2024年9月24日发(作者：柴湛芳)
Introduction
What You Need to Do
Installation Instructions
PowerFlex
®
700S and 700H Frame 11
Replacement Power Structures
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 PowerFlex 700HPowerFlex 700HPowerFlex 700SPowerFlex 700S
StringAC InputDC InputAC InputDC Input
SK-H1-PWRMOD-E46020CE46020CK46020DE46020DK460
20CF46020CM46020DF46020DM460
SK-H1-PWRMOD-E50220CE50220CK50220DE50220DK502
20CF50220CM50220DF50220DM502
SK-H1-PWRMOD-E59020CE59020CK59020DE59020DK590
20CF59020CM59020DF59020DM590
SK-H1-PWRMOD-D59020CC59020CH59020DC59020DH590
20CD59020CJ59020DD59020DJ590
SK-H1-PWRMOD-D65020CC65020CH65020DC65020DH650
20CD65020CJ65020DD65020DJ650
SK-H1-PWRMOD-D73020CC73020CH73020DC73020DH730
20CD73020CJ73020DD73020DJ730
❐ 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
2PowerFlex® 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 X1 on the ASIC
board (see Figure 1on page3
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
1on page3 for location).
Connect the other end of the cable connected to X2 on the ASIC board to the X13
connector for the Rectifier board(s) on the V Phase and W Phase (if present) power stack
(see Figure 2on page3
for location).
Connect the fan cable to the X1 connector on the ASIC board.
Install the cover on the ASIC board assembly.
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures3
Figure 1 ASIC Board Connections
X6
X9X15
H1H2H3H4H5H6H7
Connect cable to
X2 connector
X2
X1
X1 connector
H8H9H10H11H12H13
X3X4X5
Figure 2 Rectifier Board Connectors
Cable connected to
X2 on ASIC board
X13
connectors
for Rectifier
boards
4PowerFlex® 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
Positionon page6.
•Should insulate terminal X4 on the Rectifier circuit board- refer to
Insulate Terminal X4 on the Rectifier Circuit Boardon page7.
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
Positionon page6.
•Must insulate terminal X4 on the Rectifier circuit board- refer to Insulate
Terminal X4 on the Rectifier Circuit Boardon page7.
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
Positionon page6.
•Must insulate terminal X4 on the Rectifier circuit board- refer to Insulate
Terminal X4 on the Rectifier Circuit Boardon page7.
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 Structures5
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
400/480V AC
Amps
590
650
730
460
502
590
Number of Rectifying Modules
2
2
2
1
1
2
600/690V AC
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
6PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
Move the Common Mode Jumper to the Disconnected Position
the lettered steps below to move the common mode jumper to the
disconnected position (refer to Figure 3on page5 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 Structures7
Insulate Terminal X4 on the Rectifier Circuit Board
the lettered steps below to insulate terminal X4 on the Rectifier
circuit board (refer to Figure 3on page5 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
X1
X41
X4
X1
X41
Rectifier Circuit Board
8PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
Step 2:Removing Power
From the Existing Drive
Step 3:Removing the Old
Power Structure
Step 4: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 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.
off and lock out input power. Wait five minutes.
that there is no voltage at the drive’s input power terminals.
e 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.
