Home

pflex-tg006 - Rockwell Automation

Contents

1. PowerFlex Powerflex le 3 le g i AC Input Terminals Bottom View R3 pan olf Biz e Es L1 Wa ol s o Ee L2 of ee JE L3 Lo X gt HZ ry od ug Note One Rectifying Unit shown for clarity only Table 2 A Forward Biased Diode Tests on Rectifying Modules Meter Leads Nominal meter reading DC 11 DC L2 Meter should beep once and value should gradually rise to about 1 0v DC 13 L1 DC L2 DC The value should gradually rise to about 0 35 v2 L3 DC 07 The actual voltage reading may vary depending upon your equipment If your readings are not near 1 0V verify that the actual voltage measured is consistent for the Rectifying module and the Output Power modules 2 The actual voltage reading may vary depending upon your equipment If your readings are not near 0 35V verify that the actual voltage measured is consistent for the Rectifying module and the Output Power modules PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 2 4 Component Test Procedures Table 28 Reverse Biased Diode Tests on
2. e js N 9Seud uonnquisig 2 x IX E EX IX S pg 2 Nv P EE oq a 9 3dN 2 ma of ox pg Nv I I1 9 mnn od od l S 33N I T 00 00 x 1000 pg Nv 00 00 0 4 00 00 sng oq 0L amp of X Nos 2 a Ti po 12 i AAA o e a n uf IE H 7 l gers L NY IDA olo ei ex zx ex ll PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Schematics B 4 Figure B 3 NFE Converter Unit Circuitry for Drives with AC Input npolN 9seug 110 JAN UJoJJ L mie gt n gt sng 9q lt 08 X leuenuo Aouanbalj uey dnjes LS wes ovog o 10 24 Y Ll NY mez T M18 SX TAI TIS ELS 2 15 FIS lt ha OU TX u3319 M0 IBA Beo WE S m V9 rv m 408 M
3. Part Name Part No Air Flow Channel NA Balancing Resistors NA DC Bus Bar Assembly NA DC Bus Bar Terminal Assembly NA Electrolytic Capacitor ELKO 3300uf 420V for 400 480V Drives 20 PP01005 ELKO 5600uf 420V for 600 690V Drives 20 PP01099 EMC Cover NA Fan Inverter 20 2113301 Gate Driver Board 400 480V SK H1 GDB1 F13D 600 690V SK H1 GDB1 F13E Main Cooling Fan Assembly 20 F113300 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 D 4 Disassembly Assembly Diagrams Part Name Part No Output Power Module 400 480V NA 600 690V NA Power Bus Bar NA Screening Plate for Gate Driver Board NA Snubber Capacitor Assembly NA Figure D 3 Rectifying Structure Assembly DC Link Fuse Touch Covers Front Main Terminal Covers Table D C Rectifying Structure Assembly Part Numbers Part Name Part No DC Link Fuse 400 480V 1770 2150A SK H1 SFUSE1 F13 2700A 600 690V 1500 1900A SK H1 SFUSE2 F13 2250A Main Terminal Covers NA Touch Covers Front NA PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P 2009 Disassembly Assembly Diagrams D 5 Figure 0 4 Rectifying Structure Block Assembly DC Bus Bar Assembly Electrolytic Capacitor Main Cooling Fan Assembly
4. Installing the 700H I O Circuit Boards and Control Assembly Install the 700H Control and I O circuit boards in reverse order of removal Removing the 700H Fiber Optic Adapter Circuit Board The Fiber Optic Adapter board is mounted on the back of the control assembly 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Remove the 700H I O circuit boards and Control assembly Refer to Removing the 700H I O Circuit Boards and Control Assembly on page 3 13 3 Move the Control frame to expose its back Refer to Moving the Control Frame on page 3 17 PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 15 4 Disconnect the control power cable from X2 of the Fiber Optic Adapter board Sockets for Fiber Optic X1 disconnects cables from the Main Control board when you remove the board from the Control Frame Connects to 24V dc power 5 Carefully disconnect the fiber optic cables from the right side of the 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 be
5. Jog 1 and Jog 2 Acc2 Dec2 Fwd Rev Jog Jog Fwd Jog Accel 2 Decel 2 Rev Acc2 Dec2 i Accel 2 Decel 2 Jog Jog Fwd Jog Rev Fwd Rev PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Troubleshooting and Error Codes 1 15 No Name Description Action if appropriate 134 Digln CnflctB A digital Start input has been configured without a Stop input or other functions are in conflict Combinations that conflict are marked with a g and will cause an alarm Jog 1 and Jog 2 Stop Run Run Jog Jog Fwd Start CF Run Fwd Rev Jog Fwd Rev Rev Start E os lf d Stop CF Run j JH dk Jil Run Fwd i Run Rev d uk Jog Fwd Jog Rev Fwd Rev d uk 135 Digln CnflctC More than one physical input has been configured to the same input function Multiple configurations are not allowed for the following input functions Forward ReverseRun ReverseBus Regulation Mode B Speed Select 1Jog ForwardAcc2 Dec2 Speed Select 2Jog ReverseAccel 2 Speed Select 3RunDecel 2 Run ForwardStop Mode B 136 BipolarCnflct Parameter Direction Mode is set to Bipolar or Reverse Dis and one or more of the following digital input functions is configured
6. ZINS LISY 1 EX EX 90 0d 90 90 90 90 90 90 90 0 00 90 90 90 90 90 90 90 90 90 90 90 90 90 Y IX IX IX IX IX zx H ex H ex zx Hex H ex H 8x zX H ex H ex zx H ex H ex Hex H ex 8x H ex 8x H ex H ex 8x H ex H ex 8x H ex H ex 8x H EX H ox 8x H EX H ex 1 leyeAu Jeyenu leyenu leyieAu 1 1 leyeAu JeyeAu leyeAu JeyeAu leyenu ue ue Ue4 ue ue Ue4 uey ue Ue4 4 ue ue vx H sx vx Sx vx H Sx vx H Sx vx H Sx yx H Sx Sx H vx Sx H x Sx H x Sx H x Sx H x Sx H x Lad Ld Li Lis LJ J Ud LJ Uu Uu Laud LW IN IN LW LW LW LW IN IN IN IN IN 9115015 4 d 91505 4 nso ou3 Schematics B 6 PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P 2009 B 7 Schematics Figure B 6 MCCB Circuit Breaker Circuitry for Drives with AC Input Wa sAS pesn JejieAuo JAN JO 0 SI 9 0N Bulso 9 junys 9A 069 pore 3 009 gzs 00000 19 5 T Jeyeag dwy y PowerFlex 7005 700H High Performan
7. Remove cable 8 lbein 7 Remove the five screws that secure the insulator and Voltage Feedback board to the protective cover and remove the insulator and Voltage Feedback board PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 51 Installing the Voltage Feedback Circuit Board e Install the Voltage Feedback circuit board in reverse order of removal e Run the Performing the Power Circuit Diagnostic Test on 700S Drive on page 4 3 before running the drive Removing the Main Cooling Fans from the Inverters There is a Main Cooling Fan on each of the Inverters 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Remove the protective covers Refer to Removing the Protective Covers from the Inverters on page 3 42 3 If present remove the protective screens Refer to Removing the Protective Screens from the Power Structure Enclosure on page 3 48 4 Disconnect the Main Cooling Fan cable connectors on the Inverters 5 Remove the four screws that secure the fan to the Inverters Then remove the fan from the inverter frame Disconnect fan ables Remove screws a PZ2 4 Nem 85 Ibein 6 Repeat steps 4 and 5 or each remaining fan Installing the Main Cooling Fans on the Inverters Install the Main Cooling Fans in reverse order of removal Powe
8. PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 A 2 Service Tools and Equipment Item 26 Description Power supply service Details Capacity of three phase service 400 500 690Vac 30A 27 20 MAINSTND maintenance stand Maintenance stand for removing power structure from drive cabinet 28 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 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO006A EN P July 2009 Appendix B Schematics List of Schematic Diagrams For a Schematic Diagram on See page Figure B 1 Circuitry Diagram for Drives with AC Input Power Structure 1 B 2 Figure B 2 Circuitry Diagram for Drives with AC Input Power Structure 2 B 3 Figure B 3 NFE Converter Unit Circuitry for Drives with AC Input B 4 Figure B 4 Inverter Unit Circuitry for Drives with AC Input B 5 Figure B 5 Main Fan Circuit for Drives with AC Input B 6 Figure B 6 MCCB Circuit Breaker Circuitry for Drives with AC Input B 7 Figure B 7 Circuitry Diagram for Drives with DC
9. Remove screws 12 Nem 106 Ibin Remove cables PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 35 9 Remove the M6x25 torx head screws that secure the outer circuit Bus Bars and insulator to the drive frame and remove the bus bars and insulation PZ2 4 Nem 85 Ibein Remove screws d Remove insulator 10 Remove the Fan Inverter supply wires from the Bus Bars at the front of the NFE Converters Remove fan inverter supply wires PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO06A EN P July 2009 3 36 Access Procedures 11 Remove the screws that secure the inner circuit Bus Bars and insulator to the drive and remove the bus bars and insulator Q Remove bolts 106 Ibein 00 Remove DC bus bar Remove screws y Remove insulator Remove screws P79 Remove DC bus bar 4Nem 35 Ibein Remove insulator 12 Remove screws and nuts that secure the DC Feed Bus Bars and Insulator to the drive Remove screws Bolt 40 Nem 354 Ibein Nut 40 Nem 354 Ibein Remove lt 1 909 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 37 13 Remove the DC Feed Bu
10. To Gate Dri H10 7 To Gate Dri 7 To Gate Dri H12 7 To Gate Dri To Gate Dri X5 H13 X600 X11 n To Left Fan Fiber Optic ver Board X13 ver Board X14 ver Board X15 ver Board H4 ver Board H5 ver Board H6 ver Board H7 ver Board H8 ver Board H9 X8 ASIC Board DC F m X6 From DC Bus E De in Power Circuitry OEVA x2 To Rectifying Board X13 Charge X3 To Gate Driver Board X13 Relay 4 To Gate Driver Board 14 1 5 To Gate Driver Board X15 24VDC H8 To Gate Driver Board H4 i H9 To Gate Driver Board H5 X10 24V Power H10 To Gate Driver Board H6 H11 To Gate Driver Board H7 H12 To Gate Driver Board H8 H1 H13 To Gate Driver Board H9 is X600 H4 xi To Left Fan X8 H5 Control H6 H7 PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 On Power Structure 1 On Power Structure 2 Schematics B 13 Figure B 12 Circuit Board Connections for 700S Drives with Phase Il Control 7 80 Z 85 22 Port P7 RJ45 Phase Connector Control RX L1 Synchlink Board 1 Option TX 120 with all 10 7 P10 Options P6 Z Compact 16 34 Option i F
11. eoeyiejul Idd 4 gt lt 109008A 0c 06 pue LOGH 006H preog xoeqpee oL IX uod 01 8 01 eubid Bojeuy 9 1 0 00 100 902 90 uondo ASLL HO Ave Idd indo ndul sniq LX O I 91065 0105 0 10 9 1015 v 1015 9X eX preog 2 pieog 1ejdno 101 ci ONIONS Jewog Li eunjonujs OLX L4 preog 5ISV OL UO pieog 915 01 UO pJeog OISV O SUONIBULOD 21 do 19014 5009290007 ondo Jeqi4 Y Y 06H peog xoeqpee OL 06 L yoeqp994 OL PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Appendix C Connector Descriptions For information on See page Circuit Board Connections 1 ASIC Board Connectors 1 Gate Driver Board Connectors C 2 Rectifier Precharge Circuit Board Connectors C 4 PowerFlex 700H Fiber Optic Adapter Circuit Board Connectors C4 PowerFlex 700S Star Coupler Fiber Optic Interface Circuit Board Connectors C 5 PowerFlex 700H Star Couple Circuit Board C 6 ASIC Feedback Board Connectors C 7 Hardware Connections C 8 Fan
12. PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 3 18 Access Procedures Removing the Protective Covers from the NFE Converters You must remove the protective covers to gain access to the NFE Converters 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Move the control frame Refer to Moving the Control Frame on page 3 17 3 Remove the four 5 Pozi drive screws which secure each of the two or three top and connection protective covers to the drive then remove the covers Note You only need to remove the connection covers to gain access to the cooling fan connetors 2 or 3 covers Connection covers 3 Nm 7 27 bein Installing the Protective Covers on the NFE Converters Install the protective covers on the NFE Converters in reverse order of removal PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 19 Removing the Protective Screens from the Rectifying Structure Enclosure This procedure is only necessary for drives installed in NEMA UL Type 1 IP21 enclosures 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Move the control frame Refer to Moving the Control Fra
13. P 4 Overview Class 1 LED Product A 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 Product Safety A A 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 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 Chapter 1 Troubleshooting and Error Codes For information on See page Viewing the 700S Diagnostic LEDs 1 1 Viewing the 700H Diagnostic LED 1 3 Creating Fault Reports 1 4 Addressing 700S Faults 1 4 Addressing 700H Faults 1 11 Common Drive Conditio
14. communication bus and fiber connections A fast power cycle may cause the 700S Main Control board to attempt to communicate with the ASIC board before the ASIC board is energized 69 HiHp Bus WtchDog Bus Communication Watchdog Error no message Check the communication bus lines 10 pin connector on packets came through in the communication bus a the Main Control board Fiber Optic Star Interface board watchdog error was detected and fiber connections 70 HiHp Fan FdbkLs Fan Feedback Loss an inverter cooling fan did not send 1 Check the communication bus lines 10 pin connector on active feedback or did not work the Main Control board Fiber Optic Star Interface board and fiber connections 2 Check the inverter cooling fans 71 HiHp Drv OvrLoad Drive Overload the drive s operating point has exceeded Reduce mechanical load the intermittent current rating and a foldback to the continuous rating in Par 400 Rated Amps has occurred 72 HiHp PwrBd PrcEr Power board Processor Error a processor on the Fiber _ Replace the Fiber Optic Star Interface circuit board Optic Star Interface circuit board has detected a self diagnostic problem 73 HiHp PrChrg Cntc Precharge Contactor Fault the precharge contactor did not If the drive is an AC input model check the precharge send back the active feedback resistor and contactor If the drive is a DC input model check a jumper for precharge bypass switch on the Fiber Opti
15. t constant Against short circuit with Inverse short time delay trip and trip char acteristic with inverse time Pt constant selectable as an al ternative to protection function I Against short circuit with instan taneous trip selectable as an alternative to protection func tion S 19 These tolerances hold in the following conditions self powered relay at full power and or auxiliary supply two or three phase power supply 1 0 40 0 44 0 48 0 52 at 6x 0 56 0 60 0 64 0 68 t 6s 0 72 0 76 0 80 0 84 only for T2 0 88 0 92 0 96 1x In Release between 1 1 1 3 x Tolerance 10 up to 6 x In IEC 60947 2 and UL 489 2096 above 6 x In I 1 1 5 2 25 3 3 5 4 5 at 8 x In at 8 x In 55 65 7 7 5 8 85 9 t 2 0 1s t 0 258 10 x In Tolerance 1096 4 5 Tolerance 10 up to In T4 T5 1096 up to 2 x In T2 2096 above 2 x In T2 21 15 2 25 3 3 5 45 5 5 6 5 7 7 5 8 8 5 9 10xin Tolerance 10 T4 T5 20 T2 In conditions other than those considered the folowing tolerances hold Trip time s 20 1 40ms PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 E 2 MCCB Circuit Breakers Circuit Breaker Factory DIP Quantity L 51 Switch Set
16. 0 0 UTI wre ws e H QH 5 e N a e Output Power Terminals with du dt Filters PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 60 Access Procedures 12 Remove the two hexagonal screws that secure each power structure to the enclosure frames T Remove screws one each side of enclosure 13 Follow the instructions in publication PFLEX INO14 Installation Instructions PowerFlex 7008 7 700H High Power Maintenance Stand to install the Maintenance Stand part number 20 MAINSTND Remove each Inverter unit by sliding it onto the rails of the Maintenance Stand Note The Maintenance Stand is designed for removing NFE Converter and Inverter units from drives supplied in Rittal TS8 enclosures Alternate means of removal will be necessary for other types of enclosures 14 Follow the instructions in publication PFLEX INO05 Installation Instructions Lifting amp Mounting PowerFlex 700S and 700H Drives Frame 10 14 supplied with the new power structures to lift the power structures off of the Maintenance Stand Installing the Inv
17. 35 Ibein 3 M6 x 25 screws and M6 washers 4 Nem 35 Ibein Bus Bar fastening screw locations 600 690V drive Location 1 Fasteners M6 x 20 screws Torque 4 Nem 35 Ibein 2 M6 x 16 screws 4 Nem 35 Ibein 3 M6 x 25 screws and M6 washers 4 Nem 35 Ibein PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 74 Access Procedures 24 Remove the M4x8 screws that secure the Output Power module to the drive and remove the Output Power module Remove Remove screws screws m 27 Ibein 25 Repeat steps 11 24 for the remaining Output Power module s Installing the Output Power Modules e Install the Output Power module in reverse order of removal e Run the Performing the Power Circuit Diagnostic Test on a 7005 Drive on page 4 3 before running the drive Removing the DC Bus Capacitors from the Inverters 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Remove the protective covers Refer to Removing the Protective Covers from the Inverters on page 3 42 3 If present remove the protective screens Refer to Removing the Protective Screens from the Power Structure Enclosure on page 3 48 4 Remove the Gate Driver Circuit boards Refer to Removing the Gate Driver Circuit Boards on page 3 43 5 On the V Phase Inverter only remove the AS
18. Fwd Reverse Run Forward Run Reverse Jog Forward or Jog Reverse 139 UserSetCflct Not all digital inputs and datalinks in the user set you are saving are the same All user sets must be saved with the same settings for parameters 361 366 300 307 and 310 317 143 TB Man Conflict Parameter 96 TB Man Ref Sel is using an analog input Check the parameter settings to avoid problem that is programmed for another function 147 Start AtPwrUp Parameter 168 Start At PowerUp is enabled The drive may start at any time within 10 seconds of drive powerup 148 IntDB OvrHeat The drive has temporarily disabled the DB regulator because the resistor temperature has exceeded a predetermined value 149 Waking The Wake timer is counting toward a value that will start the drive 150 Sleep Config Sleep Wake configuration error With parameter 178 Sleep Wake Mode Direct possible causes include drive is stopped and parameter 180 Wake Level lt parameter 182 Sleep Level Stop CF Run Run Forward or Run Reverse is not configured in Digital Inx Sel PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 1 16 Troubleshooting and Error Codes PowerFlex 700H Fault Subcodes Fault Subcodes can be viewed in parameters 543 545 547 549 551 553 555 557 Fault x Subcode Each of these parameters corresponds with parameter
19. See page Loading the 700H EEPROM 4 1 Before Applying Power to the Drive 4 2 Testing Without a Motor 4 2 Performing the Power Circuit Diagnostic Test on a 700S Drive 4 3 Testing With the Motor Without a Mechanical Load 4 4 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 Loading the 700H EEPROM _ If you replace the Output Power Modules or Control Board in a 700H drive you must load information about the Power Modules or Control Board into the Power EEPROM Contact Allen Bradley Drives Technical Support for instructions and software tools for performing this operation 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 Pho
20. Table D D Rectifying Structure Block Assembly Part Numbers Part Name Part No Balancing Resistors NA DC Bus Bar Assembly NA DC Bus Bar Terminal Assembly NA Electrolytic Capacitor ELKO 3300uf 420V for 400 480V Drives 20 PP01005 ELKO 5600uf 420V for 600 690V Drives 20 PP01099 Insulator for Rectifier Board NA Main Cooling Fan Assembly 20 2113300 Rectifier Precharge Board 400 480V 600 690V 20 VB00462 Rectifying Module 400 480V 600 690V 20 F113306 Screening Plate for Rectifier Board NA PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 D 6 Disassembly Assembly Diagrams Figure D 5 Fan Inverter Assembly for Power Structure Fan Inverter Capacitor Fan Inverter Board Fan Inverter Assembly Table D E Fan Inverter Assembly Part Numbers Part Name Part No Fan Inverter Assembly Left NA Fan Inverter Board 20 2113301 Fan Inverter Starting Capacitor 7uf 450V AC 20 PP0060 PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Disassembly Assembly Diagrams D 7 Figure D 6 ASIC Assembly ATTENTION The sheet metal cover and mounting screws on A 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 contac
21. e Fiber Optic Adapter board fault Flashing Slowly Bad connection between circuit boards check all connections Refer to Addressing 700H Faults on page 1 11 for more information on 700H drive faults PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 1 4 Troubleshooting and Error Codes Creating Fault Reports Complete fault reports are critical for analysis and repair of modules returned to the factory At a minimum perform and record the following 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 balancine 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 Make record of the amount of dust and other additional particles on drive and drive components Make record of any mechanical damage to the drive and drive components Record the size and type of main fuses Record any other important marks and damage Addressing 700S Faults No Name Description Action 1 Abs Ovespd Det Motor speed has exceeded the limits set by 75 Rev 1 Check to see if the encoder feedback polarity is correct Speed Limit Par 76 Fwd Speed Limit and Par 335 Abs Chec
22. 13 Remove the M5 POZIDRIV screws that secure the Bus Bar terminals to the power structure 14 Slide the Bus Bar terminals out of the frame 15 Remove the bus bar Airflow Channel from the frame Remove screws PZ2 Lm 4Nem Remove insulator holding plate Remove bus bar terminals x 35 Ibein Remove airflow channel EN PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 70 Access Procedures 16 Remove the M8x20 hexagonal screws that secure the output power cables to the output power bus bar 17 Cut and remove the cable ties that secure the output power cables to the EMC cover plate and remove the cables Remove screws and output power cables 14Nem 124 Ibein 18 Remove M5x10 POZIDRIV and M4x8 POZIDRIV screws that secure the EMC cover to the drive and remove the cover 19 Remove the screws that secure the Snubber Capacitors to the Output Power module and remove the Snubber Capacitors Remove screws PZ2 4 35 Ibein Remove screw Remove EMC cover Remove screws and snubber capacitors iei P 27 bein 5 Nem 44 Ibein PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 71 20 Remove the screws that secure the Power Bus Bar and support insulators to the drive and remove the Power
