color
State
Description
PWR
(Power)
STS
(Status)
Green
Steady
Green
Flashing
Steady
Flashing
DRIVE
Control Assembly
Communications
Control
Power Structure
PORT
MOD
NET A
NET B
(1)
SYNCHLINK Green
ENABLE
(1)
Green
Red
Flashing
Flashing
Green
Green
On
Off
SynchLink LEDS are located on the SynchLink daughtercard on the main circuit board in the control cassette.
2-4
Performing Visual Inspections Visually inspect the cooling tunnels and power structure before energizing
the drive.
+
~.0L
~0.5V
+
Forward biased test
on PN-junction
2-5
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).
Figure 2.1 Measurement Points for Forward and Reverse Diode Tests
DC+
DC-
U/T1
1L1
V/T2
1L3
1L2
W/T3
2L1
2L3
2L2
L1
L2
L3
DCDCDC-
Meter Leads
+
DC+
DC+
DC+
L1
L2
L3
2-6
If the drive fails any of these measurements, replace all Rectifying modules.
4. Conduct forward and reverse biased diode tests on the Output Power
modules.
Table 2.C Forward Biased Diode Tests on Output Power Modules
DCDCDCT1
T2
T3
Meter Leads
+
T1
T2
T3
DC+
DC+
DC+
If the drive fails any of these measurements, replace all three Output
Power modules.
2-7
X1
4. Verify the fiber optic cables are properly connected (refer to Figure
B.7 on page B-8, Figure B.8 on page B-9, Figure B.9 on page B-10, or
Figure B.10 on page B-11).
5. Disconnect the cables and inspect them for scratches and cracks.
6. Reconnect the cables, replacing any damaged cables.
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.
2-8
~333 ohms
+/- 15 V
~333 ohms
Emitter
X1
X11
+/- 15 V
Gate Interface for
U, V or W Low (L)
~333 ohms
~333 ohms
+/- 15 V
Emitter
Preparing the Drive for Active Measurements on the Gate Driver Board
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
the Gate Driver board to determine if the board is
malfunctioning.
Important: A High Voltage DC Test Power Supply is required to perform
these tests.
2-9
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structure. Refer to Removing the
Covers from the Power Structure on page 3-13.
3. Disconnect the Main Fan Inverters power supply cables in order to
prevent them from running during these tests.
4. Disconnect the fiber optic cables that connect the ASIC board to the
three Gate Driver boards at the Gate Driver board ends.
5. Disconnect the plug from the X6 connector on the ASIC board.
6. Make the following connections from a High Voltage DC Test Power
Supply to X6 on the ASIC board using a new connector plug.
From High Voltage DC Test
Power Supply
DC+
DC-
7. Disconnect the DC+ wire from each of the three Gate Driver boards.
DC+
DC-
8. Connect the High Voltage DC Test Power Supply DC- to the DC- Bus
Bar.
2-10
9. Connect the High Voltage DC Test Power Supply DC+ to the DC+ on
each Gate Driver board.
10. Set the current limit on the High Voltage DC Test Power Supply to less
than or equal to 1A. Energize the Supply and increase its output to the
drives nominal DC bus voltage (650V dc for drives with 380-500V ac
input or 775V dc for drives with 600-690V ac input).
2-11
1. Locate the fiber optic receiver which transmits the signals for the U
High (UH) gate interface and connector X10 on the Gate Driver board.
X10 provides the gate interface for the UH output power transistor in
the U Phase Output Power module.
2. Measure the DC voltage at each UH gate pin and the emitter pin on X10
by placing the DC- common probe on the emitter pin and the voltage
probe on the gate pins.
X10
+15V DC
3. While shining an intense light (like a flashlight) into the fiber optic
receiver for the UH cable, measure the DC voltage at each UH gate pin
and the emitter pin on X10 with respect to DC-. Each should be +15V
dc. If the drive fails any of these tests, replace the fiber optic cable or the
Gate Driver board.
4. Repeat steps 2 and 3 with connector X11 and the UL cable. X11
provides the gate interface for the UL output power transistor in the U
Phase Output Power module. If the drive fails any of these tests, replace
the Gate Driver board.
X11
5. Repeat steps 2 and 3 with connector X10 and the VH cable. X10
provides the gate interface for the VH output power transistor in the V
Phase Output Power module. If the drive fails any of these tests, replace
the Gate Driver board.
6. Repeat steps 2 and 3 with connector X11 and the VL cable. X11
provides the gate interface for the VL output power transistor in the V
Phase Output Power module. If the drive fails any of these tests, replace
the Gate Driver board.
7. Repeat steps 2 and 3 with connector X10 and the WH cable. X10
provides the gate interface for the WH output power transistor in the W
Phase Output Power module. If the drive fails any of these tests, replace
the Gate Driver board.
8. Repeat steps 2 and 3 with connector X11 and the WL cable. X11
provides the gate interface for the WL output power transistor in the W
2-12
Phase Output Power module. If the drive fails any of these tests, replace
the Gate Driver board.
9. Connect the multi-meter (ohms) black test lead to the DC- Bus Bar and
the red test lead from the multi-meter to the output terminal on the U
Phase.
10. Shine an intense light into the UL fiber optic receiver on the Gate Driver
board. This should gate the IGBT and the multi-meter should indicate
that the IGBT is short-circuited. This will happen if the circuit from the
fiber optic receiver to the output terminal is functioning properly.
11. Connect the multi-meter red test lead to the DC+ Bus Bar and the black
test lead to the UH output terminal.
12. Shine an intense light into the UH fiber optic receiver on the Gate
Driver board. This should gate the IGBT and the multi-meter should
indicate that the IGBT is short-circuited. This will happen if the circuit
from the fiber optic receiver to the output terminal is functioning
properly.
13. Repeat steps 9 - 12 for VL and VH on the V Phase Gate Driver board.
14. Repeat steps 9 - 12 for WL and WH on the W Phase Gate Driver board.
Important: The test does not verify that both blocks are operating. If one
block is not operating, the drive will indicate an I2T hardware
fault.
