Instruction Manual

ManualsBrandsRockwell Automation ManualsEquipment20D PowerFlex 700H/S Frame 10 Replacement Power Structure

Installation Instructions

PowerFlex

700S and 700H Frame 10

Replacement Power Structures

Introduction

Use this document to install a replacement power structure on a PowerFlex

700S or 700H frame 10 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-D385 20CC385 20CH385 20DC385 20DH385

20CD385 20CJ385 20DD385 20DJ385

SK-H1-PWRMOD-D460 20CC460 20CH460 20DC460 20DH460

20CD460 20CJ460 20DD460 20DJ460

SK-H1-PWRMOD-D500 20CC500 20CH500 20DC500 20DH500

20CD500 20CJ500 20DD500 20DJ500

SK-H1-PWRMOD-E261 20CE261 20CK261 20DE261 20DK261

20CF261 20CM261 20DF261 20DM261

SK-H1-PWRMOD-E325 20CE325 20CK325 20DE325 20DK325

20CF325 20CM325 20DF325 20DM325

SK-H1-PWRMOD-E385 20CE385 20CK385 20CF385 20DK385

20CF385 20CM385 20DF385 20DM385

SK-H1-PWRMOD-E416 20CE416 20CK416 20DE416 20DK416

20CF416 20CM416 20DF416 20DM416

Summary of content (18 pages)

PAGE 1
Installation Instructions PowerFlex® 700S and 700H Frame 10 Replacement Power Structures Introduction Use this document to install a replacement power structure on a PowerFlex 700S or 700H frame 10 drive.
PAGE 2
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures ! ! 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 & -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. ! ATTENTION: HOT surfaces can cause severe burns.
PAGE 3
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures Step 1: Configuring the New Power Structure 3 Before configuring the new power structure you must remove the protective covers. Refer to the Installation Instructions - PowerFlex 700S and 700H High Power Drives, publication PFLEX-IN006…for instructions on removing these covers. Configuring a DC Input Drive Power structures are shipped from the factory pre-configured for DC input operation.
PAGE 4
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures Configuring the EMC Filter Frame 10 size drives are equipped with common mode capacitors and capacitors that are connected to the input terminals. To guard against drive damage, these capacitors should be disconnected depending upon the type of ground system on which the drive is installed.
PAGE 5
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures Figure 2 Common Mode Jumper and Rectifier Circuit Board Location Common Mode jumper There is one common mode jumper located on the upper-right side of the power structure.
PAGE 6
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures Move the Common Mode Jumper to the Disconnected Position Follow the lettered steps below to move the common mode jumper to the disconnected position (refer to Figure 2 on page 5 for jumper location): Task A Description Loosen the upper screw. B Remove the lower screw. Move the jumper to the horizontal position. C Install and tighten the screws.
PAGE 7
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 7 Insulate Terminal X4 on the Rectifier Circuit Board Follow the lettered steps below to insulate terminal X4 on the Rectifier circuit board (refer to Figure 2 on page 5 for Rectifier board location): Task A Description Remove the screw from the X4 connection on the Rectifier circuit board. B Insulate the top and bottom of the X4 connection on the Rectifier circuit board.
PAGE 8
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures Disconnect the Small Capacitors from the Input Terminals Follow the lettered steps below to disconnect the small capacitors from the input terminals: Task A B C Description Remove the screws and lock washers that secure each of the three capacitor supply wires to the input power terminals. Insulate the capacitor leads and leave disconnected. Install and tighten the screws and lock washers only.
PAGE 9
PowerFlex® 700S and 700H Frame 10 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 & -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.
PAGE 10
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures Step 5: Connecting the Power Structure to Components in the Drive You must connect the new power structure to the components in the drive. If the drive has DC input, you must also connect the pre-charge circuit.
PAGE 11
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 11 Figure 3 Connections Between the Power Structure and the 700S Phase I Control Make and verify these connections To X13 Connector for Rectifier Board (AC Input Drives Only) X2 H1 ASIC Board H2 H3 H4 H5 H6 H7 Fiber Optic Cables X10 Inside Power Structure Common Mode Filter Board J8 RS-232 Communication Daughtercard (Option) P5 Flex I/O P1 700S Main Control Board (Phase I) J35 J11 P2 P1 J2 Feedback Option Card P3 10 J17 J7 F
PAGE 12
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures Figure 5 Termination Points on the ASIC Board Connects to X13 connector for the Rectifier board on AC input drives Connects to fan on ASIC Cassette cover X2 H8 X9 Connect to Pre-charge circuitry on DC Input drives H9 H10 X15 H11 H12 H1 H13 H2 H3 X3 X1 X4 Fiber Optic connections to the Fiber Optic Interface Board H4 H5 H6 H7 X5 X6
PAGE 13
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 13 Figure 6 Termination Points on 700S Boards Fiber Optic Interface Board Power Supply Voltage Feedback Board J4 J5 J8 J9 J10 J8 J11 J12 Common Mode Filter Board J14 J13 J6 J7 J1 J5 J5 Connections to the 700H Control When installing a power structure in a PowerFlex 700H drive, you must make the following connections between the ASIC and Fiber Optic Adapter and Rectifier boards: Connect this component: termination point in …this compon
PAGE 14
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures Connect this component: termination point in …this component : termination point on the the Power Structure to … Control Frame ASIC Board : H7 (fiber optic connector) Fiber Optic Adapter Board : H7 (fiber optic connector) ASIC Board : X10 Fiber Optic Adapter Board : X3 ASIC Board: X2 Rectifier Board: X13 Figure 7 Connections Between the Power Structure and 700H Control Make and verify these connections X10 H1 ASIC Board H2 H3 H4 H5 H6 H7
PAGE 15
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 15 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. Refer to publication PFLEX-IN006…, Installation Instructions - PowerFlex 700S and 700H High Power Drives, for information regarding the pre-charge circuit.
PAGE 16
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures All frame 10 replacement power structures are shipped form the factory Step 6: Installing the Product Identification Label without a product identification label on the drive. If you are installing the on the New Power Structure power structure in a 700S drive, you should label it with the accompanying PowerFlex 700S label.
PAGE 17
PowerFlex® 700S and 700H Frame 10 Replacement Power Structures Reference Materials 17 Allen-Bradley publications are available on the internet at www.rockwellautomation.com/literature.
PAGE 18
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.