23. 15 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Chapter 3 Access Procedures Understanding Torque Figures in Assembly Diagrams 3 2 Rectifying and Power Structure Locations in Frame 14 Drives 3 3 Removing Power from the 2 2 3 4 Rectifying Structure Access 3 5 Removing the DPI HIM Assembly 2 3 5 Installing the DPI HIM 3 6 Moving the 700S Control Assembly Mounting Plate 3 6 Replacing the 700S Control Assembly Mounting Plate 3 7 Removing the 7005 Phase II Control Cassette 3 8 Installing the 7005 Phase II Control 3 9 Removing the Common Mode Filter Circuit Board 3 10 Installing the Common Mode Filter Circuit 3 10 Removing the 700S Fiber Optic Interface Board 3 11 Installing the 7005 Fiber Optic Interface Circuit Board 3 12 Removing the 7005 Phase II Control Mounting 1 3 12 Installing the 7005 Phase II Control Mounting Plate 3 12 Removing the 700H I O Circuit Boards and Control A
24. 3 20 Removing the Main Cooling Fans from the NFE Converters 3 21 Removing the Precharge Resistors 3 23 Removing the Fan Inverter Fuse Assemblies from the NFE Converters 3 24 Removing the Fan Inverters from the NFE Converters 3 25 Removing the NFE Converter Unit from the Enclosure 3 27 Removing the NFE Converters from the Frame 3 31 Removing the Rectifying Circuit Board 3 32 Removing the Rectifying Modules from the NFE Converters 3 34 Removing the Bus Capacitors from the NFE Converters 3 41 Power Structure Access Procedures 3 42 Removing the Protective Covers from the Inverters 3 42 Removing the Gate Driver Circuit Boards 3 43 Removing the ASIC Circuit Boards 3 44 Removing the Protective Screens from the Power Structure Enclosure 3 48 Removing the Voltage Feedback Circuit Board 3 49 Removing the Main Cooling Fans from the Inverters 3 51 Removing the Fan Inverters from the Inverters 3 52 Removing the Air Flow Plate from the Power Structure Enclosure 3 56 Removing the Inverter Unit from the Enclosure 3 57 Removing the Fan Inverter Fuse Assemblies from the Inverters 3 61 Removing the DC Connective Bus Bars from the Inverters 3 63 Removing the Inverters from the Frame 3 65 Removing the Output Power Modules from the Inverters 3 68 Removing the DC Bus Capacitors from the Inverters 3 74 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 2 Access Procedures Und
25. 3 31 Removing the Rectifying Modules 3 34 Removing the Rectifying Structure from the Drive Enclosure 3 27 Removing the Voltage Feedback Circuit Board 3 49 Reverse Biased Diode Tests 2 2 S Schematic Diagrams B 1 Service Tools A 1 Shear Pin Fault 1 13 Sleep Config Fault 1 15 Software Tools A 1 Spare Parts D 1 SpdRef Cnflct Fault 1 12 Start AtPwrUp Fault 1 15 Start Up After Repair 4 1 System Fault 1 11 T Take Resistance Measurements on the Rectifying Module 2 10 Taking Resistance Measurements on the Precharge Resistors 2 9 Taking Resistance Measurements on the Rectifying Circuit Board 2 9 TB Man Conflict Fault 1 15 Technical Support Options 1 25 What You Need When Calling 1 26 Wizards 1 25 Testing With the Motor Without a Mechanical Load 4 4 Testing Without a Motor 4 2 Turning the Drive Off 3 4 U Unbalanced Fault 1 12 UnderVoltage Fault 1 11 UserSet Timer Fault 1 14 UserSetCflct Fault 1 15 V VHz Neg Slope Fault 1 12 Viewing the 700H Diagnostic LED 1 3 Viewing the 700S Diagnostic LEDs 1 1 W Waking Fault 1 15 X X50 Terminal Block Connectors C 10 Z Zero Divide Fault 1 13 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414
26. 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 TGOO6A EN P July 2009 Copyright 2009 Rockwell Automation Inc All rights reserved Printed in USA
27. 90 wd gi 10 pg IX ef K Pa 19598 enses ed NVJ y IT LET kis iM Z 34N i npolN e 1 90 J 90 v ueg IX end 00 pgg un enses NVA 00 00 SAN 90 as 00 faseud leyenu HUN 19MO0d sng OL 8 d T x ur VAAAAA 21 i M Tx WAVE O H LX 0 feos oe 7 Ad ox d TX 2 2 61 s zX Tx Lor el g UH O 1 X LX 0 p LT E ox l 5 AAA olo 27 exl Tix NITY X I ex Tux pu inr Jl PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 B 3 Schematics Figure B 2 Circuitry Diagram for Drives with AC Input Power Structure 2 L M clin Lun ndu 9q Suoll939uuoo 6X 999 10 pg pieog 1 ldnoo 10 SIX 23 115 OL eX E sx 19114 1p np nse N npoN M 1enug H 1 enseoy Aaseud JOA eunseay faseud JeueAu Z UN
28. Connective Bus Bars and insulator to the Inverters DC bus bar Insulator DC bus bar nm m M10 x 20 hexagonal screws M10 spring 8 Nem 70 lbein washers and M10 washers 2 M8 x 25 hexagonal screws M8 spring 8 Nem 70 lbein washers and M8 washers 3 M6 x 12 screws 4 Nem 35 Ibein Installing the DC Connective Bus Bars on the Inverters Install the DC Connective Bus Bars in reverse order of removal PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 65 Removing the Inverters from the Frame Note The Inverters are secured to a frame that is removed from the enclosure as a single unit This unit must be removed from the enclosure before the individual Inverters and or Output Power modules can be removed 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 Remove the protective covers Refer to Removing the Protective Covers from the Inverters on page 3 42 If present remove the protective screens Refer to Removing the Protective Screens from the Power Structure Enclosure on page 3 48 Remove the Fan Inverter Fuse assemblies Refer to Removing the Fan Inverter Fuse Assemblies from the Inverters on page 3 61 Remove the DC Connective Bus Bars Refer to Removing the DC Connective Bus Bars from the Inverters on page 3 63 R
29. Current Lmt Val Check the load requirements and the value in Current Lmt has been exceeded You can enable disable this fault with Val parameter 238 Fault Config 1 65 An I O option board has been removed Clear the fault 70 Power Unit One or more of the output transistors were operating in the Clear fault active region instead of desaturation This can be caused by excessive transistor current or insufficient base drive voltage See Table 1 X on page 1 21 for more information on this fault 71 Periph Loss The communications card has fault on the network side 1 Check the DPI device event queue and corresponding fault information for the device 81 Port DPI Loss The DPI port has stopped communicating 1 If the adapter was not intentionally disconnected check A SCANport device was connected to a drive operating DPI the wiring to the port Replace the wiring port expander devices at 500k baud adapters Main control board or complete drive as required 2 Check the HIM connection 3 If an adapter was intentionally disconnected and the Logic Mask bit for that adapter is set to 1 this fault will occur To disable this fault set the bit in parameter 276 Logic Mask for the adapter to 0 94 Hardware Enbl An enable signal is missing from the control terminal block 1 Check the control wiring a Table 1 Y on page 1 22 for more information on this 2 Check the position of the h
30. Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 46 Access Procedures 7 For drives with dc input unplug the external precharge circuitry from connectors X9 and X15 from the ASIC board 8 Disconnect the other cables from sockets on the front of the ASIC board and set them aside 9 Remove the four screws that secure the ASIC assembly to the drive and remove the ASIC assembly Remove screws Remove ASIC assembly Removes screws ieee 8 lbein 10 Remove the screw that secures the ASIC board to the ASIC chassis and remove the ASIC board inc ae screw PZ2 1 35 Nem 12 Ibein 7 Remove ASIC circuit board from chassis PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 47 11 Remove the four screws that secure the plastic board holder to the metal frame and insulator and remove the metal frame and insulator Remove screws 09 Nem 8 Ibein sssssssss auf Remove metal frame and insulator 12 Carefully remove the four rivets that secure the insulator to the metal frame and remove the insulator Remove insulator errr 9 Lil d C gt Remove rivets Installing the ASIC Circuit Boards Install the ASIC circuit boards in reverse order of removal Reconnect cables to ASIC board while referring to Figure 12 on pa
31. Input Power Structure 1 B 8 Figure B 8 Circuitry Diagram for Drives with DC Input Power Structure 2 B 9 Figure B 9 Inverter Unit Circuitry for Drives with DC Input B 10 Figure B 10 Main Fan Connections for Drives with DC Input B 11 Figure B 11 ASIC Circuit Board Connections B 12 Figure B 12 Circuit Board Connections for 7005 Drives with Phase Control B 13 Figure B 13 Circuit Board Connections for 700H Drives B 14 PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Schematics B 2 Figure B 1 Circuitry Diagram for Drives with AC Input Power Structure 1 M UA 9q uim e Suonoeuuo _ SX preog gno ainpoyy n p1eog 1910 osv a xolg Jo eoeuelu SIX e 01 18 uonnquisi ued TN ax J sx ex ix ix x ueg pg 1941994 Y 7 anseo 6 ex NVA o 90 ainpow m JAN Meseld
32. Inverter Circuit Board Connectors C 8 X50 Terminal Block Connectors C 10 Circuit Board Connections The following tables detail the connection points for the frame 14 PowerFlex 700 and 700H drives circuit boards and components Figure C 1 ASIC Board Connectors V AYE L 1 AVL 1 H13 H12 H11 H10 H9 H8 X5 X4 X10 L 1 X1 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Connector Descriptions Figure C 2 Gate Driver Board Connectors Table ASIC Board to Gate Driver Board Phase U Connections From ASIC Board To Gate Driver Board Connector Pin Signal Description Connector Pin X3 1 U_Feedback X1 1 X3 2 U_Powe
33. Loosen the two mounting screws on the front of the control cassette and slide the cassette off of the mounting bracket Note Ribbon cables not shown for clarity only Installing the 700S Phase Il Control Cassette Install the control cassette in the reverse order of removal PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 10 Access Procedures Removing the Common Mode Filter Circuit Board 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Move the 700S control assembly mounting plate Refer to Moving the 700S Control Assembly Mounting Plate on page 3 6 Important Before removing connections and wires mark the connections and wires to avoid incorrect wiring during assembly 3 Disconnect the 24V power supply cable from connector J5 on the Common Mode Filter circuit board 4 Disconnect the twisted pair wires from connector J5 on the Fiber Optic Star Interface circuit board P1 0 9 8 Ibein Remove 2 four screw 24V supply cable H 1 Y H i EN Disconnect from J5 on the High U Power Fiber Optic Interface circuit board 5 Remove the four screws that secure the Common Mode Filte
34. Power OK X1 2 X5 3 W X1 3 5 4 W_ETR X1 4 X5 5 W_ITR X1 5 X5 6 DC X1 6 X5 7 WI X1 7 X5 8 DC 1 1 8 5 9 W TEMP X1 9 X5 10 W DC T X1 10 H12 fiber optic WH or Gate Top H2 fiber optic H13 fiber optic WL or Gate Bottom H4 fiber optic 7 DTR N Desat 2 w 4 ETR Phase T ITR Phase Overcurrent Cable labeled X15 at X1 connection on Gate Driver board for Phase W C 3 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 CA Connector Descriptions Figure C 3 Rectifier Precharge Circuit Board Connectors X9 X100 TT X1 X33 o o X6 22 X32 INE X10 T nee X3 amp X81 X2 le X101 X41 X1 X4 S Table C D ASIC Board to Rectifier Precharge Circuit Board Connections From ASIC Board Signal To Rectifier Precharge Board Connector Pin Description Through Connector Pin Connector Pin X2 1 SWTS DRV X1 5 X6 1 X2 2 SWTS FB X1 6 X6 2 X2 3 W DTR X1 7 X6 3 X2 4 Mains Fault X1 11 X6 4 X2 5 24V 1 12 X6 5 The signals ent
35. Rectifying Modules Nominal meter reading Dee Meter should display 0L zero load Meter Leads L1 DC L2 DC L3 DC L1 DC L2 DC L3 Important If any one of the Rectifying modules fails these measurements replace all Rectifying modules in a unit Figure 2 2 Measurement Points on the Inverter Units for Forward and Reverse Biased Diode Tests on the Output Power Modules Front View Bottom View DC DC DC DC DC DC Lr Ij gt LI el IL Lb d L 1 E SS Ananao Parer Note One Inverter Unit shown for clarity only PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Output Power Terminals Component Test Procedures 2 5 Table 2 C Forward Biased Diode Tests on Output Power Modules Meter Leads Nominal meter reading DC U T1 DC V T2 Meter should beep once and value should gradually rise to about 1 0v 0 DC W T3 U T1 DC V T2 DC The value should gradually rise to about 0 35V W T3 DC 07
36. SX H vX SX H X SX H X SX H bX SX H X SX H vX LJ I LJ LJ Gea LW IN IN IN IN IN 2 einso ou3 1nsojou3 PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 B 12 Schematics To 700S HiHP Fiber Optic Interface Board J28 Or 700H Star Coupler Board H8 To 700H Star Coupler Board Fiber Optic Ports 21 23 To 7005 HiHP Fiber Optic Interface Board Ports 1 7 for ASIC Board 1 Or 700H Star Coupler Board Ports 1 7 for ASIC Board 1 To 7005 HiHP Fiber Optic Interface Board J27 Or 700H Star Coupler Board H18 To 7008 HiHP Fiber Optic Interface Board Ports 1 7 for ASIC Board 2 Or 700H Star Coupler Board Ports 1 7 for ASIC Board 2 Figure B 11 ASIC Circuit Board Connections Feedback Board 1 Note External Wiring Shown as Dashed Lines For Input Only Do Not Install on AC Input Drives External Pre Charge Example Circuitry See Note To 700H Star Coupler Board X2 t Board 2 Feedback Fiber Optic ASIC Board X10 24V Power H1 H2 H3 H4 H5 H6 H7 Control DC 4 DC X6 B 3 From DC Bus in Power Circuitry To Rectifying Board X13 L To Gate Dri X4 To Gate Dri To Gate Dri H8 H To Gate Dri H9 L
37. TA sng lt yoeqpee Od abeyon uo lt oq d 3d 2INpoy Salas ui sde c Jo seupueig alleed A009 uoa series ui sde z Jo seuoueig alleed 9 A00F uoneunfijuo 1oyoede A009 A00P 89 0 PowerFlex 7005 700 High Performance Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 ith AC Input it for Drives w Ircul Wis dnas zo vo 40 uo ye Z 1 v9 ld ZH 08 OV ADE UJ Ure Figure B 5 Main Fan C Le zu L 1 ex IX IX
38. The actual voltage reading may vary depending upon your equipment If your readings are not near 1 0V verify that the actual voltage measured is consistent for the Rectifying module and the Output Power modules The actual voltage reading may vary depending upon your equipment If your readings are not near 0 35V verify that the actual vo tage measured is consistent for the Rectifying module and the Output Power modules Table 2 D Reverse Biased Diode Tests on Output Power Modules Meter Leads Nominal meter reading U T1 DC V T2 DC a ae Meter should display 0L zero load DC V T2 DC W T3 Important If one of the Output Power modules fails any of these measurements replace all three Output Power modules in a unit PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 2 6 Component Test Procedures Conducting Gate Driver 1 Remove power from the drive Refer to Removing Power from the Board Gate Interface Drive on page 3 4 Resistance Measurements 4 Remove the protective screens from the Rectifying structure enclosure if present Refer to Removing the Protective Screens from the Rectifying Structure Enclosure on page 3 19 3 Remove the protective covers from the Inverters Refer to Removing the Protective Covers from the Inverters on page 3 42 4 There is one Gate Driver board per Output Po
39. and off of the hinge Lift control mounting p off hinge Installing the 700S Phase Il Control Mounting Plate Install the control mounting plate in reverse order of removal PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 13 Removing the 700H I O Circuit Boards and Control Assembly 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Open the enclosure that contains the Control and I O circuit 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 Serial Port X2 x3 X4 X5 X6 Slot A SlotB SlotC SlotD Slot E PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 14 Access Procedures 5 Remove the three screws which secure the Control assembly to the drive and remove the Control assembly Do not remove enclosure cover Enclosure is illustrated without the cover for clarity 3 Nem 27 bein
40. brake to cool If the resistor is internal the model uses resistor If cold cycle power to the drive stored ihithe power str cture EERROM If cold verify Par 416 Brake PulseWatts and Par 417 If the resistor is external the model uses values of Par 416 Brake Watts are correct Brake PulseWatts and Par 417 Brake Watts Configured with Par 369 Brake OL Cnfg 39 PowerEE CRC Fail The Cycling Ring Checksum CRC of the data stored in the 1 Cycle power Power board EEPROM does not match the stored CRC 2 Check communication bus lines 10 pin connector in Main Control board Fiber Optic Star Interface board and fiber optic cable connections 40 SLink Mult Oflow A SynchLink Multiplier Overflow has occurred Par 927 SL Configured with Par 390 SL MultErr Mult State displays SynchLink multiplier overflow errors 41 Ridethru Timeout The drive has been in a bus loss ridethrough condition for 1 Verify the AC Line more than two seconds default The ridethrough timeout is 5 Verify the value in Par 407 Power Loss Time configurable by Par 407 Power Loss Time 42 DC Bus Undervolt Bus voltage has fallen below the level configured by Par 409 1 Verify the AC Line Line Undervolts 2 Verify the precharge resistor is present With power off there should be a resistance between DC and Configured with Par 393 BusUndervoltCnfg 43 VoltageFdbk Loss Loss of Motor or DC Bus Voltage Feedback has occurred 1 Check the communi
41. for each of the NFE Converters Fans 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 Move the control frame Refer to Moving the Control Frame on page 3 17 Remove the protective covers Refer to Removing the Protective Covers from the NFE Converters on page 3 18 If present remove the protective screens Refer to Removing the Protective Screens from the Rectifying Structure Enclosure on page 3 19 Remove the Fan Inverter fuse assemblies Refer to Removing the Fan Inverter Fuse Assemblies from the NFE Converters on page 3 24 Remove the screws that the secure the fan inverter protection cover to the drive and remove the cover P1 0 9 8 Ibein Remove screws PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 26 Access Procedures Important Before removing connections and wires mark the connections and wires to avoid incorrect wiring during assembly 7 To replace the Fan Inverter capacitor disconnect the capacitor wires from connectors X4 and X5 and unscrew turning counter clockwise the capacitor from the drive frame Unscrew and Capacitor ur 4 8 Disconnect wires from connectors 2 and 8 on the Fan Inverter circuit board 1 9 Remove the M4x8 screws that secure the Fan Inverter circuit board to the drive frame Remo
42. over current in the W phase of power unit 2 typical of frame 14 drives PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 Table 1 K Troubleshooting and Error Codes 1 19 Ground Fault F13 Subcode Subcode Description 273 There is a ground fault in the power unit Table 1 L Load Loss Fault F15 Subcode Subcode Description 400 The motor underload protection has tripped Table 1 M Input Phase Fault F17 Subcodes Subcode Description 273 One input line phase in the power unit is missing 289 One input line phase in power unit 1 is missing 305 One input line phase in power unit 2 is missing 529 One input line phase in a regenerative power unit is missing Table 1 N Output Phase Missing Fault F21 Subcode Subcode Description 273 There is zero current in one of the output motor phases in the power unit Table 1 0 Brake Resistor Missing Fault F28 Subcodes Subcode Description 273 No brake resistor has been detected Frame 9 drives only Table 1 P Microprocessor Watchdog Fault F30 Subcode Subcode Description 322 A microprocessor watchdog timeout has occurred on the Control board Table 1 Q IGBT Temperature Hardware Fault F31 Subcodes Subcode Description 272 273 The output current has exceeded the instantaneous current limit in the power unit 275 The output current has exceeded the instantaneous cur
43. the NFE Converters from the Frame on page 3 31 Important Before removing connections and wires mark the connections and wires to avoid incorrect wiring during assembly 7 Unplug all cables and wires from the Rectifying circuit board and set them aside amp llo xi SIO X50 gt X0 X100 X33 X23 X32 X22 X81 X21 X200 E X41 x xi PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 33 8 Remove the M4x8 screws that secure the Rectifying circuit board to the drive frame and remove the board and insulator Locking Nut 3 27 Ibsin Remove screws Remove nuts gt i 1 1 35 dt e 12 Ibein qe 2 q Rectifying Circuit Board er Hn Pd di j lt Remov screws Insulator Screening Plate 9 If necessary unscrew th
44. voltage DC power supply Use the following procedure to isolate a faulty inverter if the main fans are not running Each fan inverter should be tested individually Refer to Main Fan Circuit for Drives with AC Input on page B 6 or Main Fan Connections for Drives with DC Input on page B 11 for more information 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Remove the 6 A fuses from the fan inverter fuse base PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Component Test Procedures 2 13 3 Unplug the fan inverter wire harness from the X1 connector and connect one jumper between pin 2 and pin 8 on the X1 connector and a second Jumper between pin 9 on the X1 connector and the DC terminal on the fan inverter fuse base Fan inverter supply Fuses Disconnect DC wires from fuse base and guit d connect DC supply from external power DC FROM FUSE BASE 1112 13 15 4 Connect the power supply s DC to the DC terminal on the fuse base and the power supply s DC to the DC terminal on the fuse base 5 Set the external DC power supply voltage to a nominal value and the current limit to 1 A 6 Switch on the external DC power supply If the fan fails to run then the fan inverter is faulty and should be replaced 7 Repeat steps 2 6 for the remaining fan inverter
45. 009 Troubleshooting and Error Codes 1 9 No Name Description Action 63 Logix Closed The DriveLogix controller has closed the Controller to Verify drive is present in Configured with Par 388 Lgx Closed Cnfg 64 Logix Link Chng A required link the Controller to Drive Communication _ Clear fault Format hasbeen modiied Configured with Par 389 Lgx LinkChngCnfg 65 HiHpInPhaseLs Input Phase Loss the AC input phase voltage has 1 Check for voltage on each AC input phase fallen 2 Check the status of each external AC input fuse Configured with par 370 HiHp InPhsLs Cfg 66 HiHp Bus Com Bus Communication Time Delay the communication bus Check the communication bus lines 10 pin connector on has delayed feedback or bad communication quality the Main Control board Fiber Optic Star Interface board and fiber connections 67 HiHp Bus LinkLs Communication Link Loss bus communication Check the communication bus lines 10 pin connector on between the Fiber Optic Star Interface circuit board and the the Main Control board Fiber Optic Star Interface board Voltage Feedback circuit board has stopped and fiber connections 68 HiHp CRC Er Bus Communication CRC Error too many Cycling Ring Check the communication bus lines 10 pin connector on Checksum CRC errors have occurred in the the Main Control board Fiber Optic Star Interface board
