Rockwell Automation PowerFlex 700H Installation Instructions Manual

Brand: Rockwell Automation

Model: PowerFlex 700H

Category: Electrical relays

Type: Installation Instructions Manual

This manual is also suitable for

PowerFlex 700S

Rockwell Automation PowerFlex 700H is a high-performance variable frequency drive designed to control the speed and torque of AC induction motors. It is suitable for a wide range of applications, including machinery used in manufacturing, processing, and packaging.

The PowerFlex 700H offers several features that make it a valuable asset for industrial automation systems. These features include:

High reliability: The PowerFlex 700H is designed to withstand harsh industrial environments and is backed by a comprehensive warranty.
Energy efficiency: The PowerFlex 700H uses advanced control algorithms to minimize energy consumption, resulting in lower operating costs.

The PowerFlex 700H offers several features that make it a valuable asset for industrial automation systems. These features include:

High reliability: The PowerFlex 700H is designed to withstand harsh industrial environments and is backed by a comprehensive warranty.
Energy efficiency: The PowerFlex 700H uses advanced control algorithms to minimize energy consumption, resulting in lower operating costs.

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:

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

Voltage Class

Spare Module Catalog

String

PowerFlex

700H AC Input

PowerFlex

700H DC Input

PowerFlex

700S AC Input

PowerFlex

700S DC Input

400/480V AC

(540/650V DC)

SK-H1-PWRMOD-D1K1 20CC1K1 20CH1K1 20DC1K1 20DH1K1

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

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

Step 1: Removing Power

From the 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. 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.

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.

L1 L2 L3

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.

DC BUS CONDUCT

ORS AND CAPACITORS

OPERATE AT HIGH

VOLTAGE. REMO

VE POWER

AND W

AIT 5 MINUTES BEFORE SERVICING

DAN

GER

Three covers

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.

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-

DC+

DC-

DC+

U/T1 V/T2 W/T3

U/T1

V/T2 W/T3

Output Power Terminals

DC Bus Terminals

ASIC Board

Assembly

Power Supply Voltage

Feedback Board Assembly

Ground Terminals

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.

PowerFlex® 700S and 700H Frame 13 Replacement Power Structures 7

10. 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 #1.

12. For drives with DC input, disconnect the external precharge circuitry

from connectors X9 and X15 from the ASIC board.

H11H12H13

H9H10

X15

X3X4X5

H4H5H6 H1H2H3

X10

Disconnect fiber optic

cables (H1 - H7)

DC precharge

connections

Disconnect

cables

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.

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.

Rubber grommet and

wire bundles.

Important: Move wire

bundles to left-hand

enclosure.

Fan control cables.

Shown disconnected.

Precharge cables.

Shown disconnected.

PowerFlex® 700S and 700H Frame 13 Replacement Power Structures 9

15. 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).

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.

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.

Disconnect:

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.

18. Disconnect the cable from connector J8 on each of the Power Supply

Voltage Feedback boards, and set the cable aside.

Remove screws

J2 J1

J4 J5

Disconnect cable

PowerFlex® 700S and 700H Frame 13 Replacement Power Structures 11

19. Remove the two hexagonal screws that secure the power structure to the

enclosure frame.

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.

Remove screws - one each side of enclosure

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.

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.

Connect fan control

cables

Connect Precharge

cables

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

Figure 1 Termination Points on the ASIC Board

Figure 2 Termination Points on the Power Supply Voltage Feedback Board

Connect to Pre-charge

circuitry on DC Input drives

Fiber Optic Connections to

Fiber Optic Interface Board

H11H12H13

H9H10

X15

X3X4X5

H4H5H6 H1H2H3

X10

J2 J1

J4 J5

Fiber Optic Connections to

Fiber Optic Interface Board

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

Figure 3 Termination Points on the 700S Fiber Optic Interface Board

Figure 4 Termination Points on the 700H Fiber Optic Adapter Board

J10

J12

J11

J14

J13

Fiber Optic Connections

to ASIC Board

Fiber Optic Connections

to ASIC Board

PowerFlex® 700S and 700H Frame 13 Replacement Power Structures 15

Figure 5 Termination Points on the Common Mode Filter Board

PowerFlex 700S Phase II Drive Connections:

Figure 6 Connections Between the Power Structure and the 700S Phase II Control

Connect to J5 on Fiber Optic

Interface Board

From Connector J8 on Power

Supply Voltage Feedback Board

HIM

-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

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)

X10

Inside Power Structure

Make and verify these connections

700S Control Assembly (Phase II)

Common Mode Filter Board

To 700S Main

Control Board

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

ASIC Board Connections

Power Supply Voltage Feedback Board Connections

PowerFlex 700H Connections:

Connect this component:

termination point … to this component : termination point

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

Connect this component:

termination point …

to this component : termination

point

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

Power Supply Voltage Feedback Board: J5 (fiber optic

connector)

Fiber Optic Interface Board: J6

Power Supply Voltage Feedback Board: J4 (fiber optic

connector)

Fiber Optic Interface Board: J7

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

PowerFlex® 700S and 700H Frame 13 Replacement Power Structures 17

ASIC Board Connections

Connect this component:

termination point … to this component : termination point

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)

ASIC Board: H7 (fiber optic connector) Fiber Optic Adapter Board: H7 (fiber optic connector)

ASIC Board: X10 Fiber Optic Adapter Board: X2

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

Figure 7 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

ASIC

Board

X15

Precharge

Complete

CR1

CR2

CR1

X50

Charge

Relay*

* Refer to the “ASIC

Board Charge Relay

Contact Ratings” table

below.

External precharge circuitry is shown as dashed lines.

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 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.

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 3.

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…

DC BUS CONDUCT

ORS AND CAP

CITORS

OPERA

TE AT HIGH

VOL

TAGE. REMO

VE PO

AND W

AIT 5 MINUTES BEFOR

E SER

VICING

DANGER

www.rockwellautomation.com

mericas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 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

sia 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-IN013B-EN-P - August 2008 20 360407-P02

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 700S and

700H information:

For Allen-Bradley Drives Technical Support:

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 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

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

Programming Manual - PowerFlex 700H Drives 20C-PM001…

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

Installation Instructions - PowerFlex 700S and 700H Drives (Frames 9-14) PFLEX-IN006…

Installation Instructions - PowerFlex® 700S and 700H Drives Frames 10-14

Maintenance Stand

PFLEX-IN014…

Title Online at...

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

Rockwell Automation PowerFlex 700H Installation Instructions Manual

Brand: Rockwell Automation

Model: PowerFlex 700H

Category: Electrical relays

Type: Installation Instructions Manual

This manual is also suitable for

PowerFlex 700S

The PowerFlex 700H offers several features that make it a valuable asset for industrial automation systems. These features include:

High reliability: The PowerFlex 700H is designed to withstand harsh industrial environments and is backed by a comprehensive warranty.
Energy efficiency: The PowerFlex 700H uses advanced control algorithms to minimize energy consumption, resulting in lower operating costs.

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