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ManualsBrandsRockwell Automation ManualsEquipment20D PowerFlex 700H/S Frame 12 Replacement Power Structure

Installation Instructions

PowerFlex

700S and 700H Frame 12

Replacement Power Structures

Introduction

Important:The Power Modules on PowerFlex 700S and 700H frame 12

drives are matched at the factory and cannot be paired with any

other Power Modules. Therefore, when a Power Module fails,

you must replace both power structures on a frame 12 drive.

Use this document to install the replacement power structures on a frame 12

drive. This document covers the following replacement power structures:

Note: The frame 12 power structure kit does not contain the drive-rated

ASIC boards. You must either use the existing ASIC boards or order

replacement ASIC boards in order to complete this installation. Please refer

to the Spare Parts and Options List for PowerFlex Architecture (7) Class

Low Voltage AC Drives for part catalog numbers. This list is located at:

www.ab.com/support/abdrives/powerflex700s/phase2/index.html

From this page, click on the “Parts List” link to view a PDF of the parts list

for both 700S and 700H drives.

Spare Module Catalog String PowerFlex 700H AC Input PowerFlex 700H DC Input PowerFlex 700S AC Input PowerFlex 700S DC Input

SK-H1-PWRMOD-F12D 20CC820 20CH820 20DC820 20DH820

20CD820 20CJ820 20DD820 20DJ820

20CC920 20CH920 20DC920 20DH920

20CD920 20CJ920 20DD920 20DJ920

20CC1K0 20CH1K0 20DC1K0 20DH1K0

20CD1K0 20CJ1K0 20DD1K0 20DJ1K0

SK-H1-PWRMOD-F12E 20CE650 20CK650 20DE650 20DK650

20CF650 20CM650 20DF650 20DM650

20CE750 20CK750 20DE750 20DK750

20CF750 20CM750 20DF750 20DM750

20CE820 20CK820 20DE820 20DK820

20CF820 20CM820 20DF820 20DM820

Summary of content (28 pages)