46. 03 on Power Structure amp 1 J28 Trip P1 H903 on Power Structure 2 J27 Trip P2 Table C K 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 H23 PHW H903 on Power Structure 1 H8 Trip P1 H903 on Power Structure 2 H18 Trip P2 Figure C 8 Fan Inverter Circuit Board Connectors X3 X8 Table C L ASIC Board Phase V Fan Inverter Board Connections ASIC Board Pin Pin Phase V Fan Inverter Connector Number Signal Description Number Board Connector X11 From 2 ASIC 15V To 2 X8 From 3 FAN CONTROL To 3 To 4 FAN ALARM From 7 1 Refer to Figure C 1 on page C 1 for ASIC board connectors Table C M Phase V Fan Inverter Board Phase W Fan Inverter Board Connections Phase V Fan Inverter Pin Signal Pin Phase W Fan Inverter Board Connector Number Des
47. 2 X9 on ASIC 25 1 Precharge Complete Signal 24V DC Board 2 26 2 Precharge Complete Signal Common X15 on ASIC 21 3 Charge Relay Contact Board 2 23 4 Charge Relay Contact Jumper to Power Module 1 Terminal 21 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO006A EN P July 2009 Disassembly Assembly Diagrams and Spare Parts Numbers Appendix D Disassembly Assembly Diagrams For a Diagram on Power Structure Assembly See page D 2 Power Structure Block Assembly D 3 Rectifying Structure Assembly D 4 Rectifying Structure Block Assembly D 5 Fan Inverter Assembly for Power Structure D 6 ASIC Assembly D 7 Diagrams on the following pages illustrate disassembly and assembly of the drive and its sub systems and are followed by a list of spare part 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 14 A complete list of spare parts for PowerFlex 700S drives is available on the Allen Bradley web site at http www ab com support abdrives powerflex70 PF7ReleasedParts pdf PowerFl
48. 260 Blue Brown 34 0 Resistance to ground oo infinity 10 Reconnect the fan motor to its inverter 11 Repeat steps 8 10 for the remaining fan motor s on the power structure PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Chapter 3 Access Procedures For information on See page Understanding Torque Figures in Assembly Diagrams 3 2 Rectifying and Power Structure Locations in Frame 14 Drives 3 3 Removing Power from the Drive 3 4 Rectifying Structure Access Procedures 3 5 Removing the DPI HIM Assembly 3 5 Moving the 700S Control Assembly Mounting Plate 3 6 Removing the 7005 Phase Control Cassette 3 8 Removing the Common Mode Filter Circuit Board 3 10 Removing the 700S Fiber Optic Interface Board 3 11 Removing the 700S Phase Control Mounting Plate 3 12 Removing the 700H Circuit Boards and Control Assembly 3 13 Removing the 700H Fiber Optic Adapter Circuit Board 3 14 Moving the Control Frame 3 17 Removing the Protective Covers from the NFE Converters 3 18 Removing the Protective Screens from the Rectifying Structure Enclosure 3 19 Removing the Air Flow Plate from the Rectifying Structure Enclosure
49. 8 drives Title Publication User Manual DriveLogix System 20D UM002 Installation Instructions DriveLogix Controller 20D INO02 Installation Instructions Memory Expansion for DriveLogix Controller 200 1 007 ControlNet Daughtercard Installation Instructions 1788 13002 ControlNet Daughtercard Installation Instructions 1788 IN005 Understanding Manual Terms Conventions 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 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Additional Support Available on Internet Precautions Overview P 3 Cross References Examples 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 Additional troubleshooting information and software tools are available on the Allen Bradley Drives Support Website http www ab com support abdrives Qualified Personnel power PowerFlex 700S and 700H Drives and associated machinery should plan or implement the installation start up and subsequent mainte
50. Bus bar and insulators Support insulator Remove screws 14 Nem Q 124 Ibsin 21 Disconnect the Balancing Resistor wires from the Main DC Bus Bars Remove wire connections from DC Bus Bar end 3 Nem 35 Ibein 27 Ibein Balancing resistor assembly screws PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO06A EN P July 2009 3 72 Access Procedures 22 Remove the screws that secure the Balancing Resistor assemblies to the Output Power modules and remove the Balancing Resistor assemblies see previous illustration for screw locations 23 Remove the M4x8 screws that secure the Main DC Bus Bars and insulators to the drive and remove the Main DC Bus Bars and insulators 690V Class drive shown Bus bar 28 Remove all screws holding bus bars and GM insulators to drive frame Bus bar __ ANE plate Remove Insulator i screws PZ2 amp P2 4 35 Insulator IG I KWCWCI WIQIIF YGI Metal plate Remove Insulato screws P2 4 Nem 35 Ibein PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 73 Bus Bar fastening screw locations 400 480V drive Location Fasteners Torque 1 M6 x 20 screws 4 Nem 35 Ibein 2 M6 x 16 screws 4 Nem
51. C 7 Fan Inverter DIP Switch Settings 2 11 AutoReset Lim Fault 1 12 Fatal App Fault 1 14 AutoT Enable Fault 1 14 AutoT Lm Rot Fault 1 14 AutoT MagRot Fault 1 14 AutoT Rs Stat Fault 1 13 AutoT Saturat Fault 1 14 Auxiliary In Fault 1 11 BipolarCnflct Fault 1 15 BrakResMissing Fault 1 12 C CAN Bus Fit Fault 1 13 Checking Fan Inverter Fuses 2 11 Checking the Fan Inverter LEDs 2 10 Checking the Main Fan Motors 2 15 Checking the Rectifying Modules on AC Input Drives Only 2 8 Circuit Board Connections C 1 Conducting Gate Driver Board Gate Interface Resistance Measurements 2 6 Creating Fault Reports 1 4 D Decel Inhibit Fault 1 12 De energizing the Drive 3 4 Device Add Fault 1 13 Device Change Fault 1 13 Diagnostic LEDs 700H 1 3 7005 1 1 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 Faults Anlg In Loss 1 12 AutoReset Lim 1 12 AutoT Enable 1 14 AutoT Lm Rot 1 14 AutoT MagRot 1 14 AutoT Rs Stat 1 13 AutoT Saturat 1 14 Auxiliary In 1 11 BipolarCnflct 1 15 BrakResMissing 1 12 CAN Bus Fit 1 13 Decel Inhibit 1 12 Device Add 1 13 Device Change 1 13 DigIn CnflctA 1 14 DigIn CnflctB 1 15 DigIn CnflctC 1 15 Fan Cooling 1 12 Fatal App 1 14 Gate Disable 1 13 Ground Fault 1 11 Hardware Enbl 1 13 HeatsinkOvrTp 1 11 HeatsinkUndTp 1 13 Hrdwr Therm 1 13 I O Change 1 14 Comm Loss 1 14 Removed 1 13 IGBT OverTemp 1 11 I
52. Diag and press 8 to select Power Circuit Diagnostics 8 Press to begin the Power Circuit Diagnostic routine Follow the indications and instructions displayed on the HIM PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 4 4 Start Up After Repair Testing With the Motor Without a Mechanical Load This test allows you to measure several operating parameters and diagnose problems without connecting the motor to its mechanical load Verify that the input power wiring and grounding is connected Verify that the motor cables are connected Verify that the motor load is disconnected Energize the drive Measure the DC bus voltage and verify that the value is reflected in parameter 306 DC Bus Voltage 7005 parameter 012 DC Bus Voltage 700H Start the drive and increase the speed from zero to base speed Measure drive output current and verify that the value is reflected in the following parameters 308 Output Current 700S 003 Output Current 700H Stop the drive PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO006A EN P July 2009 Software Tools Service Tools Appendix A Service Tools and Equipment For information on See page Software Tools A 1 Service Tools A 1 DriveTools SP DriveExecutive DriveExplorer and
53. DriveObserver are software tools that can be used for uploading downloading and monitoring system parameters The following list contains the basic service tools needed 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 10 10A three phase galvanic isolation 6 Multimeter 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 Allen wrench 14 Wire cutter 15 Nose pliers 16 Crimping tools For cable terminals 1 5 240 17 Angle wrench 18 Screw driver 19 Flat nose 7 2 mm 20 POZIDRIV 1 2 3 21 Phillips 1 2 3 22 Torx 25 23 Hexagonal wrench 4 5 6 24 ESD protected place of work Working surface Floor covering seat and ground connections 25 ESD protective clothing Wrist wrap shoes overall clothing coat
54. E 9 amp X eng 9 ELX 9X gt ig 05 pJeog 19lJllo9li 1 IX 0 5 sure a L WX 00cX t M Lex EEX p1eog 34N PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 B 5 Schematics Figure B 4 Inverter Unit Circuitry for Drives with AC Input Z DIP08 19M0d PRINS T M JO ELH 9 IX 6lX A Seg 10 LLH 8 OLH S S Sz 10 6H 9 8H noes a preog OISV n T gX LIX WH 4 peog 9 SV uo OL 9X 10 99UU0D NN oueueb di s weerd IX P JO L A 40 LLIN alld Maseud 20 SX Jayla 1p np pleog JeMod yx A 10 PX 10401 H X 10 x gk ejeo peog 9 SV t 3d X ex i 50 Ed 10N ees lt woy _ 9 M aN SI 4 GLIN H 1040
55. FE Converters There is a Fan Inverter Fuse Assembly for each NFE Converter Fan 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Move the control frame Refer to Moving the Control Frame on page 3 17 3 Remove the protective covers Refer to Removing the Protective Covers from the NFE Converters on page 3 18 4 If present remove the protective screens Refer to Removing the Protective Screens from the Rectifying Structure Enclosure on page 3 19 5 Remove the Fan Inverter fuses from the fuse holder Important Before removing connections and wires mark the connections and wires to avoid incorrect wiring during assembly 6 Disconnect the DC and DC wire connectors from both ends of the fuse assembly 7 Remove the M4 POZIDRIV screw that secures the fuse holder and insulator to the fuse base and remove the fuse holder and insulator Insulator ss a Remove screw 22 Fuse holder 27 lbein 8 Repeat steps 5 7 for each remaining Fan Inverter fuse assembly Installing the Fan Inverter Fuse Assemblies on the NFE Converters Install the Fan Inverter fuse assemblies on the NFE Converters in reverse order of removal PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P 2009 Access Procedures 3 25 Removing the Fan Inverters from the NFE Converters There is a Fan Inverter
56. Flex 7005 700 High Performance Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 C 6 Connector Descriptions Figure C 6 PowerFlex 700H Star Couple Circuit Board X2 Table C F 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 700S Type to Type Board H1 J8 TX RX Gate Enable H2 J9 TX RX H2 U Gate H3 J10 TX V Gate H4 J11 TX RX W Gate H5 J12 TX RX H5 A D Convert H6 J14 TX H6 VBUS RX H7 J13 RX TX H VBUS_TX Refer to Figure on page C 1 for ASIC board fiber optic connectors PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 Connector Descriptions C 7 Table C G 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 700S Type to Type Board H11 J19 TX Hf Gate_Enable H12 J20 TX RX U_Gate H13 J21 TX RX V_Gate H14
57. GBT Temp HW 1 12 Input Phase 1 12 IntDB OvrHeat 1 15 InverterFault 1 11 Load Loss 1 12 MaxFreqCnflct 1 12 MCB PB Config 1 14 MicroWatchdog 1 12 Motor Stall 1 11 Motor Therm 1 12 MotorOverload 1 11 New 10 Option 1 14 NP Hz Cnflct 1 12 NvsReadChksum 1 13 OutPhasMissng 1 12 OverCurrent 1 11 OverSpd Limit 1 12 OverVoltage 1 11 Param Chksum 1 14 ParamsDefault 1 13 Periph Loss 1 13 Port DPI Loss 1 13 Power Loss 1 11 Power Unit 1 13 PrechargeActv 1 11 PwrBrd Chksum 1 14 Shear Pin 1 13 Sleep Config 1 15 SpdRef Cnflct 1 12 Start AtPwrUp 1 15 System Fault 1 11 TB Man Conflict 1 15 Unbalanced 1 12 UnderVoltage 1 11 UserSet Timer 1 14 UserSetCflct 1 15 VHz Neg Slope 1 12 Waking 1 15 Zero Divide 1 13 Forward and Reverse Diode Test Measurement Points Inverter Units 2 4 Rectifying Units 2 3 Forward Biased Diode Test 2 2 G Gate Disable Fault 1 13 General Precautions P 3 Ground Fault 1 11 H Hardware Connections C 8 Hardware Enbl Fault 1 13 HeatsinkOvrTp Fault 1 11 HeatsinkUndTp Fault 1 13 Hrdwr Therm Fault 1 13 Change Fault 1 14 Comm Loss Fault 1 14 Removed Fault 1 13 IGBT OverTemp Fault 1 11 IGBT Temp HW Fault 1 12 Input Phase Fault 1 12 Inspecting the Cooling Tunnels and Heatsinks 2 1 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO006A EN P July 2009 Index 3 Inspecting the Rectifying and Power Structures 2 2 IntDB OvrHeat F
58. H 2 OL IX 5 AA pius Masel 40 SX A 10 YX JeMOg aseUd JO cx OISV Wod ex SI yoeqnea oq lt preog yoeqpee lt abeo zf OL od pieog OISV uo 9X 1 PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P 2009 B 11 Schematics Figure B 10 Main Fan Connections for Drives with DC Input JeyeAuo Aouenbal4 ue4 yomg ZH 00 ADE Ue Ure od u o v9 11 07 00 relaq ue 90 od od 90 90 90 90 90 90 dcin 8X n eX H ex dorsi X H cox 8X H EX R ox 8X X H ZX Jeyenu Jeyenu ue ue ue ue ue ue
59. IC Circuit Board Refer to Removing the ASIC Circuit Boards on page 3 44 PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 75 6 Remove the Fan Inverter Fuse assemblies Refer to Removing the Fan Inverter Fuse Assemblies from the Inverters on page 3 61 7 Remove the DC Connective Bus Bars Refer to Removing the DC Connective Bus Bars from the Inverters on page 3 63 8 Remove the Air Flow Plate Refer to Removing the Air Flow Plate from the Power Structure Enclosure on page 3 56 9 Remove the Inverter unit Refer to Removing the Inverter Unit from the Enclosure on page 3 57 10 Remove the Inverters Refer to Removing the Inverters from the Frame on page 3 65 11 Remove the four M4x8 screws that secure each of the capacitors to the power structure and remove the capacitors I Nem 12 Ibein Remove screws Installing the DC Bus Capacitors in the Inverters Install the capacitors in reverse order of removal PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 76 Access Procedures Notes PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 Chapter 4 Start Up After Repair For information on
60. ICnfg Position feedback exceeds the maximum positive travel setting Par 694 Motn Mx Pos Trvl PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 1 10 Troubleshooting and Error Codes No Description Action 82 Soft Over Trvl Motion Only Configured with Par 396 Sft OvrTrvICnfg Position feedback exceeds the maximum negative travel setting Par 695 Motn Mx Neg 83 Over Motion Only Configured with Par 397 Hrd OvrTrvICnfg Signal for the hardware positive over travel appears on a digital input 84 Hard Over Trvl Motion Only Configured with Par 398 Hrd OvrTrvICnfg Signal for the hardware negative over travel appears on a digital input 85 Position Error Motion Only Verify the value in Par 696 Motn PositErrTol Error exceeded Par 696 Moin Configured with Par 399 Position ErrCnfg 86 Drive Homing When the drive is in Drive Homing mode Par 740 bit 24 or Check Par 740 bit14 Find Home or bit 27 Return bit 27 is On the Drive Homing Alarm triggers and the drive moves to a home position automatically 88 Stahl Optics Linear Stahl Encoder detected a fault Par 291 LinfStahl 1 Reconnect encoder or replace encoder Status shows the details of the fault 2 Reconnect option feedback card 92 Ride Thru The bus voltage has dro
61. J22 TX RX W_Gate H15 J23 TX RX H5 A D Convert H16 J25 TX H6 VBUS_RX H17 J24 RX ITX 7 VBUS_TX 1 Refer to Figure C 1 on page C 1 for ASIC board fiber optic connectors Figure C 7 ASIC Feedback Board Connectors H900 z H901 X900 H902 H903 Table C H 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 Pin Description Reference to ASIC Board PHU PHV PHW Trip_Out 5V 5V Table 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 to Pin o or V o o A V NO Description Reference to ASIC Board PHU PHV PHW Trip_Out 5V 5V PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 C 8 Connector Descriptions Hardware Connections Table C J ASIC Feedback Board to PowerFlex 700S Star Coupler Fiber Optic Interface Board Connections ASIC Feedback Board Description Reference to Connector Interface Board Connector Star Interface Board H9
62. PFLEX TGO006A EN P July 2009 Addressing 700H Faults Troubleshooting and Error Codes 1 11 No Name Description Action if appropriate 1 PrechargeActv The drive received a start command while inthe DC bus precharge state See Table 1 C on page 1 16 for more information on this fault 2 Auxiliary In Auxiliary input interlock is open Check remote wiring 3 Power Loss DC bus voltage remained below the value of parameter 186 Monitor the incoming AC line for low voltage or line power Power Loss Volts for longer than the time in parameter 185 interruption Power Loss Time Enable Disable this fault in parameter 238 Fault Config 1 See publication 20C PM001 Programming Manual PowerFlex 700H for parameter descriptions 4 UnderVoltage DC bus voltage fell below the minimum value of 333V for Monitor the incoming AC line for low voltage or power 400 480V drives and 461V for 600 690V drives See Table interruption 1 D on page 1 16 for more information on this fault Enable Disable this fault in parameter 238 Fault Config 1 See publication 20C PM001 Programming Manual PowerFlex 700H for parameter descriptions 5 OverVoltage DC bus voltage exceeded maximum value See Table 1 E Monitor the AC line for high line voltage or transient on page 1 16 for more information on this fault conditions Bus overvoltage can also be caused by motor regeneration Extend the decel tim
63. POZIDRIV screws that secure the fuse base to the drive and remove the fuse base PZ id 27 Remove screw fuse holder and insulator Remove screws and fuse base 8 Repeat steps 4 7 for the remaining Fan Inverter Fuse assemblies Installing the Fan Inverter Fuse Assemblies on the Inverters Install the Fan Inverter Fuse assemblies in reverse order of removal PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 63 Removing the DC Connective Bus Bars from the Inverters You must remove the DC Connective Bus Bars in order to remove the Inverters from the drive 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Remove the protective covers Refer to Removing the Protective Covers from the Inverters on page 3 42 3 If present remove the protective screens Refer to Removing the Protective Screens from the Power Structure Enclosure on page 3 48 4 Remove the ASIC circuit board Refer to Removing the ASIC Circuit Boards on page 3 44 5 Remove the Fan Inverter Fuse assemblies Refer to Removing the Fan Inverter Fuse Assemblies from the Inverters on page 3 61 PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 64 Access Procedures 6 Remove the screws that secure the DC
64. PowerFlex 700S 700H High Allen Bradi Performance AC Drive Frame 14 e adley Hardware Service Manual 1000 1600 kW 400V 1500 2300 HP 480V 1500 2000 kW 690V 1600 2400 HP 600V Rockwell Allen Bradley Rockwell Software 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 http 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 assu
65. Publication PFLEX TG006A EN P July 2009 2 8 Component Test Procedures Checking the Rectifying Complete the following tests on all Rectifying modules and connected Modules on AC Input Drives components Only 5 1500 A drives contain three Rectifying modules 1770 1900 2150 and 2250 A drives contain four Rectifying modules 2700 A drives contain six Rectifying modules Remove power from the drive Refer to Removing Power from the Drive on page 3 4 Remove the protective screens from the Rectifying structure enclosure if present Refer to Removing the Protective Screens from the Rectifying Structure Enclosure on page 3 19 Remove the protective covers from the Converters Refer to Removing the Protective Covers from the NFE Converters on page 3 18 Each NFE Converter has three precharge resistors Visually inspect the resistors Precharge Resistors on front of NFE Converter unit Rectifying Circuit Board Rectifying Module If the precharge resistors are damaged A Check the rectifiers and external connections for short circuits B Replace all Rectifying modules Refer to Removing the Rectifying Modules from the NFE Converters on page 3 34 C Check the Output Power modules Refer to Conducting Forward and Reverse Biased Diode Tests for Major Power Components on page 2 2 PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Pub
66. Reflash firmware 3 Replace Main Control board Self Diagnostic Fault Data Error 31 Precharge Error The precharge function has failed to complete within 30 1 Verify the value in Par 410 PreChrg TimeOut seconds default of the precharge request The precharge time out is configurable by Par 410 PreChrg TimeOut A 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 off 2 Verify the bit value in Par 411 PreChrg Control 1 Enbl PrChrg 3 Configured with Par 381 PreChrg Err Cnfg 32 PWM Asynch The Motor Control Processor is not synchronized with SynchLink 33 15volt Power The12V DC control voltage is outside the tolerance range Replace switch mode power supply For smaller frames The positive voltage power must be within the band from replace drive 417 00 to 11 61V DC The negative voltage power must be within the band from 17 00 to 11 61V DC 35 Parameter Chksum The checksum read from the EEPROM does not match the 1 Cycle power checksum calculated 2 Replace Main Control board 38 Brake OL Trip The calculated temperature of the dynamic braking resistor Verify actual temperature of brake E i The temperature is calculated by a thermal If hot wait for
67. Removing Power from the Drive on page 3 4 Remove the protective covers Refer to Removing the Protective Covers from the Inverters on page 3 42 If present remove the protective screens Refer to Removing the Protective Screens from the Power Structure Enclosure on page 3 48 Remove the Gate Driver Circuit Boards Refer to Removing the Gate Driver Circuit Boards on page 3 43 On the V Phase Inverter only remove the ASIC Circuit Board Refer to Removing the ASIC Circuit Boards on page 3 44 Remove the Fan Inverter Fuse assemblies Refer to Removing the Fan Inverter Fuse Assemblies from the Inverters on page 3 61 Remove the DC Connective Bus Bars Refer to Removing the DC Connective Bus Bars from the Inverters on page 3 63 Remove the Air Flow Plate Refer to Removing the Air Flow Plate from the Power Structure Enclosure on page 3 56 Remove the Inverter unit Refer to Removing the Inverter Unit from the Enclosure on page 3 57 10 Remove the Inverters Refer to Removing the Inverters from the Frame on page 3 65 11 On the V Phase Inverter only remove the capacitor leads from the DC Input Bus Bars at the top of the Inverter PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 69 12 Remove the insulator holding plate from between the Bus Bar terminals