600V ac input, 460A and 502A frame 11 drives have only one Rectifying
module. Complete the Testing 600V AC Input, 460A and 502A Drives
procedure below only if you are checking the Rectifying module on a 600V
ac input, 460A and 502A drive. If you are checking the Rectifying module
on a 400V ac input, 590A, 650A or 730A, or 600V ac input, 590A drive
refer to Testing 400V AC Input, 590A, 650A or 730A, or 600V AC Input,
590A Drives on page 2-14.
2-13
Resistance
18 1
2-14
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 3-36).
2-15
Resistance
18 1
2-16
X4
X2
X1
X3
X41
J7
J3
J11
X8
X101
X13
X6
X10
X11
X100
X50
X13: Pin 1
(24V dc Common)
X9
X12
X13: Pin 5
(24V dc Power)
X10: Pin 1
X11: Pin 1
X12: Pin 1
J3
J7
J11
No Power on X13
Meter Leads
+
Results
X9
X9
0
X9
J3
J7
J11
X9
2-17
2-18
LED
Red
Steady
Off
Flashing
Green
Steady
Flashing
Steady
Indication
Inverter Idle
Inverter Running
Inverter Faulted
or
No Control from ASIC board
2-19
Resistance 5%
60
26
34
(infinity)
2-20
Notes:
Chapter
Access Procedures
Torque Specifications
Screw
M3 x 6 Phillips
M3 x 6 Phillips
M3 x 6 Phillips
M4 x 8 self-tapping
Final Torque
0.9 N-m
(8 lb.-in.)
0.9 N-m
(8 lb.-in.)
0.9 N-m
(8 lb.-in.)
0.8 N-m
(7 lb.-in.)
3-2
Access Procedures
Item
Screw
700H Fiber Optic Adapter Board
M4 x 8 POZIDRIV
(mounting)
700S Voltage Feedback Circuit
M3 x 6 Phillips
Board (mounting)
AC Input Terminals on Power
M10 nut
Structure
Motor Output Terminals on Power
M8 x 20 hexagonal screw
Structure
Main Fan (Mounting)
M6 x 20 POZIDRIV
Main Fan
M4 x 8 POZIDRIV
M5 x 16
ASIC Fan
M4 x 16 POZIDRIV
M4 x 8 POZIDRIV
M8 x 20 hexagonal screw
M10 nut
Capacitor
M4 x 8 self tapping
M6 x 16 POZIDRIV
M6 x 20 POZIDRIV
M6 x 20 POZIDRIV
Block (Mounting)
M3 x 0.5 thread - 37 mm x
37 mm hex standoff
Final Torque
0.9 N-m
(8 lb.-in.)
0.9 N-m
(8 lb.-in.)
40 N-m
(354 lb.-in.)
20 N-m
(177 lb.-in.)
3 N-m
(27 lb.-in.)
1.7 N-m
(15 lb.-in.)
3 N-m
(27 lb.-in.)
0.4 N-m
(3.5 lb.-in.)
1 N-m
(9 lb.-in.)
14 N-m
(124 lb.-in.)
12 N-m
(106 lb.-in.)
40 N-m
(354 lb.-in.)
1 N-m
(9 lb.-in.)
4 N-m
(35 lb.-in.)
4 N-m
(35 lb.-in.)
5 N-m
(44 lb.-in.)
20 N-m
(177 lb.-in.)
0.9 N-m
(8 lb.-in.)
Access Procedures
3-3
Phillips Screw
Hexagonal Bolt
or Standoff
Hexagonal
Screw
Hexagonal Nut
PZ2
4 N-m
(35 lb.-in.)
Tightening Torque
Removing Power
1. Turn off and lock out input power. Wait five minutes.
2. Verify that there is no voltage at the drives input power terminals.
3-4
Access Procedures
3. Measure the DC bus voltage at the DC+ & DC- terminals on the Power
Terminal Block. The voltage must be zero.
L1
L2
L3
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
Important: Before removing connections and wires, mark the connections
and wires to avoid incorrect wiring during assembly.
2. Remove the two screws from the front of the DPI / HIM assembly.
Screws
P1
0.9 N-m
(8 lb.-in.)
3. Open the door, which holds the DPI interface and HIM.
4. Unplug the DPI cable from the X2 connector on the DPI Interface
Circuit Board.
X2
X4
5. On 700S drives only, unplug the cable from the X4 connector on the
circuit board.
Access Procedures
3-5
6. Remove the four mounting screws and the assembly from the Control
Frame.
Mounting Screws
P1
0.9 N-m
(8 lb.-in.)
Installation
Install the DPI / HIM Assembly in the reverse order of removal, while
referring to Torque Specifications on page 3-1.
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
Important: Before removing connections and wires, mark the connections
and wires to avoid incorrect wiring during assembly.
2. Unplug any fiber optic ControlNet and SynchLink cables from the
Control Assembly.
3-6
Access Procedures
4. Loosen the captive screw on the Control Assembly mounting plate and
swing the Control Assembly away from the drive.
Phase 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.
Access Procedures
3-7
6. Loosen the two mounting screws on the front of the Control Assembly
and slide the cassette control off the mounting bracket.
Installation
Install the 700S Control Assembly in the reverse order of removal, while
referring to Torque Specifications on page 3-1.
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the 700S Control Assembly. Refer to (Removing the 700S
Control Assembly on page 3-5.
3. Carefully disconnect the fiber-optic cables from the sockets along the
right side of the High Power Fiber Optic Interface Circuit Board (on the
backside of the Control Assembly), and carefully set them aside.
3-8
Access Procedures
Fiber-Optic
Sockets
J5
Screws
(5)
P1
0.9 N-m
(8 lb.-in.)
4. Remove the five screws which secure the High Power Fiber Optic
Interface Circuit Board to the Control Frame.
5. Remove the circuit board from the Control Frame.
Installation
Install the 700S High Power Fiber Optic Interface Circuit Board in reverse
order of removal, while referring to Torque Specifications on page 3-1.
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the 700S Main Control Assembly. Refer to Removing the 700S
Control Assembly on page 3-5.
