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pflex-tg004 - Rockwell Automation

1. Table C G ASIC Board on Power Structure 1 to Rectifier Precharge Circuit Board Power Structure 41 Connections ASIC Board Rectifier Board Connector Pin Number to Pin Number Connector X2 1 1 X13 2 2 3 3 4 4 5 5 Description SWTS DRV SWTS FB DTR Mains Fault 24V Table C H ASIC Board on Power Structure 2 to Rectifier Precharge Circuit Board on Power Structure 2 Connections ASIC Board Rectifier Board Connector Pin Number to Pin Number Connector X2 1 1 X13 2 2 3 3 4 4 5 5 Description SWTS DRV SWTS FB Mains Fault 24V Connector Descriptions C 7 Figure 4 PowerFlex 7005 High Power Star Interface Circuit Board Connectors C 8 Connector Descriptions Figure C 5 PowerFlex 700H Star Coupler Circuit Boa
2. 1 2 X3 X41 E i EM X8 X6 X10 xi iei 3d Q g o 26 o X12 O X13 Pin1 X13 Pin5 24V dc Common 24V dc Power X10 Pin 1 X11 Pin 1 X12 Pin 1 X9 Table 2 J Rectifying Board Charge Relay Test Results No Power on X13 24V dc Power on X13 Meter Leads Meter Leads Results Results J3 X9 J3 X10 Pin 1 J7 X9 00 7 X11 Pin 1 00 0V J11 X9 J11 X12 Pin 1 Checking the DC Capacitors Component Test Procedures 2 17 Important This procedure requires special equipment and training Only qualified and trained personnel should perform these procedures These tests require the recommended high voltage DC power supply 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 3 2 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 3 Setthe current limit of the DC power supply to less than 50mA 4 Power Structure 1 connect the power supply s DC to the drive s DC terminal and the power supply s DC to the drive s DC terminal 5 Setthe power supply voltage setting to zero 6 Switch on the external DC power supply 7 Slowly increase the external DC power supply output voltage to
3. Measure the gate interface resistance for each output power transistor The resistance from each gate and collector pin to the branch emitter pin should be about 500 ohms If any of the gate interfaces fails this test replace the appropriate left or right Output Power Module per Power Structure Gate Interface Resistance J8MOg 497 Ul 006 00S n 10 99 T anpo dno 009 dino 904010087 MOT A JO 99 9 09 91U sio 008 SUIYO 00S PISIS apon 1ndino 1M M 10 c suyo 006 437 ul 9H Suiuo 009 Q0 40 N eoeyleju 39 T 1 M0d Ye Ul swyo 009 id A 2 5 008 ainpoy Mdo SWYO 009 497 ul SWUO 1M 01 M 10 IH INDO 1ndino 1 1ndinQ 437 ul 20 a9 40 ere Jen s 7 3 009 suiuo 009 009 009 1ndino 1uB 49
4. t 1 pueog joi Ea apo T par ELM 2 1 CLIN us i 4 Tod 2 9pis 5 od T pueog amp DE gt mmy 8 3d lt o D gt A 4 1 U t pur Eid E gt 42 S npow apis 14654 Tod pied ursde ul 5000 A009 YYY pired usde T Ifpaeog 05 500 OL Sde Z A009 AO0t z 05 SOOL OL 7 TH 8H To ASIC Board 1 Schematics B 8 2 o4mjonas amod 1ndu seAuq 10 28964 Z EL M 2 CLIN 2 1 2 4 pueog JAA OPD pueog UOLULUOD T Adapter Board J 230N S E
5. 2 Shou Shou Shou d measure 15V dc with respect to DC with no light in VL cable d measure 15V dc with respect to DC with light in VL cable d measure 15V dc with respect to DC with no light in VL cable Shou d measure 15V dc with respect to DC with light in VL cable 2 14 Component Test Procedures Figure 2 3 Opto Coupler Checks for Right Hand Output Power Module Should measure 15V dc with respect to DC with no light in WH cable X8 Should measure 15 dc with respect to DC with light in WH cable ss Should measure 15V dc with respect to DC with no light in WH cable Should measure 15V with respect to DC with light in WH cable Should measure 15V dc with respect to DC with no light in VH cable 9 Should measure 15 dc with respect to DC with light in VH cable LI Should measure 15V dc with respect to DC with no light in VH cable Should measure 15 dc with respect to DC with light in VH cable Should measure 15V dc with respect to DC with no light in UH cable X10 Should measure
6. bd S npoi eps 3464 peed ursde z Soules uisde peed usde sous uisde Z 930N 00 saiqeo 2ndo Pq 9 ETH 8H To ASIC Board 2 From DC Bus in Power Structure From ASIC Board 2 X11 Schematics B 9 Setup Switch Fan Frequency Converter X3 X2 3 2 1 Q 1 2 3 4 loft orf on DC AC Setup Switch Fan Frequency Converter X3 2 4 Jumper Tuf gt gt 1 lt H gt 2 6 BLUE BLK T gt gt f 22uf 5 10Meg 4 Main Fan b ar S V GRN Left Side 12 34 BLK 22uf 230V AC loft orf on f 300VAC 10Meg 3 BLACK 50 Hz Setup Switch 3 gt gt Fan Frequency Converter x3 BLK Juf 1 BRN lt lt gt gt gt gt 4 In Power Structure 1 Left Side 2 6 BLUE X2 3 BLK gt gt M2 22uf X21 S vac 0 4 Y GRN Main Fan DC AC gt gt Right Side 12 3 4 22uf 230V AC loft orf on 300VAC 10Meg Black 50 Hz Fan Frequency Converter X3 BLK 1 Ba 2 4 lt lt gt gt
7. 2ndoJeqi 9 6 tH TH 8H SP SI pueog 1 r aye5 Q i e p Eun SIX GX EX 1 8 Te LO zal I IUU 20 fra OA peog 42314 lt 4 9x ge tr den ELM e 7 CUA 2 4 L zx 2 epis 391 E x 4 _ peog Jeunes Tu 5 3d uolssoudns 5 oDeyoA sure sindu E eed Jo 5 3u044 uo 2a Sun 4404 Jedun i gt E i 8 HOA in T HO _ e IET 8 0 5 01 all Te VR Re un J L JOpeag Suri epis 3 peed z Soues u SdeD A009 peed ul sdep Seues u SdeD Z 403bede A009 A00t 2 Od 3JON z 0 B 7 Schematics 1 amod 1ndu 104 2 9 8 N iJ peog Janu 93e5 so ge 9
8. Name Color State Description PWR Green Steady Iluminates when power is applied to the drive Power 575 Green Flashing Drive ready but not running amp no faults are present Status Steady Drive running no faults are present 5 Yellow Flashing When running a type 2 non configurable alarm condition S exists drive continues to run When stopped a start inhibit oa exists and the drive cannot be started D Steady A type 1 user configurable alarm condition exists but drive continues to run a Red Flashing A fault has occurred Steady A non resettable fault has occurred Red Flashing The drive is in flash recovery mode The only operation Yellow Alternately permitted is flash upgrade 2 PORT Refer to the Status of DPI port internal communications if present F MOD Communication Status of communications module when installed Adapter User Manual Status of network if connected Status of secondary network if connected T SYNCHLINK Green Steady _ The module is configured as the time keeper o or lt The module is configured as follower and synchronization is complete 8 Green Flashing The follower s are not synchronized with the time keeper 5 Red Flashing The module is configured 8sa time master on SynchLink and has received time information from another time master on SynchLink ENABLE Green The drive s ena
9. 9x M d 2 Le e 4 n zx e SInpow pis 391 9x ETX 4 S T pjeog ES z ae o a pueog vx i BAE E ted N pa p E 3 ebeyoAsuteiw F sjndu vx pepunous E st JO 34014 LLL zie uo sun 2a il E Bed ursi ON 404 nowy q a MR 1 Soa 956 LET i03 t 21 i 999 6 S Z fe Li Jopesy Sur 4 Sinpoi epis 346 4 YYY pled ursde z Soues ul de A009 Je I pueog 05 SOOL OL se Seues u sde Z A007 uoneunBuuo A009 A00t 3JON Od z jonuop 500 OL E od Schematics B 6 Z e4njonajs Indul OV seAuq 10 2 6 8
10. aci T DC Bus Bar 02 DC Bus Bar Insulator R DC Bus Bar Output Power Modul Frame Table D B Right Side of Power Structure Part Numbers Part Name Part No Air Flow Guide Right NA DC Bus Bar 20 FR10044 20 FR10052 20 FR10190 DC Bus Bar Insulator 20 FR10027 20 FR10028 20 FR10143 Discharging Resistor 2x16k 20 PP00056 Electrolytic Capacitor ELKO 3300 1 420V for 400 480V Drives 20 PP01005 ELKO 5600 1 420V for 600 690V Drives 20 PP01099 Frame NA Disassembly Assembly Diagrams D 5 Part Name Part No Output Power Module 400 480V NA 600 690V NA Rectifying Board 400 480V 20 VB00459 600 690V 20 VB00460 Rectifying Module 400 480V 20 FR10820 600 690V 20 FR10821 Snubber Capacitor Assembly 20 PP10019 D 6 Disassembly Assembly Diagrams Figure D 3 Left Side of Power Structure 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 into contact with the assembly ATTENTION The sheet metal cover and mounting screws on ASIC Assembly without ASIC Board nubber Capacitor Assembly DC Bus Bar lt gt F DC Bus Bar Insulator 7 DC Bus Bar DC Bus Bar Insulator Cover Plate Output Power Module Insulation Support Discharging Resistor Disassembly Assembly Diagrams D 7 Table D C Left
11. Be prepared to provide the following information when you contact support Product Catalog Number e Product Serial Number e Firmware Revision Level gt Before Applying Power to Check for zero volts between DC and DC the Drive 2 Perform forward and reverse biased diode tests using a digital multimeter Refer to Conducting Forward and Reverse Biased Diode Tests for Major Power Components on page 2 4 4 2 Start Up After Repair Testing with the External DC This is a low current low risk test for the Output Power Module and drive Power Supply Without Load Control board It requires the recommended High Voltage DC Test Power Optional Supply 1 2 10 11 12 13 Verify that the DC Test Power Supply is de energized Connect the power supply s DC to the drive s DC terminal and the power supply s DC to the drive s DC terminal Set the power supply voltage setting to zero Switch on the external DC Test Power Supply Slowly increase the DC Test Power Supply output voltage to the drive s nominal DC bus voltage 650V dc for drives with 380 500V ac input 775 dc for drives with 600 690V ac input Measure the DC bus voltage and verify that the value is reflected in parameter 306 DC Bus Voltage 700S parameter 012 DC Bus Voltage 700H Make configuration changes which allow the HIM to issue start and speed commands Make configuration changes which allow o
12. 4 2 Testing Without a Motor RII I eee 4 3 Performing the Power Circuit Diagnostic Test 700 4 3 Testing With the Motor 2 ook ecc AR e PRG kati eene RAL re 4 4 Appendix A Appendix B Appendix C Appendix D Software Tool oce 1 Nidwalden EI A 2 List of Schematic Diagrams llseeeeeeeee eee eee B 1 Circuit Board Connections 2 C 1 Hardware Connections 2 2 0 10 Disassembly Assembly Diagrams and Spare Parts D 1 Who Should Use this Manual What is in this Manual What is Not in this Manual Preface Overview This manual is intended for qualified service personnel responsible for troubleshooting and repairing high power PowerFlex 700H and 700S AC Drives You should have previous experience with and basic understanding of electrical terminology procedures required troubleshooting equipment equipment protection procedures and methods and safety precautions This manual contains hardware service information for Frame 12 PowerFlex 700H and 7008 drives only Verify that you are working on a Frame 12 drive by checking the data nameplate on the Control Frame The frame number is printed just above the serial number 0 460 60 Hz 420 500 630 550 840 630 Frame 12 Serial Number 2622381652
13. This manual does not contain in depth fault information for troubleshooting That information is available in publications 20C PM001 Programming Manual PowerFlex 700H Adjustable Frequency AC Drive PFLEX INOO06 Installation Instructions PowerFlex 7008 and 700H Adjustable Frequency AC Drive and 20D UMO06 User Manual PowerFlex 700S with Phase Control High Performance AC Drive 2 Overview Reference Materials Understanding Manual Conventions Allen Bradley publications are available on the internet at www rockwellautomation com literature The following publications provide general drive information Title Publication Wiring and Grounding Guide PWM AC Drives DRIVES INO01 Safety Guidelines for the Application Installation and Maintenance of SGI 1 1 Solid State Control A Global Reference Guide for Reading Schematic Diagrams 0100 2 10 Guarding Against Electrostatic Damage 8000 4 5 2 The following publications provide specific PowerFlex drive information Title Publication Programming Manual PowerFlex 700H AC Drive 20C PM001 User Manual PowerFlex 700S with Phase II Control High 20D UMOO6 Performance Drive Installation Instructions Hi Resolution Feedback Option Card for 20D IN001 PowerFlex 700S Drives Installation Instructions Multi Device Interface Option for PowerFlex 20D IN004 700S Drives Installation Instructions Main Control Board PowerF
14. 002 E 502 1190202 uondo ASLTHO VC 55 VIAN uondo uondo Idd qndno ebia PLIA snid GON Fi 1908 yy EW WIH 02 ejdueg X yog dup L Sumer 4108 0108 9306 Ps WIH Ir pueog jo uo peog Jejdno ZO6H pue TOGH 006H BE peqpaeJ OL dt euynpnug JOMOd TE GUNNS 49MOg OLX EE OL uo d 2ISv 01 UO pJeog suorpeuuo Jeqi 2ndo Jequ Y Y 06H peqpoeJ or 06H BF peqpa or B 4 Schematics 7005 HiHP Fiber Note External Wiring Shown as Optic Dashed Lines For DC Input Only Interface Do Not Install on AC Input Drives Board J28 Feedback Board 1 Or y4 H903 ASIC 700H Star 3 6 DC EI X900 8 Board g t L From