PAGE 1
Installation Instructions PowerFlex® 700S and 700H Frame 12 Replacement Power Structures Introduction Important: The Power Modules on PowerFlex 700S and 700H frame 12 drives are matched at the factory and cannot be paired with any other Power Modules. Therefore, when a Power Module fails, you must replace both power structures on a frame 12 drive. Use this document to install the replacement power structures on a frame 12 drive.
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PowerFlex® 700S and 700H Frame 12 Replacement Power Structures What You Need to Do This document contains directions for replacing one power structure mounted in a Rittal TS8 drive enclosure. These steps must be repeated for the installation of the second power structure.
PAGE 3
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures 3 1. Turn off and lock out input power and 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 2: Removing the Protective Covers from the Existing Drive 1.
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PowerFlex® 700S and 700H Frame 12 Replacement Power Structures 3. Remove the T8 Torx-head screws which secure the airflow plate to the drive. 4. Slide airflow plate off the enclosure frame.
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PowerFlex® 700S and 700H Frame 12 Replacement Power Structures 5 5. Remove the four M5 POZIDRIV screws that hold the top and bottom protective covers to the main front protective cover, then remove the top and bottom protective covers. 6. Remove the four M5 POZIDRIV screws that hold the main front protective cover to the drive, then remove the protective cover. 7. remove the side protective covers.
PAGE 6
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures Step 3: Preparing the Old Power Structure for Removal 1. Remove the motor wiring from the power structure at the front of the power structure. 2. Remove the ground connection from the lower right rear corner of the power structure. 3. Remove the input (AC or DC) from the incoming terminals at the top of the power structure.
PAGE 7
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures 7 4. Carefully disconnect the fiber-optic cables from sockets along the front of the ASIC board, and carefully set them aside. ! ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into fiber-optic ports or fiber-optic cable connectors.
PAGE 8
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures Step 4: Removing the Old Power Structure from the Drive 1. 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). Slide the power structure out of the enclosure onto the rails of the Maintenance Stand.
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PowerFlex® 700S and 700H Frame 12 Replacement Power Structures Step 5: Removing the Existing ASIC Board from the Old Power Structure 9 Important: If you are installing a new ASIC board, continue with Step 6 “Installing the ASIC Board on the New Power Structure” on page 10. If you are installing the existing ASIC board, continue with step 1 below. ! ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation.
PAGE 10
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures Step 6: Installing the ASIC Connecting a DC Input Drive Board on the New Power Power structures are shipped from the factory pre-configured for DC input Structure operation. Connecting an AC Input Drive If you are installing an existing ASIC board on the new power structure, continue with step 11 on page 12. If you are installing a new ASIC board on the new power structure, continue with step 1 below. 1.
PAGE 11
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures 11 4. Slide the old ASIC board out of its chassis. 5. Slide the new ASIC board into the chassis. ASIC Board 6. If you are installing a replacement power structure on a drive with AC input, remove the X2 plug from its protective sleeve and plug the cable into the X2 socket on the ASIC board.
PAGE 12
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures 10. Secure the cover of the ASIC assembly and reconnect the DC- bus cable to the cover. 11. Secure the ASIC board and assembly to the new power structure. ! 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. 12.
PAGE 13
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures 13 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 14. • Must insulate terminal X4 on the Rectifier circuit board- refer to Insulate Terminal X4 on the Rectifier Circuit Board on page 15.
PAGE 14
PowerFlex® 700S and 700H Frame 12 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 13 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 15
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures 15 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 13 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 16
PowerFlex® 700S and 700H Frame 12 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 17
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures Step 9: Connecting the Power Structure to Components on the Drive 17 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.
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PowerFlex® 700S and 700H Frame 12 Replacement Power Structures ASIC Board Connections - Power Structure #1 Connect this component : termination point . . .
PAGE 19
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures 19 Figure 4 Termination Points on the ASIC Boards Connects to X13 on Rectifying circuit board on AC Input drives X2 X11 H8 Connects to fan on ASIC assembly cover X9 H9 H10 X15 X26 H11 H12 H1 H13 H2 Connect to X50 terminal block for Pre-charge circuitry on DC Input drives H3 X3 H4 X1 H5 H6 ahw0994.
PAGE 20
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures ASIC Feedback Board Connections - Power Structure #1 Connect this component : termination point . . . ASIC Feedback Board: X900 ASIC Feedback Board: H903 to this component : termination point ASIC Board Power Structure #1: X26 Star Coupler Fiber Optic Interface Board: J28 ASIC Feedback Board Connections - Power Structure #2 Connect this component : termination point . . .
PAGE 21
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures 21 Figure 7 Termination Points on 700S Boards Star Coupler Fiber Optic Interface Board Power Supply Voltage Feedback Board J4 J5 J28 J13 J14 J12 J11 J10 J9 J8 J8 J7 J6 J27 J24 700S Common Mode FIlter Board J25 J23 J22 J1 J21 J20 J19 J5 J5
PAGE 22
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures Figure 8 700H Connections Feedback Board #1 X26 X9 1 25 M 26 2 3 Sample Pre-Charge Connection Shown in Dashed Lines 4 M CR1 X1 2 2 X10 24V Power H1 H2 H3 H4 H5 H6 H7 2 3 4 5 6 7 6 X900 X9 1 M 26 +24V 0EVA 21 22 23 X15 Charge Relay 25 2 3 4 X1 X50 PS #2 1 2 X10 Fiber Optic H1 H2 H3 H4 H5 H6 H7 1 2 3 4 5 6 7 2 1 2 1 2 +24VDC GND 5 7 T 6 3 4 1 2 X2 X3 X4 X5 +24VDC H8 DCH9 24V Power H10 H11 H12 H13 X600 Fan X11
PAGE 23
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures 23 ASIC Board Connections - Power Structure #1 Connect this component : termination point . . .
PAGE 24
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures ASIC Feedback Board Connections - Power Structure #1 Connect this component : termination point . . .
PAGE 25
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures 25 DC Input Precharge Control Wiring If you are installing a DC input drive with a precharge interlock you must make the following connections on the X50 terminal block from the precharge circuit. Refer to Figure 10 below for additional information.
PAGE 26
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures Step 10: Installing the Product Identification Label on the New Power Structures All frame 12 replacement power structures are shipped form 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.
PAGE 27
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures Reference Materials 27 Allen-Bradley publications are available on the internet at www.rockwellautomation.com/literature.
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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.