Access Procedures
3-9
3. Remove the 700S High Power Fiber Optic Interface Circuit Board.
Refer to Removing the 700S High Power Fiber Optic Interface Circuit
Board on page 3-7.
4. Lift the Control Assembly up and off of the hinge.
Installation
Install the 700S Control Assembly in reverse order of removal.
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Open the enclosure that contains the Control and I/O Boards and
carefully unplug the DPI cable and any I/O cables.
3-10
Access Procedures
3. Remove the I/O Boards from the Control Board and enclosure. Note the
order of the boards and the keys which prevent placement of boards in
the incorrect slots.
Do not remove enclosure cover.
Enclosure is illustrated without
the cover for clarity.
Keys
X2
(Slot A)
X3
(Slot B)
X4
(Slot C)
X5
(Slot D)
X6
(Slot E)
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.
PZ2
3 N-m
(27 lb.-in.)
Installation
Install the 700H Control and I/O Boards in reverse order of removal, while
referring to Torque Specifications on page 3-1.
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the I/O boards and Control Assembly. Refer to Removing the
700H I/O Boards and Control Assembly on page 3-9.
3. Move the Control Frame to expose its back, while referring to
Removing the Covers from the Power Structure on page 3-13.
3-12
Access Procedures
4. Disconnect the control power cable from X2 of the Fiber Optic Adapter
Board.
H7
H6
X1 connects
to Main
Control
H5
H4
Sockets for
Fiber-Optic
cables
H3
H2
H1
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.
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.
PZ2
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 Torque Specifications on page 3-1.
3-14
Access Procedures
3. Loosen the T8 Torx-head screws, which secure the Control Frame to the
drive enclosure.
4. Swing the Control Frame out and away from the power structure.
Loosen T8 Torx-head
screws
Installation
Install the Control Frame in reverse order of removal, while referring to
Torque Specifications on page 3-1.
Access Procedures
3-15
Screws
3-16
Access Procedures
Installation
Install the Airflow Plate in reverse order of removal, while referring to
Torque Specifications on page 3-1.
DA
Risk
Disc of elec
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Foll DC power, ck and
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Ear inst volt wait dea
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ions befo utes
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ired
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.
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.
NG
ER
Access Procedures
3-17
Installation
Install the Protective Covers in reverse order of removal, while referring to
Torque Specifications on page 3-1.
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structure on page 3-13.
3. Carefully disconnect the fiber-optic cables from J4 and J5 sockets at the
top of the Voltage Feedback Circuit Board, and carefully set them aside.
J2
J3
J4 J5
J8
3-18
Access Procedures
6. Remove the five screws which secure the Voltage Feedback Circuit
Board to the drive.
7. Remove the circuit board from the drive.
P1
0.9 N-m
(8 lb.-in.)
Screws
(5)
Installation
Install the 700S Voltage Feedback Circuit Board in reverse order of
removal, while referring to Torque Specifications on page 3-1.
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structure on page 3-13.
3. Disconnect the DC +/- supply from X1 of the Gate Driver Board.
Access Procedures
3-19
4. Carefully disconnect the fiber-optic cables from sockets along the top of
the Gate Driver Board, and carefully set them aside.
Installation
1. Install the Gate Driver Board in the reverse order of removal.
3-20
Access Procedures
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structure on page 3-13.
3. Remove the cover from the ASIC assembly and the -DC bus connection
from the cover.
4. Unplug the fan, which mounts on the cover, from connector X1 of the
ASIC board.
5. Carefully disconnect the fiber-optic cables from sockets of the ASIC
Board, and carefully set them aside.
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. Remove the plastic board holder.
Installation
Install the ASIC Board in reverse order of removal, while referring to
Torque Specifications on page 3-1. Reconnect cables to ASIC Board, while
referring to Figure B.10 on page B-11 or Figure B.7 on page B-8).
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structure on page 3-13.
3. Remove the motor wiring from the power structure at the front of the
power structure.
4. Remove the ground connection from the lower right corner of the power
structure.
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
1L1
V/T2
1L3
1L2
W/T3
2L1
2L3
2L2
AC Power
Terminals
Ground
Connection
PE
Access Procedures
3-23
6. Remove the six screws that secure the Power Structure to the enclosure
frame.
Remove screws
Remove screws
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.
Removal
There are three main fans on the drive.
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the bottom protective cover from the power structure. Refer to
Removing the Covers from the Power Structure on page 3-13.
3. Disconnect the fan cable connectors under the power structure.
4. Remove the two screws which secure each fan to the drive. Then
remove the fans.
Access Procedures
3-25
Installation
Install the fans in reverse order of removal, while referring to Torque
Specifications on page 3-1.
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structure on page 3-13.
3. Remove the power structure from the drive cabinet. Refer to Removing
the Power Structure from the Drive Cabinet on page 3-21.
4. Verify the following default DIP switch settings.
Switch
S1
S2
S3
S4
Setting
Off
Off
On
Off
ON
S1
S2
S3
OFF
S4
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.
Remove cable-ties
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
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
11. Remove two M5 POZIDRIV screws, which secure the inverter board
and its heatsink to the assembly carriage. Proper tightening torque for
reassembly is 4 N-m (35 lb.-in.).
12. Carefully remove the inverter board and its heatsink from the assembly
carriage.
Remove two screws and remove inverter
board and heatsink
Installation
Install the fan inverters in reverse order of removal, while referring to
Torque Specifications on page 3-1.
Access Procedures
3-29
Removal
Important: Do not attempt to disassemble the Output Power Module.
Important: Always replace all three Output Power Modules (do not replace
just one module).
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structure on page 3-13.
3. Remove the power structure from the drive cabinet. Refer to Removing
the Power Structure from the Drive Cabinet on page 3-21.
4. Disconnect the output leads from the bottom of the Output Power
Module.
5. Remove the screws that secure the DC Bus Bars connecting the Input
Power Terminals to the Main DC Bus Bars and remove the Bus Bars.
DC Bus Bars
6. Disconnect the rectifying circuit wiring from the Main DC Bus Bars.
3-30
Access Procedures
7. Remove the screws that secure the Main DC Bus Bars to the Power
Structure and remove the Main Bus Bars.