68. ans from the Inverters on page 3 51 respectively 3 Inspect the cooling tunnels and heatsinks Clean the heatsinks and tunnels if necessary PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 2 2 Component Test Procedures Conducting Forward and Reverse Biased Diode Tests for Major Power Components Inspecting the Rectifying and Power Structures 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 Remove the protective covers from the NFE Converters if present and Inverters Refer to Removing the Protective Covers from the NFE Converters on page 3 18 and Removing the Protective Covers from the Inverters on page 3 42 respectively Check all components for burn marks breakage or foil delamination on circuit boards Check all the boards on the NFE Converters if present and Inverters including those on the Rectifying modules if present and Output Power modules 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 A reverse biased diode test should find an open circuit and the meter should display a value close to zero Ex 0L zero load Important The actual voltage rea
69. ardware enable jumper t i 3 Check the digital input programming 95 AutoT Rs Stat The Autotune Rs Static Test has failed 1 Verify that the motor is not rotating when autotune is enabled 2 Check the motor connections PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 1 14 Troubleshooting and Error Codes No Name Description Action if appropriate 96 AutoT Lm Rot The Autotune Lm rotate test has failed 1 Check the motor nameplate data 2 Check the motor connections 3 that the Accel Time lt Base Speed 40 x 33 sec Note 33 sec time limit to bring motor to 40 Hz 97 AutoT MagRot The Autotune magnetizing current rotate test has failed 1 Check the motor nameplate data 2 Check the motor connections 3 that the Accel Time lt Base Speed 40 x 33 sec see Note above 98 AutoT Saturat The Autotune saturation curve test has failed 1 Check the motor nameplate data 2 Check the motor connections 99 UserSet Timer A User Set load or save was not completed less than 5 Attempt to save the User Set again Seconds If this error occurs again replace the Main Control board 100 Param Chksum The checksum read from the Main Control board does not 1 Restore the drive to the factory defaults match the checksum calculated 2 Cycle the power See Table 1 7 on page 1 22 for more inform
70. ate Description PWR Power Green Steady Illuminates when power is applied to the drive STS Green Flashing Drive is ready but not running and no faults are present e Status Steady Drive is running and no faults are present Yellow Flashing When running a Type 2 non configurable alarm condition exists and the drive E continues to run When stopped a start inhibit exists and the drive cannot be 9 started 2 Steady A Type 1 user configurable alarm condition exists and the drive continues to run s a Red Flashing A fault has occurred Steady A non resettable fault has occurred T Red Yellow Flashing Alternately The drive is in flash recovery mode The only operation permitted is a flash upgrade z PORT Refer to the User Manual for the Status of the DPI port internal communications if present 5 MOD appropriate Communication Status of the communications module when installed NETA Adapter Status of the network if connected Status of the secondary network if connected oO 2 0 SYNCHLINK Green Steady The module is configured as the time keeper or the module is configured as a 5 follower and synchronization is complete 5 Green Flashing The follower s are not synchronized with the time keeper s Red Flashing The module is configured as a time master on SynchLink and has received time information from another time master on SynchLink ENABLE Green On The drive s enable input is
71. ation on this fault 3 Reload User Set if used 104 PwrBrd Chksum The checksum read from the EEPROM does not match the 1 Cycle the power checksum calculated from the EEPROM data 2 Contact Technical Support See Table 1 U on page 1 20 for more information on this fault 3 If the problem persists replace the drive 106 MCB PB Config The drive rating information stored on the power board 1 Reset the fault or cycle the power incompatible with the Main Control board See Table 1 AA on page 1 22 for more information on this fault 2 Replace the Main Control board 107 New IO Option A New option board was added to the Main Control board 1 Restore the drive to the factory defaults we Table 1 U on page 1 20 for more information on this 2 Reprogram parameters as necessary ault 113 Fatal App A Fatal Application error has occurred Replace the Main Control board 114 AutoT Enable Autotune is enabled but has not started Press the Start key within 20 seconds of enabling autotune 120 Change An option board has been replaced Reset the fault See Table 1 U on page 1 20 for more information on this fault 121 l O Comm Loss An I O board lost communications with the Main Control 1 Check the connector board 2 Check for induced noise 3 Replace I O board or Main Control board 133 Digln CnflctA Digital input functions are in conflict Combinations marked with will cause an alarm
72. ault 1 15 InverterFault 1 11 Isolating a Faulty Fan Inverter on the Power Structure 2 14 Isolating a Faulty Fan Inverter on the Rectifying Structure 2 12 L Load Loss Fault 1 12 Loading the 700H EEPROM 4 1 M MaxFreqCnflct Fault 1 12 MCB PB Config Fault 1 14 MCCB Circuit Breaker Settings E 1 Factory Switch Settings E 2 Trip Curves E 3 MicroWatchdog Fault 1 12 Motor Stall Fault 1 11 Motor Therm Fault 1 12 MotorOverload Fault 1 11 Moving the Control Frame 3 17 N New IO Option Fault 1 14 NP Hz Cnflct Fault 1 12 NvsReadChksum Fault 1 13 OutPhasMissng Fault 1 12 OverCurrent Fault 1 11 OverSpd Limit Fault 1 12 OverVoltage Fault 1 11 P Param Chksum Fault 1 14 ParamsDefault Fault 1 13 Performing the Power Circuit Diagnostic Test on a 7005 Drive 4 3 Performing Visual Drive Inspections 2 1 Periph Loss Fault 1 13 Port DPI Loss Fault 1 13 Power Loss Fault 1 11 Power Unit Fault 1 13 Powering Down 3 4 PrechargeActv Fault 1 11 PwrBrd Chksum Fault 1 14 R Reference Materials P 2 Removing Power from the Drive 3 4 Removing the 700H Fiber Optic Adapter Circuit Board 3 14 Removing the 700H I O Circuit Boards and Control Assembly 3 13 Removing the 7005 Phase I Control Cassette 3 8 Removing the 700S Phase I Control Mounting Plate 3 12 Removing the Air Flow Plate from the Power Structure 3 56 Removing the Air Flow Plate from the Rectifying Structure 3 20 Removing the ASIC Circuit Board 3 44 Re
73. black insulation to the drive frame 10 Remove the Fan Inverter assembly from the drive PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO06A EN P July 2009 3 54 Access Procedures 11 To remove the Fan Inverter circuit board from the old inverter assembly unplug the cables from the following connectors a X4 and X5 Disconnect X4 and X5 b X8 and X2 Disconnect X2 and X8 PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 55 12 Remove the two M5 POZIDRIV screws that secure the Fan Inverter board and its heatsink to the assembly carriage Then carefully remove the Fan Inverter board and its heatsink from the assembly carriage hs uf 22 we 3 Nem 4 Remove screws 27 13 Repeat steps 6 12 for the remaining Fan Inverter assemblies Installing the Fan Inverters Install the Fan Inverters in reverse order of removal PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 56 Access Procedures Removing the Air Flow Plate from the Power Structure Enclosure You must remove the Air Flow Plate in order to remove the Inverters from the drive 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 If present remove
74. c Star Interface circuit board 74 HiHp PwrEE Error Power EEPROM Error the Cycling Ring Checksum CRC 1 Cycle power of the data stored in the Fiber Optic Star Interface circuit 2 Check the communication bus lines 10 pin connector on board EEPROM does not match the stored CRC the Main Control board Fiber Optic Star Interface board and fiber connections 75 PwrBd Otemp Power board Over Temperature the temperature of the Lower the ambient temperature Fiber Optic Star Interface circuit board has exceeded 85 C 76 HiHP HardwareVer The left and right side inverter units have different current Check the version of each inverter left and right units then ratings or the ASIC board on the power board is not replace the unit functioning 77 HiHP CurrUnbince The output current between the left and right side inverter Check motor wiring for each unit units are unbalanced 20 of current feedback rating e g 184A 920A 0 2 78 HiHP VoltUnbince The bus voltage for the left and right side inverter units is Check input power and wiring for each unit unbalanced 6 of normal bus voltage e g 41Vdc 675Vdc 0 06 79 HiHP Bus Data Communication Bus data are mismatched between left side Check communication bus lines 10 pin connector on Main unit and right side unit Control board Fiber Optic Star Interface board and fiber connections 81 Soft Over Trvl Motion Only Configured with Par 395 Sft OvrTrv
75. cation line between Motor Control because of a communication failure between Motor Control and Voltage Feedback board and Voltage Feedback board 2 Replace the Voltage Feedback board Configured with Par 394 VoltFdbkLossCnfg 44 Runtime DataRst Runtime data hours energy has been reset to zero due to a checksum error 45 Enable Health Safety circuit is active Check input signal to the Safety circuit 46 Interp Out Synch Interpolator for position feedback lost synchronization with Configured with Par 378 Interp Fit Cnfg Velocity Position Loop VPL 47 MC CML Task Fail Current Minor Loop CML task has been delayed or run _ Cycle power with incorrect interval 48 No Ctrl Device The controlling device HIM or controller has been disconnected while the drive was running PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 1 8 Troubleshooting and Error Codes No Name Description Action 49 DPI Loss Port 1 The device at port 1 has stopped communicating with Verify DPI device is present and functional at port 1 Configured with Par 391 DPI CommLoss Cfg A SCANport device is connected to a drive operating DPI devices at 500k Baud 50 DPI Loss Port 2 The device at port 2 has stopped communicating with Verify DPI device is present and functional at port 2 Conf
76. ce AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 B 8 Schematics External Wiring Shown Dashed Figure B 7 Circuitry Diagram for Drives with DC Input Power Structure 1 To DC Bus R1 CR2 L I DC Source Y lg F2 R2 CR2 4 To Customer Supplied Precharge Circuit See Circuit Board Connections with DC Input Power Unit 1 Inverter Phase U Module L1 du dt 2 u i Filter VT 2 WTB xi W xi X5 X1 Xt C 1 X3 25 Precharge 5 eus Complete To Star _ B m Interface Coupler Board X5 See Circuit ASIC Board Board 4 Connections Lo with DC Input PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Schematics B 9 Figure B 8 Circuitry Diagram for Drives with DC Input Power Structure 2 Power Unit 2 Inverter To DC Bus F7 DC Phase U Module F8 DC U 2 External Wiring sos Shown Dashed Gate Drvr xt F1 R j M DC F9 DC T 1 J T 2 U T1 P
77. ces eae ee Be Index PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 Who Should Use this Manual What is in this Manual Preface Overview This manual is intended for qualified service personnel responsible for troubleshooting and repairing frame 14 PowerFlex 700S and 700H AC drives You should have previous experience with and an understanding of electrical terminology procedures required troubleshooting equipment equipment protection procedures and methods and safety precautions Refer to safety related practices contained in publication NFPA 70E Standard for Electrical Safety in the Work Place This manual contains hardware service information for frame 14 PowerFlex 700S and 700H drives Verify that you are working on a Frame 14 drive by checking the data nameplate on the control frame The frame number is printed Just above the serial number zj 0 460 60 Hz 420 500 630 550 840 630 Serial Number 4622381652 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 P 2 Overview Reference Materials Allen Bradley publications are available on the internet at www rockwellautomation com literature The following publications provide general drive informa
78. configuration changes that allow operation without an encoder and motor Start the drive by pressing aq the start button Increase the speed command from zero to base speed by pressing gt the up button Measure the output voltage on each phase and verify that it is balanced If it is unbalanced troubleshoot the drive Stop the drive by pressing the stop button 10 Re configure the drive to suit the application PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Start Up After Repair 4 3 Performing the Power The Power Circuit Diagnostic Test on the 700S drive allows you to diagnose Circuit Diagnostic Test on a problems in the drive s power structure without applying large amounts of 700S Drive power 1 Verify that the input power wiring and grounding is connected 2 Verify that the motor cables are connected 3 Energize the drive 4 Measure the DC bus voltage and verify that the value is reflected in parameter 306 DC Bus Voltage 700S 5 From the Monitor menu on the HIM press the escape button to navigate to the Main menu 6 Press e the down button to move the cursor to the Start Up selection and press to select Start Up Then press again to verify your intention to continue with the Start Up menu 7 Press 6 the down button to move the cursor to Power Circuit Diagnostics Pwr Circuit
79. cription Number Board Connector X3 From 2 15V To 2 X8 From 3 FAN CONTROL To 3 NEXT To 4 FAN_ALARM From 7 PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 NFE 1 Fan Inverter Board Connector X3 NFE 2 Fan Inverter Board Connector X3 Connector Descriptions C 9 Table C N Phase W Fan Inverter Board Phase U Fan Inverter Board Connections Phase W Fan Inverter Pin Signal Pin Phase U Fan Inverter Board Connector Number Description Number Board Connector X3 From 2 15V To 2 X8 From 3 FAN CONTROL To 3 NEXT To 4 FAN_ALARM From 7 Table C O Phase U Fan Inverter Board NFE Converter 1 Fan Inverter Board Connections Phase U Fan NFE 1 NFE 1 Fan Inverter Board Pin Signal Connector Pin Inverter Board Connector Number Description Pin Number Connector X3 From 2 15V X1 8 To 2 X8 From 3 FAN_CONTROL X1 9 NEXT To 4 FAN_ALARM X1 10 From 7 Table C P NFE 1 Fan Inverter Board NFE Converter 2 Fan Inverter Board Connections NFE1 NFE 2 NFE 2 Fan Pin Signal Connector Connector Pin Inverter Board Number Description Pin Pin Number Connector From 2 15V To X1 2 To X1 8 To 2 X8 From 3 FAN CONTROL To X1 3 To X1 9 To 3 NEXT To 4 FAN ALARM From 1 13 From X1 10 From 7 Table C Q NFE 2 Fan Inverter Board NFE Converte
80. ctions or a board has been damaged replace the loose or missing connections or repair or replace any of the boards as needed Otherwise continue with step 4 A contact with the assembly 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 4 Complete the Conducting Forward and Reverse Biased Diode Tests for Major Power Components on page 2 2 for the Output Power modules If the test is not completed successfully replace the Output Power modules Otherwise continue with step 5 5 Check the motor windings and motor cables with a high resistance DVM megger Repair or replace the motor as needed PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 1 24 Troubleshooting and Error Codes Blown Input Fuse If the drive causes the AC input line fuse to open complete the following tests to verify that the power structure is functioning properly before replacing the AC input line fuse and reapplying power to the drive Diagnostic Procedure 1 Disconnect the motor leads Corrective Action Continue with step 2 2 Complete the Conducting Forward and Reverse Biased Diode Tests for Major Power Components on page 2 2 for the Rectifier
81. cuit board in Slot E of the control unit has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged 289 A device or circuit board in power unit 1 has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged typical of frame 12 and 14 drives PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Troubleshooting and Error Codes 1 21 Subcode Description 290 The Power board in power unit 1 has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged typical of frame 12 and 14 drives 294 The circuit board in Slot A of the control unit has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged typical of frame 12 and 14 drives 295 The circuit board in Slot B of the control unit has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged typical of frame 12 and 14 drives 298 The circuit board in Slot E of the control unit has been changed added removed has experienced a checksum error or is n
82. d to install the Maintenance Stand Remove the NFE Converter unit by sliding it onto the rails of the Maintenance Stand Note The Maintenance Stand is designed for removing NFE Converter and Inverter units from drives supplied in Rittal TS8 enclosures Alternate means of removal will be necessary for other types of enclosures 11 Follow the instructions in publication PFLEX INOOS Installation Instructions Lifting amp Mounting PowerFlex 7008 and 700H Drives Frame 10 14 supplied with the new power structures to lift the power structures off of the Maintenance Stand Installing the NFE Converter Unit Install the NFE Converter unit in reverse order of removal Refer to the publication PFLEX INOOG6 Installation Instructions PowerFlex 7005 and 700H AC Drives for tightening torques of AC Input DC bus input and ground connection terminations PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 31 Removing the NFE Converters from the Frame 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Move the control frame Refer to Moving the Control Frame on page 3 17 3 Remove the protective covers Refer to Removing the Protective Covers from the NFE Converters on page 3 18 4 If present remove the protective screens Refer to Removing the Protective Screens from the Rec
83. d remove the Balancing Resistor assembly see previous illustration for screw locations Remove balancing resistor assembly Remove screws PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO06A EN P July 2009 3 40 Access Procedures 19 Remove the screws that secure the Rectifying module to the drive and remove the Rectifying module Remove rectifying module Remove screws 27 Ibein 20 Repeat steps 8 19 to remove the remaining Rectifying module s Installing the Rectifying Modules on the NFE Converters e Install the Rectifying modules in reverse order of removal e Run the Performing the Power Circuit Diagnostic Test on 7005 Drive on page 4 3 before running the drive PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 41 Removing the Bus Capacitors from the NFE Converters 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 Move the control frame Refer to Moving the Control Frame on page 3 17 Remove the protective covers Refer to Removing the Protective Covers from the NFE Converters on page 3 18 If present remove the protective screens Refer to Removing the Protective Screens from the Rectifying Structure Enclosure on page 3 19 Removing the NFE Conver
84. dbk P2 11 P2 50 Fdbk Option T T Compact P4 Inputs Board 12 P1 Flash Option I LEOB I 80 Optional 16 E ect Safe Off Option Ls Comm Input TBI L 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 O 6 0 0 01610 0 6 G O 2 5 2 SSSSSSSZ2 Vk 4 27 4 12V 4 34 Is V J6 Tx J17 J7 Rx DPI Fiber Optic Star n nterface LED J2 Fan Power STATUS J16 18 External 24V DC 1 24V 3 Common 75W min 9 7 Common Mode Filter Board 2 7 J5 2 20 x PWR 7 us A STS Example 20 HIM A3 T PORT FIBER 1 a comm m MOD Voltage OPTION n NETA zL TxJ5 Feedback WIT3 ____ HIM FIBER 1 5 DPI Assembly E External DPI PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Schematics B 14 Figure B 13 Circuit Board Connections for 700H Drives Idd IVN83LX3 cdd v guessv dd alan n 002 uos X
85. dings may vary depending upon your equipment If your readings are not near the indicated values in the tables below verify that the actual voltage measured is consistent for the Rectifying modules and Output Power modules Remove power from the drive Refer to Removing Power from the Drive on page 3 4 Remove the protective screens from the Rectifying structure enclosure if present Refer to Removing the Protective Screens from the Rectifying Structure Enclosure on page 3 19 Remove the protective screens from the Power structure enclosure if present Refer to Removing the Protective Screens from the Power Structure Enclosure on page 3 48 Disconnect the motor leads from the output power terminals Refer to Figure 2 2 on page 2 4 for terminal location Conduct forward and reverse biased diode tests on the Rectifying Modules if present and the Output Power Modules PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Component Test Procedures 2 3 Figure 2 1 Measurement Points on the Rectifying Units for Forward and Reverse Biased Diode Tests on the Rectifying Modules Front View DC DC DC DC DC DC
86. e 20C DG1 option board replace the Main Control board 10071 A single hardware problem has been detected in the safe disable Replace the 20C DG1 option board If this fault occurs again inputs on the 20C DG1 option board replace the Main Control board 10327 A single hardware problem has been detected in the safe disable Replace the 20C DG1 option board If this fault occurs again inputs on the 20C DG1 option board replace the Main Control board 10583 A single hardware problem has been detected in the thermistor Replace the 20C DG1 option board input on the 20C DG1 option board 10839 A single hardware problem has been detected in the thermistor Replace the 20C DG1 option board input on the 20C DG1 option board 11096 A single hardware problem has been detected in the thermistor Replace the 20C DG1 option board input on the 20C DG1 option board 11351 A single hardware problem has been detected in the safe disable Replace the 20C DG1 option board If this fault occurs again inputs or in the thermistor input on the 20C DG1 option board replace the Main Control board 11607 single hardware problem has been detected in the safe disable Replace the 20C DG1 option board If this fault occurs again inputs or in the thermistor input on the 20C DG1 option board replace the Main Control board 11863 single hardware problem has been detected in the safe disable Replace the 20C DG1 option board If this fault occurs again inputs or i
