Allen-Bradley PowerFlex 700S Installation Instructions Manual

Brand: Allen-Bradley

Model: PowerFlex 700S

Category: Electrical relays

Type: Installation Instructions Manual

This manual is also suitable for

PowerFlex 700H

The Allen-Bradley PowerFlex 700S is a high-performance AC drive that provides precise control of motor speed and torque. It is designed for a wide range of applications, including conveyors, fans, pumps, and compressors. The PowerFlex 700S is easy to use and maintain, and it offers a variety of features to help you get the most out of your motor.

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

2 PowerFlex® 700S and 700H Frame 10 Replacement Power Structures

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 power structure to components in drive

❐ Step 6: Install product identification label on new power structure

❐ Step 7: Start drive

ATTENTION: To avoid an electric shock hazard, ensure that all

power to the drive has been removed before performing the

following.

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. Do not

touch the heatsink surface during operation of the drive. After

disconnecting power allow time for cooling.

ATTENTION: Hazard of permanent eye damage exists when

using optical transmission equipment. This product emits intense

light and invisible radiation. Do not look into SynchLink

fiber-optic ports or SynchLink fiber-optic cable connectors.

ATTENTION: This drive contains ESD (Electrostatic

Discharge) sensitive parts and assemblies. Static control

precautions are required when installing, testing, servicing or

repairing this assembly. Component damage may result if ESD

control procedures are not followed. If you are not familiar with

static control procedures, reference A-B publication 8000-4.5.2,

“Guarding Against Electrostatic Damage” or any other

applicable ESD protection handbook.

ATTENTION: The sheet metal cover and mounting screws on

the ASIC Board located on the power structure are energized at

(-) DC bus potential high voltage. Risk of electrical shock, injury,

or death exists if someone comes in contact with the assembly.

PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 3

Step 1: Configuring the

New Power Structure

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.

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.

Figure 1 ASIC Board Connections

Task Description

Remove the screw that secures the X6 connector wire to the ASIC cover and remove the

wire.

Remove the remaining screws that secure the cover to the ASIC assembly and remove the

cover.

Disconnect the ASIC fan from the assembly by unplugging the cable from X1 on the ASIC

board (see Figure 1

below 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

below for location).

Connect the other end of the cable connected to X2 on the ASIC board to the X13

connector for the Rectifier board on the upper right side of the power structure.

Connect the fan cable to the X1 connector on the ASIC board.

Install the cover on the ASIC board assembly.

H11

H12

H13

H10

X15

Connect cable to

X2 connector

X1 connector

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.

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.

• Must disconnect the small capacitors from the input terminals - refer to

Disconnect the Small Capacitors from the Input Terminals

on page 8.

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.

• Must disconnect the small capacitors from the input terminals - refer to

Disconnect the Small Capacitors from the Input Terminals

on page 8.

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.

• Must disconnect the small capacitors from the input terminals - refer to

Disconnect the Small Capacitors from the Input Terminals

on page 8.

Note: Refer to the 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 10 Replacement Power Structures 5

Figure 2 Common Mode Jumper and Rectifier Circuit Board Location

Common

Mode jumper

Rectifier Circuit Board

Front View

of Assembly

There is one common

mode jumper located on

the upper-right side of the

power structure.

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 Description

Loosen the upper screw.

Remove the lower screw.

Move the jumper to the horizontal position.

Install and tighten the screws.

Rectifier Circuit Board

Front View of

Power Structure

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):

Important:Do not install the screw and washer that was removed from this

connection.

Task 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.

X41

Rectifier Circuit Board

Side View of Power Structure

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:

Important:Do not re-install the capacitor leads.

Task 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.

Capacitor

Insulator

Capacitor lead -

leave disconnected

Input power terminal

Front View of Input

Power Terminals

Side View of Input

Power Terminals

PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 9

Step 2: Removing Power

From the Existing Drive

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. 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.

Step 3: Removing the Old

Power Structure

Refer to the PowerFlex 700H/S Frame 10 Hardware Service Manual,

publication PFLEX-TG002…, for information about removing the old

power structure.

Step 4: Installing the New

Power Structure

Refer to the PowerFlex 700H/S Frame 10 Hardware Service Manual,

publication PFLEX-TG002…, for information about installing the new

power structure.

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.

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.

L1 L2 L3

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.

Connections to the 700S Control

When installing a power structure in a PowerFlex 700S drive, you must

make the following connections between the ASIC board and the Fiber

Optic Interface, Power Supply Voltage Feedback, Common Mode Filter and

Rectifier boards.