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.
9. Remove the screws that secure the Air Flow Guide to the Power
Structure and remove the Air Flow Guide.
Input Power Terminal Assembly
Access Procedures
3-31
10. Remove the screws that secure the U Phase (left side) Power assembly
to the drive and remove the Power assembly.
11. Remove the screws that secure the motor connection leads to the Power
Module assembly and remove the motor connection leads.
Motor
Connection
Leads
12. Remove the screws that secure the Snubber Capacitors and remove the
Snubber Capacitors.
13. Remove the screws that secure the DC Bus Bars to the U Phase (left
side) power module and remove the DC Bus Bars.
Snubber
Capacitors
DC Bus Bars
Insulator
3-32
Access Procedures
14. Remove the screws which secure the Output Power Module to the drive.
15. Disconnect the Power Module Circuit Board from the Adapter Board.
16. Remove the Output Power Module from the drive.
Installation
Install the Output Power Module in reverse order of removal, while
referring to Torque Specifications on page 3-1.
Access Procedures
3-33
Removal
Important: Do not attempt to disassemble the Output Power Module.
Important: Always replace all three Output Power Modules (do not replace
just one module).
Important: 600V ac input, 460A and 502A frame 11 drives only have one
Rectifying module. The Rectifying module is contained in the
W Phase (right) Power assembly.
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structure on page 3-13.
3. Remove the power structure from the drive cabinet. Refer to Removing
the Power Structure from the Drive Cabinet on page 3-21.
4. Disconnect the output leads from the bottom of the Output Power
Module.
5. Remove the screws that secure the V Phase (middle) Power assembly to
the drive and remove the Power assembly.
6. Disconnect all the wiring from the Rectifying Board and carefully set it
aside.
Important: For 690V 460A and 502A units, the X50 Jumper must be
removed from the Rectifying Board.
7. Remove the balancing resistor wires from bus bars.
8. Disconnect the cables from the AC input terminals on the Rectifying
Module.
Balancing Resistors
Balancing Resistor Wires
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.
Snubber Capacitors
DC Bus Bars
Insulator
Access Procedures
3-35
12. Remove the screws that secure the Rectifying Module to the power
structure and remove the Rectifying Module.
13. Remove the screws that secure the Output Power Module to the power
structure, and remove the Output Power Module.
Rectifying Module
Installation
Install the Output Power Module in reverse order of removal, while
referring to Torque Specifications on page 3-1.
3-36
Access Procedures
Balancing Resistors
Balancing Resistor Wires
Access Procedures
3-37
9. Remove the five screws that secure the Rectifying Circuit Board to the
drive and remove the Rectifying Circuit Board.
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.
Snubber Capacitors
DC Bus Bars
Insulator
3-38
Access Procedures
12. Remove the screws that secure the Rectifying Module to the power
structure and remove the Rectifying Module.
13. Remove the screws that secure the Output Power Module to the power
structure, and remove the Output Power Module.
Rectifying Module
Installation
Install the Output Power Module in reverse order of removal, while
referring to Torque Specifications on page 3-1.
Removal
1. Remove power from the drive. Refer to Removing Power from the
Drive on page 3-3.
2. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structure on page 3-13.
3. Remove the power structure from the drive cabinet. Refer to Removing
the Power Structure from the Drive Cabinet on page 3-21.
4. Remove the Rectifying Module and Output Power Module. Refer to
Removing the U Phase (Left-Side) Output Power Module on page 3-29,
Removing the V Phase (Middle) Rectifying Board, Rectifying Module
and Output Power Module on page 3-33, and Removing the W Phase
(Right-Side) Rectifying Board, Rectifying Module and Output Power
Module on page 3-36.
Important: It is not necessary to remove the Rectifying Board, Rectifying
Module, or Output Power Module in order to remove the DC
Bus Capacitors.
Access Procedures
3-39
5. Remove the four screws that secure the capacitor to the power structure,
and remove the capacitor.
Installation
Install the capacitors in reverse order of removal, while referring to Torque
Specifications on page 3-1.
3-40
Notes:
Access Procedures
Chapter
Phone
United States/
Canada
1.262.512.8176 (7 AM - 6 PM CST)
1.440.646.5800 (24 hour support)
Outside United
States/Canada
You can access the phone number for your country via
the Internet:
Go to http://www.ab.com
Click on Support (http://
support.rockwellautomation.com/)
Under Contact Customer Support, click on Phone
Support
Internet
Go to http://www.ab.com/support/abdrives/
support@drives.ra.rockwell.com
4-2
Testing with the External DC This is a low current - low risk test for the Output Power Module and drive
Power Supply Without Load Control board. It requires the recommended High Voltage DC Test Power
Supply.
(Optional)
1. Verify that the DC Test Power Supply is de-energized.
2. Connect the power supplys DC+ to the drives DC+ terminal and the
power supplys DC- to the drives DC- terminal.
3. Set the power supply voltage setting to zero.
4. Switch on the external DC Test Power Supply.
5. Slowly increase the DC Test Power Supply output voltage to the drives
nominal DC bus voltage (650V dc for drives with 380-500V ac input or
775V dc for drives with 600-690V ac input).
6. 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)
7. Make configuration changes which allow the HIM to issue start and
speed commands.
8. Make configuration changes which allow operation without an encoder
and motor.
9. Start the drive, by pressing
4-3
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. Energize the drive.
3. Make configuration changes which allow the HIM to issue start and
speed commands.
4. Make configuration changes which allow operation without an encoder
and motor.
5. Start the drive, by pressing
The Power Circuit Diagnostic Test, on the 700S, allow you to diagnose
problems in the drives power structure without applying large amounts of
power.
1. Verify that input power wiring and grounding is connected.
2. Verify that the motor cables are connected.
3. Energize the drive.
4. From the Monitor menu on the HIM press
navigate to the Main menu.
Esc
5. Use
(the down button) to move the cursor to the Start-Up
selection, and
to select Start-Up. Then press
again to verify
your intention to continue with the Start-Up menu.