L1L2L3
I
O
Refer to the PowerFlex 700H/S Frame 11 Hardware Service Manual,
publication PFLEX-TG003…, for information about removing the 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 Structures9
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 (fiber optic connector)
ASIC Board: H2 (fiber optic connector)
ASIC Board: H3 (fiber optic connector)
ASIC Board: H4 (fiber optic connector)
ASIC Board: H5 (fiber optic connector)
ASIC Board: H6 (fiber optic connector)
ASIC Board: H7 (fiber optic connector)
ASIC Board: X10
ASIC Board: X2
Power Supply Voltage Feedback Board: J8
Power Supply Voltage Feedback Board: J5
(fiber optic connector)
Power Supply Voltage Feedback Board: J4
(fiber optic connector)
…this component : termination point on the
Control Frame
Fiber Optic Interface Board: J8 (fiber optic connector)
Fiber Optic Interface Board: J9 (fiber optic connector)
Fiber Optic Interface Board: J10 (fiber optic connector)
Fiber Optic Interface Board: J11 (fiber optic connector)
Fiber Optic Interface Board: J12 (fiber optic connector)
Fiber Optic Interface Board: J14 (fiber optic connector)
Fiber Optic Interface Board: J13 (fiber optic connector)
Insulate and do not connect
Rectifier Board: X13 (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 X13 Connector for Rectifier Board (AC Input Drives Only)
X2
ASIC Board
H1 (Gate Enable)
RJ45
Connector
Embedded
P2
P1
EtherNet I/P
Option Board
TX
RX
P1
H2 (U Gate)
H3 (V Gate)
H4 (W Gate)
H5 (ADconv)
H6 (Vbus Tx)
RS232
P3
P7
P9
H7 (Vbus Rx)
SynchLink
Option Board
CompactFlash
Memory
Compact I/O
80
Comm
Input
P1
Fiber Optic Cables
X10
P2
P2
P3
Logix
Expansion
Board
120
P1
P10
J8J9J10J11J12J14J13
+24 V Iso
J1
40
P11
P1
J2
Common Mode Filter Board
Inside Power Structure
30
P2
J5
2
J1
J5
2
J8
+24V
NetLinx
Daughtercard
Feedback
Inputs
34
P2
P1
Feedback
Option
Board
Fiber Optic
Interface
Board
+12 V
-12 V
+5V
J6 Tx
J7 Rx
80W
Power
Supply
J2
DC-
DC+
J1
-U
-V
-W
8
Fiber
9
9
9
8
J5 Rx
J4 Tx
P3
34
P12
Main
Control
Board
P6
Power Supply
Voltage
Feedback
J3
10
J17
2
J16
2
DriveLogix
Battery
J18
J15
2
External
24V DC
1 = 24V
3 = Common
(75W min)
X4
J4
X2
20-VB00601
Second Encoder
P3
or
Safe Off Option Board
16
P13
P4
TB1
P5
TB2
P21
DPI
Interface
X1
Board
X3
20
J2
DPI
Bezel
J3
J1
HIM
DOOR
EXAMPLE:
20-HIM-A3
2
PWR
STS
PORT
MOD
NET A
NET B
700S Control Assembly (Phase II)
M6
Control
Pan Fan
M
DPI
Comm
Option
DPI Assembly
HIM
EXTERNAL DPI
10PowerFlex® 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
X6
X9X15
H1H2H3H4H5H6H7
Connect to Pre-charge
circuitry on DC input drives
X2
X1
Connects to X13
connector for the Rectifier
boards on the center and
right side power stacks on
AC input drives
Connects to fan on
ASIC assembly cover
H8H9H10H11H12H13
X3X4X5
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures11
Figure 6 Termination Points on 700S Boards
Fiber Optic Interface Board
J8
J9
J10
J11
J12
J14
J13
J6
J7
J5
Power Supply Voltage Feedback Board
J4J5
J8
Common Mode Filter Board
J1
J5
12PowerFlex® 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 …this component : termination point on the
the Power Structure to …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)
ASIC Board: H7 (fiber optic connector)Fiber Optic Adapter Board: H7
(fiber optic connector)
ASIC Board: X10Fiber Optic Adapter Board: X2
ASIC Board: X2Rectifier Board: X13
Figure 7 Connections Between the Power Structure and Control Frame (700H Drives)
Make and verify these connections
X10
H1
H2
H3
H4
H5
H6
H7
To X13 Connector for Rectifier Board (AC Input Drives Only)
X2
ASIC
Board
Fiber Optic Cables
X2H1H2H3H4H5H6H7
Inside Power Structure
X3
+24V1
Common2
Fiber Optic Adapter Board
X1
37
X1
X2
X7
(RS-232
Programming
Port)
700H Control Board
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)
10
Analog
I/O
8 / 10
Digital
Inputs
X3
(Slot B)
X4
(Slot C)
X5
(Slot D)
X6
(Slot E)
X1
20C-DPI1
(DPI Communications
Option)
DPI
Interface
X1J2
X4
HIM
Bezel
J3
J1
HIM
X3
20
20C-DO1
(Digital Output
Option)
PWR
STS
PORT
MOD
NET A
NET B
DPI Assembly
Option
Board
Option
Board
DPI
COMM
(Option)
HIM
X3
33
DigitalDigital
OutputsOutputs
X2
700H Control Assembly
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures13
Figure 8 Termination Points on Fiber Optic Adapter Board (700H Drives)
Back View
H7
H6
H5
H4
H3
H2
H1
X2
14PowerFlex® 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 X15 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
ConnectorTerminal
X925
26
X1521
23
toX50 TerminalPre-Charge Circuit Connection Description
. . . 1Pre-charge Complete Signal (+24V DC)
. . . 2Pre-charge Complete Signal (Common)
. . . 3Charge Relay Contact
. . . 4Charge Relay Contact
Figure 9 Sample Pre-charge Wiring Diagram
Customer Connections - External precharge
circuitry is shown as dashed lines.