15. For a Diagram on See Main Power Structure Assembly page D 2 Right Side of Power Structure page D 4 Left Side of Power Structure page D 6 Fan Inverter Assembly page D 7 ASIC Assembly page D 8 ASIC Assembly page D 8 Main Fan Assembly page D 9 Disassembly Assembly Diagrams on the following pages illustrate disassembly and assembly of the Diagrams and Spare Parts drive and its sub systems and are followed by a list of spare part numbers Numbers where applicable When ordering spare parts you must provide the serial number of the drive The serial number is located on the data nameplate on the Control Frame just above the bar code 0 460 60 Hz 420 500 630 550 840 630 Frame 12 Serial Number 2622381652 complete list of spare parts for PowerFlex 700H S drives 15 available on the Allen Bradley web site at http www ab com support abdrives powerflex70 PF7ReleasedParts pdf D 2 Disassembly Assembly Diagrams Figure D 1 Main Power Structure Assembly 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 into contact with the assembly ATTENTION The sheet metal cover and mounting screws on Main Terminal Covers Touch Cover Front Rs c mec Touch Cover Side Plates
16. P X4 E ofM 7 X5 C 4X6 Figure C 2 Gate Driver Board Connectors HHH wl bs Fb xs Ei zx le xo 95 E gg IE X13 X14 X15 s l Xi Connector Descriptions C 3 Table ASIC Board on Power Structure 1 to Gate Driver Board on Power Structure 1 Phase U Connections Gate Driver ASIC Board Board Connector Pin Number to Pin Number Connector Description X3 1 1 X13 U Feedback 2 2 Power OK 3 3 U See Below 4 4 U 5 5 U_ITR 6 6 U_DC 7 7 UI 8 8 U DC I 9 9 U TEMP 10 10 DCT H8 fiber optic H8 H4 H4 fiber optic UH or Gate Top H9 fiber optic H9 H5 H5 fiber optic UL or Gate Bottom Note See page C 4 for footnotes Table ASIC Board on Power Structure 1 to Gate Driver Board on Power Structure 1 Phase V Connections ASIC Board Connector X4 Pin Number 1 to 1 Pin Number Connector X14 Cc CO CO N On e Gate Driver Board Description V Feedback V Power OK v DTR V V_ITR V DC VI V DC I V TEMP V DC T H10 fiber optic n H6 fiber optic VH or Gate Top H11 fiber optic B x 54
17. LED visible through this hole LED Steady Indication The drive is operational and has no faults Flashing Quickly e Switching power supply overload Rectifier Board fault e Fan or fan inverter fault Brake Chopper fault e Fiber Optic Adapter Board Fault Flashing Slowly Bad connection between circuit boards check all connections The PowerFlex 700S contains a Run LED controller LEDs and SynchLink LEDs These LEDs are only operational when the drive is energized and are only visible when the drive door is open The status of these LEDs can also be viewed from the HIM or from an application program e g DriveExplorer in parameter 554 LED Status This feature is only available with DriveLogix version 15 03 or later ATTENTION The RUN LED and the controller LEDs are only operational when the drive is energized Servicing energized equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Follow Safety related practices of NFPA 70E ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES DO NOT work alone on energized equipment DRIVE Component Test Procedures 2 3 oc _ e Me S 90000 55899 O U Table C Drive Status Indicator Descriptions
18. Note See page C 4 for footnotes H7 fiber optic VL or Gate Bottom C4 Connector Descriptions Table ASIC Board on Power Structure 1 to Gate Driver Board on Power Structure 1 Phase W Connections ASIC Board Gate Driver Board Connector Pin Number to Pin Number Connector Description X5 1 1 X15 W Feedback 2 2 W Power OK 3 3 4 4 W_ETR 5 5 W_ITR 6 6 W_DC 7 7 WI 8 8 W DC I 9 9 W TEMP 10 10 W_DC T H12 fiber optic H12 H8 H8 fiber optic WH or Gate Top H13 fiber optic H13 H9 H9 fiber optic WL or Gate Bottom DTR N 2 ETR Phase I2T 3 TR Phase Overcurrent Table C D ASIC Board on Power Structure 2 to Gate Driver Board on Power Structure 2 Phase U Connections Gate Driver ASIC Board Board Connector Pin Number to Pin Number Connector Description X3 1 1 X13 U Feedback 2 2 U Power OK 3 3 U See Note Below 4 4 U 5 5 U_ITR 6 6 U_DC 7 7 UI 8 8 U DC I 9 9 U TEMP 10 10 U_DC T H8 fiber optic H8 H4 H4 fiber optic or Gate Top H9 fiber optic H9 H5 H5 fiber optic UL or Gate Bottom Note See page C 5 for footnotes Connector Descriptions C 5 Table ASIC Board on Power Structure 2 to Gate Driver Board on Power Structure 42 Phase V Connections ASIC Board Connector
19. 4 B xe Es Do Not remove this Do Not remove this stacker connector 15 Y stacker connector V LI 6 X11 EE X125 EXT v Dg rd CN d OR A GOODDOD 7 X13 x14 X15 v ques OO x1 Access Procedures 3 23 9 Carefully remove the board and the remaining connectors 10 Remove the cable ties that secure the Adapter Board to the circuit boards on the Output Power Modules and remove the Adapter Board 11 Repeat steps 3 10 to remove the Gate Driver and Adapter Boards from Power Structure 2 3 24 Access Procedures Installation 1 On Power Structure 1 replace the Adapter Board and install the cable ties which secure it to the circuit boards on the Output Power Modules Plug the old stacker connectors into the new Gate Driver Board so the pins do not protrude through the connectors on the back of the board Align the Gate Driver Board so that its connectors align with the mating connectors on the Adapter Board While supporting the Adapter Board from behind press the Gate Driver Board onto it Verify the proper alignment of the mounting with a mirror Verify that none of the pins in the stacker connectors have missed the mating connectors Install the brackets and install and tighten the mounting screws Connect all of the cables on the new Gate Driver Board Repeat steps 1 7 to install the Gate Driver and Adapter Boards on Power Structure 2 Removing the
20. ATTENTION Only qualified personnel familiar with high power PowerFlex 7005 and 700H Drives and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged before performing any work on the drive Measure the DC bus voltage at the amp DC terminals The voltage must be zero ATTENTION Potentially fatal voltages may result from improper usage of an oscilloscope and other test equipment The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded If an oscilloscope is used to measure high voltage waveforms use only a dual channel oscilloscope in the differential mode with X 100 probes It is recommended that the oscilloscope be used in the A minus B Quasi differential mode with the oscilloscope chassis correctly grounded to an earth ground Chapter 1 Troubleshooting and Error Codes gt gt ATTENTION 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 performing any work on the drive Measure the DC bus voltage at the amp DC terminals The voltage must be zero ATTENT
21. B Wu Allen Bradley 700S High Performance AC Drive and 700H Adjustable Frequency AC Drive Frame 12 450 560kW 400V 700 900HP 480V 630 800kW 690V 700 900HP 600V Hardware Service Manual Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls Publication SGI 1 1 available from your local Rockwell Automation sales office or online at www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of
22. Check Surrounding Air Temperature Check Motor Current Current and Load cid Levels pecification Frequency Too High for Lead Length and Surrounding Temp Check PWM Frequency No Check Fans and Air Flow Through the Drive Proper Space At Inlet Yes Airlflow Blockages No Fans Running Provide Additional Airflow or Air Conditioning Reduce Load or Procure a Drive With a Higher Rating Lower PWM Frequency Remedy Spacing at Inlet Remove Air Flow Blockages Properly No Check Power Power Voltage Voltage on Fan Equals Bus Inverters Voltage Check Connection Between ASIC Board and Fan Connection Inverters Good Yes Check Fan Inverter Outputs on X1 X4 and X5 Output Equals 50 Hz 220V rms Yes Check Fan Motors fan Motor has for Short and Open or Short Open Circuits Circuits No Contact Allen Bradley Yes Check Fan Inverter Fuses F1 and F2 Repair Connection Replace Fan Inverter s Replace Fan Motor s Drives Technical Support Viewing the 700H Diagnostic LED Chapter 2 Component Test Procedures gt gt 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
23. 15V dc power Fan Control Fan Alarm Connector Descriptions C 11 Table C Q Right Side Main Cooling Fan Inverter Connections Comes Plumber Comecior Description Connector Connector Description 15V dc power X3 2 4 X3 15V dc power Fan Alarm 4 2 Fan Alarm Figure C 8 X50 Terminal Block Connectors Customer Connections Terminal Blocks Drive Connections Example External Precharge Circuitry X50 1 ASIC Board 1 24V DC TH 26 oDe Charge 8 Relay CRI Pilot Relay 0 CR1 M Main DC Contactor M X50 42 ASIC Board 2 recharge X9 D 25 24V DC M s 2 ae 25 B X15 For DC Input Only Q Do Not Install on AC Input Drives Table C R X50 Terminal Block Precharge Circuit Connections ASIC Board Connector Terminal ito 50 Terminal Block Description X9 on ASIC 25 ae 1 Precharge Complete Signal Board 1 26 2 Precharge Complete Signal X15 on ASIC 21 3 Charge Relay Contact Board 1 23 4 Charge Relay Contact X9 on ASIC 25 1 Precharge Complete Signal Board 2 26 2 Precharge Complete Signal X15 on ASIC 21 3 Charge Relay Contact Board 2 23 4 Charge Relay Contact C 12 Connector Descriptions Notes Disassembly Assembly Diagrams
24. Additional troubleshooting information and software tools are available on the Allen Bradley Drives Support Website http www ab com support abdrives 4 Overview General Precautions Class 1 LED Product gt gt gt gt gt gt ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into module ports or fiber optic cable connectors 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 into contact with the assembly 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 An incorrectly applied or installed drive can result in component damage or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system
25. Check the motor and external than 2596 of drive rating Ground fault wiring to the drive output level is 50 of the drive s heavy duty terminals for a grounded current rating The current must condition appear for 800ms before the drive will fault InverterFault 14 Hardware problem in the power Cycle power structure Replace drive System Fault 10 Hardware problem exists in the power Cycle power structure Replace drive Load Loss 15 not use this fault in 700H Check that parameter 238 applications Fault Config 1 bit 0 Power Loss and parameter 259 Alarm Config 1 bit 13 Load Loss are set to zero Precharge Error 31 The precharge function has failed to Verify the value in parameter complete within 30 seconds default 410 PreChrg TimeOut of the precharge request The Verify the bit value in parameter precharge time out is configurable by 411 PreChrg Control bit 01 Par 410 PreChrg TimeOut PreChrg Enable precharge request is initiated when the DC Bus voltage is above the Undervoltage Trip level and the precharge input is high the requirement for the precharge being high can be bypassed by setting Par 411 PreChrg Control bit 01 PreChrg Enable to be off Power Unit 70 Oneor more of the output transistors Clear fault were operating in the active region instead of desaturation This can be caused by excessive transistor current or insufficient base drive voltage Diagno
26. Install the 7005 High Power Fiber Optic Interface Circuit Board in reverse order of removal while referring to Torque Specifications on page 3 1 3 10 Access Procedures Removing the 7005 Control Removal Assembly Mounting Plate 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 3 2 Remove the 7005 Phase II Control Assembly Refer to Removing the 7005 Phase II Control Assembly on page 3 6 3 Remove the 700S High Power Fiber Optic Interface Circuit Board Refer to Removing the 700S High Power Fiber Optic Interface Circuit Board on page 3 8 4 Liftthe Control Assembly mounting plate up and off the hinge Installation Install the 700S Control Assembly mounting plate in reverse order of removal Access Procedures 3 11 Removing the 700H I O Removal Boards and Control Assembly 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 3 2 Open the enclosure that contains the Control and I O Boards and carefully unplug the DPI cable and any I O cables 3 Remove the I O Boards from the Control Board and enclosure Note the order of the boards and the keys which prevent placement of boards in incorrect slots Do not remove enclosure cover Enclosure is illustrated without the cover for clarity X7 Q Serial Port X2 X3 X4 X5 X6 Slot A SlotB 51060 S