Connect this component: termination point in

the Power Structure to …

…this component : termination point on the

Control Frame

ASIC Board: H1 (fiber optic connector) Fiber Optic Interface Board: J8 (fiber optic

connector)

ASIC Board: H2 (fiber optic connector) Fiber Optic Interface Board: J9 (fiber optic

connector)

ASIC Board: H3 (fiber optic connector) Fiber Optic Interface Board: J10 (fiber optic

connector)

ASIC Board: H4 (fiber optic connector) Fiber Optic Interface Board: J11 (fiber optic

connector)

ASIC Board: H5 (fiber optic connector) Fiber Optic Interface Board: J12 (fiber optic

connector)

ASIC Board: H6 (fiber optic connector) Fiber Optic Interface Board: J14 (fiber optic

connector)

ASIC Board: H7 (fiber optic connector) Fiber Optic Interface Board: J13 (fiber optic

connector)

ASIC Board: X10 Insulate and do not connect

ASIC Board: X2 Rectifier Board: X13

Power Supply Voltage Feedback Board: J8 Common Mode Filter Board: J5

Power Supply Voltage Feedback Board: J4

(fiber optic connector)

Fiber Optic Interface Board: J6

Power Supply Voltage Feedback Board: J6

(fiber optic connector)

Fiber Optic Interface Board: J7

PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 11

Figure 3 Connections Between the Power Structure and the 700S Phase I Control

Figure 4 Connections Between the Power Structure and the 700S Phase II Control

Fiber Optic

Interface

Board

ASIC

Board

Fiber Optic Cables

J8 J9 J10 J11 J12 J14 J13

J17

Fan

Power

J15

J6 TX

J7 RX

J16

+24v

RX J5

TX J4

U-

V-

W-

80W

Power

Supply

Power Supply

Voltage Feedback

Fiber

Fiber 89

DPI

COMM

(Option)

DPI

Interface

HIM

Bezel

HIM

DPI Assembly

PWR

STS

PORT

MOD

NET A

NET B

J10

J35

700S

Main

Control

Board

(Phase I)

TB1

J11

J34

J8 J9

SynchLink

TB2

TX RX

DriveLogix

Controller

(Option)

Feedback

Option

Card

RS-232

Flex I/O

Communication

Daughtercard

(Option)

700S Control Assembly (Phase I)

Auxiliary

Power

24 V dc

Inside Power Structure

Make and verify these connections

Common Mode Filter Board

To X13 Connector for Rectifier Board (AC Input Drives Only)

X10

HIM

P10

P12

P21

Comm

Input

Feedback

Inputs

P11

120

Compact I/O

-U

-V

-W

DC-

DC+

+24V

J4 Tx

J5 Rx

X3 J3

HIM

DOOR

EXTERNAL DPI

PWR

STS

PORT

MOD

NET A

NET B

DPI Assembly

EXAMPLE:

20-HIM-A3

20-VB00601

Main

Control

Board

Feedback

Option

Board

Logix

Expansion

Board

NetLinx

Daughtercard

J17

J18

J15

External

24V DC

1 = 24V

3 = Common

(75W min)

J6 Tx

J7 Rx

+24 V Iso

+12 V

-12 V

+5V

Pan Fan

Control

J16

Fiber Optic

Interface Board

80W

Power

Supply

Power Supply

Voltage

Feedback

DPI

Interface

Board

DPI

Comm

Option

DPI

Bezel

Fiber Optic Cables

J8 J9 J10 J11 J12 J14 J13

Fiber

ASIC Board

H1 (Gate Enable)

H2 (U Gate)

H3 (V Gate)

H4 (W Gate)

H5 (ADconv)

H6 (Vbus Tx)

H7 (Vbus Rx)

DriveLogix

Battery

P5P4

TB2TB1

RS232

CompactFlash

Memory

P13

Second Encoder

Safe Off Option Board

SynchLink

Option Board

Embedded

EtherNet I/P

Option Board

RJ45

Connector

Inside Power Structure

Make and verify these connections

700S Control Assembly (Phase II)

Common Mode Filter Board

To X13 Connector for Rectifier Board (AC Input Drives Only)

X10

12 PowerFlex® 700S and 700H Frame 10 Replacement Power Structures

Figure 5 Termination Points on the ASIC Board

H11

H12

H13

H10

X15

Connects to X13 connector for the

Rectifier board on AC input drives

Connect to Pre-charge circuitry

on DC Input drives

Connects to fan on ASIC

Cassette cover

Fiber Optic connections to the

Fiber Optic Interface Board

PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 13

Figure 6 Termination Points on 700S Boards

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:

J4 J5

J10

J12

J11

J14

J13

Power Supply Voltage Feedback Board

Fiber Optic Interface Board

Common Mode Filter Board

Connect this component: termination point in

the Power Structure to …

…this component : termination point on the

Control Frame

ASIC Board : H1 (fiber optic connector) Fiber Optic Adapter Board : H1

(fiber optic connector)

