PowerFlex 700S and 700H Frame 13 Replacement Power Structures

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1 Installation Instructions PowerFlex 700S and 700H Frame 13 Replacement Power Structures Introduction Use this document to install a replacement power structure on a PowerFlex 700S or 700H frame 13 drive. This document covers the following replacement power structures: Spare Module Catalog PowerFlex PowerFlex PowerFlex PowerFlex Voltage Class String 700H AC Input 700H DC Input 700S AC Input 700S DC Input 400/480V AC SK-H1-PWRMOD-D1K1 20CC1K1 20CH1K1 20DC1K1 20DH1K1 (540/650V DC) 20CD1K1 20CJ1K1 20DD1K1 20DJ1K1 SK-H1-PWRMOD-D1K3 20CC1K3 20CH1K3 20DC1K3 20DH1K3 20CD1K3 20CJ1K3 20DD1K3 20DJ1K3 SK-H1-PWRMOD-D1K4 20CC1K4 20CH1K4 20DC1K4 20DH1K4 20CD1K4 20CJ1K4 20DD1K4 20DJ1K4 600/690V AC (810/932V DC) SK-H1-PWRMOD-E920 20CE920 20CK920 20DE920 20DK920 20CF920 20CM920 20DF920 20DM920 SK-H1-PWRMOD-E1K0 20CE1K0 20CK1K0 20DE1K0 20DK1K0 20CF1K0 20CM1K0 20DF1K0 20DM1K0 SK-H1-PWRMOD-E1K1 20CE1K1 20CK1K1 20DE1K1 20DK1K1 20CF1K1 20CM1K1 20DF1K1 20DM1K1 What You Need to Do Step 1: Remove power from the drive Step 2: Remove the old power structure Step 3: Install the new power structure Step 4: Connect the new power structure to the components in the drive Step 5: Install the product identification label on the new power structure Step 6: Start the drive

2 2 PowerFlex 700S and 700H Frame 13 Replacement Power Structures Step 1: Removing Power From the Drive! ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before servicing the drive. Check the DC bus voltage at the Power Terminal Block by measuring between the +DC and -DC terminals, between the +DC terminal and the chassis, and between the -DC terminal and the chassis. The voltage must be zero for all three measurements. Remove power before making or breaking cable connections. When you remove or insert a cable connector with power applied, an electrical arc may occur. An electrical arc can cause personal injury or property damage by: sending an erroneous signal to your system s field devices, causing unintended machine motion causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts may create electrical resistance. 1. Turn off and lock out input power. Wait five minutes. 2. Verify that there is no voltage at the drive s input power terminals. 3. Measure 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. L1 L2 L3 I O

3 PowerFlex 700S and 700H Frame 13 Replacement Power Structures 3 Step 2: Removing the Old Power Structure Before you can remove the old power structure from the drive, you must remove the protective screens, protective covers and air flow plate from the drive. Removing the Protective Screens and Covers 1. For NEMA/UL Type 1 enclosures, remove the screws that secure the protective screens to the enclosure and remove the screens. 2. Remove the four M5 POZIDRIV screws that secure each of the three protective covers to the power structure and remove the protective covers. 1 2 Three covers! DANGER DC BUS CONDUCTORS AND CAPACITORS OPERATE AT HIGH VOLTAGE. REMOVE POWER AND WAIT 5 MINUTES BEFORE SERVICING

4 4 PowerFlex 700S and 700H Frame 13 Replacement Power Structures Removing the Air Flow Plate 3. Remove the four T8 Torx-head screws that secure the airflow plate to the drive. 4. Slide the airflow plate off of the drive. 4 3

5 PowerFlex 700S and 700H Frame 13 Replacement Power Structures 5 Important: Before removing connections and wires, mark the connections and wires to avoid incorrect wiring during assembly. 5. Remove the motor wiring from the output power terminals on the power structure. 6. Remove the ground connection from the lower right corner of the power structure. 7. Remove the input connections from the incoming DC bus terminals at the top of the power structure. DC- DC+ DC Bus Terminals DC- DC+ DC- DC+ U/T1 V/T2 W/T3 ASIC Board Assembly Power Supply Voltage Feedback Board Assembly Ground Terminals U/T1 V/T2 W/T3 Output Power Terminals

6 6 PowerFlex 700S and 700H Frame 13 Replacement Power Structures 8. Remove the four screws that secure the cover to the ASIC assembly and remove the -DC bus connection from the cover. 9. Unplug the cooling fan that mounts to the ASIC assembly cover from connector X1 on the ASIC board and remove the ASIC assembly cover. = Remove -DC bus connection.