27. Should measure 15V dc with respect to DC with no light in VH cab Should measure 15V dc with respect to DC with light in VH Should measure 15V dc with respect to DC with no light in VH cab Should measure 15V dc with respect to DC with light in VH Should measure 15V dc with respect to DC with no light in UH cable Should measure 15 dc with respect to DC with light in UH cable Should measure 15V dc with respect to DC with no light in UH cable Should measure 15 dc with respect to DC with light in UH cable Should measure 15V dc with respect to DC with no light in WL Should measure 15V dc with respect to DC with light in WL cabl Should measure 15V dc with respect to DC with no light in WL Should measure 15V dc with respect to DC with light in WL cabl Should measure 15V dc with respect to DC with no light in UL cab Should measure 15 dc with respect to DC with light in UL Should measure 15V dc with respect to DC with no light in UL cab Should measure 15 dc with respect to DC with light in UL X5 0 H6 9 7 5 0181
28. gt gt Jumper From DC Bus in Power Structure DCH DC 6A From ASIC Board 1 X11 F1 P 2 6 BLUE 2 3 X BLK 22 220 2 1 E 5 10Meg 4 YIGRN Main Fan C 1 5 gt gt Left Side 12 3 4 IK Sivac 10Me dH AC ofr orr On 3 i 3 BLAC 4 BLK In Power Structure Z2 Right Side 2 6 BLUE BLK T gt gt 22uf 5 300vAc L 10Meg 4 Y GRN gt gt H 2 2uf OVAC 10Meg BLACK 3 BLK gt gt n Tuf 1 lt H gt M4 Main Fan Right Side 230V AC 50 Hz Figure B 8 Fan Inverter Connections Schematics B 10 Ssuonoeuuo JOJOW 6 g ni suorneuuoyJaulosny 3noKe 6 WS lt B 11 Schematics suonoeuuo 1030 018 anfia peijddns awon 3no e je u3euu AS lt ZL A TL N Lil 4 H Ti 4 4 2 A IN 2 UNDNNS FS HER 9d Ti 2 40d IN ro TH 17 B 12 Schematics Notes Circuit Board Connections Connector Descriptions Appendix C For a Schematic Diagram on See ASIC Board on Power Structure 1 to Gate Driver Board on Power page Structure 1 Phase
29. Bus Bars 6 Remove the four 4 screws that secure the capacitor to the power structure and remove the capacitor a 7 Repeat steps 4 6 to remove the DC Bus Capacitors from Power Structure 2 3 42 Access Procedures Installation Install the capacitors in reverse order of removal while referring to Torque Specifications on page 3 1 Chapter 4 Start Up After Repair the following start up procedure Some of the voltages present are at incoming line potential To avoid electric shock hazard or damage to equipment only qualified service personnel should perform the following procedure Thoroughly read and understand the procedure before beginning If an event does not occur while performing this procedure Do Not Proceed Remove Power including user supplied control voltages User supplied voltages may exist even when main AC power is not applied to then drive Correct the malfunction before continuing ATTENTION Power must be applied to the drive to perform Phone United States 1 262 512 8176 7 AM 6 PM CST Canada 1 440 646 5800 24 hour support Outside United You can access the phone number for your country via States Canada the Internet Go to http www ab com Click on Support http support rockwellautomation com Under Contact Customer Support click on Phone Support Internet Go to http Avww ab com support abdrives E mail
30. DC H901 1 in Power Circuitr BoardH8 H902 X9 pe ower Circuitry p e OEVA To 700H Star X15 X2 To Rect fying Board X13 Coupler Board Charge X3 To Gate Driver Board X13 Fiber Optic External Pre Charge e 4 Relay X4 Gate Driver Board X14 Example Circuitry 25 4 Ports See Note CR CRI X50 x1 X5 LI To Gate Driver Board X15 5 21 23 LP esse M 1I 24VDC H8 To Gate Driver Board H4 00 To 700H Star H cre T H9 To Gate Driver Board H5 i5 mud Coupler Board X2 M 5 H10 To Gate Driver Board H6 5 iHP Fiber Optic 4 H11 To Gate Driver Board H7 5 EN E OWS H12 LI To Gate Driver Board H8 ASIC Board 1 cO E H13 To Gate Driver Board H9 H3 X600 3 Or L H4 Fan To Left Fan X8 Control 700H Star 5 H5 Coupler Board Hefe i Ports 1 7 for ASIC Board 1 Fiber Optic Feedback Board 2 7005 HiHP Fiber Optic DC des ita xe From DC Bus 404 1 06 Power Circuitry Or M xs X2 L Rectifying Board X13 700H Star FT Charge X3 LJ To Gate Driver Board X13 Coupler Board J Relay X4 1 To Gate Driver Board X14 H18 X50 x1 X5 L To Gate Driver Board X15 1 1 24VDC H8 To Gate Driver Board H4 1 DC H9 To Gate Driver Board H5 5 LJ X10 24V Power H10 To Gate Driver Bo
31. H901 X900 H902 H903 Table ASIC Feedback Board on Power Structure 1 to ASIC Board on Power Structure 1 Connections ASIC Feedback Board Connector X900 ASIC Board Connector X26 Pin to or Description Reference to ASIC Board PHU PHV PHW Trip Out 5V 5V Table C L ASIC Feedback Board on Power Structure 2 to ASIC Board on Power Structure 2 Connections ASIC Feedback Board Connector X900 ASIC Board Connector X26 Pin o oA V N A V Description Reference to ASIC Board PHU PHV PHW Trip_Out 5V 5V C 10 Connector Descriptions Hardware Connections Table C M ASIC Feedback Board to PowerFlex 700S High Power Star Interface Board Connections ASIC Feedback Board Connector H903 on Power Structure 1 High Power Star Interface Board Connector J28 Description Reference to Star Interface Board Trip P1 H903 on Power Structure 2 J27 Trip P2 Table C N ASIC Feedback Board to PowerFlex 700H Star Coupler Board Connections ASIC Feedback Board Description Reference to Connector to Star Coupler Board Connector Star Coupler Board H900 on Power Structure 1 H21 PHU H901 on Power Structure 1 H22 PHV H902 on Power Structure 1 H2
32. alone on energized equipment ATTENTION The inverter LEDs are only operational when LED Red Green Indication Steady Steady Inverter Idle Off Flashing Inverter Running Flashing Steady Inverter Faulted or No Control from ASIC Board Checking Fan Inverter Fuses A pair of fuses F1 and F2 feed DC Bus power to both inverters on each Power Structure Locate these fuses and using a multi meter verify that they are not open Isolating a Faulty Fan Inverter The ASIC Board one on each of the Power Structures controls a pair of fan inverters A cable connects X11 on the ASIC Board to X8 on the left hand fan inverter Another cable connects X3 of the left hand fan inverter to X8 on the right hand fan inverter A jumper terminates X3 on the right hand fan inverter Refer to Figure B 8 on page B 9 Use the following procedure to isolate a faulty fan inverter if the fans are not running 1 On Power Structure 1 disconnect the cable from of the left hand inverter 2 Remove the jumper from X3 of the right hand inverter and connect it to X3 of the left hand inverter 3 Energize the drive If the left hand fan runs then the right hand fan inverter is faulty 4 Repeat steps 1 3 for Power Structure 2 Component Test Procedures 2 19 Checking the Main Fan Motors 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 3 2 Remove the covers from the power structures
33. for Power Structure 2 Meter Leads Nominal meter reading DCH R 214 DC4R 212 DC R 2L3 Meter should beep once and value 2L1 DC should gradually rise to about 0 5V 2L2 DC 213 DC T drive does not contain the brake chopper option the DC R terminal will be labeled Table 2 C Reverse Biased Diode Tests on Rectifying Module for Power Structure 1 Meter Leads Nominal meter reading 1L1 DC 1L2 DC rS m m Meter should display OL zero load DC R 1L2 DC R 1L3 T ifthe drive does not contain the brake chopper option the DC R terminal will be labeled DC Table 2 D Reverse Biased Diode Tests on Rectifying Module for Power Structure 2 Meter Leads Nominal meter reading 2L1 DC 212 DC R0 ae Meter should display 00 zero load DC4R 212 DC4R 2L3 UI If the drive does not contain the brake chopper option the DC R terminal will be labeled If the drive fails any of these measurements replace the appropriate Rectifying Module 4 Conduct forward and reverse biased diode tests on the Output Power Modules Table2 E Forward Biased Diode Tests on Output Power Modules for Power Structure 1 Meter Leads Nominal meter reading DC 1U T1 DC 1V T2 DC 1W T3 DCR Meter should display 00 zero load 1V T2 DC R 1W T3 DC R ifthe dri
34. information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss gt Important Identifies information that is critical for successful application and understanding of the product ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you e identify a hazard e avoid the hazard e recognize the consequences Shock Hazard labels may be located on or inside the equipment e g drive or motor to alert people that dangerous voltage may be present Burn Hazard labels may be located on or inside the equipment e g drive or motor to alert people that surfaces may be at dangerous temperatures gt e D PowerFlex is a registered trademark of Rockwell Automation Inc DriveExplorer DriveExecutive and SCANport are trademarks of Rockwell Automation Inc PLC is a registered trademark of Rockwell Automation Inc Preface Chapter 1 Chapter 2 Chapter 3 Chapter 4 Table of Contents
35. 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 fiber optic ports or 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 The following table lists fastener torque specifications Item Screw Final Torque DPI HIM Assembly Door M3 x 6 Phillips 0 9 N m 8 Ib in DPI HIM Assembly mounting M3 x 6 Phillips 0 9 N m 8 Ib in 7005 High Power Fiber M3 x 6 Phillips 0 9 N m Optic Interface Circuit Board 8 Ib in mounting 700H I O and Control Assembly M4 x 8 self tapping 0 8 N m 7 lb in 3 2 Access Procedures Item Screw Final Torque 700H Star Coupler Board x 8 POZIDRIV 0 9 N m mounting 8 Ib in 700S Voltage Feedback Circuit M3 x 6 Phillips 0 9 N m Board mounting 8 Ib in AC Input Terminals on Power M10 nut 40
36. these tests replace the fiber optic cable or the Gate Driver Board Repeat steps 3 and 4 with connector X4 and the VH cable X4 provides the gate interface for the VH output power transistor in the left hand Output Power Module If the drive fails any of these tests replace the Gate Driver Board Repeat steps 3 and 4 with connector X5 and the UH cable X5 provides the gate interface for the UH output power transistor in the left hand Output Power Module If the drive fails any of these tests replace the Gate Driver Board Repeat steps 3 and 4 with connector X6 and the cables for WL VL and UL If the drive fails any of these tests replace the Gate Driver Board Should measure 15V dc with respect to DC with no light in WL Should measure 15V dc with respect to DC with light in WL cabl Should measure 15V dc with respect to DC with no light in WL Should measure 15V dc with respect to DC with light in WL cabl Should measure 15V dc with respect to DC with no light in UL cab Should measure 15V dc with respect to DC with light in UL Should measure 15V dc with respect to DC with no light in UL cab Should measure 15 dc with respect to DC with light in UL X6 Should measure 15V dc with respect to DC with no light in VL cable Should measure 15 dc with respect to DC with light in VL cable Sh
37. transformer when removing or installing the inverter Access Procedures 3 39 6 Remove the Inverter from the old Inverter Assembly Description Disconnect the cables at connectors X4 Blue and X5 Black Right hand Inverter Shown Remove two M5 Pozi drive screws which secure the inverter board B and its heatsink to the assembly carriage Proper tightening torque for reassembly is 4 N m 35 Ib in Carefully remove the inverter board and its heatsink from the assembly carriage 7 Repeat steps 4 6 to remove the Fan Inverters from Power Structure 2 Installation Install the fan inverters in reverse order of removal while referring to Torque Specifications on page 3 1 3 40 Access Procedures Removing the DC Bus Removal itor Capacitors 1 Remove power from the drive Removing Power from the Drive on page 3 3 2 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 3 Remove the power structures from the drive cabinet Removing the Power Structures from the Drive Enclosure on page 3 25 4 For Power Structure 1 remove the balancing resistor wires from bus bars Balancing Resistors AC Input Terminals L1 L2 L3 Balancing Resistor Wires Access Procedures 3 41 5 Remove the screws that secure DC Bus Bars to right side of power structure and remove the DC
38. 15 dc with respect to DC with light in UH cable se Should measure 15V dc with respect to DC with no light in UH cable Should measure 15V dc with respect to DC with light in UH cable Should measure 15V dc with respect to DC with no light in WL cable Should measure 15 dc with respect to DC with light in WL cable X11 o re Should measure 15V dc with respect to DC with no light in VL cable Should measure 15V dc with respect to DC with no light in WL cable Should measure 15V dc with respect DC with light in VL cable Should measure 15 dc with respect to DC with light in WL cable v Should measure 15V dc with respect to DC with no light in UL cable EE Should measure 15V dc with respect to DC with no light in VL cable Should measure 15 dc with respect to DC with light in UL cable e Should measure 15 dc with respect to DC with light in VL cable Should measure 15V dc with respect to DC with no light in UL cable Should measure 15V dc with respect to DC with light in UL cable Checking Rectifying Module Important This procedure requires special equipment and training Only on AC Input Drives Only qualified and trained personnel should perform these procedures 1 Remove power from the drive Refer to Removing Power fro