87. e Circuit Breakers MCCBs Trips 1 25 Technical Support Options 2 1 25 Technical Support Wizards 2 eee een enna 1 25 What You Need When You Call Tech Support 1 26 Component Test Procedures Performing Visual Inspections 2 1 Inspecting the Cooling Tunnels and Heatsinks 2 1 Inspecting the Rectifying and Power Structures 2 2 Conducting Forward and Reverse Biased Diode Tests for Major Power Components 2 2 Conducting Gate Driver Board Gate Interface Resistance Measurements 2 6 Checking the Rectifying Modules on AC Input Drives 2 8 Taking Resistance Measurements on the Precharge Resistors 2 9 Taking Resistance Measurements on the Rectifying Circuit Board 2 9 Taking Resistance Measurements on the Rectifying 2 10 Checking the Main Fan Inverters and 2 10 Checking the Fan Inverter 2 II 2 10 Checking Fan Inverter 2 2 1 2 11 Fan Inverter DIP Switch Settings 2 2 11 Isolating a Faulty Fan Inverter on the NFE Unit 2 12 Isolating a Faulty Fan Inverter on the Inverter Unit 2 14 Checking the Main Fan Motors 2 2
88. e M4 nuts that secure the EMC protection plate to the drive frame and remove the plate 10 Repeat steps 7 9 for the remaining Rectifying circuit boards Installing the Rectifying Circuit Board Install the Rectifying circuit board in reverse order of removal PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 34 Access Procedures Removing the Rectifying Modules from the NFE Converters 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 Move the control frame Refer to Moving the Control Frame on page 3 17 Remove the protective covers Refer to Removing the Protective Covers from the NFE Converters on page 3 18 If present remove the protective screens Refer to Removing the Protective Screens from the Rectifying Structure Enclosure on page 3 19 Removing the NFE Converter Unit Refer to Removing the NFE Converter Unit from the Enclosure on page 3 27 Remove the NFE Converters Refer to Removing the NFE Converters from the Frame on page 3 31 Remove the Rectifying circuit board Refer to Removing the Rectifying Circuit Board on page 3 32 Remove the M10x20 hexagonal screws that secure the input power cables and the Rectifier circuit board bus bars to the terminals at the top of the Rectifying modules and remove the cables and bus bars Remove bus bars
89. e NFE Converters Install the Main Cooling Fans in reverse order of removal PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 23 Removing the Precharge Resistors 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Move the control frame Refer to Moving the Control Frame on page 3 17 3 Remove the protective covers Refer to Removing the Protective Covers from the NFE Converters on page 3 18 4 If present remove the protective screens Refer to Removing the Protective Screens from the Rectifying Structure Enclosure on page 3 19 Important Before removing connections and wires mark the connections and wires to avoid incorrect wiring during assembly 5 Disconnect the precharge resistor wires from connectors X31 X32 and X33 on the Rectifying circuit board 6 Remove the 4x8 screws that secure the precharge resistors to the drive frame and remove the precharge resistors D Nem 8 Ibsin QU 50 M Uu a tas adj f Remove screws Installing the Precharge Resistors Install the precharge resistors in reverse order of removal PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 24 Access Procedures Removing the Fan Inverter Fuse Assemblies from the N
90. e for U V or W Low L 7 j Xt C mes 1 s risa O H Y y om p da Extinguishing OO s W fa 166 ohms 0 Enter og xo e e xii gO B B Ignition Or X yy BAP H2 166 ohms r3 l Emitter Extinguishing Gate Interface for U V or W High H Note Connectors X7 and X8 are connected in parallel with connectors X10 and X11 respectively and therefore do not have to be tested Important If any of the gate interfaces fails this test replace the appropriate left middle or right Output Power module Refer to Removing the Output Power Modules from the Inverters on page 3 68 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual
91. e is a heatsink over temperature on the Power board of power unit 2 typical of frame 12 and 14 drives 307 There is a heatsink over temperature in the U phase of power unit 2 typical of frame 12 and 14 drives 308 There is a heatsink over temperature in the V phase of power unit 2 typical of frame 12 and 14 drives 309 There is a heatsink over temperature in the W phase of power unit 2 typical of frame 12 and 14 drives 530 There is a Thermistor over temperature on the Power board typical of frame 12 and 14 drives Table 1 H IGBT Over Temperature Fault F9 Subcode Subcode Description 273 The output transistors have exceeded their maximum operating temperature due to an excessive load Table 1 1 System Fault F10 Subcodes Subcode Description Action 273 There is an output phase feedback fault from the motor cables 275 There is an output phase feedback fault from the U phase motor cable typical of frame 11 and 13 drives 276 There is an output phase feedback fault from the V phase motor cable typical of frame 11 and 13 drives 277 There is an output phase feedback fault from the W phase motor cable typical of frame 11 and 13 drives 1042 There is a disturbance at the ASIC fault input of the Power board ribbon cable software 1058 There is a disturbance at the ASIC fault input of the Power board in power unit 1 ribbon cable so
92. e or install a dynamic brake option 6 Motor Stall The motor is operating at high current and low frequency 1 Run an Autotune and is not accelerating 2 Reduce the Load See Table 1 F on page 1 16 for more information on this fault 7 MotorOverload Internal electronic overload trip You can enable disable this 1 Run an Autotune fault with parameter 238 Fault Config 1 2 Verify the settings of parameters 48 Motor OL Factor and 47 Motor OL Hertz 3 Reduce the load so that the drive output current does not exceed the current set by the value in parameter 42 Motor NP FLA 8 HeatsinkOvrTp The heatsink temperature has exceeded the maximum 1 Verify that the maximum ambient temperature has not allowable value been exceeded 85 degrees C Alarm 2 Check the fans including the ASIC board on frame 10 90 degrees C Fault and higher drives See Table 1 G on page 1 16 for more information on this fault 3 Check for an excess load 4 Check the carrier frequency 9 IGBT OverTemp The output transistors have exceeded their maximum 1 Verify that the maximum ambient temperature has not operating temperature due to an excessive load been exceeded See Table 1 H on page 1 17 for more information on this Check the fan s fault S 3 Check for an excess load 10 System Fault A hardware problem exists in the power structure 1 Cycle the power See Table 1 1 on page 1 17 for more information on this 2 Verify the fiber optic connectio
93. emove the Air Flow Plate Refer to Removing the Air Flow Plate from the Power Structure Enclosure on page 3 56 Remove the Inverter unit Refer to Removing the Inverter Unit from the Enclosure on page 3 57 PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 66 Access Procedures 8 Remove the M10 x 25 hexagonal screws that secure the output power cables to the Output Power terminals 20 Nem 177 Ibein Remove screws and washers 9 Remove the insulator from between the DC Input Bus Bars emove insulator PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 67 10 Remove the M8x20 hexagonal screws that secure the power module blocks to the drive frame Remove screws Remove screws 11 Lift the Inverters off of the frame Installing the Inverters Install the Inverters in the reverse order of removal PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 68 Access Procedures Removing the Output Power Modules from the Inverters Important Do not attempt to disassemble the Output Power modules Important Always replace all three Output Power modules do not replace Just one module Remove power from the drive Refer to
94. emperature in the W phase of power unit 1 typical of frame 14 drives 304 305 There is a heatsink under temperature in power unit 2 typical of frame 12 and 14 drives 307 There is a heatsink under temperature in the U phase of power unit 2 typical of frame 14 drives 308 There is a heatsink under temperature in the V phase of power unit 2 typical of frame 14 drives 309 Table 1 U There is a heatsink under temperature in the W phase of power unit 2 typical of frame 14 drives Device Change F44 Device Added F45 I O Option board Removed F65 Power board Checksum F104 New I O Option board F107 and I O Option board Change F120 Fault Subcodes Subcode 273 Description The power unit has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged 274 The Power board has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged 278 The circuit board in Slot A of the control unit has been changed added removed has experienced a checksum error or is new and the parameters for the device board remai unchanged gt 279 The circuit board in Slot B of the control unit has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged 282 The cir
95. end occur 17 Inv OLoad Trip The drive s operating point has exceeded the intermittent Reduce the mechanical load current rating and a foldback to the continuous rating in Par 400 Rated Amps has occurred Configured with Par 377 Inv OL Trip Cnfg PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 1 6 Troubleshooting and Error Codes No Name Description Action 18 Ext Fault Input A digital input has detected an external fault Configured with par 379 Ext FIt AIm Cnfg Enter a value of 3 Ext Fault or 38 ExtFault Inv in one of the following parameters to configure an input to detect an external fault Par 825 Digin 1 Sel Par 826 Digin 2 Sel Par 827 Digin 3 Sel Par 828 Dig In4 Sel Par 829 Dig In5 Sel Par 830 Dig In6 Sel 19 DSP Memory Error Flash memory does not match the SRAM memory 1 Cycle the drive power 2 If the fault remains replace the Main Control board 20 DSP Device Error A DSP Velocity Position Loop interrupt task has not been 1 Cycle the drive power completed in the allotted time 2 If the fault remains replace the Main Control board 22 Over Frequency Encoderless algorithm fails to converge on correct speed Two possible causes 1 Velocity regulator is attempting to run below motors slip speed 2 Frequency regulator pulls out and commanded motor frequency s
96. er connector X1 for NFE1 and on to it s Rectifier Precharge Circuit board and also feeds connector X1 for NFE2 and onto it s Rectifier Precharge Circuit board and also feeds connector X1 for NFE3 and onto it s Rectifier Precharge Circuit board if present Figure 4 PowerFlex 700H Fiber Optic Adapter Circuit Board Connectors PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO006A EN P July 2009 Connector Descriptions C 5 Table C E PowerFlex 700H Fiber Optic Adapter Board to ASIC Circuit Board Connections 700H Fiber Optic Signal Description Reference to ASIC Board Fiber Adapter Connector Type _ ASIC Board Type Connector 1 Gate_Enable RX H1 H2 TX U_Gate RX H2 H3 TX V_Gate RX H3 H4 TX W_Gate RX H4 H5 TX A D Convert RX H5 H6 TX VBUS RX RX H6 H7 RX VBUS TX TX H7 X2 From 24 DC Power To X10 Refer to Figure C 1 on page 1 for ASIC board fiber optic connectors Figure C 5 PowerFlex 700S Star Coupler Fiber Optic Interface Circuit Board Connectors Power
97. erFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO006A EN P July 2009 Access Procedures 3 7 3 Disconnect the and communications cables from the control cassette and set them aside 4 Loosen the captive screw on the control assembly mounting plate and swing the control assembly mounting plate away from the drive Loosen captive screw Replacing the 700S Control Assembly Mounting Plate Replace the 700S control assembly mounting plate in the reverse order of moving PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 3 8 Access Procedures Removing the 7005 Phase II Control Cassette 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Move the 700S control assembly mounting plate Refer to Moving the 700S Control Assembly Mounting Plate on page 3 6 3 Carefully unplug the ribbon cables from the sockets on the Fiber Optic Star Interface circuit board on the back of the control mounting plate and carefully set them aside Disconnect ribbon cables LA Note Control mounting plate A M not shown for clarity only PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 9 4
98. erstanding Torque Icons and numbers in the assembly diagrams indicate how to tighten Figures in Assembly hardware after re assembly Di agrams Fastener Type POZIDRIV Screw Tool Type and Size PZ indicates POZIDRIV screwdriver bit Phillips Screw P indicates Phillips screwdriver bit Hexagonal Bolt or Standoff Hexagonal Screw pum a Tightening Torque Hexagonal Nut Torx Head Screw Q O OO e d POZIDRIV is a registered trademark of the Phillips Screw Company Phillips is a registered trademark of Phillips Screw Company PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO006A EN P July 2009 Access Procedures 3 3 Rectifying and Power The Rectifying structures contain the Non Regenerative Front End NFE Structure Locations in Converters which contain the Rectifying modules The Power structures Frame 14 Drives contain the Inverters which contain the Output Power modules The access procedures below are split into two main sections one for the components contained in the Rectifying structures and one for the components contained in the Power structures See Rectifying Structure Access Procedures on page 3 5 or Power Structure Access Procedures on page 3 42 1500A Drive 1770A 1900A 2150A amp 2250A Drives Rectifying Power Power Rectifying Power Power Rectifying Structure S
99. erter Unit Install the Inverter unit in reverse order of removal Refer to the publication PFLEX INO06 Installation Instructions PowerFlex 7005 and 700H AC Drives for tightening torques of motor DC bus input and ground connection terminations PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 61 Removing the Fan Inverter Fuse Assemblies from the Inverters There is a Fan Inverter Fuse assembly for each Main Cooling Fan in the Power structure 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Remove the protective covers Refer to Removing the Protective Covers from the Inverters on page 3 42 3 If present remove the protective screens Refer to Removing the Protective Screens from the Power Structure Enclosure on page 3 48 4 Remove the Fan Inverter Fuses from the fuse assembly 5 Disconnect the DC and DC wire connectors from both ends of the fuse assembly Remove DC and DC wires A Remove fuses Remove DC and DC wires PowerFlex 7008 700H High Performance Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 62 Access Procedures 6 Remove the POZIDRIV screw that secures the fuse holder and insulator to the fuse base and remove the fuse holder and insulator 7 Remove the two M4
100. ew and the parameters for the device board remain unchanged typical of frame 12 and 14 drives 305 A device or circuit board in power unit 2 has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged 321 A device or circuit board has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged 322 The Control board has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged 326 The circuit board in Slot A of the control unit has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged 327 The circuit board in Slot B of the control unit has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged 330 The circuit board in Slot E of the control unit has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged 369 The Star Coupler board on the control unit has been changed added removed has experienced a checksum error or is new and the parameters for the device board remain unchanged typical of frame 12 and 14 drives 370 The Star Coupler board has been changed added removed has experienced a check
101. ex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 D 2 Disassembly Assembly Diagrams Figure D 1 Power Structure Assembly a Wut cM Lu as i ASIC Assembly Upgrade Kit 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 Touch Covers Front Main Terminal Covers Bus Bar Assembly Fuse Holders for Fan Inverters Table D A Power Structure Assembly Part Numbers Part Name ASIC Assembly Upgrade Kit without ASIC Board Part No 20 FR10850 Bus Bar Assembly NA Fuse Holders for Fan Inverters 20 PP20300 Main Terminal Covers NA Touch Covers Front NA PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Main Cooling Fan Assembly Disassembly Assembly Diagrams D 3 Figure 0 2 Power Structure Block Assembly EMC Cover Snubber Capacitor Assembly DC Bus Bar Assembly Power Bus Bar Electrolytic Capacitor Output Power Module DC Bus Bar Terminal Assembly IE Plate g Table D B Power Structure Block Assembly Part Numbers
102. f the fan fails to run then the fan Inverter is faulty and should be replaced 8 Repeat steps 2 7 for the remaining fan inverters Checking the Main Fan Motors 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Remove the covers from the NFE Converter structure Refer to Removing the Protective Covers from the NFE Converters on page 3 18 3 Disconnect the 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 G below replace the fan Refer to Removing the Main Cooling Fans from the NFE Converters on page 3 21 5 Reconnect the fan motor to its inverter 6 Repeat steps 3 5 for the remaining fan motor s on the NFE Converter structure 7 Remove the covers from the power structure Refer to Removing the Protective Covers from the Inverters on page 3 42 8 Disconnect the fan motor from its inverter PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 2 16 Component Test Procedures 9 Measure the resistance of the fan windings If the resulting measurements are not similar to those in Table 2 G below replace the fan Refer to Removing the Main Cooling Fans from the Inverters on page 3 51 Table 2 G Correct Fan Measurements Connection Wires Resistance 5 Brown Black 60 Q Blue Black
103. f the power structure enclosures 11 Remove the input connections from the incoming DC bus terminals at the top of both power structures DC Bus Terminals 20 Nem DC 177 Ibein Front Terminals Output Power Terminals without du dt Filters ojo Ie OR RR RG 5 DC 8 LARA A p ak 8 Back Terminals UTi vi WI3 ERN m ASIC Board Assembly H Power Supply Voltage 5 Side View Feedback Board Assembly i s a a prt Ground Terminals oo
104. five Screws Disconnect Fiber Optic cables PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 12 Access Procedures Carefully unplug the three ribbon cables from the sockets on the Fiber Optic Interface board and carefully set them aside Disconnect the 24V Power Supply cable from connector J5 on the Fiber Optic Interface board Remove the five screws which secure the Fiber Optic Interface board to the mounting plate and remove the board from the mounting plate Installing the 700S Fiber Optic Interface Circuit Board Install the Fiber Optic Interface circuit board in reverse order of removal Removing the 700S Phase II Control Mounting Plate 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 Move the 700 control assembly mounting plate Refer to Moving the 7005 Control Assembly Mounting Plate on page 3 6 Remove the 7008 control cassette Refer to Removing the 7005 Phase II Control Cassette on page 3 8 Remove the 7005 Fiber Optic Interface circuit board Refer to Removing the 7005 Fiber Optic Interface Board on page 3 11 Lift the control mounting plate up
105. for Configured with Par 365 Fdbk LsCnfg Pri Par 366 Fdbk port 0 of the Hi Resolution Encoder Feedback Option _ LsCnfg Alt and Par 367 Fdbk LsCnfgPosit Card e Par 264 Heidenhain0 Stat displays the fault status for port 0 of the Heidenhain Feedback Option Card e Par 269 Resolver0 Status displays the fault status for port 0 of the Resolver Feedback Option Card 6 OptPort 1 Loss The Linear sensor portion of the MDI feedback option card 1 Reconnect encoder or replace encoder has detected a fault condition 2 Reconnect option feedback card e Par 286 Linear1 Status displays the fault status for linear portion of the MDI feedback Option Card Configured with Par 365 Fdbk LsCnfg Pri Par 366 Fdbk LsCnfg Alt and Par 367 Fdbk LsCnfgPosit 7 Params Defaulted All parameters are reset to default by user PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO006A EN P July 2009 Troubleshooting and Error Codes 1 5 No Name Description Action 8 SLink HW Fail A fault on loading SynchLink firmware into FPGA on Main Replace Main Control board Control board at power up 9 SLink Comm Fail A SynchLink communication fault has occurred Verify the SynchLink configuration in e Par 904 SL Node Cnfg e Par 902 SL Error Status displays SynchLink errors Par 905 SL Rx CommFormat and e Par 910 SL Tx CommFormat Reconnect SynchLink communication fiber
106. ftware typical of frame 12 and 14 drives 1074 There is a disturbance at the ASIC fault input of the Power board in power unit 2 ribbon cable software typical of frame 12 and 14 drives 1090 There is a disturbance at the ASIC fault input of the Control board application software 1298 There is too much disturbance in system bus traffic on the Power board 1314 There is too much disturbance in system bus traffic on the Power board in power unit 1 typical of frame 12 and 14 drives 1330 There is too much disturbance in system bus traffic on the Power board in power unit 2 typical of frame 12 and 14 drives 1553 The charging relay feedback is not working 1810 The charging relay control is not set on the Power board 1826 The charging relay control is not set on the Power board on power unit 1 typical of frame 12 and 14 drives 1827 The charging relay control is not set configured on the Power board on power unit 2 typical of frame 12 and 14 drives 2065 The Gate Driver board is without auxiliary voltage Power ASIC TRIN 2067 The Gate Driver board for the U phase is without auxiliary voltage typical of frame 11 and 13 drives 2068 The Gate Driver board for the V phase is without auxiliary voltage typical of frame 11 and 13 drives 2069 The Gate Driver board for the W phase is without auxiliary voltage typical of frame 11 and 13 drives 2080 The Gate Driver board in power unit 1 is without auxiliary voltage 2081 The Gate Driver board in
107. g the Voltage Feedback Circuit Board on page 3 49 Note It is net necessary to remove the Voltage Feedback board assembly from the Inverter Only disconnect the fiber optic cables and other wires from the board that connect to boards in the Rectifying structure Remove the Air Flow Plate Refer to Removing the Air Flow Plate from the Power Structure Enclosure on page 3 56 Remove the insulator material between the DC Bus Bar terminals at the top of the Inverters Insulators PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 58 Access Procedures 8 Remove the M10 nut and washer that secure the DC Link fuse to the DC Bus Bars at the top of the Inverters by securing the top of the M10 headless screw with an Allen wrench and removing the M10 nut and washer at the bottom of the fuse Then remove the fuse Secure top of headless screw with Allen wrench 40 Nem C gt 354 Ibein Remove nut and washer at bottom of fuse PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 59 9 Remove the motor connections from the output power terminals on both of the power structures Note The terminals are located in different positions depending on whether du dt filters are installed or not 10 Remove the ground connections from the bottom o
