PowerFlex 700S and 700H Frame 11 Replacement Power Structures

Installation Instructions PowerFlex 700S and 700H Frame 11 Replacement Power Structures Introduction Use this document to install a replacement power structure on a PowerFlex 700S or 700H frame 11 drive. This document covers the following replacement power structures: Spare Module Catalog String PowerFlex 700H AC Input PowerFlex 700H DC Input PowerFlex 700S AC Input PowerFlex 700S DC Input SK-H1-PWRMOD-E460 20CE460 20CK460 20DE460 20DK460 20CF460 20CM460 20DF460 20DM460 SK-H1-PWRMOD-E502 20CE502 20CK502 20DE502 20DK502 20CF502 20CM502 20DF502 20DM502 SK-H1-PWRMOD-E590 20CE590 20CK590 20DE590 20DK590 20CF590 20CM590 20DF590 20DM590 SK-H1-PWRMOD-D590 20CC590 20CH590 20DC590 20DH590 20CD590 20CJ590 20DD590 20DJ590 SK-H1-PWRMOD-D650 20CC650 20CH650 20DC650 20DH650 20CD650 20CJ650 20DD650 20DJ650 SK-H1-PWRMOD-D730 20CC730 20CH730 20DC730 20DH730 20CD730 20CJ730 20DD730 20DJ730 What You Need to Do Step 1: Configure new power structure Step 2: Remove power from existing drive Step 3: Remove old power structure Step 4: Install new power structure Step 5: Connect new power structure to components in drive Step 6: Install product identification label on new power structure Step 7: Start drive

2 PowerFlex 700S and 700H Frame 11 Replacement Power Structures Step 1: Configuring the New Power Structure Before configuring the power structure you must remove the protective covers from the drive. Refer to publication PFLEX-IN006, Installation Instructions - PowerFlex 700S and 700H High Power Drives, for assistance in removing these covers. Configuring a DC Input Drive Power structures are shipped from the factory pre-configured for DC input operation. Connecting an AC Input Drive Power structures are shipped from the factory pre-configured for DC input operation. When installing a replacement power structure on a drive with AC input, you must remove the X2 plug from it s protective sleeve and plug the cable into the ASIC and Rectifier board(s). Task A B C D E F Description Remove the cover from the ASIC board assembly. Disconnect the ASIC fan from the assembly by unplugging the cable from on the ASIC board (see Figure 1 on page 3 for location). Remove the cover from the connector on the loose cable (bundled with the flat gate driver board cables) and connect the cable to the X2 connector on the ASIC board (see Figure 1 on page 3 for location). Connect the other end of the cable connected to X2 on the ASIC board to the 3 connector for the Rectifier board(s) on the V Phase and W Phase (if present) power stack (see Figure 2 on page 3 for location). Connect the fan cable to the connector on the ASIC board. Install the cover on the ASIC board assembly.

PowerFlex 700S and 700H Frame 11 Replacement Power Structures 3 Figure 1 ASIC Board Connections X9 5 H1 H2 H3 H4 H5 H6 H7 X6 Connect cable to X2 connector X2 connector H8 H9 H10 H11 H12 H13 X3 X4 X5 Figure 2 Rectifier Board Connectors Cable connected to X2 on ASIC board 3 connectors for Rectifier boards

4 PowerFlex 700S and 700H Frame 11 Replacement Power Structures Configuring the EMC Filter Frame 11 size drives are equipped with common mode capacitors. To guard against drive damage, these capacitors should be disconnected depending upon the type of ground system on which the drive is installed. Installation on an Ungrounded Distribution System or High Resistive Ground If you are installing a 400/480V AC input drive on an ungrounded distribution system or high resistive ground, you: Must move the common mode jumper to the disconnected position - refer to Move the Common Mode Jumper to the Disconnected Position on page 6. Should insulate terminal X4 on the Rectifier circuit board- refer to Insulate Terminal X4 on the Rectifier Circuit Board on page 7. If you are installing a 600/690V AC input drive on an ungrounded distribution system or high resistive ground, you: Must move the common mode jumper to the disconnected position - refer to Move the Common Mode Jumper to the Disconnected Position on page 6. Must insulate terminal X4 on the Rectifier circuit board- refer to Insulate Terminal X4 on the Rectifier Circuit Board on page 7. Installation on a Grounded B Phase Delta System If you are installing a drive on a grounded B phase Delta system, you: Must move the common mode jumper to the disconnected position - refer to Move the Common Mode Jumper to the Disconnected Position on page 6. Must insulate terminal X4 on the Rectifier circuit board- refer to Insulate Terminal X4 on the Rectifier Circuit Board on page 7. Note: Refer to Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives - Installation Instructions, publication DRIVES-IN001, for additional information on an ungrounded distribution system or high resistive ground installation.