39. 3 PHW H903 on Power Structure 1 H8 Trip P1 H903 on Power Structure 2 H18 Trip P2 Figure C 7 Fan Inverter Circuit Board Connectors X3 X8 Note There is a left and right main cooling fan inverter on both Power Structures The connections for each pair of fan inverters are the same Table C O ASIC Board to Left Side Main Cooling Fan Inverter Connections Description 15V dc power to Fan Inverter board Fan Control Alarm from Fans 1 ASIC Board X11 Connector Refer to Figure C 1 on page C 2 for ASIC board fiber optic connectors Fan Inverter Pin Number Pin Number Connector 2 2 X8 3 3 4 7 Description 15V dc power from ASIC board Fan Alarm to ASIC board Table C P Left Side Main Cooling Fan Inverter to Right Side Main Cooling Fan Inverter Connections Description 15V dc power Fan Control Fan Alarm Left Side Fan Inverter Connector X11 Right Side Fan Inverter Pin Number Pin Number Connector 2 2 X8 3 3 4 7 Description
40. 7 ul HA UBIH A 20 eoepeiu ejeo HA A 99 19yur3 009 5 009 Suo 009 1ndino 1618 ul HM YBIH M 20 8125 jeu 00S 009 Suluo 009 1ndinQ 497 HM M 20 e eyeju FEMTE 5 009 SWYO 009 2 10 Component Test Procedures Preparing the Drive for Active Measurements on the Gate Driver Boards Important This procedure requires special equipment and training Only qualified and trained personnel should perform these procedures f you do not have the special equipment replace each Gate Driver Board to determine if the boards are malfunctioning 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 3 2 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 3 On Power Structure 1 disconnect the fiber optic cables which connect the ASIC Board to the Gate Driver Board at the Gate Driver Board ends 4 You may want to remove the fuses for the Main Fan Inverters in order to prevent them from running during these tests Inverters could cause the drive to overheat or fault Possible equipment damage could occur You must replace the fuses befor
41. 700S and 700H High Power Drives for tightening torques of motor terminations Removal 1 Remove power from the drive Removing Power from the Drive on page 3 3 2 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 3 On Power Structure 1 disconnect the fan cable connectors under the power structure 4 Remove the two screws that secure each fan assembly to the drive Then remove the fans 5 Repeat steps 3 and 4 to remove the main fans from Power Structure 2 Removing the ASIC Boards Fiber Optic cable connections lt Access Procedures 3 27 Installation Install the fans in reverse order of removal while referring to Torque Specifications on page 3 1 Removal the ASIC Boards located on the power structures are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION The sheet metal cover and mounting screws on 1 Remove power from the drive Removing Power from the Drive on page 3 3 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 p On Power Structure 1 remove the cover from the ASIC assembly and the DC bus connection from the cover Unplug the fan that mounts on the cover from connector X1 of the ASIC board m Disconnect the Feedb
42. Board watch dog timer to expire and Voltage Feedback Circuit Board 2 Check connections between the Main Control Board and the Power Interface Circuit Board 3 Replace the Voltage Feedback Circuit Board 4 Replace the Power Interface Circuit Board 5 Replace the Main Control Board HiHp FdbkLs 70 Feedback Loss a fan feedback 1 Check the main cooling fan signal has been lost 2 Check the Main Control Board cooling fan Troubleshooting and Error Codes 1 3 Fault No Description Action if appropriate HiHp Drv OvrLoad 71 Drive Overload the circuit board on Measure output current of the the Power Module has detected an drive If the level is ever greater overload than the maximum drive rated output current level reduce the load If the levels are always well below the drive rated levels then replace the power module HiHp PwrBd PrcEr 72 Power Board Processor Error a 1 Check fiber optic microprocessor on the Power Board connections between the has detected a communication error Power Interface Circuit Board and Voltage Feedback Circuit Board 2 Check connections between the Main Control Board and the Power Interface Circuit Board 3 Replace the Voltage Feedback Circuit Board 4 Replace the Power Interface Circuit Board 5 Replace the Main Control Board HiHp PrChrg 73 Precharge Contactor Fault proper Check precharg
43. C 10 Left Side Main Cooling Fan Inverter to Right Side Main Cooling Fan page C 10 Inverter Connections Right Side Main Cooling Fan Inverter Connections page C 11 X50 Terminal Block Precharge Circuit Connections page C 11 The following tables detail the connection points for the frame 12 PowerFlex 7005 and 700H AC input drives circuit boards and components C 2 Connector Descriptions Figure C 1 ASIC Board Connectors E r H8 H9 A 1 ii EL 12 Ht H2 TP
44. ION 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 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 1 2 Troubleshooting and Error Codes Creating Fault Reports Addressing 700S Hardware Faults Clear and complete fault reports are critical for analysis and repair of modules returned to the factory At a minimum perform and record the following e Record the contents of the fault queue faults and times of occurrence Make record of any burn marks on the rectifying module DC capacitors inverter bridge charging resistors balancing precharging resistors printed circuit boards bus bars cabling and fiber optic cabling e Make record of any liquid and condensation marks on printed circuit boards components and mechanical parts e Make record of the amount of dust and other additional particles on drive and drive components e Make record of any mechanical damage to the drive and drive components Record the size a
45. Important User Information leeeeeeeeee 1 2 Who Should Use this 7 P 1 Whatisinthis Manual i lee er lleve iene Ce eats ba ee P 1 What is Not in this 1 sese P 1 Reference Materials oc fated cata ede aaa ae be ted eae TES Uds 2 Understanding Manual Conventions leen 2 Additional Support Available on 3 General PrecautiohsS soles _____________ P 4 Creatine Fault Reports con vet acorn detenti nb aes be teat 1 2 Addressing 7008 Hardware Faults 2 eee 1 2 Addressing 700H Hardware 2 0 1 4 Diagnostic Procedures by 2 ees 1 5 Viewing the 700H Diagnostic LED sslseeeeeee 2 1 Viewing the 7008 Diagnostic 2 III 2 2 Performing Visual Inspections 2 0 2 4 Conducting Forward and Reverse Biased Diode Tests for Major Power Components 2 4 Checking Fiber Optic Connections to the Gate Driver 2 8 Conducting Gate Driver Board 2 8 Checking Rectifying Module on AC Input Drives 2 14 Checking the DC Bus Capacitors 2 0 2 17 Checking the Main Fan Inverters and 2 18 Torque Specifications sesei eano ky ead Shae ee ee 3 1 Removi
46. Input Terminal Cable Insulator Input Terminal Assembly Bia Bus Bar MM d Connector Assembly Insulator for Bus Bar Gate Driver Board LeitSide Board Bracke Right Side Board Bracket ASIC Assembly e Board 52 Plastic Cover z E Base Right Fan Inverter Capacitor Plastic Cover Base Top Left Fan Inverter Assembly Left Fan Inverter Assembly Disassembly Assembly Diagrams D 3 Table D A Main Power Structure Assembly Part Numbers Part Name Part No Adapter Board 20 VB00330 Air Flow Guide Right NA ASIC Assembly Upgrade Kit without ASIC Board 20 FR10850 Bus Bar NA Fan Inverter Assembly Left 20 FR10844 Fan Inverter Assembly Right 20 FR10845 Fan Inverter Capacitor 7uf 450V ac 20 PP00060 Gate Driver Board 400 480V SK H1 GDB1 F10D 600 690V SK H1 GDB1 F10E Input Terminal Assembly NA Input Terminal Cable Insulator NA Insulator For Bus Bar NA Left Side Board Bracket NA Main Terminal Cover NA Plastic Cover Base Top Left NA Plastic Cover Base Top Right NA Right Side Board Bracket NA Touch Cover Front NA Touch Cover Side Plate NA D 4 Disassembly Assembly Diagrams Figure D 2 Right Side of Power Structure Air Flow Guide Right 8s Snubber Capacitor Assembly de Rectifying Board DC Bus Bar _ 5 DC Bus Bar Insulator
47. N m Structure 354 Ib in Motor Output Terminals on Power M8 x 20 hexagonal screw 20 N m Structure 177 lb in Main Fan Mounting M6 x 20 POZIDRIV 3 N m 27 Ib in Main Fan x 8 POZIDRIV 1 7 15 Ib in Touch Cover Main Fan M5 x 16 3 N m 27 Ib in ASIC Fan M4 x 16 POZIDRIV 0 4 N m 3 5 Ib in Rectifier board Mounting M4 x 8 POZIDRIV 1 N m 9 Ib in Output Power Module Output 8 x 20 hexagonal screw 14 N m Terminals U V W 124 Ib in Rectifying Module Input M10 x 20 hexagonal screw 12 N m Terminals L1 L2 L3 106 Ib in Y Bus Bar M10 nut 40 N m 354 Ib in Capacitor M4 x 8 self tapping 1 N m 9 Ib in Capacitor Bus Bar M6 x 16 POZIDRIV 4 N m 85 Ib in Capacitor Bus Bar M6 x 20 POZIDRIV 4 N m 85 Ib in DC DC Terminals M6 x 20 POZIDRIV 5 N m 44 Ib in Block Mounting M10 x 12 hexagonal screw 20 N m 177 Ib in 7005 Voltage Feedback Circuit Board mounting OO amp 9 9000 29 amp d d 9 O X 68 M3 x 0 5 thread 37 mm x 37 mm hex standoff POZIDRIV is a registered trademark of the Phillips Screw Company Phillips is a registered trademark of Phillips Screw Company 0 9 N m 8 Ib in Removing Power from the Drive Access Procedures 3 3 Understanding the Torque Figures in Assembly Diagrams Icons and numbers in the assembly diagrams indicate how to tighten hardware Tool Type and Size F
48. Power Structures from the Drive Enclosure Access Procedures 3 25 Removal 1 Remove power from the drive Removing Power from the Drive on page 3 3 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 On Power Structure 1 remove the motor wiring from the power structure at the front of the power structure Remove the ground connection from the lower right rear corner of the power structure Remove the input AC or DC and brake wiring if equipped from the incoming terminals at the top of the power structure AC Power Connection Terminals Ground Motor Connection Connection Terminals Follow the instructions in publication PFLEX INO14 Installation Instructions PowerFlex 7008 700H High Power Maintenance Stand to install the Maintenance Stand 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 Repeat steps 3 6 to remove Power Structure 2 from its enclosure 3 26 Access Procedures Removing the Main Fans Installation Install the power structures in reverse order of removal while referring to Torque Specifications on page 3 1 Refer to the publication PFLEX INOO6 Installation Instructions PowerFlex
49. Refer to Removing the Covers from the Power Structures on page 3 15 3 On Power Structure 1 disconnect the left hand fan motor from its inverter 4 Measure the resistance of the fan windings If the resulting measurements are not similar to those in Table 2 K below replace the fan See Removing the Main Fans on page 3 26 Table 2 K Correct Fan Measurements Connection Wires Resistance 5 Black Brown 60 Brown Blue 26 Blue Black 34 Resistance to ground OL Zero Load 5 Reconnect the left hand fan motor to its inverter 6 Repeat steps 3 and 4 for the right hand fan motor 7 Repeat steps 3 6 for Power Structure 2 2 20 Component Test Procedures Notes Torque Specifications Chapter 3 Access Procedures ATTENTION To avoid an electric shock hazard ensure that all gt 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 performing any work on the drive Measure the DC bus voltage at the DC amp DC terminals The voltage must be zero 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 into contact with the assembly ATTENTION HOT surfaces can cause severe burns Do
50. Remove power from the drive Removing Power from the Drive on page 3 3 Important Before removing connections and wires mark the connections and wires to avoid incorrect wiring during assembly 2 Remove the two screws from front of DPI HIM assembly Screws P d N m U 8 Ib in 3 Open the door which holds the DPI interface and HIM 4 Unplug the DPI cable from X2 connector on the DPI Interface Circuit Board x2 x4 Ag gt Back view of DPI Circuit Board which should remain mounted on the back of the assembly 5 On 7008 drives only unplug the cable from X4 connector on the circuit board 6 Remove the four mounting screws and the assembly from the Control 3 6 Access Procedures Frame Mounting Screws P1 amp 0 9 N m 8 Ib in o Q ne n Installation Install the DPI HIM Assembly in reverse order of removal while referring to Torque Specifications on page 3 1 Removing the 700S Phasel Removal Control Assembly 1 Remove power from the drive Removing Power from the Drive on page 3 3 Important Before removing connections and wires mark the connections and wires to avoid incorrect wiring during assembly 2 Unplug any fiber optic ControlNet and SynchLink cables from the Control Assembly using optical transmissi