7 PowerFlex 700S and 700H Frame 13 Replacement Power Structures Disconnect the fiber optic cables (H1 - H7) from the ASIC board. 11. For drives with 700H control, disconnect the +24V supply cable from connector X10 on ASIC board # For drives with DC input, disconnect the external precharge circuitry from connectors X9 and X15 from the ASIC board. X5 X4 X3 H13 H12 H11 H10 H9 H8 X10 Disconnect cables X1 X2 DC precharge connections H7 H6 H5 H4 H3 H2 H1 X15 X9 Disconnect fiber optic cables (H1 - H7)

8 8 PowerFlex 700S and 700H Frame 13 Replacement Power Structures 13. Pull the rubber grommet, through which the ASIC board and Power Supply Voltage Feedback board wire bundles are routed, out of the drive frame and secure the wire bundles in the left-hand enclosure of the drive. Rubber grommet and wire bundles. Important: Move wire bundles to left-hand enclosure. 14. For drives with AC input, disconnect the precharge cable from the Rectifying modules and the fan control cables, located in the power structure to the left of the ASIC board. Precharge cables. Shown disconnected. Fan control cables. Shown disconnected.

9 PowerFlex 700S and 700H Frame 13 Replacement Power Structures For drives with 700H control, continue with step 19 on page 11. For drives with 700S control, disconnect the DC bus connection cable from the connector J2 and the motor feedback connection cable from connector J1 at the top of each the Power Supply Voltage Feedback boards (see illustration below for location). 16. Carefully disconnect the fiber-optic cables from sockets J4 and J5 on the side of each of the Power Supply Voltage Feedback boards and carefully set them aside (see illustration below for location).! ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into fiber-optic ports or fiber-optic cable connectors. Important: Minimum inside bend radius for fiber-optic cable is 25.4 mm (1 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable. Signal attenuation increases with decreased inside bend radii. Disconnect: J2 J1 J4 J5

10 10 PowerFlex 700S and 700H Frame 13 Replacement Power Structures 17. Remove the four screws that secure each of the Power Supply Voltage Feedback board assemblies to the fan housing on the power structures and carefully remove the Power Supply Voltage Feedback board assemblies. Remove screws 18. Disconnect the cable from connector J8 on each of the Power Supply Voltage Feedback boards, and set the cable aside. J2 J1 J4 J5 Disconnect cable J8

11 PowerFlex 700S and 700H Frame 13 Replacement Power Structures Remove the two hexagonal screws that secure the power structure to the enclosure frame. Remove screws - one each side of enclosure 20. Follow the instructions in publication PFLEX-IN014, Installation Instructions - PowerFlex 700S / 700H High Power Maintenance Stand, to install the Maintenance Stand (part number 20-MAINSTND). Remove the power structure by sliding it onto the rails of the Maintenance Stand. Note: The Maintenance Stand is designed for removing power structures from drives supplied in Rittal TS8 enclosures. Alternate means of removal will be necessary for other types of enclosures. 21. Follow the instructions in publication PFLEX-IN005, Installation Instructions - Lifting & Mounting PowerFlex 700S and 700H Drives (Frame 10-14), supplied with the new power structure, to lift the power structure off of the Maintenance Stand. Step 3: Installing the New Power Structure Install the new power structure in reverse order of removal. Refer to the publication PFLEX-IN006, Installation Instructions - PowerFlex 700S and 700H High Power Drives, for tightening torques of power and motor terminations.

12 12 PowerFlex 700S and 700H Frame 13 Replacement Power Structures Step 4: Connecting the Power Structure to Components in the Drive 1. For drives with AC input, connect the precharge cable and remove the jumper from the fan control connector and connect the fan control cable from the Rectifying modules to the Power Structure. = Connect Precharge cables Connect fan control cables 2. Use the tables and illustrations below to make all connections between the ASIC, Power Supply Voltage Feedback and Fiber Optic Interface (700S) or Fiber Optic Adapter (700H) and Common Mode Filter circuit boards for your installation. Refer to PowerFlex 700S Phase II Drive Connections: on page 15 for a PowerFlex 700S circuit board connection diagram. Refer to PowerFlex 700H Connections: on page 16 for a PowerFlex 700H circuit board connection diagram. Important: If the drive has DC input, you must also connect the precharge circuit. Refer to Pre-Charge Connections on Drives with DC Input on page 18.