6. Use
(the down button) to move the cursor to Power Circuit
Diagnostics (Pwr Circuit Diag), and
to select Power Circuit
Diagnostics.
7. Press
to begin the Power Circuit Diagnostic routine. Follow
indications and instructions on the HIM.
4-4
This test allows you to measure several operating parameters and diagnose
problems without connecting the motor to its mechanical load.
1. Verify that input power wiring and grounding is connected.
2. Verify that the motor cables are connected.
3. Verify that the motor load is disconnected.
4. Energize the drive.
5. Start the drive and increase the speed from zero to base speed.
6. Measure drive output current and verify that the value is reflected in:
parameter 308 [Output Current] (700S)
parameter 003 [Output Current] (700H)
7. Stop the drive.
Appendix
Software Tools
Service Tools
This list of basic service tools which will cover needs of tools for repair and
maintenance measurements.
Item
1
2
3
4
Description
Oscilloscope
Current clamp
Soldering station
Adjustable power supply
Multi meter
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Insulation tester
Torque wrench
Torque wrench
box wrench
socket extension
Wrench
Wire cutter
Nose pliers
Crimping tools
Angle wrench
Screw driver
*Flat nose
*POZIDRIV
*Phillips
*Torx
Hexagonal wrench
ESD-protected place of work
24
ESD-protective clothing
Details
Portable, digitizing, dual channel scope, with isolation
1000A(ac, rms), signal output
Soldering / de soldering
0...1300Vdc, 1A, adjustable current limit. Efore LPS
750-HV or equivalent.
0...690Vac (+10%), 10A, three phase, galvanic
isolation
Digital multi meter, capable of ac and dc voltage,
continuity, resistance, capacitance measurements,
and forward diode bias tests. Fluke model 87 III or
equivalent.
1000Vdc
1...12Nm
6...50Nm
7mm, 8mm, 10mm, 13mm, 17mm, 19mm, 22mm
230mm
7mm, 8mm, 10mm, 13mm, 17mm, 19mm, 22mm
7*2(mm)
1, 2, 3
1, 2, 3
25
4, 5, 6
Working surface, Floor covering, seat and ground
connections
Wrist wrap, shoes, overall clothing (coat)
A-2
Item
25
26
Description
Power supply (service)
20-MAINSTD maintenance stand
27
Details
Capacity of three phase service 400/500/690Vac, 30A
Maintenance stand for removing power structure from
drive cabinet
Agilent HFBR-4593 Polishing Kit, consisting of a
Polishing Fixture, 600 grit abrasive paper and 3 mm
pink lapping film (3M Company, OC3-14).
For Agilent HFBR-4532 latching connectors and
HFBR-RL cable. Refer to Agilent publications
5988-9777EN and 5988-3625EN.
Appendix
Schematics
List of Schematic Diagrams
For a Schematic Diagram on
Phase U Power Circuitry for Drives with AC Input
Phase V Power Circuitry for Drives with AC Input
Phase W Power Circuitry for Drives with AC Input
Phase U Power Circuitry for Drives with DC Input
Phase V Power Circuitry for Drives with DC Input
Phase W Power Circuitry for Drives with DC Input
Circuit Board Connections for 700H Drives with AC Input
Circuit Board Connections for 700H Drives with DC Input
Circuit Board Connections for 700S Drives - Phase II Control with AC Input
Circuit Board Connections for 700S Drives - Phase II Control with DC Input
Fan Inverter and Main Fan Connections
See...
page B-2
page B-3
page B-4
page B-5
page B-6
page B-7
page B-8
page B-9
page B-10
page B-11
page B-12
TERM 1
U_HI
X6
Driver Board
H16
X11
X10
H15
I1
X7
TERM 2
X6
V_HI
10
U_LO
Power Board
X12
X8
I2
X1
See Note 1
I3
W_LO
To Voltage
Feedback J1
U/T1
To ASIC Board X6
DC- DC+
From Phase V
B-2
Schematics
W_HI
TERM 3
V_LO
X2
X2
X2
X3
X3
X3
X2 is 400/480 V Tap
X3 is 500 V Tap
Line Reactor
X1
X1
X1
X6
X13
X50
TO FAN
SEE SHEET 3
From ASIC X4
From ASIC H10
From ASIC H11
X6
H15
X10
X6
I1
H16
X11
X7
V_LO
10
X1
Power Board
See Note 1
U_LO
From ASIC X2
Mains Voltage
Suppression
X12
DC+
W_HI
W_LO
TERM 3
I3
To Voltage
Feedback J1
V/T2
X12
X8
I2
TERM 1
Rectifier Board
X8
X11
DC-
U_HI
X4
X4i
X3
X2
X1
X10
K3
V_HI
PE
L3/T
L2/S
LI/R
X9
K1
K2
Schematics
B-3