M
DC+
Terminal BlockDrive Connections
X50
X9
1
M
2
26
21
23
X15
CR1
Pilot Relay
25
ASIC Board
Precharge
Complete
F1R1CR2
DC Source
3
4
Charge
Relay*
M
DC-
CR1
M
Main DC Contactor
F2R2CR2
*Refer to the “ASIC Board
Charge Relay Contact
Ratings” table below.
Important: For DC Input Only.
Do Not Install on AC Input Drives
M
CR2
Precharge
ASIC Board Charge Relay Contact Ratings
Load
Rated load
Rated carry current
Max. switching voltage
Max. switching current
Max. switching power
Failure rate (reference value)
Resistance load (cos φ = 1)
8 A at 250 VAC: 5 A at 30 VDC
8 A
250 VAC; 30 VDC, (400 VAC)
AC 8 A; DC 5 A
2,000 VA; 150 W
5 VDC 10 mA (for gold plating 0.35 µ min.)
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures15
All frame 11 replacement power structures are shipped from the factory
Step 6:Installing the
Product Identification Label
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
on New Power Structure
PowerFlex 700S label. If you are installing the power structure in a 700H
drive, you should label it with the accompanying PowerFlex 700H label.
!
D
A
N
G
E
R
OR
Step 7:Starting the Drive
l 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.
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
/literature.
The following manuals are recommended for general drive information:
Title
Wiring and Grounding Guidelines for Pulse Width Modulated Drives
Industrial Automation Wiring and Grounding Guidelines
Preventive Maintenance of Industrial Control and Drive System Equipment
Safety Guidelines for the Application, Installation and Maintenance of Solid
State Control
A Global Reference Guide for Reading Schematic Diagrams
Guarding Against Electrostatic Damage
Publication
DRIVES-IN001…
1770-4.1
DRIVES-TD001…
SGI-1.1
0100-2.10
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
Allen-Bradley Drives Technical Support
/support/abdrives
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
Supersedes PFLEX-IN011B-EN-P - March 2006
16 360399-P03
Copyright © 2008 Rockwell Automation. All rights reserved. Printed in the U.S.A.
2024年9月24日发(作者：柴湛芳)
Introduction
What You Need to Do
Installation Instructions
PowerFlex
®
700S and 700H Frame 11
Replacement Power Structures
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 PowerFlex 700HPowerFlex 700HPowerFlex 700SPowerFlex 700S
StringAC InputDC InputAC InputDC Input
SK-H1-PWRMOD-E46020CE46020CK46020DE46020DK460
20CF46020CM46020DF46020DM460
SK-H1-PWRMOD-E50220CE50220CK50220DE50220DK502
20CF50220CM50220DF50220DM502
SK-H1-PWRMOD-E59020CE59020CK59020DE59020DK590
20CF59020CM59020DF59020DM590
SK-H1-PWRMOD-D59020CC59020CH59020DC59020DH590
20CD59020CJ59020DD59020DJ590
SK-H1-PWRMOD-D65020CC65020CH65020DC65020DH650
20CD65020CJ65020DD65020DJ650
SK-H1-PWRMOD-D73020CC73020CH73020DC73020DH730
20CD73020CJ73020DD73020DJ730
❐ 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
2PowerFlex® 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 X1 on the ASIC
board (see Figure 1on page3
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
1on page3 for location).
Connect the other end of the cable connected to X2 on the ASIC board to the X13
connector for the Rectifier board(s) on the V Phase and W Phase (if present) power stack
(see Figure 2on page3
for location).
Connect the fan cable to the X1 connector on the ASIC board.
Install the cover on the ASIC board assembly.
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures3
Figure 1 ASIC Board Connections
X6
X9X15
H1H2H3H4H5H6H7
Connect cable to
X2 connector
X2
X1
X1 connector
H8H9H10H11H12H13
X3X4X5
Figure 2 Rectifier Board Connectors
Cable connected to
X2 on ASIC board
X13
connectors
for Rectifier
boards
4PowerFlex® 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
Positionon page6.
•Should insulate terminal X4 on the Rectifier circuit board- refer to
Insulate Terminal X4 on the Rectifier Circuit Boardon page7.
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
Positionon page6.
•Must insulate terminal X4 on the Rectifier circuit board- refer to Insulate
Terminal X4 on the Rectifier Circuit Boardon page7.
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
Positionon page6.
•Must insulate terminal X4 on the Rectifier circuit board- refer to Insulate
Terminal X4 on the Rectifier Circuit Boardon page7.