13 PowerFlex 700S and 700H Frame 13 Replacement Power Structures 13 Figure 1 Termination Points on the ASIC Board X5 X4 X3 H13 H12 H11 H10 H9 H8 X10 X1 X2 H7 H6 H5 H4 H3 H2 H1 X15 X9 Fiber Optic Connections to Fiber Optic Interface Board Connect to Pre-charge circuitry on DC Input drives Figure 2 Termination Points on the Power Supply Voltage Feedback Board Fiber Optic Connections to Fiber Optic Interface Board J2 J1 J4 J5 J8

14 14 PowerFlex 700S and 700H Frame 13 Replacement Power Structures Figure 3 Termination Points on the 700S Fiber Optic Interface Board J8 J9 J10 J11 J12 J14 Fiber Optic Connections to ASIC Board J13 J6 J7 Figure 4 Termination Points on the 700H Fiber Optic Adapter Board H7 H6 H5 H4 Fiber Optic Connections to ASIC Board H3 H2 H1

15 PowerFlex 700S and 700H Frame 13 Replacement Power Structures 15 Figure 5 Termination Points on the Common Mode Filter Board Connect to J5 on Fiber Optic Interface Board J1 J5 From Connector J8 on Power Supply Voltage Feedback Board PowerFlex 700S Phase II Drive Connections: Figure 6 Connections Between the Power Structure and the 700S Phase II Control Make and verify these connections X10 ASIC Board H1 (Gate Enable) H2 (U Gate) H3 (V Gate) H4 (W Gate) H5 (ADconv) H6 (Vbus Tx) H7 (Vbus Rx) Fiber Optic Cables Inside Power Structure To 700S Main Control Board J8 J9 J10 J11 J12 J14 J V Iso J1 +12 V -12 V J2 +5V J3 J17 M6 Control Pan Fan Fiber Optic Interface Board J18 M 2 J15 2 External 24V DC 1 = 24V 3 = Common (75W min) J5 J6 Tx J7 Rx J4 J Common Mode Filter Board 2 J1 J5 700S Control Assembly (Phase II) 2 Fiber 9 2 J8 +24V X3 J5 Rx J4 Tx X2 20-VB00601 X4 9 8 DPI Interface Board 20 DPI Comm Option X1 80W Power Supply Power Supply Voltage Feedback J2 PWR STS PORT MOD NET A NET B DPI Assembly J3 J2 DC- DC+ J1 -U -V -W DPI Bezel J1 HIM DOOR EXAMPLE: 20-HIM-A3 HIM EXTERNAL DPI

16 16 PowerFlex 700S and 700H Frame 13 Replacement Power Structures ASIC Board Connections Connect this component: termination point ASIC Board: H1 (fiber optic connector) ASIC Board: H2 (fiber optic connector) ASIC Board: H3 (fiber optic connector) ASIC Board: H4 (fiber optic connector) ASIC Board: H5 (fiber optic connector) ASIC Board: H6 (fiber optic connector) ASIC Board: H7 (fiber optic connector) ASIC Board: X10 to this component : termination point Fiber Optic Interface Board: J8 (fiber optic connector) Fiber Optic Interface Board: J9 (fiber optic connector) Fiber Optic Interface Board: J10 (fiber optic connector) Fiber Optic Interface Board: J11 (fiber optic connector) Fiber Optic Interface Board: J12 (fiber optic connector) Fiber Optic Interface Board: J14 (fiber optic connector) Fiber Optic Interface Board: J13 (fiber optic connector) Insulate and do not connect Power Supply Voltage Feedback Board Connections Connect this component: termination point Power Supply Voltage Feedback Board: J8 Power Supply Voltage Feedback Board: J5 (fiber optic connector) Power Supply Voltage Feedback Board: J4 (fiber optic connector) to this component : termination point Common Mode Filter Board: J5 Fiber Optic Interface Board: J6 Fiber Optic Interface Board: J7 PowerFlex 700H Connections: Make and verify these connections X10 H1 H2 H3 H4 ASIC Board H5 H6 H7 Fiber Optic Cables Inside Power Structure X2 H1 H2 H3 H4 H5 H6 H7 Fiber Optic Adapter Board X1 X3 +24V 1 Common 2 37 X2 (Slot A) 20C-DA1-A (24V dc Digital Input w/ Analog I/O) or 20C-DA1-B (115V ac Digital Input w/ Analog I/O) X3 (Slot B) 20C-DO1 (Digital Output Option) X1 700H Control Board X4 X5 (Slot C) (Slot D) Option Option Board Board X6 (Slot E) X1 20C-DPI1 (DPI Communications Option) X3 X2 X7 (RS-232 Programming Port) X2 DPI Interface X1 X4 X3 20 DPI COMM (Option) J2 PWR STS PORT MOD NET A NET B HIM Bezel J1 HIM J3 HIM 10 Analog I/O 8 / 10 Digital Inputs 3 3 Digital Digital Outputs Outputs DPI Assembly 700H Control Assembly