ASIC Board : H2 (fiber optic connector) Fiber Optic Adapter Board : H2

(fiber optic connector)

ASIC Board : H3 (fiber optic connector) Fiber Optic Adapter Board : H3

(fiber optic connector)

ASIC Board : H4 (fiber optic connector) Fiber Optic Adapter Board : H4

(fiber optic connector)

ASIC Board : H5 (fiber optic connector) Fiber Optic Adapter Board : H5

(fiber optic connector)

ASIC Board : H6 (fiber optic connector) Fiber Optic Adapter Board : H6

(fiber optic connector)

14 PowerFlex® 700S and 700H Frame 10 Replacement Power Structures

Figure 7 Connections Between the Power Structure and 700H Control

Figure 8 Termination Points on Fiber Optic Adapter Board (700H Drives)

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

Connect this component: termination point in

the Power Structure to …

…this component : termination point on the

Control Frame

Fiber Optic Adapter Board

ASIC

Board

X10

Fiber Optic Cables

H1 H2 H3 H4 H5 H6 H7

DPI

COMM

(Option)

DPI

Interface

HIM

Bezel

HIM

DPI Assembly

PWR

STS

PORT

MOD

NET A

NET B

700H Control Assembly

Inside Power Structure

Make and verify these connections

+24V

Common

(Slot A)

20C-DA1-A

(24V dc Digital Input

w/ Analog I/O)

20C-DA1-B

(115V ac Digital Input

w/ Analog I/O)

Analog

I/O

8 / 10

Digital

Inputs

(Slot B)

20C-DO1

(Digital Output

Option)

Digital

Outputs

Digital

Outputs

(Slot C)

Option

Board

(Slot D)

Option

Board

(Slot E)

20C-DPI1

(DPI Communications

Option)

X3 X2

(RS-232

Programming

Port)

700H Control Board

(AC Input Drives Only) To X13 Connector for Rectifier Board(s)

Back View

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.

X50 Terminal Block Connections

Figure 9 Sample Pre-charge Wiring Diagram

ASIC Board Charge Relay Contact Ratings

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)

X15 21 . . . 3 Charge Relay Contact

23 . . . 4 Charge Relay Contact

F2 R2 CR2

DC+

DC Source

DC-

CR2R1F1

CR1

Pilot Relay

CR1

Main DC Contactor

CR2

Precharge

Complete

X15

ASIC Board

X50

Charge

Relay*

*Refer to the “ASIC Board

Charge Relay Contact

Ratings” table below.

Customer Connections - External precharge

circuitry is shown as dashed lines.

Drive ConnectionsTerminal Block

Important: For DC Input Only.

Do Not Install on AC Input Drives

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.)

16 PowerFlex® 700S and 700H Frame 10 Replacement Power Structures

Step 6: Installing the

Product Identification Label

on the New Power Structure

All frame 10 replacement power structures are shipped form 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.

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 I Control,

20D-UM001

– User Manual - PowerFlex 700S Drives with Phase II Control,

20D-UM006

– Programming Manual - PowerFlex 700H Drives, 20C-PM001.

DAN

GER!

D C

CITO

ATE

AT HIG

TAG E

. R

POW

D WA

5 M

UTE

E SE

ICIN

DANGER

PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 17

Reference Materials

Allen-Bradley publications are available on the internet at

www.rockwellautomation.com/literature.

The following manuals are recommended for general drive information:

The following manuals are recommended for detailed PowerFlex 700H and

700S information:

For Allen-Bradley Drives Technical Support and access to the proper

Hardware Service Manual:

Title Publication

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 State

Control

SGI-1.1

A Global Reference Guide for Reading Schematic Diagrams 0100-2.10

Guarding Against Electrostatic Damage 8000-4.5.2

Title Publication

PowerFlex 700S Reference Manual - Phase I Control PFLEX-RM002…

PowerFlex 700S Reference Manual - Phase II Control PFLEX-RM003…

PowerFlex 700H Programming Manual 20C-PM001…

PowerFlex 700S User Manual - Phase I Control 20D-UM001…

PowerFlex 700S User Manual - Phase II Control 20D-UM006…

Installation Instructions - PowerFlex 700S and 700H High Power Drives PFLEX-IN006…

Hardware Service Manual - PowerFlex 700S and 700H Frame 10 Drives PFLEX-TG002…

Title Online at...

Allen-Bradley Drives Technical Support www.ab.com/support/abdrives

www.rockwellautomation.com

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

Power, Control and Information Solutions Headquarters

Publication PFLEX-IN008D-EN-P - August 2008 18 351483-P04