PowerFlex 700S and 700H Frame 11 Replacement Power Structures 5 The jumper is located on the Rectifying Module(s). For drives with one Rectifying Module, it is located on the upper-right side of the middle power stack (V Phase). For drives with two Rectifying Modules, they are located on the upper-right side of the middle (V Phase) and right-side (W Phase) power stacks. Voltage Class Amps Number of Rectifying Modules 400/480V AC 590 2 650 2 730 2 600/690V AC 460 1 502 1 590 2 Figure 3 Common Mode Jumper and Rectifier Circuit Board Location Common Mode jumper There is one jumper located on each Rectifying Module. The Rectifying Modules are located on the upper-right side of the center and right side power stack of the drive s power structure. Front View of Assembly Rectifier Circuit Board

6 PowerFlex 700S and 700H Frame 11 Replacement Power Structures Move the Common Mode Jumper to the Disconnected Position 1. Follow the lettered steps below to move the common mode jumper to the disconnected position (refer to Figure 3 on page 5 for jumper location). Task A B C D Description Loosen the upper screw. Remove the lower screw. Move the jumper to the horizontal position. Install and tighten the screws. A Front View of Power Structure D C B Rectifying Circuit Board

PowerFlex 700S and 700H Frame 11 Replacement Power Structures 7 Insulate Terminal X4 on the Rectifier Circuit Board 1. Follow the lettered steps below to insulate terminal X4 on the Rectifier circuit board (refer to Figure 3 on page 5 for jumper location). Task A B Description Remove the screw from the X4 connection on the Rectifier circuit board. Insulate the top and bottom of the X4 connection on the Rectifier circuit board. Important: Do not install the screw and washer that was removed from this connection. A Side View of Power Structure B X4 X4 X41 X41 Rectifier Circuit Board

8 PowerFlex 700S and 700H Frame 11 Replacement Power Structures Step 2: Removing Power From the Existing 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 Step 3: Removing the Old Power Structure Refer to the PowerFlex 700H/S Frame 11 Hardware Service Manual, publication PFLEX-TG003, for information about removing the power structure. Step 4: Installing the New Power Structure Refer to the PowerFlex 700H/S Frame 11 Hardware Service Manual, publication PFLEX-TG003, for information about installing the power structure.