51. Side of Power Structure Part Numbers Part Name Part No ASIC Assembly without ASIC Board NA Cover Plate NA DC Bus Bar 20 FR10048 20 FR10052 20 FR10191 DC Bus Bar Insulator 20 FR10026 20 FR10028 20 FR10143 Discharging Resistor 2x16k 20 PP00056 Electrolytic Capacitor ELKO 3300 1 420V for 400 480V Drives 20 PP01005 ELKO 5600 420V for 600 690V Drives 20 PP01099 Frame NA Insulation Support NA Output Power Module 400 480V NA 600 690V NA Snubber Capacitor Assembly 20 PP10019 Figure D 4 Fan Inverter Assembly Fan Inverter Capacitor Inverter Board Fan Inverter Assembly Left and Right Table D D Fan Inverter Assembly Part Numbers Part Name Part No Fan Inverter Assembly Left 20 FR10844 Fan Inverter Assembly Right 20 FR10845 Fan Inverter Board 20VB00299 Fan Inverter Capacitor 7uf 450V ac 20 PP00060 D 8 Disassembly Assembly Diagrams Figure D 5 ASIC Assembly the ASIC Board located on the power structure are energized at ATTENTION The sheet metal cover and mounting screws on DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ASIC Assembly Cover ASIC Board ASIC Assembly Bracket ASIC Assembly Bracket ASIC Assembly Bracket ASIC Assembly Bracket Table D E ASIC Assembly Part Numbers Part Name ASIC Assembly Bracket ASIC Assembly Bracket ASIC Assemb
52. U Connections ASIC Board on Power Structure 1 to Gate Driver Board on Power Structure 1 Phase V Connections ASIC Board on Power Structure 1 to Gate Driver Board on Power 4 Structure 1 Phase W Connections ASIC Board on Power Structure 2 to Gate Driver Board on Power 4 Structure 2 Phase U Connections ASIC Board on Power Structure 2 to Gate Driver Board on Power 5 Structure 2 Phase V Connections ASIC Board on Power Structure 2 to Gate Driver Board on Power 5 Structure 2 Phase W Connections ASIC Board on Power Structure 1 to Rectifier Precharge Circuit page C 6 Board on Power Structure 1 Connections ASIC Board on Power Structure 2 to Rectifier Precharge Circuit page C 6 Board on Power Structure 2 Connections PowerFlex 700H and 7005 Interface Board to ASIC Board on Power page C 8 Structure 1 Fiber Optic Connections PowerFlex 700H and 7005 Interface Board to ASIC Board on Power page C 9 Structure 2 Fiber Optic Connections ASIC Feedback Board on Power Structure 1 to ASIC Board on page C 9 Power Structure 1 Connections ASIC Feedback Board on Power Structure 2 to ASIC Board on page C 9 Power Structure 2 Connections ASIC Feedback Board to PowerFlex 7005 High Power Star Interface page C 10 Board Connections ASIC Feedback Board to PowerFlex 700H Star Coupler Board page C 10 Connections ASIC Board to Left Side Main Cooling Fan Inverter Connections page
53. Vdc 675Vdc 0 06 for each unit 14 Troubleshooting and Error Codes Addressing 700H Hardware Faults ame No Description Action if appropriate Auxiliary In 2 Auxiliary input interlock is open Check remote wiring Power Loss 3 DC bus voltage remained below Monitor the incoming AC line for parameter 186 Power Loss Volts for low voltage or line power longer than parameter 185 Power interruption Loss Time Enable Disable with parameter 238 Fault Config 1 For more information refer to publication 20C PMO001 Programming Manual PowerFlex 700H UnderVoltage 4 DC bus voltage fell below the Monitor the incoming AC line for minimum value of 333V for 400 480V low voltage or power drives and 461V for 600 690V drives interruption Enable Disable with parameter 238 Fault Config 1 For more information refer to publication 20C PM001 Programming Manual PowerFlex 700H OverVoltage 5 DC bus voltage exceeded maximum Monitor the AC line for high line value voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install and external dynamic brake option Input Phase 17 Oneinputline phase missing Check user supplied fuses Check AC input line voltage OutPhasMissng 21 Zero current in one output motor Check motor wiring phase Check motor for open phase Ground Fault 13 A current path to earth ground greater
54. X4 1 Pin Number to Pin Number 1 Gate Driver Board Connector X14 CO CO CO NI PO e Description V Feedback V Power OK V ETR ITR V DC VI V DC I V TEMP V DCT H10 fiber optic T H6 fiber optic VH or Gate Top H11 fiber optic L 54 H7 fiber optic Note Refer to footnotes below Table C F VL or Gate Bottom Table C F ASIC Board on Power Structure 42 to Gate Driver Board on Power Structure 42 Phase W Connections ASIC Board Gate Driver Board Connector Pin Number to Pin Number Connector Description X5 1 1 X15 W Feedback 2 2 W Power OK 3 3 W_DTR 4 4 W_ETR 5 5 W_ITR 6 6 W_DC 7 7 WI 8 8 W DC I 9 9 W TEMP 10 10 W_DC T H12 fiber optic H12 H8 H8 fiber optic WH or Gate Top H13 fiber optic H13 H9 H9 fiber optic WL or Gate Bottom N 0 Phase I2T 8 TR Phase Overcurrent C 6 Connector Descriptions Figure C 3 Rectifier Precharge Circuit Board Connectors Qo Xi X GO 1 on 60 xe X13 X6 x10 xt por cim o X12
55. ack board that mounts on the ASIC assembly cover from connector X26 on the ASIC board M Feedback Board connection 1 Fan connection EE F H10 X15 Fit X26 12 Hi P Tis H2 H3 1 2 Fiber Optic s cable H5 connections x8 28 3 28 Access Procedures 6 Carefully disconnect the fiber optic cables from sockets of the ASIC Board and carefully set them aside using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when 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 7 Disconnect the other cables from sockets on the front of the ASIC Board and set them aside 8 Remove the fan from the ASIC Board 9 Slide the ASIC Board assembly out of its chassis 10 Remove the plastic board holder 11 Repeat steps 3 10 to remove the ASIC Board from Power Structure 2 Installation Install the ASIC Boards in reverse order of removal while referring to Torque Specifications on page 3 1 Reconnect cables to ASIC Bo
56. als You can remove the other covers without removing the top and bottom ones 5 Remove the four M5 Pozi drive screws which secure the main front protective cover to the drive then remove the protective cover 6 Remove the side protective covers 3 18 Access Procedures 7 Repeat step 4 6 to remove the protective covers from Power Structure 2 AN Installation Install the Protective Covers in reverse order of removal while referring to Torque Specifications on page 3 1 Access Procedures 3 19 Removing the 7005 Voltage Removal Feedback Circuit Board 1 Remove power from the drive Removing Power from the Drive on page 3 3 2 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 3 Carefully disconnect the fiber optic cables from J4 and J5 sockets along the top of the Voltage Feedback Circuit Board and carefully set them aside using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when 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 insi
57. ard H6 5 To 7005 H11LL To Gate Driver Board H7 HiHP Fiber Optic H12 To Gate Driver Board H8 Interface Board O H1 H13 To Gate Driver Board H9 ate ry for ASIC 2 E 0 oan a Fan X11 LI To Left Fan X8 Or 5 5 Control 700H Star E C 7 Coupler Board Fiber Optic Ports 1 7 for ASIC Board 42 Figure B 3 ASIC Circuit Board Connections B 5 Schematics L Indu Dy seAuq 10 2 p g N i4 UL Og JAMO CERRO Od e m Czy Sz 6 222 gt gt DE nk E Ies ARGS ARB 2 Ae eo z A x saiqeo 2080 9 _ vx TX 6H vH ETH 8H 5 st st peog 6 91385 LTX zx Iqeo pr i p i ex SIX xx iv 1 TIX T E HoH l z pjeog 20 t ver L
58. ards while referring to refer to Figure B 3 on page B 4 Access Procedures 3 29 Removing the Rectifying Removal Boards 1 Remove power from the drive Removing Power from the Drive on page 3 3 2 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 3 On Power Structure 1 disconnect all the wiring from the Rectifying Board and carefully set it aside 4 Remove the screws that secure the circuit board to the Rectifying Module and remove the board 5 Repeat steps 3 and 4 for the Rectifying Board from Power Structure 2 xe Xi X2 X3 on 38 uds i X13 X6 x10 xt x o o o X12 Installation Install the Rectifying Boards in reverse order of removal while referring to Torque Specifications on page 3 1 3 30 Access Procedures Removing the Left Side Output Power Modules Removal Important Do not attempt to disassemble the Output Power Modules Important Always replace the Output Power Modules in pairs do not replace just one module 1 Remove power from the drive Removin
59. astener T 0 PZ indicates POZIDRIV screwdriver bit POZIDRIV Screw P indicates Phillips screwdriver bit Phillips Screw Hexagonal Bolt or Standoff P72 Hexagonal gt 000 Nm Screw 35 Ib in lt at Tightening Torque Hexagonal Nut OOOO Torx Head Screw ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged before performing any work on the drive Measure the DC bus voltage at the DC amp DC terminals The voltage must be zero 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 e sending an erroneous signal to your system s field devices causing unintended machine motion e 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 3 4 Access Procedures Removing Power 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 the DC bus voltage at the DC amp DC terminals on the Power Terminal Block The voltage must be zero L1 L2 L3 Access Procedures 3 5 Removing the DPI HIM Removal Assembly 1
60. ble input is high Green Off The drive s enable input is low SynchLink LEDS are located on the SynchLink daughtercard on the main circuit board in the control cassette 2 4 Component Test Procedures Performing Visual Inspections Visually inspect the cooling tunnels and power structures before energizing Conducting Forward and Reverse Biased Diode Tests for Major Power Components the drive Inspecting the Cooling Tunnels 1 Remove the main cooling fans from the bottom of the power structures Refer to Removing the Main Fans on page 3 26 2 Inspect the tunnels Clean the heatsinks and tunnels if necessary Inspecting the Power Structures 1 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 2 Check components for burn marks breakage or foil delamination on circuit boards Check all the boards on the power structures including those on the Output Power Modules and the Rectifying Modules if present Replace any of these components without further testing if they show evidence of burn marks breakage or foil delamination A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 0 5V If the test finds a short the meter will display 000 If the test finds an open circuit or reversed polarity the meter wi
61. c Damaged or improperly connected fiber optic cables can cause apparent Connections to the Gate Gate Driver Board malfunctions Driver Boards 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 3 2 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 3 On Power Structure 1 locate the Gate Driver Board on the front of the power structure 1 Note There is one Gate Driver Board for each Power Structure in the drive 4 Verify the fiber optic cables are properly connected refer to Figure B 4 on page B 5 Figure B 5 on page B 6 Figure B 6 on page B 7 or Figure B 7 on page B 8 5 Disconnect the cables and inspect them for scratches and cracks 6 Reconnect the cables replacing any damaged cables 7 Repeat steps 3 6 for Power Structure 2 Conducting Gate Driver Remove power from the drive Refer to Removing Power from the Board Measurements Drive on page 3 3 2 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 2 9 Component Test Procedures
62. de bend radii 4 Disconnect the cable from J8 socket of the Voltage Feedback Circuit Board and set it aside TT MN J5 o O Rockwell Automation n o ammo 5 Remove the five screws which secure the Voltage Feedback Circuit Board to the drive 6 Remove the circuit board from the drive 3 20 Access Procedures P1 0 9 N m 8 Ib in Remove five screws Installation Install the 7005 Voltage Feedback Circuit Board in reverse order of removal while referring to Torque Specifications on page 3 1 Removing the Gate Driver and Adapter Boards Access Procedures 3 21 Removal 1 Remove power from the drive Removing Power from the Drive on page 3 3 2 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 3 On Power Structure 1 disconnect the wires from the fuse block that holds the fuses for the Fan Inverters Then remove the fuses 4 Remove the screws that secure the fuse block to the bracket beneath it and remove the fuse block 5 Carefully disconnect the fiber optic cables from sockets along the top of the Gate Driver Board and carefully set them aside ATTENTION Hazard of perma