17 PowerFlex 700S and 700H Frame 13 Replacement Power Structures 17 ASIC Board Connections Connect this component: termination point ASIC Board: H1 (fiber optic connector) ASIC Board: H2 (fiber optic connector) ASIC Board: H3 (fiber optic connector) ASIC Board: H4 (fiber optic connector) ASIC Board: H5 (fiber optic connector) ASIC Board: H6 (fiber optic connector) ASIC Board: H7 (fiber optic connector) ASIC Board: X10 to this component : termination point Fiber Optic Adapter Board: H1 (fiber optic connector) Fiber Optic Adapter Board: H2 (fiber optic connector) Fiber Optic Adapter Board: H3 (fiber optic connector) Fiber Optic Adapter Board: H4 (fiber optic connector) Fiber Optic Adapter Board: H5 (fiber optic connector) Fiber Optic Adapter Board: H6 (fiber optic connector) Fiber Optic Adapter Board: H7 (fiber optic connector) Fiber Optic Adapter Board: X2

18 18 PowerFlex 700S and 700H Frame 13 Replacement Power Structures Pre-Charge Connections on Drives with DC Input You must connect the ASIC board connectors X9 and X15 to the X50 terminal block for the pre-charge circuit. The X50 terminal block is located on the Control Frame in the left-hand enclosure. Refer to Figure 7 on page 18 for the location of these connection points. Refer to publication PFLEX-IN006, Installation Instructions - PowerFlex 700S and 700H Frame 9-14 Drives, for more information regarding the pre-charge circuit. X50 Terminal Block Connections ASIC Board Connector Terminal to X50 Terminal Pre-Charge Circuit Connection Description X Pre-charge Complete Signal (+24V DC) Pre-charge Complete Signal (Common) X Charge Relay Contact Charge Relay Contact Figure 7 Sample Pre-charge Wiring Diagram External precharge circuitry is shown as dashed lines. F1 M R1 CR2 DC+ M X X9 ASIC Board Precharge Complete DC Source X15 Charge Relay* M DC- CR1 M CR1 M CR2 * Refer to the ASIC Board Charge Relay Contact Ratings table below. F2 R2 CR2 ASIC Board Charge Relay Contact Ratings Load Resistance load (cos φ = 1) Rated load 8 A at 250 VAC: 5 A at 30 VDC Rated carry current 8 A Max. switching voltage 250 VAC; 30 VDC, (400 VAC) Max. switching current AC 8 A; DC 5 A Max. switching power 2,000 VA; 150 W Failure rate (reference value) 5 VDC 10 ma (for gold plating 0.35 µ min.)

19 PowerFlex 700S and 700H Frame 13 Replacement Power Structures 19 Step 5: Installing the Product Identification Label on New Power Structure All frame 13 replacement power structures are shipped from the factory without a product identification label on the drive. If you are installing the power structures in a 700S drive, you should label it with the accompanying PowerFlex 700S label. If you are installing the power structures in a 700H drive, you should label it with the accompanying PowerFlex 700H label.! DANGER DC BUS CONDUCTORS AND CAPACITORS OPERATE AT HIGH VOLTAGE. REMOVE POWER AND WAIT 5 MINUTES BEFORE SERVICING OR Step 6: Starting the Drive 1. Install the protective covers and screens and the air flow plate on the drive. Installation is in the reverse order of removal as indicated in Step 3: Removing the Old Power Structure on page Start up the drive. Refer to the Start Up procedures in the appropriate publication: User Manual - PowerFlex 700S Drives with Phase II Control, 20D-UM006 Programming Manual - PowerFlex 700H Drives, 20C-PM001

20 Reference Materials Allen-Bradley publications are available on the internet at The following manuals are recommended for general drive information: Title Publication Wiring and Grounding Guidelines for Pulse Width Modulated DRIVES-IN001 Drives Industrial Automation Wiring and Grounding Guidelines Preventive Maintenance of Industrial Control and Drive System DRIVES-TD001 Equipment Safety Guidelines for the Application, Installation and Maintenance SGI-1.1 of Solid State Control A Global Reference Guide for Reading Schematic Diagrams Guarding Against Electrostatic Damage The following manuals are recommended for detailed PowerFlex 700S and 700H information: Title User Manual - PowerFlex 700S Drives with Phase II Control Programming Manual - PowerFlex 700H Drives Reference Manual - PowerFlex 700S Drives with Phase II Control Installation Instructions - PowerFlex 700S and 700H Drives (Frames 9-14) Installation Instructions - PowerFlex 700S and 700H Drives Frames Maintenance Stand Publication 20D-UM006 20C-PM001 PFLEX-RM003 PFLEX-IN006 PFLEX-IN014 For Allen-Bradley Drives Technical Support: Title Online at... Allen-Bradley Drives Technical Support Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI USA, Tel: (1) , Fax: (1) Europe/Middle East/Africa: Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) , Fax: (32) Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) , Fax: (852) Publication PFLEX-IN013B-EN-P - August P02 Supersedes PFLEX-IN013A-EN-P - April 2006 Copyright 2008 Rockwell Automation. All rights reserved. Printed in the U.S.A.

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