PowerFlex 700S and 700H Frame 11 Replacement Power Structures 9 Step 5: Connecting the Power Structure to Components in the Drive You must connect the power structure to control components on the control frame. If the drive has DC input, you must also connect the precharge circuit. Connections to the 700S Control Frame When installing a power structure in a PowerFlex 700S drive, you must make the following connections between the ASIC and Fiber Optic Interface, Power Supply Voltage Feedback, Common Mode Filter and Rectifier boards. Connect this component: termination point in the Power Structure to ASIC Board: H1 ASIC Board: H2 ASIC Board: H3 ASIC Board: H4 ASIC Board: H5 ASIC Board: H6 ASIC Board: H7 ASIC Board: 0 ASIC Board: X2 Power Supply Voltage Feedback Board: J8 Power Supply Voltage Feedback Board: J5 Power Supply Voltage Feedback Board: J4 this component : termination point on the Control Frame Fiber Optic Interface Board: J8 Fiber Optic Interface Board: J9 Fiber Optic Interface Board: J10 Fiber Optic Interface Board: J11 Fiber Optic Interface Board: J12 Fiber Optic Interface Board: J14 Fiber Optic Interface Board: J13 Insulate and do not connect Rectifier Board: 3 (AC input drives only) Common Mode Filter Board: J5 Fiber Optic Interface Board: J6 Fiber Optic Interface Board: J7 Figure 4 Connections for 700S Drives with Phase II Control Make and verify these connections To 3 Connector for Rectifier Board (AC Input Drives Only) X2 ASIC Board RJ45 Connector Embedded P2 P1 EtherNet I/P Option Board H1 (Gate Enable) H2 (U Gate) H3 (V Gate) H4 (W Gate) TX RX P1 SynchLink Option Board RS232 H5 (ADconv) H6 (Vbus Tx) H7 (Vbus Rx) Comm Input P1 NetLinx Daughtercard CompactFlash Memory Compact I/O 80 Feedback Inputs P2 P2 P3 P1 Logix Expansion Board Feedback Option Board P1 P2 P3 Second Encoder or P3 Safe Off Option Board 700S Control Assembly (Phase II) 120 34 34 16 P3 P10 P11 P12 P13 Main Control Board P4 TB1 P7 P5 TB2 P9 P2 P1 P6 P21 30 40 10 2 J1 J2 J3 J17 DriveLogix Battery M6 Control Pan Fan J8 J9 J10 J11 J12 J14 J13 +24 V Iso +12 V -12 V +5V Fiber Optic Interface Board J18 M 2 J15 2 External 24V DC 1 = 24V 3 = Common (75W min) Fiber Optic Cables Common Mode Filter Board J5 2 J1 J5 8 J6 Tx J7 Rx 9 J4 J16 2 Fiber 9 2 X2 X4 9 8 X3 0 Inside Power Structure J8 +24V J5 Rx J4 Tx 20-VB00601 DPI Interface Board 20 DPI Comm Option 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

10 PowerFlex 700S and 700H Frame 11 Replacement Power Structures Figure 5 Termination Points on the ASIC Board Fiber Optic connections to the Fiber Optic Interface board Connect to Pre-charge circuitry on DC input drives X9 5 H1 H2 H3 H4 H5 H6 H7 X6 X2 Connects to 3 connector for the Rectifier boards on the center and right side power stacks on AC input drives Connects to fan on ASIC assembly cover H8 H9 H10 H11 H12 H13 X3 X4 X5

PowerFlex 700S and 700H Frame 11 Replacement Power Structures 11 Fiber Optic Interface Board Figure 6 Termination Points on 700S Boards Power Supply Voltage Feedback Board J4 J5 J8 J9 J10 J8 J11 J12 J14 J13 J6 J7 Common Mode Filter Board J1 J5 J5

12 PowerFlex 700S and 700H Frame 11 Replacement Power Structures Connections to the 700H Control Frame When installing a power structure in a PowerFlex 700H drive, you must make eight connections between the ASIC and Fiber Optic Adapter and Rectifier boards. Connect this component: termination point in the Power Structure to ASIC Board: H1 ASIC Board: H2 ASIC Board: H3 ASIC Board: H4 ASIC Board: H5 ASIC Board: H6 ASIC Board: H7 ASIC Board: 0 ASIC Board: X2 this component : termination point on the Control Frame Fiber Optic Adapter Board: H1 Fiber Optic Adapter Board: H2 Fiber Optic Adapter Board: H3 Fiber Optic Adapter Board: H4 Fiber Optic Adapter Board: H5 Fiber Optic Adapter Board: H6 Fiber Optic Adapter Board: H7 Fiber Optic Adapter Board: X2 Rectifier Board: 3 Figure 7 Connections Between the Power Structure and Control Frame (700H Drives) Make and verify these connections 0 H1 H2 H3 H4 ASIC Board To 3 Connector for Rectifier Board (AC Input Drives Only) H5 H6 H7 X2 Fiber Optic Cables Inside Power Structure X2 H1 H2 H3 H4 H5 H6 H7 Fiber Optic Adapter Board 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) 700H Control Board X4 X5 (Slot C) (Slot D) Option Option Board Board X6 (Slot E) 20C-DPI1 (DPI Communications Option) X3 X2 X7 (RS-232 Programming Port) X2 DPI Interface 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