63. discharged before performing any work on the drive Measure the DC bus voltage at the amp DC terminals The voltage must be zero 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 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 The Control Assembly on 700H drives contains a diagnostic LED which is visible through the cover of the Control Assembly the Control Assembly is located in the upper left hand drive enclosure ATTENTION The Control Assembly LED is only operational when the drive is energized and only visible with the door of the drive enclosure is open Servicing energized equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Follow Safety related practices of NFPA 70E ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES DO NOT work alone on energized equipment 2 2 Component Test Procedures Viewing the 700S Diagnostic LEDs
64. e circuit contactor feedback has not occurred wiring The precharge contactor has probably e Check for loose connections failed to pick up or the feedback signal X50 terminal block and or has failed This fault only applies to the X9 and X15 connectors DC input drives on the ASIC Board HiHp PwrEE Error 74 Power EEPROM Error the rating of Replace output power module the drive and data in the Power or program a new power board EEPROM on the Power Board do not match HiHP PwrBd OTemp 75 Power Board Over Temperature Check the main cooling fan and temperature of the Power Board fan power supply replace if has exceeded 85 C necessary HiHP HardwareVer 76 High Horse Power Star coupler board Check the version of each frame 12 drives only The left side and inverter left and right units right side inverter units have different then replace the units in pairs current ratings or the ASIC on power board is not functioning HiHP CurrUnblnce 77 High Horse Power Star coupler board Check motor wiring for each frame 12 drives only The output unit current between the left side and right side inverter units are unbalanced 2096 of current feedback rating e g 184A 920A 0 2 HiHP VoltUnblnce 78 High Horse Power Star coupler board Check input power and wiring frame 12 drives only The bus voltage for the left and right side inverter units is unbalanced 6 of normal bus voltage e g 41
65. e running the drive ATTENTION Running the drive without the Main Fan 5 Disconnect the DC and DC wires from the bus bars above the Gate Driver Board These wires connect the DC bus to the circuit boards in the power structure disconnected will damage the ASIC Boards You must reconnect ATTENTION Running the drive with the DC bus wires these wires before running the drive Component Test Procedures 2 11 6 Connect the minus probe of the multimeter to the DC wire Make sure these DC and DC connections are insulated from all objects 7 Connect the High Voltage DC Test Power Supply to these wires ATTENTION The sheet metal cover and mounting screws on the ASIC Boards located on the power structures are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly Servicing energized equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Follow Safety related practices of NFPA 70E ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES DO NOT work alone on energized equipment ATTENTION Certain pins in connectors X7 and X12 on the Gate Driver Boards will be energized at DC bus potential high voltage Risk of electrical shock personal injury or death property damage or economic loss exists if personnel or equipment comes into contact with these pi
66. er to Removing the Covers from the Power Structures on page 3 15 3 Remove the power structures from the drive cabinet Removing the Power Structures from the Drive Enclosure on page 3 25 4 Prepare Power Structure 1 for Inverter Assembly Removal Description Remove the cable ties that secure the cables with orange insulation on both left hand and right hand sides This will allow you to move the cables while removing the inverter assemblies Left hand Inverter Right hand Inverter Left hand Side View Front View on Left hand Side 3 38 Access Procedures 5 Remove the Inverter Assemblies Task Description Remove the two M5 Pozi drive screws which secure the front of the A fan inverter to the drive Proper tightening torque for reassembly is 4 N m 35 Ib in Disconnect the fan motor cable under the inverter Remove the four M5 Pozi drive screws which secure the bottom of the fan inverter to the drive Proper tightening torque for reassembly is 4 N m 35 Ib in Disconnect the cables at X2 X8 and X3 on left hand and center D inverters and X2 and X8 on right hand inverter Note This step is not shown Carefully remove the inverters by sliding them out towards the front of E the drive En m L Bottom View of Power Structure Important Do not damage the output
67. fications on page 3 1 Removal 1 Remove power from the drive Removing Power from the Drive on page 3 3 2 Remove the 7005 Control Assembly Removing the 7005 Phase II Control Assembly on page 3 6 3 Carefully disconnect the fiber optic cables from the sockets along the right side of the High Power Fiber Optic Interface Circuit Board on the backside of the Control Assembly and carefully set them aside using optical transmission equipment This product emits intense ATTENTION Hazard of permanent eye damage exists when light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors Access Procedures 3 9 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 4 Disconnect the other cables from the sockets on the High Power Fiber Optic Interface Circuit Board and set them aside 5 Remove the five screws which secure the High Power Fiber Optic Interface Circuit Board to the Control Frame Remove five screws Disconnect Fiber Optic cables AS N m 8 Ib in 6 Remove the circuit board from the Control Frame Installation
68. g Power from the Drive on page 3 3 2 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 3 Remove the power structures from the drive cabinet Removing the Power Structures from the Drive Enclosure on page 3 25 4 On Power Structure 1 remove the cable tie which secures the Power Module Circuit Board to the Adapter Board 5 Disconnect the output leads from the bottom of the Output Power Module 6 Loosen but do not remove the screws that secure the Y Bus Bars to the drive Y Bus Bars Access Procedures 3 31 7 Remove the balancing resistor wires from bus bars Balancing Resistor Wires Snubber Capacitors P Snubber Fastening Screws 8 Remove the screws that secure the Snubber Capacitors and remove the Snubber Capacitors 9 Remove the screws that secure the DC Bus Bars to the left side of the power structure and remove the DC Bus Bars 10 Remove the screws which secure the Output Power Module to the drive 11 Disconnect the Power Module Circuit Board from the Adapter Board 3 32 Access Procedures 12 Remove the Output Power Module from the drive 13 Repeat steps 4 12 to remove the left side Output Power Module from Power Structure 2 Installation Install the Output Power Modules in reverse order of removal while referring to Torque Specifications on page 3 1 Access Procedures 3 33 Removing
69. ing and OK Damaged Reliefs Yes Replace Capacitors Measure Power Voltages within Replace Power Supply Voltages Specification Na Supply Check Board Does Drive Connections Run No Replace Main Does Drive Control Board Run Replace Power Does Drive Interface Board Run on 700S No Replace Voltage Feedback Board on 700S Troubleshooting and Error Codes 1 7 No HIM Display Use this procedure when the HIM does not function Check HIM Connection and Seating Reseat or Properly Connected No reconnect HIM Yes DC Bus Measure DC Bus Voltage within Voltage Specification Perform forward No diode tests on Rectifying Module Rectifying Module OK Replace Rectifying Module Examine Bus Capacitors for Capacitors Charring and OK Damaged Reliefs Replace veg Capacitors Yes Measure Power Supply on X4 of No Replace Power Interface Board on 7005 DPI Circuit Board Replace Output Power Module on 700H Check DPI and Power Supply Connections Does HIM Function No Replace HIM Troubleshooting and Error Codes Over Temperature Faults Use this procedure to troubleshoot drive over temperature faults 14 Inv Otemp Pend and 15 Inv Otemp Trip in 7008 or 8 Heatsink OvrTemp and 9 Trnsistr OvrTemp in 700H Temperature Exceeds Specification
70. lex 700S Drives 20D INO005 Installation Instructions Control Assembly Cover for PowerFlex 7005 20D INOO6 Drives Installation Instructions PowerFlex 7005 700H High Power 20D IN014 Maintenance Stand Installation Instructions PowerFlex 700S and 700H Drives PFLEX INOO6 Reference Manual PowerFlex 7005 with Phase II Control Adjustable PFLEX RM003 Frequency Drives The following publications provide information that is necessary when applying the DriveLogix Controller Title Publication User Manual DriveLogix System 20D UM002 Installation Instructions DriveLogix Controller 20D IN002 Installation Instructions Memory Expansion for DriveLogix Controller 20D INO07 ControlNet Daughtercard Installation Instructions 1788 IN002 ControlNet Daughtercard Installation Instructions 1788 INO005 Terms The following words are used throughout the manual to describe an action Word Meaning Can Possible able to do something Cannot Not possible not able to do something May Permitted allowed Must Unavoidable you must do this Shall Required and necessary Should Recommended Should Not Not recommended Additional Support Available on Internet Overview P 3 Cross References Figure 2 2 on page 2 6 is a cross reference to figure 2 2 on page 5 of Chapter 2 Figure on page C 2 is a cross reference to figure C 1 on page 2 of Appendix C
71. ll display OL zero load A reverse biased diode test should find an open circuit and the meter should display 0L zero load Forward biased test Reverse biased test on PN junction on PN junction Component Test Procedures 2 5 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 3 2 Disconnect all motor leads from the drive 3 Conduct forward and reverse biased diode tests on the Rectifying Modules if present Figure 2 1 Measurement Points for Forward and Reverse Diode Tests O DC DC DC DC 1V T2 ll o 1U T1 2V T2 o 1W T3 5 2U T1 2W T3 o e 211 212 dt 213 Power Structure 2 1L1 1L2 1L3 Power Structure 1 cede TT Table 2 Forward Biased Diode Tests on Rectifying Module for Power Structure 1 Meter Leads Nominal meter reading DC R 111 DC R 1L2 DC R 1L3 Meter should beep once and value 1L1 DC should gradually rise to about 0 5V 1L2 DC 1L3 DC UT if the drive does not contain the brake chopper option the DC R terminal will be labeled DC 2 6 Component Test Procedures Table 2 B Forward Biased Diode Tests on Rectifying Module
72. lotD Slot E 3 12 Access Procedures 5 Remove the three screws which secure the Control Assembly to the drive Do not remove enclosure cover Enclosure is illustrated without the cover for clarity a Nm 27 Ib in 6 Remove the Control Assembly Installation Install the 700H Control and I O Boards in reverse order of removal while referring to Torque Specifications on page 3 1 Access Procedures 3 13 Removing the 700H Star Removal Coupler Board 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 3 2 Referring to Removing the 700H I O Boards and Control Assembly on page 3 11 remove the I O boards and Control Assembly 3 Move the Control Frame to expose its back while referring to Removing the Covers from the Power Structures on page 3 15 4 Disconnect the control power cable from X2 of the Star Coupler Board X1 connects to Main Control Board H1 H23 sockets for Fiber Optic cables X2 connects to 24V dc power 5 Carefully disconnect the fiber optic cables from right side of the Star Coupler Board and carefully set them aside using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic por
73. ly Bracket ASIC Assembly Bracket ASIC Assembly Cover Part No Included in 20 FR10850 ASIC Board for 400 480V Drives SK H1 ASICBD D820 SK H1 ASICBD D920 SK H1 ASICBD D1030 ASIC Board for 600 690V Drives SK H1 ASICBD E650 SK H1 ASICBD E750 SK H1 ASICBD E820 Disassembly Assembly Diagrams D 9 Figure D 6 Main Fan Assembly Main Fan ain Fan Housing Left and Right Intake Cone Table D F Main Fan Assembly Part Numbers Part Name Part No Intake Cone NA Main Fan 230W 20 PP01080 Main Fan Housing Left and Right NA D 10 Disassembly Assembly Diagrams Notes 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 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 E Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication PFLEX TG004A EN P May 2006 Copyright 2006 Rockwell Automation Inc All rights reserved Printed in USA