108. ge 13 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO06A EN P July 2009 3 48 Access Procedures Removing the Protective Screens from the Power Structure Enclosure This procedure is only necessary for drives installed in NEMA UL 1 IP21 enclosures 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Remove the screws that secure the protective screens to the enclosure and remove the screens Remove screws Remove screws Remove screws Remove screw Installing the Protective Screens on the Power Structure Enclosure Install the protective screens in reverse order of removal PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 49 Removing the Voltage Feedback Circuit Board The Voltage Feedback board is located near the bottom of the middle Inverter on Power Structure 1 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 If present remove the protective screens Refer to Removing the Protective Screens from the Power Structure Enclosure on page 3 48 3 Disconnect the DC bus connection cable from the J2 socket and the motor feedback connection cable from the J1 socket at the top of the Voltage Feedback board 4 Carefully disconnect the fiber
109. harge cables and Fan Inverter cables from connectors X2 and X3 respectively on the Inverters NFE Converter Unit Inverter Unit 6 Remove the AC input wiring or bus bars from the terminals at the bottom of the NFE Converters 20 Nem NFE Converters Bottom View 177 Ibein 4 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 29 7 Remove the insulator material between the DC Bus Bar terminals at the top of the NFE Converters Insulators 8 Remove the M10 nut and washer that secure the DC Link fuse to the DC Bus Bars at the top of the NFE Converters by securing the top of the M10 headless screw with an Allen wrench and removing the M10 nut and washer at the bottom of the fuse Then remove the fuse Secure top of headless screw with Allen wrench 40 Nem 354 Remove nut and washer at bottom of fuse PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 30 Access Procedures 9 Remove the two hexagonal screws that secure the NFE Converter unit to the enclosure frame Powertig Powerex Povere Remove screws one each side of enclosure 10 Follow the instructions in publication PFLEX IN014 Installation Instructions PowerFlex 700S 700H High Power Maintenance Stan
110. hase L2 duit DC Source Module 4 1 Filter VT M F10 V L3 2 D Q lg Ac DC F2 R CR Measure L R Gate Drvr xt X Fan PE F F11 DC Phase Module F12 DC W Measure L R Gate Drvr Bd Xt x Fan 5 L L X11 X3 To Customer Precharge Supplied s 29 Complete Precharge 1 Star See Cic MTS Interface or Connections m X50 ie Board with DC Input ASIC Connec Board 2 with DC Input PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Schematics B 10 Figure B 9 Inverter Unit Circuitry for Drives with DC Input ejnpojy 4223 Seues ui sde c Jo v A009 eseug uoea Seues ui sde z Jo SOYOURLG e eled XIS AQ09 AO0F 5910 1p np si 10 LA 40 leuje seud 10 ON Chuo annys J MOd 90 cit JeMog plus 02 X ii BLY M 10 ELH 9 LH oe O aiqe9 uoqqiu A 9 10 LLH 9 OLH 81 8SeUd 10 6H 9 p pjeog OISV Wol4 T 21x peog 39 Y
111. he HIM cradle The voltage should be approximately 12V DC If the DC voltage is incorrect e PowerFlex 700S drives Replace the High Power Fiber Optic Interface circuit board e PowerFlex 700H drives Replace the output power modules Otherwise continue with step 3 3 Check for loose or missing connections between the DPI circuit board and the High Power Fiber Optic Interface circuit board If there are loose or missing connections or a board has been damaged replace the loose or missing connections or repair or replace any of the boards as needed Otherwise Replace the HIM PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 Molded Case Circuit Breakers MCCBs Trips Troubleshooting and Error Codes 1 25 The electronic trip unit will open the circuit breaker in the case of a drive overload overcurrent condition When a voltage drop U lt 0 7 x Un or loss of the main supply occurs the undervoltage release coil of the circuit breakers will open The trip indicator contacts of the circuit breakers are connected in series Therefore if one circuit breakers trips due to an undervoltage or overload overcurrent condition all circuit breakers will open trip If the circuit breakers have opened due to an overcurrent fault the condition that caused the fault must be corrected and the fault cleared before the circuit breakers can be
112. he ASIC Circuit Boards Removing the Protective Screens from the Power Structure Enclosure Installing the Protective Screens on the Power Structure Enclosure Removing the Voltage Feedback Circuit Board Installing the Voltage Feedback Circuit Removing the Main Cooling Fans from the Inverters Installing the Main Cooling Fans on the Inverters Removing the Fan Inverters from the Inverters Installing the Fan Inverters Removing the Air Flow Plate from the Power Structure Enclosure Installing the Air Flow Plate on the Power Structure Removing the Inverter Unit from the 1 Installing the Inverter Unit cee eee ene Removing the Fan Inverter Fuse Assemblies from the Inverters Installing the Fan Inverter Fuse Assemblies on the Inverters Removing the DC Connective Bus Bars from the Inverters Installing the DC Connective Bus Bars on the Removing the Inverters from the Frame Installing the InVert r r a aaa aa Ca a RI eas Removing the Output Power Modules from the Inverters Install
113. high Green Off The drive s enable input is low 1 SynchLink LEDS are located on the SynchLink daughtercard on the main circuit board in the control cassette Refer to Addressing 700S Faults on page 1 4 for more information PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 Troubleshooting and Error Codes 1 3 Viewing the 700H Diagnostic The control assembly on 700H drives contains a diagnostic LED which is LED visible through the cover and provides an indication of certain drive faults The control assembly is located in the upper left hand drive enclosure on the control frame 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 ATTENTION The control assembly LED is only operational Figure 1 2 PowerFlex 700H Diagnostic LED LED visible through this hole Table 1 B PowerFlex 700H Diagnostic LED Indications LED Indication Steady The drive is operational and has no faults Flashing Quickly e Switching power supply overload e Rectifier board fault e Fanor Fan inverter fault e Brake Chopper fault
114. igured with Par 391 DPI CommLoss Cfg A SCANport device is connected to a drive operating DPI devices at 500k Baud 51 DPI Loss Port 3 The device at DPI port 3 has stopped communicating with Verify DPI device is present and functional at port 3 Configured with Par 391 DPI CommLoss Cfg A SCANport device is connected to a drive operating DPI devices at 500k Baud 52 DPI Loss Port 4 The device at port 4 has stopped communicating with Verify DPI device is present and functional at port 4 the drive Configured with Par 391 DPI CommLoss Cfg A SCANport device is connected to a drive operating DPI devices at 500k Baud 53 DPI Loss Port 5 The device at port 5 has stopped communicating with Verify DPI device is present and functional at port 5 Configured with Par 391 DPI CommLoss Cfg A SCANport device is connected to a drive operating DPI devices at 500k Baud 54 DPI Loss Port 6 The device at port 6 has stopped communicating with Verify DPI device is present and functional at port 6 Configured with Par 391 DPI CommLoss Cfg A SCANport device is connected to a drive operating DPI devices at 500k Baud 55 Net Loss DPI P1 A communications fault has occurred between the 1 Verify network connection communication adapter at DPI port 1 and the network 2 Verify status of network Configured with Par 392 NetLoss DPI Cnfg 56 NetLoss DPI P2 A communications fault has occurred between the 1 Verify network c
115. ing the Output Power Modules Removing the DC Bus Capacitors from the Inverters Installing the DC Bus Capacitors in the Start Up After Repair Loading the 700H EEPROM 0 cece Before Applying Power to the Testing Without a Motor Performing the Power Circuit Diagnostic Test on a 7005 Testing With the Motor Without a Mechanical Load Service Tools and Equipment Software Tools es eR Re e eR UU Nor eed Sue era e Dee URS Service Tools uin u a uu bu dae dug Schematics List of Schematic Diagrams 2 0 Connector Descriptions Circuit Board Connections Hardware Connections Disassembly Assembly Diagrams Disassembly Assembly Diagrams and Spare Parts Numbers PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Appendix E MCCB Circuit Breakers Circuit Breaker Protection Functions Circuit Breaker Factory DIP Switch Settings Trip Curves dep tga ege he ES ee See ela
116. ion PFLEX TG006A EN P July 2009 1 20 Troubleshooting and Error Codes Table 1 R Fan Cooling Fault F32 Subcodes Subcode 273 Description The fan s in the power unit does not work according to feedback information 289 The fans in power unit 1 does not work according to feedback information typical of frame 12 and 14 drives 305 Table 1 5 Subcode 338 Table 1 T Subcode 272 273 The fans in power unit 2 does not work according to feedback information typical of frame 12 and 14 drives Communication Bus Fault F34 Subcode Description A sent message was not acknowledged Heatsink Under Temperature Fault F37 Subcodes Description There is a heatsink under temperature in the power unit 275 There is a heatsink under temperature in the U phase of the power unit typical of frame 11 and 13 drives 276 There is heatsink under temperature in the V phase of the power unit typical of frame 11 and 13 drives 277 There is a heatsink under temperature in the W phase of the power unit typical of frame 11 and 13 drives 288 289 There is a heatsink under temperature in power unit 1 typical of frame 12 and 14 drives 291 There is a heatsink under temperature in the U phase of power unit 1 typical of frame 14 drives 292 There is a heatsink under temperature in the V phase of power unit 1 typical of frame 14 drives 293 There is a heatsink under t
117. ion PFLEX TGOO6A EN P July 2009 Component Test Procedures 2 11 Checking Fan Inverter Fuses 1 Remove the protective covers from the Converters and Inverters Refer to Removing the Protective Covers from the NFE Converters on page 3 18 or Removing the Protective Covers from the Inverters on page 3 42 2 Using a multi meter verify that the fuses are not open Fan Inverter DIP Switch Settings 1 The Fan Inverters must be removed from the drive in order to verify the DIP Switch settings Refer to Removing the Fan Inverters from the NFE Converters on page 3 25 and Removing the Fan Inverters from the Inverters on page 3 52 2 Verify the following DIP switch settings on each Fan Inverter Switch Setting To indicate the following 51 Off 50 Hz fan motor frequency S2 Off 220 V AC motor voltage S3 On 230 V AC motor voltage 4 Off Frame size 9 13 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 2 12 Component Test Procedures ON S1 852 53 54 OFF Isolating a Faulty Fan Inverter on the NFE Unit Important This procedure requires special equipment and training Only qualified and trained personnel should perform these procedures These tests require the recommended high
118. k to see if the drive is in torque mode selected in OverSpd Lim Par 110 Speed TorqueMode value 2 Torque Ref If the drive is in torque mode verify that there is a load present 3 Verify min max settings in Par 75 Rev Speed Lim and Par 76 Fwd Speed Lim Check to see if the load is overhauling If it is overhauling turn the bus regulator off using Par 414 Brake Bus Cnfg bit 2 BusRef High 2 Vref Decel Fail The value of Par 301 Motor Spd Ref has failed to decrease during a ramp to zero speed stop This could possibly be due to a speed trim from Par 21 Speed Trim 1 Par 22 Speed Trim 2 or Par 23 Speed Trim 3 3 Encoder 0 Loss One of the following has occurred on encoder 0 Reconnect encoder or replace encoder e missing encoder broken wire e quadrature error Configured with Par 365 Fdbk LsCnfg Pri Par 366 Fdbk e phase loss LsCnfg Alt and Par 367 Fdbk LsCnfgPosit 4 Encoder 1 Loss One of the following has occurred on encoder 1 Reconnect encoder or replace encoder e missing encoder broken wire e quadrature error Configured with Par 365 Fdbk LsCnfg Pri Par 366 Fdbk e phase loss LsCnfg Alt and Par 367 Fdbk LsCnfgPosit 5 OptPortO Loss A fault on port 0 of the Hi Resolution Encoder Feedback 1 Reconnect encoder or replace encoder Option Card MDI Option Card Heidenhain or Resolver 2 Reconnect option feedback card Feedback Option Card has occurred e Par 260 Stegmann Status displays the fault status
119. le of Contents Important User Information 2 1 2 Overview Who Should Use this 7 cence eens P 1 What 15 in this Manual P 1 Reference Materials usu seua exa bea a w aaa sa esta 2 Understanding Manual 2 0 2 SEMPER BE Rs C XE SL bte d p 2 Cross References 2 sl auca eh P 3 Additional Support Available on P 3 PRECAUTIONS ossa p RAG An od ER a Reo eA OU ad ee eo P 3 Qualified Personnel uos eae sey oa eiue Desa DO es P 3 Personal Safety cere wa eek Re d aes P 3 Class 1 LED Product isses sete ek RR RR DR qaqa aa kuwa P 4 Product Safety e n eee epo ed obl dei ed P 4 Troubleshooting and Error Codes Viewing the 7005 Diagnostic 2 III 1 1 Viewing the 700H Diagnostic LED 2 I 1 3 Creating Fault Reports i socie mea E RR RR EEG saa A dats 1 4 Addressing 7005 Faults u sassa qaa 1 4 Addressing 700H Faults tarum et era wlagiaa cela ive ehawede ns 1 11 PowerFlex 700H Fault Subcodes 1 16 Common Drive Conditions and Corrective Actions 1 23 Molded Cas
120. lication PFLEX TG006A EN P July 2009 Component Test Procedures 2 9 Taking Resistance Measurements on the Precharge Resistors 6 Disconnect the wires from connectors 13 21 and X31 X22 and X32 and X23 and X33 on the Rectifying circuit board 7 Perform resistance measurements using a digital multimeter on the resistor wires that you have disconnected from connectors X21 and X31 X22 and X32 and X23 and X33 on the Rectifying circuit board 8 Verify that the resistance of each resistor is approximately 47 Q Important If any of the precharge resistors fails this test replace the resistor Disconnect precharge resistor wires from Rectifying circuit board Taking Resistance Measurements on the Rectifying Circuit Board 9 Perform resistance measurements using a digital multimeter on the points listed in Table 2 E below Table 2 E Rectifying Circuit Board Resistance Measurements Measurement Points on Board X31 to X9 X32 to X9 X33 to X9 Resistance 09 Important If the Rectifying circuit board fails any of these tests replace it Refer to Removing the Rectifying Circuit Board on page 3 32 PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 2 10 Component Test Procedures Taking Resistance Measurements on the Rectifying Module 10 Disconnect the wires from connectors 10 11 X12 and X13 on the Rectif
121. lows to maximum frequency limit 23 MC Commissn Fail The drive has failed to complete either the Motor Autotuning 1 Verify that motor nameplate data is entered correctly into procedure or the Power Circuits Diagnostics test Par 463 the drive MC Diag Error 1 Par 464 MC Diag Error 2 and Par 465 2 Verify the motor is wired for the correction voltage MC Diag Error 3 display Motor Autotuning and Power entering into the drive Circuit Diagnostic faults 465 Diag Error 3 Drive current inductance 3 Verify the encoder if used and velocity feedback is voltage and speed are not within motor nameplate correct f f specifications This fault occur most frequently on low 4 Change tuning mode in to Par 515 FVC Tune Config to horsepower motors 9 NoRotate Tune 24 DC Bus Overvolt Refer to Protection in Appendix of the PowerFlex 700S 1 Verify the AC Line Phase II AC Drive User Manual publication 20D UM006 for 2 verify that either the brake or bus regulator is enabled DC Bus Overvoltage Trip levels Par 414 Brake Bus Cnfg bit 0 Brake Enable or bit 3 Bus Reg Enable respectively 3 Verify that Par 128 Regen Power Lim is set properly 4 If Par 414 Brake Bus Cnfg bit 0 Brake Enable is set verify braking resistor is properly sized 25 Trans The IGBT detects a transistor failure Desat 26 Ground Fault A current to earth exceeds 3596 of the peak drive rating Check
122. me on page 3 17 3 Remove the protective covers Refer to Removing the Protective Covers from the NFE Converters on page 3 18 4 Remove the screws that secure the protective screens to the enclosure and remove the screens Remove screw Remove screws Remove screw Remove screws Installing the Protective Screens on the Rectifying Structure Enclosure Install the protective screens in reverse order of removal PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 20 Access Procedures Screws Removing the Air Flow Plate from the Rectifying Structure Enclosure You must remove the Air Flow Plate in order to remove the Converters from the drive 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 Move the control frame Refer to Moving the Control Frame on page 3 17 Remove the protective covers Refer to Removing the Protective Covers from the NFE Converters on page 3 18 If present remove the protective screens Refer to Removing the Protective Screens from the Rectifying Structure Enclosure on page 3 19 Remove the four T8 Torx head screws which secure the Air Flow Plate to the drive frame Slide the Air Flow Plate off of the drive frame Screws N Installing the Airflow Plate on the Rectifying Str
123. med by Rockwell Automation Inc with respect to use of 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 that can cause an explosion in a hazardous environment which may lead WARNING Identifies information about practices or circumstances to personal injury or death property damage or economic loss 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 identify a hazard avoid a hazard and recognize the consequences 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 Shock Hazard labels may be located on or inside the equipment e g PowerFlex DriveExplorer DriveExecutive DPI and SCANport are either trademarks or registered trademarks of Rockwell Automation Inc PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Preface Chapter 1 Chapter 2 Tab
124. meters ue LL 3 Parameter 53 Motor Cntl Sel may need to be set to fault Custom V Hz 4 Verify the values set in parameters 62 IR Voltage Drop and 63 Flux Current Ref 5 Contact Technical Support 32 Fan Cooling Fan is not energized at start command 1 Check the status LEDs on the fan inverter s See Table 1 R on page 1 20 for more information on this Check the fan s fault 33 AutoReset Lim The drive unsuccessfully attempted to reset a fault and Correct the cause and manually clear the fault resumed running for the programmed number of Auto Rstrt Tries You can enable disable this fault with parameter 238 Fault Config 1 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 Troubleshooting and Error Codes 1 13 No Name Description Action if appropriate 34 CAN Bus Fit A sent message was not acknowledged 1 Cycle the power See Table 1 5 on page 1 20 for more information on this gt Replace the Main Control board fault 37 HeatsinkUndTp The ambient temperature is too low Raise the ambient temperature See Table 1 T on page 1 20 for more information on this fault 44 Device Change The new power unit or option board installed is a different Clear the fault and reset the drive to the factory defaults type See Table 1 U on page 1 20 fo
125. module If the test is not completed successfully replace the Rectifying module Continue with step 3 3 Complete the Conducting Forward and Reverse Biased Diode Tests for Major Power Components on page 2 2 for the Output Power modules If the test is not completed successfully replace the Output Power modules Continue with step 4 4 Examine the DC bus capacitors If there is evidence of charring and damaged reliefs replace the DC bus capacitors Otherwise continue with step 5 5 Check the motor windings and motor cables with a high resistance DVM megger Repair or replace the motor as needed Otherwise continue with step 6 6 Disconnect and check the AC choke with a high resistance DVM megger e Verify that the line to line is open e Verify that the line to ground is open e Verify that the input to output is low resistance but not shorted Repair or replace the AC choke as needed Continue with step 7 7 Reconnect the AC choke and motor leads No HIM Display If the HIM does not display complete the following procedure to verify that power is available Diagnostic Procedure 1 Measure the DC bus voltage Corrective Action If the DC bus is not within specification repair or replace the Rectifying module as needed Otherwise continue with step 2 2 Measure the DC voltage supply at connector X4 on the DPI circuit board on the back of t
126. move the four M5 POZIDRIV screws which secure each of the three top and connection protective covers to the Inverters then remove the covers Note You only need to remove the connection covers to gain access to the cooling fan connections Connection covers 3 Nem 27 bein Installing the Protective Covers on the Inverters Install the protective covers in reverse order of removal PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 43 Removing the Gate Driver Circuit Boards There is a Gate Driver board located on the front of each of the Inverters 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Remove the protective covers Refer to Removing the Protective Covers from the Inverters on page 3 42 3 Unplug the DC supply from X1 of the first Gate Driver board 4 Carefully unplug the fiber optic cables from sockets along the top of 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 Important Minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Any bends with a shorte