PowerFlex 700S and 700H Frame 11 Replacement Power Structures 13 Figure 8 Termination Points on Fiber Optic Adapter Board (700H Drives) Back View H7 H6 H5 H4 H3 H2 H1 X2

14 PowerFlex 700S and 700H Frame 11 Replacement Power Structures Pre-Charge Connections on Drives with DC Input You must connect the ASIC board connectors X9 and 5 to the X50 terminal block for the pre-charge circuit. The X50 terminal block is located on the Control Frame. Refer to the Installation Instructions - PowerFlex 700S and 700H High Power Drives, publication PFLEX-IN006, for information regarding the pre-charge circuit. X50 Terminal Block Connections ASIC Board Connector Terminal to X50 Terminal Pre-Charge Circuit Connection Description X9 25... 1 Pre-charge Complete Signal (+24V DC) 26... 2 Pre-charge Complete Signal (Common) 5 21... 3 Charge Relay Contact 23... 4 Charge Relay Contact Figure 9 Sample Pre-charge Wiring Diagram Customer Connections - External precharge circuitry is shown as dashed lines. Terminal Block Drive Connections F1 M R1 CR2 DC+ M X50 1 2 X9 25 26 ASIC Board Precharge Complete DC Source 3 4 21 23 5 Charge Relay* CR1 Pilot Relay M DC- F2 R2 CR2 CR1 M Main DC Contactor *Refer to the ASIC Board Charge Relay Contact Ratings table below. M CR2 Precharge Important: For DC Input Only. Do Not Install on AC Input Drives 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.)

PowerFlex 700S and 700H Frame 11 Replacement Power Structures 15 Step 6: Installing the Product Identification Label on New Power Structure All frame 11 replacement power structures are shipped from the factory without a product identification label on the drive. If you are installing the power structure in a 700S drive, you should label it with the accompanying PowerFlex 700S label. If you are installing the power structure in a 700H drive, you should label it with the accompanying PowerFlex 700H label.! DANGER Risk of electric shock and death. Disconnect power, wait 5 minutes and verify DC bus voltage before servicing. Follow instructions in manual before use. Earth ground required. OR! DANGER Risk of electric shock and death. Disconnect power, wait 5 minutes and verify DC bus voltage before servicing. Follow instructions in manual before use. Earth ground required. Step 7: Starting the Drive 1. Install the protective covers on the drive. Refer to publication PFLEX-IN006, Installation Instructions - PowerFlex 700S and 700H High Power Drives, for assistance in installing these covers. 2. 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.

Reference Materials Allen-Bradley publications are available on the internet at www.rockwellautomation.com/literature. The following manuals are recommended for general drive information: Title Publication Wiring and Grounding Guidelines for Pulse Width Modulated Drives DRIVES-IN001 Industrial Automation Wiring and Grounding Guidelines 1770-4.1 Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001 Safety Guidelines for the Application, Installation and Maintenance of Solid SGI-1.1 State Control A Global Reference Guide for Reading Schematic Diagrams 0100-2.10 Guarding Against Electrostatic Damage 8000-4.5.2 The following manuals are recommended for detailed PowerFlex 700H and 700S information: Title Reference Manual - PowerFlex 700S Drives with Phase II Control User Manual - PowerFlex 700S Drives with Phase II Control Programming Manual - PowerFlex 700H Drives Installation Instructions - PowerFlex 700S and 700H High Power Drives Hardware Service Manual - PowerFlex 700S and 700H Frame 11 Drives Publication PFLEX-RM003 20D-UM006 20C-PM001 PFLEX-IN006 PFLEX-TG003 For Allen-Bradley Drives Technical Support: Title Online at... Allen-Bradley Drives Technical Support www.ab.com/support/abdrives www.rockwellautomation.com Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204 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-IN011C-EN-P - August 2008 16 360399-P03 Supersedes PFLEX-IN011B-EN-P - March 2006 Copyright 2008 Rockwell Automation. All rights reserved. Printed in the U.S.A.