74. m the Drive on page 3 3 2 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 3 On Power Structure 1 visually inspect the pre charging resistors If pre charging resistors are damaged A Replace the Rectifying Module See Removing the Right Side Output Power Modules and Rectifying Modules on page 3 33 B Check the capacitors rectifiers and external connections for short circuits See Checking the DC Bus Capacitors on page 2 17 C Check the Output Power Modules See Conducting Forward and Reverse Biased Diode Tests for Major Power Components on page 2 4 4 5 Component Test Procedures 2 15 Verify that the plugs on the cable that connects X13 on the Rectifying Board to X2 on the ASIC Board are properly seated Verify that the jumper at X50 on the Rectifying board is in place Taking Measurements on the Rectifying Module 6 7 Disconnect connectors X13 X12 X11 and X10 Perform resistance measurements using a digital multimeter on the points listed in Table 2 1 on page 2 15 on AC Three Phase drives These points are on the back of the X10 X11 and X12 plugs which you have disconnected from the board If the Rectifying Module fails any of these tests replace it See Removing the Right Side Output Power Modules and Rectifying Modules on page 3 33 Table 2 Rectifying Module Resistance Measurements Measurement poin
75. nd type of main fuses Record any other important marks and damage Fault No Description Action if appropriate HiHp In PhaseLs 65 Input Phase Loss AC voltage is 1 Check for voltage on each not present on one or two input input phase phases 2 Check the status of each external input fuses HiHp Bus Com 66 Bus Communication Time Delay the Check fiber optic connections processor has not received proper _ between the Power Interface periodic feedback information Circuit Board and Voltage Feedback Circuit Board HiHp Bus LinkLS 67 Communication Link Loss bus Check fiber optic connections communication between the Power between the Power Interface Interface Circuit Board and Voltage Circuit Board and Voltage Feedback Circuit Board has halted Feedback Circuit Board HiHp Bus CRC Er 68 Bus Communication CRC Error too Check fiber optic connections many Cycling Ring Checksum CRC between the Power Interface errors have occurred in the Circuit Board and Voltage communication bus Feedback Circuit Board A fast power cycle may cause the Wait five minutes before 700S Main Control Board to attempt re energizing the drive to communicate with the ASIC Board before the ASIC Board is energized HiHp Bus WtchDog 69 Bus Communication Watchdog Error 1 Check fiber optic communication has halted in the connections between the communication bus causing the Power Interface Circuit
76. nent 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 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 6 Disconnect the other cables from sockets of the Gate Driver Board and set them aside 3 22 Access Procedures 7 Remove the six screws which secure the brackets to the drive Then remove the brackets 8 Remove eight of the stacker connectors from the Gate Driver Board leaving the two connectors that are third from the top Y H4 H9 H7 H5 He
77. ng Power from the Drive 3 3 Removing the DPI HIM 2 eh 3 5 Removing the 7005 Phase II Control 3 6 Removing 700S High Power Fiber Optic Interface Circuit 3 8 Removing the 7005 Control Assembly Mounting 3 10 Removing the 700H I O Boards and Control Assembly 3 11 Removing the 700H Star Coupler Board 3 13 Removing the Covers from the Power 3 15 Removing the 7005 Voltage Feedback Circuit 3 19 Removing the Gate Driver and Adapter 3 2 Removing the Power Structures from the Drive Enclosure 3 25 Removing the Main Fans 2 0 3 26 Removing the ASIC Boards 2 2 0 3 27 Removing the Rectifying Boards 2 eee 3 29 Removing the Left Side Output Power Modules 3 30 Removing the Right Side Output Power Modules and Rectifying Modules 3 33 Removing the Fan Inverters 2 0 3 37 Removing the DC Bus Capacitors 3 40 Before Applying Power to the 4 1 Testing with the External DC Power Supply Without Load Optional
78. ng large amounts of power 1 Verify that input power wiring and grounding is connected 2 Verify that the motor cables are connected 3 Energize the drive 4 From the Monitor menu on the HIM press the escape button to navigate to the Main menu 5 Use ED the down button to move the cursor to the Start Up selection and to select Start Up Then press again to verify your intention to continue with the Start Up menu 6 Use 6 the down button to move the cursor to Power Circuit Diagnostics Pwr Circuit Diag and to select Power Circuit Diagnostics 7 Press a to begin the Power Circuit Diagnostic routine Follow indications and instructions on the HIM 4 4 Start Up After Repair Testing With the Motor This test allows you to measure several operating parameters and diagnose problems without connecting the motor to its mechanical load 1 2 3 4 5 6 Verify that input power wiring and grounding is connected Verify that the motor cables are connected Verify that the motor load is disconnected Energize the drive Start the drive and increase the speed from zero to base speed Measure drive output current and verify that the value is reflected in parameter 308 Output Current 700S parameter 003 Output Current 700H Stop the drive Service Tools and Equipment Software Tools DriveTools SP DriveExecutive DriveExplorer and DriveObserver are software tool
79. ns 8 Setthe current limit on the High Voltage DC Test Power Supply to less than or equal to 1A Energize the Supply and increase its output to the drive s nominal DC bus voltage 650V dc for drives with 380 500V ac input or 775V dc for drives with 600 690V ac input 2 12 Component Test Procedures Checking the Opto Couplers Class 1 LED Product using optical transmission equipment This product emits intense ATTENTION Hazard of permanent eye damage exists when light and invisible radiation Do not look into module ports or fiber optic cable connectors On Power Structure 1 locate the fiber optic receiver which transmits the signals for W High WH gate interface and connector X3 on the Gate Driver Board X3 provides the gate interface for the WH output power transistor in the left hand Output Power Module Measure the DC voltage at the WH gate and collector pins on X3 with respect to DC It should be 15V dc Should measure 15V dc with respect to DC with no light in WH cable Should measure 15V dc with respect to DC with light in WH cable x3 Should measure 15V dc with respect to DC with no light in WH cable Should measure 15V dc with respect to DC with light in WH cable While shining an intense light like a flashlight into the fiber optic receiver for the WH cable measure the DC voltage at the WH gate and collector pins on X3 with respect to DC It should be 15 dc If the drive fails any of
80. on equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when Important Minimum inside bend radius for SynchLink and ControlNet 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 3 Unplug any remaining I O and communications cables from the Control Assembly and set them aside Access Procedures 3 7 4 Loosen the captive screw on the Control Assembly mounting plate and swing the Control Assembly away from drive Captive Screw 5 Carefully disconnect the ribbon cables from the sockets on the High Power Fiber Optic Interface Circuit Board on the back of the control mounting plate and carefully set them aside Disconnect ribbon cables LA Note Control mounting plate not shown for clarity only 3 8 Access Procedures Removing the 700S High Power Fiber Optic Interface Circuit Board Loosen the two mounting screws on the front of the Control Assembly and slide the control cassette off the mounting bracket Note Ribbon cables not shown for clarity only Installation Install the 7005 Phase II Control Assembly in reverse order of removal while referring to Torque Speci
81. ould measure 15V dc with respect to DC with no light in VL cable Should measure 15 dc with respect to DC with light in VL cable 7 Repeat steps 3 and 4 with connector X8 and the WH cable X8 provides the gate interface for the WH output power transistor in the right hand Component Test Procedures 2 13 Output Power Module If the drive fails any of these tests replace the Gate Driver Board 8 Repeat steps 3 and 4 with connector X9 and the VH cable X9 provides the gate interface for the VH output power transistor in the right hand Output Power Module If the drive fails any of these tests replace the Gate Driver Board 9 Repeat steps 3 and 4 with connector X10 and the cables for WL VL and UL If the drive fails any of these tests replace the Gate Driver Board 10 Repeat steps 1 9 for Power Structure 2 11 Reconnect the DC and DC wires on the bus bars above the Gate Driver Board on both Power Structures Refer to Step 4 on page 2 10 ATTENTION Running the drive with the DC bus wires disconnected will damage the ASIC Boards You must reconnect these wires before running the drive Figure 2 2 Opto Coupler Checks for Left Hand Output Power Module Should measure 15V dc with respect to DC with no light in WH cable Should measure 15V dc with respect to DC with light in WH cable Should measure 15V dc with respect to DC with no light in WH cable Should measure 15V dc with respect to DC with light in WH cable
82. peration without an encoder and motor Start the drive by pressing m the start button Increase the speed command from zero to base speed by pressing the up button Stop the drive by pressing the stop button Re configure the drive to suit the application Decrease the DC Test Power Supply output voltage to zero Wait until DC bus voltage has decreased to zero Switch off the external DC power supply Testing Without a Motor Performing the Power Circuit Diagnostic Test on a 7005 Start Up After Repair 4 3 This test allows you to measure several operating parameters and diagnose problems without connecting the motor 1 Verify that input power wiring and grounding is connected 1 Verify that the motor cables are disconnected 2 Energize the drive 3 Make configuration changes which allow the HIM to issue start and speed commands 4 Make configuration changes which allow operation without an encoder and motor 5 Start the drive by pressing Cp the start button 6 Increase the speed command from zero to base speed by pressing the up button 7 Measure the output voltage on each phase and verify that it is balanced If it is unbalanced troubleshoot the drive 8 Stop the drive by pressing the stop button 9 Re configure the drive to suit the application The Power Circuit Diagnostic Test on the 700 allow you to diagnose problems in the drive s power structure without applyi
83. puts j ye Flash Option LEOB e id cmm 2d Optional 2 Elect Option P3 Second Encoder P2 P13 P21 Battery Safe Off Option Comm Input TB1 TB2 To Feedback Board 1 H903 To Feedback Board 2 H903 Fiber Optic Connections Fiber Optic Connections to ASIC Board 1 on to ASIC Board 2 on Power Structure 1 Power Structure 2 D OIO E HHHHHO 8585888 RRERRRSS E J3 12 V 4 I 32v 4 ls HV 34 Tx Rx iHP Fi DPI J4 D oe nterface Boar _ m m i 115 status 11 2 External 24V DC 2 DOOR as Rj4 Voltage a 5 Feedback 5 5 575 Example 20 HIM A3 FIBER 5 DPI 3 PORT E COMM x MOD B OPTION xi NETA PE _ NETB aid E T DPI Assembly Figure B 1 Circuit Board Connections for 7005 Drives with Phase II Control B 3 Schematics SeAug H00Z 10 Suomnoeuuo NDI z g ote qndu 01 HA 20 mm 1va quuessy Idd L 3
84. rd Connectors Table PowerFlex 700H and 7005 Interface Board to ASIC Board on Power Structure 1 Fiber Optic Connections Interface Board Fiber ASIC Board Optic Connector Fiber Connector Description Reference to ASIC 700H 7005 Type to Board H1 J8 TX RX Gate Enable H2 J9 TX U Gate H3 J10 TX V Gate H4 J11 TX W Gate H5 J12 TX A D Convert H6 J14 TX H6 VBUS RX H7 J13 RX H7 VBUS TX Refer to Figure C 1 on page C 2 for ASIC board fiber optic connectors Connector Descriptions C 9 Table C J PowerFlex 700H and 700S Interface Board to ASIC Board on Power Structure 2 Fiber Optic Connections Interface Board Fiber ASIC Board Optic Connector Fiber Connector Description Reference to ASIC 700H 7005 to Type Board H11 J19 TX Hf Gate Enable H12 J20 TX H2 U Gate H13 J21 TX V Gate H14 J22 TX RX W Gate H15 J23 TX H5 A D Convert H16 J25 TX H6 VBUS_RX H17 J24 RX 7 VBUS_TX 1 Refer to Figure C 1 on page C 2 for ASIC board fiber optic connectors Figure C 6 Termination Points on ASIC Feedback Boards m3 H900