127. moving the Bus Capacitors from the Rectifying Structure 3 41 Removing the Common Mode Filter Circuit Board 3 10 Removing the DC Bus Capacitors from the Power Structure 3 74 Removing the DC Connective Bus Bars from the Power Structure 3 63 Removing the DPI HIM Assembly 3 5 Removing the Fan Inverter Fuse Assemblies from the Power Structure 3 61 Removing the Fan Inverter Fuse Assemblies from the Rectifying Structur 3 24 Removing the Fan Inverters from the Power Structure 3 52 Removing the Fan Inverters from the Rectifying Structure 3 25 Removing the Gate Driver Circuit Boards 3 43 Removing the High Power Fiber Optic Interface Circuit Board 3 11 Removing the Main Cooling Fans from the Power Structure 3 51 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 Index 4 Removing the Main Cooling Fans from the Rectifying Structure 3 21 Removing the Output Power Modules 3 68 Removing the Power Module Blocks from the Drive 3 65 Removing the Power Structure from the Drive Enclosure 3 57 Removing the Pre Charging Resistors 3 23 Removing the Protective Covers from the Power Structure 3 42 Removing the Protective Covers from the Rectifying Structure 3 18 Removing the Protective Screens from the Power Structure 3 48 Removing the Protective Screens from the Rectifying Structure 3 19 Removing the Rectifying Module Blocks from the Drive
128. n the thermistor input on the 20C DG1 option board replace the Main Control board 12119 The 20C DG1 option board has been mounted in an incompatible Replace the Main Control board Main Control board that is not equipped with the Safe Disable function 12376 Parameter expander board slot B Therm Trip is set to OFF even if the jumper X12 is not cut Over Current Fault F12 Subcodes There is an over current in the power unit There is an over current in the U phase of the power unit typical of frame 11 and 13 is an over current in the V phase of the power unit typical of frame 11 and 13 is an over current in the W phase of the power unit typical of frame 11 and 13 is an over current in power unit 1 typical of frame 12 drives is an over current in the U phase of power unit 1 typical of frame 14 drives is an over current in the V phase of power unit 1 typical of frame 14 drives is an over current in the W phase of power unit 1 typical of frame 14 drives is an over current in power unit 2 typical of frame 12 drives is an over current in the U phase of power unit 2 typical of frame 14 drives is an over current in the V phase of power unit 2 typical of frame 14 drives Table 1 J Subcode Description 272 273 275 drives 276 There drives 277 There drives 288 289 There 291 There 292 There 293 There 304 305 There 307 There 308 There 309 There is an
129. nance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION Only qualified personnel familiar with high Personal Safety the ASIC Board located on the inverters of 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 voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION To avoid an electric shock hazard verify that the 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 Q ATTENTION Potentially fatal voltages may result from PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009
130. nds e If this fault and subcode occurs again replace the 20C DG1 option board PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 1 18 Troubleshooting and Error Codes Subcode Description Action 8023 A thermistor short circuit has been detected on the 20C DG1 option e Verify the thermistor connections and correct if necessary board e Verify that the jumper at X10 is in the correct position 8279 The 20C DG1 option board has been removed Set parameter 359 20C DG1 Status to 1 Remove and then back to 0 Ready 8535 There is an EEPROM error on the 20C DG1 option board Replace the 20C DG1 option board 8791 A supply voltage hardware problem has been detected on the Replace the 20C DG1 option board 20C DG1 option board 9047 A supply voltage hardware problem has been detected on the Replace the 20C DG1 option board 20C DG1 option board 9303 A supply voltage hardware problem has been detected on the Replace the 20C DG1 option board 20C DG1 option board 9559 A single hardware problem has been detected in the safe disable Replace the 20C DG1 option board inputs on the 20C DG1 option board If this fault occurs again replace the Main Control board 9815 A single hardware problem has been detected in the safe disable Replace the 20C DG1 option board If this fault occurs again inputs on th
131. nds with a shorter inside radius can permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 16 Access Procedures 6 Remove the four screws which secure the Fiber Optic Adapter board to the stand offs on the back of the Control frame and remove the Fiber Optic Adapter board conn 8 Ibein Installing the 700H Fiber Optic Adapter Circuit Board Install the 700H Fiber Optic Adapter circuit board in reverse order of removal PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 Access Procedures 3 17 Moving the Control Frame 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 If moving the control frame from a DC input drive with precharge interlock disconnect the wiring from terminal strip X50 X50 terminal block 3 Loosen the T8 Torx head screws which secure the control frame to the drive enclosure 4 Swing the control frame out and away from the Rectifying structure Loosen T8 Torx head screws Replacing the Control Frame Replace the control frame in reverse order of removal
132. ne Support Internet Go to http Avww ab com support abdrives E mail support drives ra rockwell com Be prepared to provide the following information when you contact support Product Catalog Number e Product Serial Number e Firmware Revision Level PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 4 2 Start Up After Repair Before Applying Power to 1 the Drive Check the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements 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 2 Testing Without a Motor This test allows you to measure several operating parameters and diagnose problems without connecting the motor to the drive 1 1 9 Verify that the input power wiring and grounding is connected Verify that the motor cables are disconnected Energize the drive 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 that allow the HIM to issue start and speed commands Make
133. ns fault on 3 Contact Technical Support 4 If the problem persists replace the drive 12 OverCurrent The drive output current has exceeded the hardware Check programming for an excess load improper DC boost current limit setting DC brake voltage set too high or other causes of See Table 1 J on page 1 18 for more information on this excess current Check for shorted motor leads or a shorted fault motor 13 Ground Fault A current path to earth ground exists that is greater than _ Check the motor and external wiring to the drive output 50 of the drive s heavy duty rating The current must terminals for a grounded condition appear for 800ms before the drive will fault See Table 1 K on page 1 19 for more information on this fault 14 nverterFault Hardware problem in the power structure 1 Cycle the power 2 Contact Technical Support 3 If the problem persists replace the drive PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 1 12 Troubleshooting and Error Codes No Name Description Action if appropriate 15 Load Loss Do not use this fault in PowerFlex 700H applications Check that parameter 238 Fault Config 1 bit 0 Power See Table 1 L on page 1 19 for more information on this Loss and parameter 259 Alarm Config 1 bit 13 Load fault Loss are se
134. ns and Corrective Actions 1 23 Molded Case Circuit Breakers MCCBs Trips 1 25 Technical Support Options 1 25 Viewing the 7005 Diagnostic The PowerFlex 7008 contains a drive power and status LED LEDs communication LEDs and SynchLink LEDs if the SynchLink option board is installed that provide an indication of certain drive faults See Table 1 A on page 1 2 for a description of the power and status LED indicators 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 only available with DriveLogix version 15 03 or later 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 The RUN LED and the controller LEDs are only operational when the drive is energized PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 1 2 Troubleshooting and Error Codes Figure 1 1 PowerFlex 700S HIM and Status LEDs OOOOO OOOOO QOOOO A M OOOOO oF See ie Table 1 4 PowerFlex 700S Status Indicator Descriptions Name Color St
135. onnection communication adapter at DPI port 2 and the network 2 Verify status of network Configured with Par 392 NetLoss DPI Cnfg 57 Net Loss DPI P3 A communications fault has occurred between the 1 Verify network connection communication adapter at DPI port 3 and the network 2 Verify status of network Configured with Par 392 NetLoss DPI Cnfg 58 NetLoss DPI P4 A communications fault has occurred between the 1 Verify network connection communication adapter at DPI port 4 and the network 2 Verify status of network Configured with Par 392 NetLoss DPI Cnfg 59 NetLoss DPI P5 A communications fault has occurred between the 1 Verify network connection communication adapter at DPI port 5 and the network 2 Verify status of network Configured with Par 392 NetLoss DPI Cnfg 60 Net Loss DPI P6 A communications fault has occurred between the 1 Verify network connection communication adapter at DPI port 6 and the network 2 Verify status of network Configured with Par 392 NetLoss DPI Cnfg 61 Logix Out of Run The DriveLogix controller is in a Non Run mode Non Run Clear fault bi include program remote program and faulted Configured with Par 386 Lgx OutOfRunCntg 62 Logix Timeout The communication connection to the DriveLogix controller Configured with Par 387 Lgx Timeout Cnfg has timed out PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2
136. oper grounding techniques 3 Disable bus regulation and or add a dynamic brake resistor and or extend the deceleration time 25 OverSpd Limit Functions such as Slip Compensation or Bus Regulation Remove the excessive load or overhauling conditions or have attempted to add an output frequency adjustment increase the value in Overspeed Limit greater than the value programmed in parameter 83 Overspeed Limit 26 VHz Neg Slope Parameter 53 Motor Cntl Sel Custom V Hz amp the V Hz slope is negative 27 SpdRef Cnflct Speed Ref x Sel or Reference Sel is set to Reserved 28 BrakResMissing No brake resistor has been detected 1 Program Bus Reg Mode x to not use the brake option See Table 1 0 on page 1 19 for more information on this 2 Install a brake resistor and set parameter 163 DB fault Resistor Type to 1 External Res frame 9 drives only 29 AnljlnLoss An analog input is configured to fault on a signal loss A 1 Check parameter settings signal loss has occurred Configure this fault with Anlg In x 2 Check for broken loose connections at the inputs Loss 30 MicroWatchdog A microprocessor watchdog timeout has occurred 1 Cycle the power See Table 1 P on page 1 19 for more information on this 2 Replace the Main Control board fault 31 IGBT Temp HW The drive output current has exceeded the instantaneous 1 Check for an excess load n biti 2 Raise the value set in either Accel Time x para
137. optic cables from sockets J4 and J5 on the side of the Voltage Feedback circuit board and carefully set them aside see illustration below for location 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 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 50 Access Procedures 5 Remove the four screws that secure the protective cover insulator and Voltage Feedback Circuit board to the fan housing on the drive and carefully remove the protective cover insulator and Voltage Feedback board Remove screws Nem 12 Ibein 6 Disconnect the cable from J8 socket of the Voltage Feedback board and set it aside 12 J Rockwell Automation Remove screws Remove screws TNS ZNR
138. power unit 1 is without auxiliary voltage typical of frame 12 and 14 drives 2083 The Gate Driver board for the U phase in power unit 1 is without auxiliary voltage typical of frame 14 drives 2084 The Gate Driver board for the V phase in power unit 1 is without auxiliary voltage typical of frame 14 drives 2085 The Gate Driver board for the W phase in power unit 1 is without auxiliary voltage typical of frame 14 drives 2097 The Gate Driver board in power unit 2 is without auxiliary voltage typical of frame 12 and 14 drives 2099 The Gate Driver board for the U phase in power unit 2 is without auxiliary voltage typical of frame 14 drives 2100 The Gate Driver board for the V phase in power unit 2 is without auxiliary voltage typical of frame 14 drives 2101 The Gate Driver board for the W phase in power unit 2 is without auxiliary voltage typical of frame 14 drives 2370 The TX fiber optic cable connected to H6 on the 700H Control board is broken 2594 The fiber optic cable connected to TRIP on the Star Coupler board for power unit 1 is broken typical of frame 12 and 14 drives 2610 The fiber optic cable connected to TRIP on the Star Coupler board for power unit 2 is broken typical of frame 12 and 14 drives 2834 The fiber optic cable connected to H5 on the ASIC board is broken 7767 The safe disable inputs on the 20C DG1 option board have beenin e Verify all connections to the 20C DG01 option board a different state for more than 5 seco
139. pped to the Ride Through level Check the AC input voltage and DC bus voltage specified in Par 408 Power Loss Level 93 12volt Power The12V DC control voltage is outside the tolerance range Alarm Alarm The positive voltage power exceeds 15 50 V DC The negative voltage power exceeds 15 50V DC 94 Analog In 1 Loss Analog Input channel 1 is lost For configuration of Analog Check condition of Analog Input channel 1 Input channel 1 Ses Par 1098 TRE Change configuration for parameter 1093 Anlg In1LossCnfg 95 Analog In 2 Loss Analog Input channel 2 is lost For configuration of Analog Check condition of Analog Input channel 2 Input channel 2 see Par 1094 Anlg In2LossCnfg Change configuration for parameter 1094 Anlg In2LossCnfg 96 Analog In 3 Loss Analog Input channel is lost For configuration of Analog Check condition of Analog Input channel 3 Input channel 3 see Par 1095 Anlg In3LossCnfg Change configuration for parameter 1095 Anlg In3LossCnfg 129 Faults Cleared Indicates that all faults have been cleared Informational only 130 Fault Cleared Indicates that the fault queue has been cleared Informational only 131 Alarm Cleared Indicates that all alarms have been cleared Informational only 132 Alarm Q Cleared indicates that the alarm queue has been cleared Informational only PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication
140. r 3 Fan Inverter Board Connections NFE 2 NFE 3 NFE 3 Fan Pin Signal Connector Connector Pin Inverter Board Number Description Pin Pin Number Connector From 2 15V To X1 2 To X1 8 2 X8 From 3 FAN CONTROL To X1 3 To 1 9 3 To 4 FAN_ALARM From X1 13 From X1 10 From 7 Table C R NFE Converter 3 Fan Inverter Board Connections NFE 3 Fan Through NFE pn metn Signal Inverter Board 3 Connector Inverter Board Signal Description Connector Pin Connector Description 15V X3 2 X1 2 4 X3 FAN_ALARM PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 C 10 Connector Descriptions Figure C 9 X50 Terminal Block Connectors External precharge circuitry is shown as dashed lines M DC EN anp dud HL Precharge F1 Ri CR M Complete DC Source uu PU2 T 1 i ASIC ES Precharge 2 ur EHH ee Complete F2 R2 CR2 L X15 eu conie Table C S X50 Terminal Block Precharge Circuit Connections ASIC Board Connector Terminal to X50 Terminal Block Description Power Module 1 X9 on ASIC 25 1 Precharge Complete Signal 24V DC Board 1 26 2 Precharge Complete Signal Common X15 on ASIC 21 vais 3 Charge Relay Contact Jumper to Power Board 1 Module 2 Terminal 4 23 is 4 Charge Relay Contact Power Module
141. r board to the four standoffs on the control frame and remove the Common Mode Filter board Installing the Common Mode Filter Circuit Board Install the Common Mode Filter Circuit Board in the reverse order of removal PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 11 Removing the 700S Fiber Optic Interface Board 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Move the 7008 control assembly mounting plate Refer to Moving the 700S Control Assembly Mounting Plate on page 3 6 Important Before removing connections and wires mark the connections and wires to avoid incorrect wiring during assembly 3 Carefully unplug the fiber optic cables from the sockets along the right side of the Fiber Optic Interface circuit board on the backside of the control assembly mounting plate 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 P is Nem 1 8 Ibein Remove
142. r inside radius can permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii 5 Disconnect the other cables from sockets of the Gate Driver board and set them aside 6 Remove the five screws that secure the Gate Driver board and support bracket to the Inverter Remove screws P2 3 Nem 27 Ibein Remove Gate Driver circuit board support bracket N screws 1 Nem 12 Ibein PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 44 Access Procedures 7 Carefully remove the Gate Driver board and the board support bracket 8 Carefully remove the two plastic screws that secure the Gate Driver board screening plate to the Inverter and remove the screening plate 9 Remove the two plastic stand offs that support the Gate Driver board Remove plastic screws PZ2 1 35 Nem 12 Ibein lt Remove EMC protection plate Remove plastic stand offs 1 5 gt 13 Ibein 10 Repeat steps 3 9 for the remaining Gate Driver board s Installing the Gate Driver Circuit Boards Install the Gate Driver circuit boards in the reverse order of removal Removing the ASIC Circuit Boards There is an ASIC board mounted on the middle Inverter of each Power structure the ASIC circuit board located on the power structure are energized at DC bus potential high voltage Ri
143. r more information on this fault 45 Device Add A new option board was added Clear the fault See Table 1 U on page 1 20 for more information on this fault 47 NvsReadChksum There was an error reading parameters 9 Elapsed MWh 1 Cycle the power and 10 Elapsed Run Time from EEPROM 2 Replace the Main Control board See Table 1 V on page 1 21 for more information on this fault 48 ParamsDefault The drive was commanded to write default values to 1 Clear the fault or cycle power to the drive EEPROM 2 Program the drive parameters as needed 54 Zero Divide This event occurred because a mathematical function had a 1 Cycle the power dividend of zero 2 Replace the main Control board 59 Gate Disable Both of the digital gate disable inputs SD 1 and SD 2 are 1 Check the motor not enabled on the 20C DG1 option board 2 Verify that the option board is properly wired 3 Replace the option board See Appendix E Instructions for ATEX Approved PowerFlex 700H Drives in Group II Category 2 Applications with ATEX Approved Motors in the PowerFlex 700H S High Power Drives Installation Manual publication PFLEX INOOG for information on installing this option board 60 Hrdwr Therm The thermistor input is activated gt 4 on the 20C DG1 1 Check the motor option board 2 The resistance of the thermistor input must go below 2 kQ before the drive can be reset 63 Shear Pin The value programmed in parameter 148
144. rFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 52 Access Procedures Removing the Fan Inverters from the Inverters Each Fan Inverter is located behind a Main Cooling Fan on an Inverter 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Remove the protective covers Refer to Removing the Protective Covers from the Inverters on page 3 42 W If present remove the protective screens Refer to Removing the Protective Screens from the Power Structure Enclosure on page 3 48 4 Remove the Voltage Feedback circuit board Refer to Removing the Voltage Feedback Circuit Board on page 3 49 5 Remove the Main Cooling Fans Refer to Removing the Main Cooling Fans from the Inverters on page 3 51 6 Disconnect the Fan Inverter cables from the connections on the front of the Inverters Fan inverter cable connectors 7 Push the Fan Inverter cables and connectors largest first through the rubber grommet into the frame where the Main Cooling Fan was located PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 53 8 Remove the two M5 POZIDRIV screws that secure the Fan Inverter to the drive 35 Ibsin Fan inverters Screws 9 Remove the cable ties that secure the cables with
145. r_OK X1 2 X3 3 U DTR X1 3 X3 4 U ETR X144 X3 5 1 5 X3 6 U_DC X1 6 X3 7 UI X1 7 X3 8 U DC I X1 8 X3 9 U_TEMP X1 9 X3 10 U_DC T X1 10 H8 fiber optic UH or Gate Top H2 fiber optic H9 fiber optic UL or Gate Bottom fiber optic 7 DTR N 3 4 2 Phase T ITR Phase Overcurrent Cable labeled X13 at X1 connection on Gate Driver board for Phase U PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO006A EN P July 2009 Table C B ASIC Board to Gate Driver Board Phase V Connections From ASIC Board Connector Pin Signal Description Connector Descriptions To Gate Driver Board Connector X4 1 V Feedback X1 1 X4 2 V Power OK X1 2 X4 3 X1 3 X4 4 v ETR X14 X4 5 V_ITR 1 5 X4 6 V_DC X1 6 X4 7 VI X1 7 X4 8 V DC I X1 8 X4 9 V TEMP X1 9 X4 10 V DC T X1 10 H10 fiber optic VH or Gate Top H2 fiber optic H11 fiber optic VL or Gate Bottom H4 fiber optic 1 2 DTR N Desat ETR Phase I T 4 Table C C ASIC Board to Gate Driver Board Phase W Connections TR Phase Overcurrent Cable labeled X14 at X1 connection on Gate Driver board for Phase V From ASIC Board To Gate Driver Board Connector Pin Signal Description Connector Pin X5 1 W Feedback X1 1 X5 2 W
146. rent limit in the U phase of the power unit typical of frame 11 and 13 drives 276 The output current has exceeded the instantaneous current limit in the V phase of the power unit typical of frame 11 and 13 drives 277 The output current has exceeded the instantaneous current limit in the W phase of the power unit typical of frame 11 and 13 drives 288 289 The output current has exceeded the instantaneous current limit in power unit 1 typical of frame 14 drives 291 The output current has exceeded the instantaneous current limit in the U phase of power unit 1 typical of frame 14 drives 292 The output current has exceeded the instantaneous current limit in the V phase of power unit 1 typical of frame 14 drives 293 The output current has exceeded the instantaneous current limit in the W phase of power unit 1 typical of frame 14 drives 304 305 The output current has exceeded the instantaneous current limit in power unit 2 typical of frame 12 and 14 drives 307 The output current has exceeded the instantaneous current limit in the U phase of power unit 2 typical of frame 14 drives 308 The output current has exceeded the instantaneous current limit in the V phase of power unit 2 typical of frame 14 drives 309 The output current has exceeded the instantaneous current limit in the W phase of power unit 2 typical of frame 14 drives PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publicat