TERM 2
X2 X3
X2 X3
X2 X3
* X2 is 400/480 V Tap
X3 is 500 V Tap
Line Reactor
X1
X1
X1
X6
From ASIC X5
From ASIC H12
From ASIC H13
DC-
X6
H15
X10
X6
I1
H16
X11
X7
X12
X8
I2
5
W_LO
W_HI
TERM 3
I3
To Voltage Feedback J1
W/T3
V_LO
10
X1
Power Board
See Note 1
TERM 1
Jumper
X50
X12
U_HI
X13
X11
Mains Voltage
Suppression
Rectifier Board
X8
X10
DC+
From Phase V
U_LO
X4i
X4
X3
X2
X1
K1
K3
V_HI
L3/T
L2/S
LI/R
X9
K2
B-4
Schematics
TERM 2
R1 CR2
R2 CR2
PE
To 80W Power
Supply Connection
J2
DC-
DC+
From ASIC X3
From ASIC H8
From ASIC H9
10
U_HI
TERM 1
U_LO
X6
H15
H16
X11
X10
X7
TERM 2
X6
I1
5
V_HI
X1
Power Board
See Note 1
V_LO
To ASIC Board
Connection X6
EXTERNAL WIRING
SHOWN DASHED
F2
DC Source
F1
X12
X8
I2
W_LO
W_HI
DC- To Phase
V and W
I3
To Voltage Feedback
Connection J1
U/T1
DC+ To Phase
V and W
Schematics
TERM 3
B-5
DC-
DC+
To Fan
From ASIC X4
From ASIC X10
From ASIC H11
DC+
DC-
10
U_HI
TERM 1
H15
H16
X11
X10
V_LO
X6
Driver Board
U_LO
X1
X7
TERM 2
X6
I1
X12
X8
I2
V_HI
Power Board
See Note 1
To U and
W Phase
W_LO
W_HI
I3
To Voltage Feedback
Connaction J1
V/T2
B-6
Schematics
TERM 3
DC-
From V Phase
DC+
From ASIC X5
From ASIC H12
From ASIC H13
10
U_HI
TERM 1
H16
V_LO
X6
H15
X11
X10
U_LO
X1
X7
TERM 2
X6
I1
5
V_HI
Power Board
See Note 1
W_LO
W_HI
TERM 3
I3
X12
X8
I2
To Voltage Feedback
Connection J1
W/T3
Schematics
B-7
frm11_circuit_bd_conns_700H_AC.eps
Analog
I/O
(10)
Digital
Inputs
(8/10)
20C-DA1-AB
(115V ac Digital
Input w/ Analog I/O)
20C-D01
(Digital Output
Option)
(Slot B)
(Slot A)
20C-DA1-A
(24V dc Digital
Input w/ Analog I/O)
X3
X2
Control Board
Fiber Optics
Adapter Board
X4
X2
Option
Board
(Slot C)
+24V
X1
X1
H1 H2
37
H6
Option
Board
(Slot D)
X5
H3 H4 H5
H7
X3
X1
(Slot E)
X6
X3
X2
0EVA
+24V
24V POWER
RS-232
Programming
Port
X7
H7
H6
H5
H4
H3
H2
H1
X10
X1
X26
20C-DPI1
(DPI Communcations
Option)
1
GND 2
+24V
23
22
21
X9
ASIC
Board
X29
X2
H13
H12
X5
H11
H10
X4
X600
20
20C-DPI1
DPI
Comm
Option
X3
J3
DPI Assembly
PORT
MOD
NET A
NET B
PWR
J2
HIM
Bezel
J1
HIM
EXTERNAL DPI
HIM
EXAMPLE:
20-HIM-A3
DOOR
H9
DC-
DC+
20-VB00601
DPI
Interface X1
X4
Board
X2
1
2
H8
X3
X6
To Fan Inverter X8
25
26
B-8
Schematics
CR2
frm11_circuit_bd_conns_700H.eps
Analog
I/O
(10)
Digital
Inputs
(8/10)
20C-DA1-AB
(115V ac Digital
Input w/ Analog I/O)
20C-DA1-A
(24V dc Digital
Input w/ Analog I/O)
20C-D01
(Digital Output
Option)
X3
(Slot B)
X2
(Slot A)
Control Board
Fiber Optics
Adapter Board
X4
X3
X1
X1
H1 H2
37
X5
H5
H6
Option
Board
(Slot D)
H3 H4
To Fan Inverter X8
Option
Board
(Slot C)
+24V
Precharge
Main DC Contactor
CR1
Pilot Relay
CR1
H7
X2
25
X1
(Slot E)
X6
23
22
21
26
X3
0EVA
+24V
H7
H6
H5
H4
H3
H2
H1
X2
RS-232
Programming
Port
X7
X1
X26
X9
20C-DPI1
(DPI Communcations
Option)
1
GND 2
+24V
X50
ASIC
Board
1
20
20C-DPI1
DPI
Comm
Option
X3
20-VB00601
DPI
Interface X1
X4
Board
X2
X29
X2
H13
H12
X5
J3
DPI Assembly
PORT
MOD
NET A
NET B
PWR
J2
HIM
Bezel
J1
HIM
EXTERNAL DPI
HIM
EXAMPLE:
20-HIM-A3
DOOR
H10
H11
X4
X600
H9
DC-
DC+
H8
X3
X6
Schematics
B-9
COM
INPUT
COMM
OPTION
COMPACT
FLASH OPTION
COMPACT
I/O OPTION
P1
80
50
16
TX
RX
P1
P3
P4
LEOB
OPTIONAL
P2
SYNC
LINK P1
OPTION
P2
ENET
OPTION
P1
FDBK
OPTION
BOARD
SECOND ENCODER
SAFE OFF OPTION
FDBK
INPUTS
120
80
P2
P3
P2
16
34
34
RS-232
PORT
TB1
P13
P12
P4
P11
P10
P3
PHASE II
CONTROL
BOARD
WITH ALL
OPTIONS
SHOWN
P7
P5
P21
P1
P2
P6
P9
TB2
40
30
10
ELC
BATTERY
J2
J1
J17
J3
J13
J14
J11 J12
J18
External
24 V DC
1=24V
3=Common
(75W min)
J15
+5V
-12 V
+12 V
+24 V Iso
J9 J10
J8
(Gate Enable)
P1
(W Gate)
RJ45
CONNECTOR
(V Gate)
(U Gate)
(Vbus Tx)
(ADconv)
To Fan Inverter X8
(Vbus Rx)
25
J6
J7
0EVA
+24V
J4
Fiber
9
8
X29
X2
H13
H12
20
DPI
Comm
Option
X3
DPI ASSEMBLY
PORT
MOD
NET A
NET B
PWR
STS
J3
9
DPI
Bezel
J1
J2
-U
-V
-W
J2
-DC+
J1
External DPI
HIM
Example:
20-HIM-A3
DOOR
HIM
H11
X5
H10
X4
X600
H9
DC-
DC+
H8
-DC-
Voltage
Feedback
Board
20-VB00601
1
2
X3
X6
80 W
Power
Supply
DPI
Interface
X4 Board X1
X2
Tx J4
Rx J5
+24V
J8
ASIC
Board
Rx