85. s Bars to the drive Y Bus Bars Balancing Resistors AC Input Terminals L1 L2 L3 Balancing Resistor Wires 10 Disconnect all wiring from the circuit board on the Rectifying Module 11 Disconnect the cables from the AC input terminals on the Rectifying Module 12 Remove the circuit board from the Rectifying Module refer to Removing the Rectifying Boards on page 3 29 Access Procedures 3 35 13 Remove the screws that secure the Snubber Capacitors and remove the Snubber Capacitors Snubber Capacitors Snubber Capacitor Fastening Screws 14 Remove the screws that secure DC Bus Bars to right side of power structure and remove the DC Bus Bars 3 36 Access Procedures 15 Remove the screws that secure the Rectifying Module to the power structure and remove the Rectifying Module ph 11 ay T 16 Remove the screws that secure the Output Power Module to the power structure and remove the Output Power Module 17 Repeat steps 4 16 to remove the right side Output Power Module and Rectifying Module from Power Structure 2 Installation Install the Output Power Modules and Rectifying Modules in reverse order of removal while referring to Torque Specifications on page 3 1 Access Procedures 3 37 Removing the Fan Inverters Removal 1 Remove power from the drive Removing Power from the Drive on page 3 3 2 Remove the covers from the power structures Ref
86. s for uploading downloading and monitoring system parameters A 2 Service Tools and Equipment Service tools This list of basic service tools which will cover needs of tools for repair and maintenance measurements Item Description Details 1 Oscilloscope Portable digitizing dual channel scope with isolation 2 Current clamp 1000A ac rms signal output 3 Soldering station Soldering de soldering 4 Adjustable power supply 0 1300Vdc 1A adjustable current limit Efore LPS 750 HV or equivalent 5 Adjustable power supply 0 690Vac 41096 10A three phase galvanic isolation 6 Multi meter Digital multi meter capable of ac and dc voltage continuity resistance capacitance measurements and forward diode bias tests Fluke model 87 III or equivalent 7 Insulation tester 1000Vdc 8 Torque wrench 1 12 9 Torque wrench 6 50Nm 10 box wrench 7mm 8mm 10mm 13mm 17mm 19mm 22mm 11 Socket extension 230mm 12 Wrench 7mm 8mm 10mm 13mm 17mm 19mm 22mm 13 Wire cutter 14 Nose pliers 15 Crimping tools For cable terminals 1 5 240 16 Angle wrench 17 Screw driver 18 Flat nose 7 2 mm 19 POZIDRIV 1 2 3 20 Phillips 1 2 3 21 Torx 25 22 Hexagonal wrench 4 5 6 23 ESD protected place of work Working surface Floor covering seat and ground connections 24 ESD protective clothing Wrist wrap shoes overall clothing coat 25 Power
87. stic Procedures by Symptom Disconnect Motor Leads Troubleshooting and Error Codes 1 5 The following charts list drive symptoms symptom descriptions and recommended actions Blown Input Fuses Use this procedure when a drive clears any of its external circuit breaker or power fuses Replace No Rectifying Module Perform Forward Diode Tests on Rectifying Module Rectifying Module OK Yes Replace No Power Modules Perform Forward Power Diode Tests on Modules Output Power OK Modules Examine Bus Capacitors for Capacitors Charring and OK Damaged Reliefs Replace No Capacitors Yes Remedy Motor No and Lead Problems Check Motor and Motor and Lead Resistances Lead Resistances at 1000V gt 1 Mohm Yes Disconnect AC Are There Choke from Any Line to Rectifying Module Load Shorts Yes No Are There Any Line to Line Shorts Reconnect Reconnect Motor Choke Leads 1 6 Troubleshooting and Error Codes No Output Voltage Use this procedure when there is no voltage present at the drive output terminals even though the drive indicates the motor is running DC Bus Measure DC Bus Voltage within Voltage Specification Perform forward No diode tests on Rectifying Module Rectifying Module OK Replace Rectifying Module Examine Bus Capacitors for Capacitors Charr
88. supply service Capacity of three phase service 400 500 690Vac 30A 26 20 MAINSTND maintenance stand Maintenance stand for removing power structure from drive cabinet 27 Fiber optic repair kit Agilent HFBR 4593 Polishing Kit consisting of a Polishing Fixture 600 grit abrasive paper and 3 mm pink lapping film 3M Company OC3 14 For Agilent HFBR 4532 latching connectors and HFBR RL cable Refer to Agilent publications 5988 9777EN and 5988 3625EN List of Schematic Diagrams Appendix B Schematics For a Schematic Diagram on See Circuit Board Connections for 7005 Drives with Phase II Control page 2 Circuit Board Connections for 700H Drives page B 3 ASIC Circuit Board Connections page B 4 Power Circuitry for Drives with AC Input Power Structure 1 page B 5 Power Circuitry for Drives with AC Input Power Structure 2 page B 6 Power Circuitry for Drives with DC Input Power Structure 1 page B 7 Power Circuitry for Drives with DC Input Power Structure 2 page B 8 Fan Power Supply Connections page B 9 AC Input Motor Connections page B 10 DC Input Motor Connections page B 11 B 2 Schematics 85 232 Port P7 Phase AD onnector Control Wm e TX 120 with all 10 P10 Options Compact 16 vi 1 0 Option is E Fdbk P11 PUDE Compact so In
89. the drive s nominal DC bus voltage 650V dc for drives with 380 500V ac input or 775V dc for drives with 600 690V ac input 8 Monitor the current while testing 9 Leakage current should be less than 3mA when voltage has stabilized 10 Abort test if current leakage is significantly higher when voltage has stabilized 11 Decrease the DC power supply output voltage to zero Wait until DC bus voltage has decreased to zero Switch off the external DC power supply 12 As precaution use a resistor to discharge each capacitor after testing Use a resistor with the proper resistance and power handling capability for the discharge current 13 If any capacitor has failed Replace all the capacitors in the same series connection See Removing the DC Bus Capacitors on page 3 40 14 Repeat steps 3 13 for Power Structure 2 2 18 Component Test Procedures Checking the Main Fan Inverters and Fans Checking Inverter LEDs A frame 12 drive has four fans and four fan inverters two fans and two fan inverters per Power Structure Each fan inverter has a red and a green diagnostic LED the drive is energized and only visible with the covers removed from the power structure Servicing energized equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Follow Safety related practices of NFPA 70E ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES DO NOT work
90. the Right Side Output Power Modules and Rectifying Modules Removal Important Do not attempt to disassemble the Output Power Modules Important Always replace the Output Power Modules in pairs do not replace just one module 1 Remove power from the drive Removing Power from the Drive on page 3 3 2 Remove the covers from the power structures Refer to Removing the Covers from the Power Structures on page 3 15 3 Remove the power structures from the drive cabinet Removing the Power Structures from the Drive Enclosure on page 3 25 4 On Power Structure 1 carefully disconnect the fiber optic cables from the Gate Driver Board and carefully set them aside using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when Minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Any bends with a shorter inside radius can permanently 5 Remove the cables from X13 X14 and X15 sockets on the Gate Driver Board and carefully set them aside Also disconnect DC Bus wiring from the Gate Driver Board 6 Remove the cable tie which secures the Power Module Circuit Board to the Adapter Board 7 Disconnect the output leads from the bottom of the Output Power Module 3 34 Access Procedures 8 Loosen but do not remove the screws that secure the Y Bu
91. ts Resistance X10 red to X10 black X11 red to X11 black 180 10 X12 red to X12 black 8 Without applying power to X13 verify that there is no resistance between the following points J3 and X9 J7 and X9 and J11 and X9 Refer to Rectifying Board Charge Relay Test Results on page 2 16 If the Rectifying Module fails any of these tests replace it See Removing the Right Side Output Power Modules and Rectifying Modules on page 3 33 Connect the DC Test Power Supply to X13 positive to pin 5 and common to pin 1 Raise the output of the DC Test Power Supply to 24V dc Important Power supply polarity is critical during these tests Reversing the polarity will damage components on the circuit board 10 Verify that the voltage and resistance between the following points is zero J3 and X10 Pin 1 J7 and X11 Pin 1 and J11 and X12 Pin 1 Refer to Rectifying Board Charge Relay Test Results on page 2 16 If the Rectifying Module fails any of these tests replace it See Removing the Right Side Output Power Modules and Rectifying Modules on page 3 33 11 Repeat steps 3 10 for Power Structure 2 2 16 Component Test Procedures Figure 24 Rectifying Board Layout and Measurement Points Precharging Resistors NN
92. ts or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when 3 14 Access Procedures 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 6 Remove the six screws which secure the Star Coupler Board to the stand offs on the back of the Control Frame PZ2 0 9 N m 8 Ib in 7 Remove the Star Coupler Board from the Control Frame Installation Install the 700H Star Coupler Board in reverse order of removal while referring to Torque Specifications on page 3 1 Access Procedures 3 15 Removing the Covers from Moving the Control Frame the Power Structures Removal 1 Remove power from the drive Removing Power from the Drive on page 3 3 2 Loosenthe T8 Torx head screws which secure the Control Frame to the drive enclosure 3 Swing the Control Frame out and away from the power structure Installation Install the Control Frame in reverse order of removal while referring to Torque Specifications on page 3 1 3 16 Access Procedures Removing the Airflow Plates The drive is equipped with metal plates at the top of both enclosures that manage airflow through the drive You must remove these plates in order to access the protective co
93. ve does not contain the brake chopper option the DC R terminal will be labeled DC Component Test Procedures 2 7 Table 2 F Forward Biased Diode Tests on Output Power Modules for Power Structure 2 Meter Leads Nominal meter reading DC 2U T1 DC 2V T2 1 Meter should display 00 zero load 2V T2 2W T3 DC R T ifthe drive does not contain the brake chopper option the DC R terminal will be labeled DC Table 2 6 Reverse Biased Diode Tests on Output Power Modules for Power Structure 1 Meter Leads Nominal meter reading 1U T1 DC 1V T2 DC 1W T3 DC Meter should beep once and value 1071 should gradually rise to about 0 5V DC R 1V T2 DC R 1W T3 UI if the drive does not contain the brake chopper option the DC R terminal will be labeled DC Table 2 H Reverse Biased Diode Tests on Output Power Modules for Power Structure 2 Meter Leads Nominal meter reading 2071 DC 2V T2 DC 2W T3 DC Meter should beep once and value DC R 2071 should gradually rise to about 0 5 DC R 2V T2 DC R 2W T3 7 drive does not contain the brake chopper option the DC R terminal will be labeled DC If the drive fails any of these measurements replace both Output Power Modules for the appropriate Power Structure 2 8 Component Test Procedures Checking Fiber Opti
94. vers Removal 1 Remove power from the drive Removing Power from the Drive on page 3 3 2 Move the Control Frame away from the power structure in the left hand enclosure Removing the Covers from the Power Structures on page 3 15 Screws S 3 On Power Structure 1 remove the T8 Torx head screws four per plate that secure the airflow plate to the drive 4 Slide the airflow plate off of the drive 5 Repeat steps 3 and 4 to remove the airflow plate from Power Structure 2 Access Procedures 3 17 Installation Install the Airflow Plates in reverse order of removal while referring to Torque Specifications on page 3 1 Removing the Protective Covers from the Power Structures You must remove the protective covers to gain access to the power structures Removal 1 Remove power from the drive Removing Power from the Drive on page 3 3 2 Move the Control Frame away from the power structure in the left hand enclosure Removing the Covers from the Power Structures on page 3 15 3 Remove the Airflow Plates Removing the Airflow Plates on page 3 16 4 On Power Structure 1 remove the four M5 Pozi drive screws which secure the top and bottom protective covers to the main front protective cover then remove the top and bottom protective covers Note you only need to remove the top and bottom covers to gain access to the power termin

pflex-tg004 - Rockwell Automation

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