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 Structures5
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
400/480V AC
Amps
590
650
730
460
502
590
Number of Rectifying Modules
2
2
2
1
1
2
600/690V AC
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
6PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
Move the Common Mode Jumper to the Disconnected Position
the lettered steps below to move the common mode jumper to the
disconnected position (refer to Figure 3on page5 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 Structures7
Insulate Terminal X4 on the Rectifier Circuit Board
the lettered steps below to insulate terminal X4 on the Rectifier
circuit board (refer to Figure 3on page5 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
X1
X41
X4
X1
X41
Rectifier Circuit Board
8PowerFlex® 700S and 700H Frame 11 Replacement Power Structures
Step 2:Removing Power
From the Existing Drive
Step 3:Removing the Old
Power Structure
Step 4: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 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.
off and lock out input power. Wait five minutes.
that there is no voltage at the drive’s input power terminals.
e 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.
L1L2L3
I
O
Refer to the PowerFlex 700H/S Frame 11 Hardware Service Manual,
publication PFLEX-TG003…, for information about removing the 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 Structures9
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 (fiber optic connector)
ASIC Board: H2 (fiber optic connector)
ASIC Board: H3 (fiber optic connector)
ASIC Board: H4 (fiber optic connector)
ASIC Board: H5 (fiber optic connector)
ASIC Board: H6 (fiber optic connector)
ASIC Board: H7 (fiber optic connector)
ASIC Board: X10
ASIC Board: X2
Power Supply Voltage Feedback Board: J8
Power Supply Voltage Feedback Board: J5
(fiber optic connector)
Power Supply Voltage Feedback Board: J4
(fiber optic connector)
…this component : termination point on the
Control Frame
Fiber Optic Interface Board: J8 (fiber optic connector)
Fiber Optic Interface Board: J9 (fiber optic connector)
Fiber Optic Interface Board: J10 (fiber optic connector)
Fiber Optic Interface Board: J11 (fiber optic connector)
Fiber Optic Interface Board: J12 (fiber optic connector)
Fiber Optic Interface Board: J14 (fiber optic connector)
Fiber Optic Interface Board: J13 (fiber optic connector)
Insulate and do not connect
Rectifier Board: X13 (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 X13 Connector for Rectifier Board (AC Input Drives Only)
X2
ASIC Board
H1 (Gate Enable)
RJ45
Connector
Embedded
P2
P1
EtherNet I/P
Option Board
TX
RX
P1
H2 (U Gate)
H3 (V Gate)
H4 (W Gate)
H5 (ADconv)
H6 (Vbus Tx)
RS232
P3
P7
P9
H7 (Vbus Rx)
SynchLink
Option Board
CompactFlash
Memory
Compact I/O
80
Comm
Input
P1
Fiber Optic Cables
X10
P2
P2
P3
Logix
Expansion
Board
120
P1
P10
J8J9J10J11J12J14J13
+24 V Iso
J1
40
P11
P1
J2
Common Mode Filter Board
Inside Power Structure
30
P2
J5
2
J1
J5
2
J8
+24V
NetLinx
Daughtercard
Feedback
Inputs
34
P2
P1
Feedback
Option
Board
Fiber Optic
Interface
Board
+12 V
-12 V
+5V
J6 Tx
J7 Rx
80W
Power
Supply
J2
DC-
DC+
J1
-U
-V
-W
8
Fiber
9
9
9
8
J5 Rx
J4 Tx
P3
34
P12
Main
Control
Board
P6
Power Supply
Voltage
Feedback
J3
10
J17
2
J16
2
DriveLogix
Battery
J18
J15
2
External
24V DC
1 = 24V
3 = Common
(75W min)
X4
J4
X2
20-VB00601
Second Encoder
P3
or
Safe Off Option Board
16
P13
P4
TB1
P5
TB2
P21
DPI
Interface
X1
Board
X3
20
J2
DPI
Bezel
J3
J1
HIM
DOOR
EXAMPLE:
20-HIM-A3
2
PWR
STS
PORT
MOD
NET A
NET B
700S Control Assembly (Phase II)
M6
Control
Pan Fan
M
DPI
Comm
Option
DPI Assembly
HIM
EXTERNAL DPI
10PowerFlex® 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
X6
X9X15
H1H2H3H4H5H6H7
Connect to Pre-charge
circuitry on DC input drives
X2
X1
Connects to X13
connector for the Rectifier
boards on the center and
right side power stacks on
AC input drives
Connects to fan on
ASIC assembly cover
H8H9H10H11H12H13
X3X4X5
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures11