Tx
J5
H7
H6
H5
H4
H3
H2
H1
X1
X9
LED J16
Status
DPI
23
22
21
26
B-10
Schematics
Circuit Board Connections for 700S Drives - Phase II Control with AC Input
COM
INPUT
COMM
OPTION
COMPACT
FLASH OPTION
COMPACT
I/O OPTION
P1
RJ45
CONNECTOR
80
50
16
TX
RX
P1
P3
P4
LEOB
OPTIONAL
P2
SYNC
LINK P1
OPTION
P2
ENET
OPTION
P1
P1
FDBK
OPTION
BOARD
SECOND ENCODER
SAFE OFF OPTION
FDBK
INPUTS
120
80
P2
P3
P2
16
34
34
RS-232
PORT
TB1
P13
P12
P11
P10
P4
P3
CR2
M
Precharge
P5
P21
P1
P2
P6
P9
TB2
40
30
10
ELC
BATTERY
J2
J1
J17
J3
PHASE II
CONTROL
BOARD
WITH ALL
OPTIONS
SHOWN
P7
Main DC Contactor
CR1
J13
J14
J11 J12
J18
External
24 V DC
1=24V
3=Common
(75W min)
J15
+5V
-12 V
+12 V
+24 V Iso
J10
J9
J8
To Fan Inverter X8
(Gate Enable)
CR1
(V Gate)
(U Gate)
Pilot Relay
(W Gate)
(Vbus Tx)
(ADconv)
(Vbus Rx)
X50
1
25
J6
J7
0EVA
+24V
J4
Rx
Tx
J5
H7
H6
H5
H4
H3
H2
H1
X1
X26
Fiber
9
8
X4
20
DPI
Comm
Option
X3
J2
X29
X2
H13
-U
-V
-W
J3
9
DPI
Bezel
J1
DPI ASSEMBLY
PORT
MOD
NET A
NET B
PWR
STS
J2
-DC+
J1
External DPI
HIM
Example:
20-HIM-A3
DOOR
HIM
X5
H12
H11
H10
X4
X600
DC-
DC+
H9
-DC-
Voltage
Feedback
Board
20-VB00601
1
2
H8
X3
X6
80 W
Power
Supply
DPI
Interface
Board X1
X2
Tx J4
Rx J5
+24V
J8
ASIC
Board
X9
LED J16
Status
DPI
23
22
21
26
Schematics
B-11
Circuit Board Connections for 700S Drives - Phase II Control with DC Input
DC-
DC+
From DC Bus in
Power Structure
6A
F1
(-)
DC- X2-1
(-)
(+)
On Off
On Off
S1 Setup Switch
Off Off
(-)
X2-1
DC-
(+)
DC+ X2-3
S1 Setup Switch
Off Off
DC- X2-1
DC+ X2-3
On Off
S1 Setup Switch
Off Off
(+)
DC+ X2-3
V1
X8
V1
V1
X8
X3
X8
X5-1
X4-1
X5-1
X4-1
X5-1
X4-1
Jumper
DC/AC
U1
DC/AC
U1
DC/AC
U1
Black 1
Black 2
Black 1
Black 2
Black 1
Black 2
3
Black
5
Black
4
Black
6
Black
3
Black
5
Black
4
Black
6
Black
3
Black
5
Black
4
Black
6
Black
2.2uf
2.2uf
2.2uf
300Vac
2.2uf
300Vac
2.2uf
300VAC
2.2uf
300VAC
Brown
Black
Yellow/Green
Blue
Brown
Black
Yellow/Green
Blue
Brown
Black
Yellow/Green
Blue
Main Fan
W Phase
230Vac
50Hz
Main Fan
V Phase
230Vac
50Hz
Main Fan
U Phase
230Vac
50Hz
7uf
10 M
10 M
7uf
10 M
10 M
7uf
10 M
10 M
B-12
Schematics
Appendix
Connector Descriptions
For Information on
ASIC Board to Gate Driver Board Phase U Connections
ASIC Board to Gate Driver Board Phase V Connections
ASIC Board to Gate Driver Board Phase W Connections
ASIC Board to Rectifier/Precharge Circuit Board Phase V Connections
Rectifier/Precharge Circuit Board Phase V to Rectifier/Precharge Circuit Board Phase W
Connections
PowerFlex 700H Fiber Optic Adapter Circuit Board to ASIC Board Fiber Optic
Connections
PowerFlex 700S High Power Fiber Optic Interface Board to ASIC Board Fiber Optic
Connections
PowerFlex 700S High Power Fiber Optic Interface Board to Voltage Feedback Board
Fiber Optic Connections
ASIC Board to Main Cooling Fan Inverter Phase U Connections
Main Cooling Fan Inverter Phase U to Main Cooling Fan Inverter Phase V Connections
Main Cooling Fan Inverter Phase V to Main Cooling Fan Inverter Phase W Connections
Main Cooling Fan Inverter Phase W Connections
X50 Terminal Block Precharge Circuit Connections
See...
page C-3
page C-3
page C-3
page C-4
page C-4
page C-5
page C-6
page C-6
page C-7
page C-7
page C-7
page C-7
page C-8
The following tables detail the connection points for the frame 11
PowerFlex 700S and 700H ac input drives circuit boards and components.
C-2
Connector Descriptions
X6
X9
X15
H1 H2 H3 H4 H5 H6 H7
X2
X11
X3
X4
X5
H15
H16
X6
X1
Connector Descriptions
Pin Number
1
2
3
4
5
6
7
8
9
10
H8 (fiber optic)
H8
H9 (fiber optic)
H9
to
...
...
...
...
...
...
...
...
...
...
...
...
Gate Driver
Board
Pin Number Connector
1
X6
2
3
4
5
6
7
8
9
10
H15
H15 (fiber optic)
H16
H16 (fiber optic)
Description
U_Feedback
U_Power_OK
U_DTR(1) See Note Below
U_ETR(2)
U_ITR(3)
U_DCUI
U_DC-_I
U_TEMP
U_DC-T
UH or Gate Top
UL or Gate Bottom
Pin Number
1
2
3
4
5
6
7
8
9
10
H10
H11
to Pin Number
...
1
...
2
...
3
...
4
...
5
...
6
...
7
...
8
...
9
...
10
...
H15
...