Figure 6 Termination Points on 700S Boards
Fiber Optic Interface Board
J8
J9
J10
J11
J12
J14
J13
J6
J7
J5
Power Supply Voltage Feedback Board
J4J5
J8
Common Mode Filter Board
J1
J5
12PowerFlex® 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 …this component : termination point on the
the Power Structure to …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)
ASIC Board: H7 (fiber optic connector)Fiber Optic Adapter Board: H7
(fiber optic connector)
ASIC Board: X10Fiber Optic Adapter Board: X2
ASIC Board: X2Rectifier Board: X13
Figure 7 Connections Between the Power Structure and Control Frame (700H Drives)
Make and verify these connections
X10
H1
H2
H3
H4
H5
H6
H7
To X13 Connector for Rectifier Board (AC Input Drives Only)
X2
ASIC
Board
Fiber Optic Cables
X2H1H2H3H4H5H6H7
Inside Power Structure
X3
+24V1
Common2
Fiber Optic Adapter Board
X1
37
X1
X2
X7
(RS-232
Programming
Port)
700H Control Board
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)
10
Analog
I/O
8 / 10
Digital
Inputs
X3
(Slot B)
X4
(Slot C)
X5
(Slot D)
X6
(Slot E)
X1
20C-DPI1
(DPI Communications
Option)
DPI
Interface
X1J2
X4
HIM
Bezel
J3
J1
HIM
X3
20
20C-DO1
(Digital Output
Option)
PWR
STS
PORT
MOD
NET A
NET B
DPI Assembly
Option
Board
Option
Board
DPI
COMM
(Option)
HIM
X3
33
DigitalDigital
OutputsOutputs
X2
700H Control Assembly
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures13
Figure 8 Termination Points on Fiber Optic Adapter Board (700H Drives)
Back View
H7
H6
H5
H4
H3
H2
H1
X2
14PowerFlex® 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 X15 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
ConnectorTerminal
X925
26
X1521
23
toX50 TerminalPre-Charge Circuit Connection Description
. . . 1Pre-charge Complete Signal (+24V DC)
. . . 2Pre-charge Complete Signal (Common)
. . . 3Charge Relay Contact
. . . 4Charge Relay Contact
Figure 9 Sample Pre-charge Wiring Diagram
Customer Connections - External precharge
circuitry is shown as dashed lines.
M
DC+
Terminal BlockDrive Connections
X50
X9
1
M
2
26
21
23
X15
CR1
Pilot Relay
25
ASIC Board
Precharge
Complete
F1R1CR2
DC Source
3
4
Charge
Relay*
M
DC-
CR1
M
Main DC Contactor
F2R2CR2
*Refer to the “ASIC Board
Charge Relay Contact
Ratings” table below.
Important: For DC Input Only.
Do Not Install on AC Input Drives
M
CR2
Precharge
ASIC Board Charge Relay Contact Ratings
Load
Rated load
Rated carry current
Max. switching voltage
Max. switching current
Max. switching power
Failure rate (reference value)
Resistance load (cos φ = 1)
8 A at 250 VAC: 5 A at 30 VDC
8 A
250 VAC; 30 VDC, (400 VAC)
AC 8 A; DC 5 A
2,000 VA; 150 W
5 VDC 10 mA (for gold plating 0.35 µ min.)
PowerFlex® 700S and 700H Frame 11 Replacement Power Structures15
All frame 11 replacement power structures are shipped from the factory
Step 6:Installing the
Product Identification Label
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
on New Power Structure
PowerFlex 700S label. If you are installing the power structure in a 700H
drive, you should label it with the accompanying PowerFlex 700H label.
!
D
A
N
G
E
R
OR
Step 7:Starting the Drive
l 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.
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
/literature.
The following manuals are recommended for general drive information:
Title
Wiring and Grounding Guidelines for Pulse Width Modulated Drives
Industrial Automation Wiring and Grounding Guidelines
Preventive Maintenance of Industrial Control and Drive System Equipment
Safety Guidelines for the Application, Installation and Maintenance of Solid
State Control
A Global Reference Guide for Reading Schematic Diagrams
Guarding Against Electrostatic Damage
Publication
DRIVES-IN001…
1770-4.1
DRIVES-TD001…
SGI-1.1
0100-2.10
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
Allen-Bradley Drives Technical Support
/support/abdrives
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
Supersedes PFLEX-IN011B-EN-P - March 2006
16 360399-P03
Copyright © 2008 Rockwell Automation. All rights reserved. Printed in the U.S.A.