H16
Pin Number
1
2
3
4
5
6
7
8
9
10
H12 (fiber optic)
H12
H13 (fiber optic)
H13
(1)
DTR = N Desat
(2)
(3)
to Pin Number
...
1
...
2
...
3
...
4
...
5
...
6
...
7
...
8
...
9
...
10
...
H15
...
H16
C-3
C-4
Connector Descriptions
X1
X3
X41
J9
J5
J1
J7
J3
J11
J11
X8
X101
X13
X6
X10
X11
X100
X50
X9
X12
Pin Number
1
2
3
4
5
Description
SWTS_DRV
SWTS_FB
DC Mains Fault
+24V
Rectifier Board
to Pin Number Phase W Connector
...
1
X13
...
2
...
3
...
4
...
5
Description
SWTS_DRV
SWTS_FB
DC Mains Fault
+24V
Connector Descriptions
C-5
Figure C.4 PowerFlex 700H Fiber Optic Adapter Circuit Board Connectors
H7
H6
H5
H4
H3
H2
H1
Table C.F PowerFlex 700H Fiber Optic Adapter Circuit Board to ASIC Board Fiber
Optic Connections
Description
ENA Out
UH
VH
WH
A/D Convert
VBUS_TX
VBUS_RX
(1)
Type
TX
TX
TX
TX
TX
TX
RX
to
...
...
...
...
...
...
...
Type
RX
RX
RX
RX
RX
RX
TX
Refer to Figure C.1 on page C-2 for ASIC board fiber-optic connectors.
Description
Gate_Enable
U_Gate
V_Gate
W_Gate
A/D Convert
VBUS_RX
VBUS_TX
C-6
Connector Descriptions
Figure C.5 PowerFlex 700S High Power Fiber Interface Circuit Board Connectors
J8
J9
J10
J11
J12
J14
J13
J6
J7
Table C.G PowerFlex 700S High Power Fiber Optic Interface Board to ASIC Board
Fiber Optic Connections
Description
Gate_Enable
U_Post
V_Post
W_Post
A/D Convert
VBUS_TX
VBUS_RX
(1)
700SInterface Board
Fiber Optic Connector
J8
J9
J10
J11
J12
J14
J13
Type
TX
TX
TX
TX
TX
TX
RX
to
...
...
...
...
...
...
...
Type
RX
RX
RX
RX
RX
RX
TX
Description
Gate_Enable
U_Gate
V_Gate
W_Gate
A/D Convert
VBUS_RX
VBUS_TX
Refer to Figure C.1 on page C-2 for ASIC board fiber-optic connectors.
Table C.H PowerFlex 700S High Power Fiber Optic Interface Board to Voltage
Feedback Board Fiber Optic Connections
700SInterface Board
Description Fiber Optic Connector
TX
J6
RX
J7
Voltage Feedback
Type to Type Board Connector
TX
. . . RX
J5
RX
. . . TX
J4
Description
RX
TX
Connector Descriptions
C-7
Table C.I ASIC Board to Main Cooling Fan Inverter Phase U Connections
Description
+15V dc power to
Fan Inverter boards
Fan Control
Alarm from Fans
(1)
ASIC Board
Fan Inverter
Connector(1) Pin Number Pin Number Connector Description
X11
2
2
X8
+15V dc power from
ASIC board
3
3
Fan Control
4
7
Fan Alarm to ASIC
board
Refer to Figure C.1 on page C-2 for ASIC board fiber-optic connectors.
Table C.J Main Cooling Fan Inverter Phase U to Main Cooling Fan Inverter Phase V
Connections
Description
+15V dc power
Fan Control
Fan Alarm
Fan Inverter
Phase U
Connector Pin Number Pin Number
X3
2
2
3
3
4
7
Fan Inverter
Phase V
Connector
X8
Description
+15V dc power
Next Fan Control
Fan Alarm
Table C.K Main Cooling Fan Inverter Phase V to Main Cooling Fan Inverter Phase W
Connections
Description
+15V dc power
Fan Control
Fan Alarm
Fan Inverter
Phase V
Connector
Pin Number Pin Number
X3
2
2
3
3
4
7
Fan Inverter
Phase W
Connector
Description
X8
+15V dc power
Next Fan Control
Fan Alarm
Description
+15V dc power
Fan Alarm
Fan Inverter
Phase W
Connector
X3
Fan Inverter
Phase W
Pin Number Pin Number Connector Description
2
4
X3
+15V dc power
4
2
Fan Alarm
C-8
Connector Descriptions
Hardware Connections
Customer Connections
Drive Connections
X50
ASIC Board
X9
25
+24V DC
26
0V DC
21
23
Charge
Relay
X15
CR1
Pilot Relay
CR1
M
Main DC Contactor
CR2
Precharge
Description
Precharge Complete Signal
Precharge Complete Signal
Charge Relay Contact
Charge Relay Contact
Isolated
Appendix
Disassembly/Assembly
Diagrams and Spare Parts
Numbers
See...
page D-2
page D-3
page D-4
page D-5
page D-6
page D-7
page D-8
D-2
Main Terminal
Cover
Intervening
DC+ Bus
Bar
Capacitor 7f 450V ac
Intervening
DC- Bus
Bar
ASIC
Assembly
Upgrade Kit
(without ASIC
Board)
Output Transformer
Assembly for Fan Inverter
Main Fan Assembly 230W
Power Structure
Rating
400/480V, 590A
400/480V, 650A
400/480V, 730A
600/690V, 460A
600/690V, 502A
600/690V, 590A
D-3
D-4
Electrolytic Capacitor
D-5
Rectifying Module
Electrolytic
Capacitor
D-6
Part Name
Output Power Module
Rectifying Module
400/480V
400/480V
400/480V
600/690V
600/690V
600/690V
400/480V
600/690V
Output Transformer
Assembly for Fan
Inverter
Fan Capacitor
D-7
ASIC Assembly
Cover
ASIC Board
ASIC Assembly
Bracket
ASIC Assembly
Bracket
ASIC Assembly
Bracket
D-8
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 March 2006
Copyright 2006 Rockwell Automation, Inc. All rights reserved. Printed in USA.
Allen-Bradley