147. reset and the drive started In this case refer to Charging the MCCB Motor Operators in the PowerFlex 7008 700H AC Drive Installation Manual publication PFLEX INO06 Also refer Appendix E MCCB Circuit Breakers for more information and to Figure B 6 on page B 7 for a schematic diagram of the MCCBs Figure 1 3 MCCB locations Drives above 1500 Amps 1500 Amp Drives Rectifying Structure Rectifying Rectifying Structure Structure Technical Support Options Technical Support Wizards If you are connected to a drive via DriveExplorer or DriveExecutive you can run a Tech Support wizard to gather information that will help diagnose problems with your drive and or peripheral device The information gathered by the wizard is saved as a text file and can be emailed to your remote technical support contact See What You Need When You Call Tech Support on page 1 26 for more information PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 1 26 Troubleshooting and Error Codes To run a Tech Support wizard in DriveExplorer select Wizards from the Actions menu In DriveExecutive select Wizards from the Tools menu Or click the siz button Follow the prompts complete the wizard What You Need When You Call Tech Support When you con
148. rminals 3 Check the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO006A EN P July 2009 Access Procedures 3 5 Rectifying Structure Access Below are the instructions for removing and installing components Procedures including the rectifying modules in or on the NFE Converters of the drive For instructions on removing and installing components including the output power modules on the Inverters refer to Power Structure Access Procedures on page 3 42 Removing the DPI HIM Assembly 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 Important Before removing connections and wires mark the connections and wires to avoid incorrect wiring during assembly 2 Remove the two screws from the front of the DPI HIM assembly Remove screws Nem 8 Ibein 3 Open the metal plate that holds the DPI interface and HIM 4 Unplug the DPI cable from the X2 connector on the DPI Interface circuit board X2 X4 Back view of the DPI circuit board which should remain mounted on the back of the metal pla
149. rters 3 27 Removing the NFE Converter Unit from the Enclosure 3 27 Installing the NFE Converter e 3 30 Removing the NFE Converters from the Frame 3 3 Installing the NFE Converters llle 3 31 Removing the Rectifying Circuit Board 3 32 Installing the Rectifying Circuit 3 33 Removing the Rectifying Modules from the NFE Converters 3 34 Installing the Rectifying Modules on the NFE Converters 3 40 Removing the Bus Capacitors from the NFE Converters 3 41 Installing the Bus Capacitors the NFE Converters 3 41 Power Structure Access Procedures 3 42 Removing the Protective Covers from the Inverters 3 42 Installing the Protective Covers on the Inverters 3 42 Removing the Gate Driver Circuit Boards 3 43 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Chapter 4 Appendix Appendix B Appendix C Appendix D Installing the Gate Driver Circuit Removing the ASIC Circuit Boards Installing t
150. s PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO06A EN P July 2009 2 14 Component Test Procedures Isolating a Faulty Fan Inverter on the Inverter Unit 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 Use the following procedure to isolate a faulty inverter if the main fans are not running Each fan inverter should be tested individually Refer to Main Fan Circuit for Drives with AC Input on page B 6 for more information 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Remove the 6 A fuses from the fan inverter fuse base 3 Disconnect the DC Bus supply from the X6 connector on the ASIC board 4 Connect the power supply s DC and DC to the X6 connector on the ASIC board PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Component Test Procedures 2 15 5 Connect the power supply s DC to the DC terminal on the fuse base and the power supply s DC to the DC terminal on the fuse base 6 Set the external DC power supply voltage to a nominal value and the current limit to 1 A 7 Switch on the external DC power supply If you receive a fault reset the fault I
151. s Configured with par 384 SL CommLoss Cnfg 10 Drive PowerLoss e DC Bus voltage has fallen below the minimum value Verify AC line power Par 306 DC Bus Voltage displays bus voltage Par 330 Fault TP Data displays the minimum value when Par 329 Fault TP Sel is set to five The drive must first complete precharge before this check is made 11 Motor OLoad Trip A motor overload trip has occurred Par 308 Output 1 Reduce mechanical load Current is squared scaled and integrated over time When 2 Enter correct motor nameplate full load amps Par 2 this integrated value exceeds 1 0 this Exception Event Motor NP FLA occurs Configured with Par 371 Mtr OL Trip Cnfg The integrator s output can be viewed in Par 330 Fault TP Data when Par 329 Fault TP Sel is set to 13 Mtr OL Outpt The overload integration rate is affected by Par 336 Motor OL Factor Par 337 Mtr I2T Curr Min Par 338 Mtr I2T Spd Min and par 339 Mtr I2T Calibrat 12 Motor OLoad A motor overload is pending Par 308 Output Current is 1 Reduce mechanical load Squared scaled and integrated over time When this 2 Enter correct motor nameplate full load amps Par 2 integrated value exceeds 0 5 this exception event occurs Motor NP FLA The integrator s output can be viewed in Par 330 Fault TP Configured with Par 371 Mtr OL Trip Cnfg Data when par 329 Fault TP Sel is set to 13 Mtr OL Outpt The overload integration ra
152. s 243 245 247 249 251 253 255 257 Fault x Code For example if parameter 243 Fault 1 Code displays 5 and parameter 543 Fault 1 Subcode displays 273 an over voltage fault F5 has occurred in the power unit of the drive Table 1 C Subcode 273 Precharge Active Fault F1 Subcodes Description The precharge circuit in the power unit is active 289 The precharge circuit in power unit 1 is active 305 Table 1 D Subcode 273 The precharge circuit in power unit 2 is active Under Voltage Fault F4 Subcodes Description The DC Bus voltage in the power unit is too low while the drive is in a run state 529 The DC Bus voltage in the power unit is too low while the drive is in a run state 545 The DC Bus voltage in power unit 1 is too low while the drive is in a run state 561 The DC Bus voltage in power unit 2 is too low while the drive is in a run state 785 Table 1 E Subcode 273 The DC Bus voltage in the power unit fell too low during a fast stop Over Voltage Fault F5 Subcodes Description There is an over voltage in the power unit 289 There is an over voltage in power unit 1 276 There is an over voltage in power unit 2 277 Table 1 F Subcode 400 Table 1 G Subcode 272 273 There is an over voltage in the power unit Motor Stall Fault F6 Subcode Description The motor is operating at high current and low frequency and i
153. s Bars and Insulator from the drive If necessary remove the screw that secures the insulator to the DC Bus Bars and remove the insulator Remove DC bus bars a on ewn nese ee Remove m Remove insulator Remove DC bus PZ2 4 35 Ibein 14 If necessary remove the Insulator from the bracket between the DC Bus terminal assemblies Remove insulator PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO06A EN P July 2009 3 38 Access Procedures 15 If necessary remove the screws that secure the DC Bus terminal assemblies and Insulator bracket to the drive and remove the DC Bus terminal assemblies and Insulator bracket Remove insulator holder Remove screws Remove screws NE iit T PZ2 f T 8 a T i b d Bo Remove DC Bus Terminals 16 Remove the gate leads from the top of the Rectifying module Remove gate leads PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 39 17 Remove the Balancing Resistor wires from the DC Bus Bars Remove wire connections from DC Bus Bar end im 27 bein PZ2 3Nem 27 lbein Balancing resistor assembly screws 18 Remove the screws that secure the Balancing Resistor assembly to the Rectifying module an
154. s not accelerating Heatsink Over Temperature Fault F8 Subcodes Description There is a heatsink over temperature in the power unit 274 There is a heatsink over temperature on the Power board of the power unit 275 There is a heatsink over temperature in the U phase of the power unit typical of frame 11 and 13 drives 276 There is a heatsink over temperature in the V phase of the power unit typical of frame 11 and 13 drives 277 There is a heatsink over temperature in the W phase of the power unit typical of frame 11 and 13 drives 288 289 There is a heatsink over temperature in power unit 1 typical of frame 12 and 14 drives 290 There is a heatsink over temperature on the Power board of power unit 1 typical of frame 12 and 14 drives 291 There is a heatsink over temperature in the U phase of power unit 1 typical of frame 12 and 14 drives 292 There is a heatsink over temperature in the V phase of power unit 1 typical of frame 12 and 14 drives 293 There is a heatsink over temperature in the W phase of power unit 1 typical of frame 12 and 14 drives 304 305 There is a heatsink over temperature in power unit 2 typical of frame 12 and 14 drives PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Troubleshooting and Error Codes 1 17 Subcode Description 306 Ther
155. sk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION The sheet metal cover and mounting screws on PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 45 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Remove the protective covers Refer to Removing the Protective Covers from the Inverters on page 3 42 3 Remove the four screws that secure the ASIC cover to the ASIC assembly and remove the ASIC cover 4 Remove the DC bus connection from the ASIC cover emove screws and cover 2o o 8 Ibein Remove DC bus connection 5 Unplug the fan which mounts on the cover from connector X1 of the ASIC circuit board 6 Carefully unplug 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 PowerFlex 7008 700H High Performance AC Drive
156. ssembly 3 13 Installing the 700H Circuit Boards and Control Assembly 3 14 Removing the 700H Fiber Optic Adapter Circuit 3 14 Installing the 700H Fiber Optic Adapter Circuit Board 3 16 Moving the Control Frame 2 3 17 Replacing the Control Frame 0 0 0 eee es 3 17 Removing the Protective Covers from NFE Converters 3 18 Installing the Protective Covers on the NFE Converters 3 18 Removing the Protective Screens from the Rectifying Structure Enclosure 3 19 Installing the Protective Screens on the Rectifying Structure Enclosure 3 19 Removing the Air Flow Plate from the Rectifying Structure Enclosure 3 20 Installing the Airflow Plate on the Rectifying Structure 3 20 Removing the Main Cooling Fans from the NFE Converters 3 2 Installing the Main Cooling Fans on NFE Converters 3 22 Removing the Precharge Resistors 3 23 Installing the Precharge Resistors 2 eee ees 3 23 Removing the Fan Inverter Fuse Assemblies from the NFE Converters 3 24 Installing the Fan Inverter Fuse Assemblies on the NFE Converters 3 24 Removing the Fan Inverters from the NFE Converters 3 25 Installing the Fan Inverters on the NFE Conve
157. sum error fault history entries device valid system menu parameters has occurred on the Control board Table 1 AA Main Control board Power board Configuration Fault F106 Subcode Subcode 385 Description The software and the power unit are incompatible PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO006A EN P July 2009 Common Drive Conditions and Corrective Actions No Output Voltage Troubleshooting and Error Codes 1 23 The drive has no output voltage to the motor even though the drive indicates that the motor is running Diagnostic Procedure 1 Measure the DC bus voltage Corrective Action If the DC bus is not within specification repair or replace the Rectifying module as needed Otherwise continue with step 2 2 Measure the AC output voltage at the motor terminals using a VAC RMS meter and compare the measurement to the AC output voltage displayed on the HIM Par 307 Output Voltage for 700S drives Par 6 Output Voltage for 700H drives If the AC output voltage at the motor terminals does not match the output voltage displayed on the HIM repair or replace the Output Power modules as needed Otherwise continue with step 3 3 Verify that there no loose or missing connections between the Gate Driver board and ASIC board and the Gate Driver board and Adapter board If there are loose or missing conne
158. sum error or is new and the parameters for the device board remain unchanged typical of frame 12 and 14 drives 528 The power level in power unit 2 is not equal to the power level in power unit 1 after a microprocessor reset typical of frame 12 and 14 drives 561 The power level in power unit 2 is not equal to the power level in power unit 1 after a microprocessor reset typical of frame 12 and 14 drives Table 1 V NVS Read Checksum Fault F47 Subcode Subcode Description 322 An operating time or energy counter checksum error has occurred on the Control board Table 1 W Motor Over Temperature Fault F16 Subcode Subcode Description 400 The motor is operating at high current and low frequency and is not accelerating Table 1 X Power Unit Fault F70 Subcodes Subcode Description 272 273 There is saturation in the power unit 275 There is saturation in the U phase of the power unit typical of frame 11 and 13 drives 276 There is saturation in the V phase of the power unit typical of frame 11 and 13 drives 277 There is saturation in the W phase of the power unit typical of frame 11 and 13 drives 288 289 There is saturation in power unit 1 typical of frame 12 and 14 drives 291 There is saturation in the U phase of power unit 1 typical of frame 14 drives 292 There is saturation in the V phase of power unit 1 typical of frame 14 drives 293 There is saturation in the W phase of power unit 1 typical of frame 14 drives Po
159. t 1 Time Time stamp of the fault occurrence 246 Fault 2 Time 248 Fault 3 Time 250 Fault 4 Time 252 Fault 5 Time 254 Fault 6 Time 256 Fault 7 Time 258 Fault 8 Time 262 269 Alarm Code 1 8 A code that represents a drive alarm No time stamp available PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 Chapter 2 Component Test Procedures For information on See page Performing Visual Inspections 2 1 Conducting Forward and Reverse Biased Diode Tests for Major Power Components 2 2 Conducting Gate Driver Board Gate Interface Resistance Measurements 2 6 Checking the Rectifying Modules on AC Input Drives Only 2 8 Checking the Main Fan Inverters and Fans 2 10 Important Review all precautions beginning on page 3 prior to beginning any of the component test procedures contained in this chapter Performing Visual Inspections Visually inspect the cooling tunnels and heatsinks and components on the NFE Converter and Inverter structures before energizing the drive Inspecting the Cooling Tunnels and Heatsinks 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Remove the main cooling fans from the bottom of the NFE converter if present and inverter structures Refer to Removing the Main Cooling Fans from the NFE Converters on page 3 21 and Removing the Main Cooling F
160. t to zero 16 Motor Therm The option board thermistor input is greater than the limit 1 Check to ensure that the motor is cooling properly 2 Check for an excess load 3 Verify the thermistor connection If the thermistor connection on the option board is not used it must be shorted 17 Input Phase One input line phase is missing 1 Check all user supplied fuses See Table 1 M on page 1 19 for more information on this 2 Check the AC input line voltage fault 19 Unbalanced An imbalance between the power modules exists 1 Check for DC voltage imbalance between the power modules 2 Check for current output imbalance between the power modules 21 OutPhasMissng There is zero current in one of the output motor phases 1 Check the motor wiring See Table 1 N on page 1 19 for more information on this 2 Check the motor for an open phase fault 22 NP Hz Cnflct The fan pump mode is selected in Motor Cntl Sel and the ratio of parameter 43 Motor NP Hertz to 55 Maximum Freq is greater than 26 23 MaxFreqCnflct The sum of parameters 82 Maximum Speed and 83 Overspeed Limit exceeds 55 Maximum Freq Raise Maximum Freq or lower Maximum Speed and or Overspeed Limit so that the sum is less than or equal to Maximum Freq 24 Decel Inhibit The drive cannot follow the commanded decel due to bus 1 Verify that the input voltage is within the specified limits limiting 2 Verify that the system ground impedance follows the pr
161. t with the assembly ASIC Assembly ASIC Board gt ASIC Insulator ASIC Assembly Bracket gt gt Table D F ASIC Assembly Part Numbers Part Name Part No ASIC Assembly Bracket ASIC Assembly Cover Included in 20 FR10850 ASIC Assembly Insulator ASIC Board 400 480V 1770A SK H1 ASICBD D1770 21504 SK H1 ASICBD D2150 27004 SK H1 ASICBD D2700 600 690V 1500A SK H1 ASICBD E1500 1900A SK H1 ASICBD E1900 22504 SK H1 ASICBD E2250 PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 D 8 Disassembly Assembly Diagrams Notes PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Circuit Breaker Protection Functions Appendix E MCCB Circuit Breakers For information on See page Circuit Breaker Protection Functions E 1 Circuit Breaker Factory DIP Switch Settings E 2 Trip Curves E 3 The circuit breakers MCCB used for frame 14 drives are equipped with electronic trip units The trip units provide protection functions against overload L and short circuit S or I With this version you can choose between protection S or I simply by moving the DIP switch Figure E 1 Protection Function Settings Against overload with long in verse time delay trip and trip characteristic according to an inverse time curve
162. tact Technical Support please be prepared to provide the following information Order number Product catalog number and drives series number if applicable Product serial number Firmware revision level Most recent fault code Your application The data contained in the following parameters will help in initial troubleshooting of a faulted PowerFlex 700H drive You can use the table below to record the data provided in each parameter listed Param s Name Description Parameter Data 224 Fault Frequency Captures and displays the output speed of drive at time of last fault 225 Fault Amps Captures and displays motor amps at time of last fault 226 Fault Bus Volts Captures and displays the DC bus voltage of drive at time of last fault 227 Status 1 Fault Captures and displays Drive Status 1 bit pattern at time of last fault 228 Status 2 Fault Captures and displays Drive Status 2 bit pattern at time of last fault 229 Alarm 1 Fault Captures and displays Drive Alarm 1 bit pattern at time of last fault 230 Alarm 2 Fault Captures and displays Drive Alarm 2 bit pattern at time of last fault 243 Fault 1 Code A code that represents the fault that tripped 245 Fault2Code drive 247 Fault 3 Code 249 Fault 4 Code 251 Fault 5 Code 253 Fault 6 Code 255 Fault 7 Code 257 Fault 8 Code 244 Faul
163. te J f PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 6 Access Procedures 5 On 700S drives only unplug the cable from the X4 connector on the circuit board 6 Remove the four mounting screws and the assembly from the control frame Mounting screws Metal plate with DPI 5 circuit board and 1 HIM in open position 0 9 Nem 0 SE PM 8 Ibein o ne e mn L Installing the DPI HIM Assembly Install the DPI HIM assembly in the reverse order of removal Moving the 700S Control Assembly Mounting Plate 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 Important Before removing connections and wires mark the connections and wires to avoid incorrect wiring during assembly 2 Disconnect any fiber optic ControlNet and SynchLink cables from the 700S control cassette 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 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 Pow
164. te is affected by Par 336 Motor OL Factor Par 337 Mtr I2T Curr Min Par 338 Mtr 12T Spd Min and Par 339 Mtr I2T Calibrat 13 Motor Stalled The motor has stalled These three conditions have 1 Increase torque limit occurred at the same time for the amount of time specified 5 Reduce mechanical load in Par 373 Motor Stall Time 1 Drive is not stopped Par 150 Logic State Mach not Configured with Par 374 Motor Stall Cnfg equal to zero 2 Drive is on limit Par 304 Limit Status not equal to zero 3 Drive is at zero speed Par 155 Logic Status bit 13 At Zero Spd is set 14 Inv OTemp Pend Par 313 Heatsink Temp is within 10 C of maximum 1 Reduce the mechanical load 2 Lower the ambient temperature View the maximum heat sink temperature in Par 348 Drive OL TP Data when Par 347 Drive OL TP Sel is set to 30 Configured with Par 375 Inv OT Pend 15 Inv OTemp Trip Par 313 Heatsink Temp is above the maximum limit 1 Reduce the mechanical load temperature sensor has failed shorted or open 2 Lower the ambient temperature See Par 346 Drive OL Status bit 0 NTC Shorted and bit 1 NTC Open 16 Inv OLoad Pend The drive s operating point is approaching the intermittent Reduce the load on the drive current rating limitation If output current remains at or above present levels an inverter overload condition will Configured with Par 376 Inv OL P
165. ter Unit Refer to Removing the NFE Converter Unit from the Enclosure on page 3 27 Remove the NFE Converters Refer to Removing the NFE Converters from the Frame on page 3 31 Remove the Rectifying circuit board Refer to Removing the Rectifying Circuit Board on page 3 32 Remove the Rectifying modules Refer to Removing the Rectifying Modules from the NFE Converters on page 3 34 Remove the screws that secure the Capacitors to the drive frame and remove the capacitors Remove screws E PZ T 1T 1 35N m si i 12 Ibsin Remove capacitors Installing the Capacitors on the 5 Install the bus capacitors in the reverse order of removal PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 42 Access Procedures Power Structure Access Below are the instructions for removing and installing components Procedures including the output power modules on the Inverters of the drive For instructions on removing and installing components including the rectifying modules on the NFE Converters refer to Rectifying Structure Access Procedures on page 3 5 Removing the Protective Covers from the Inverters You must remove the protective covers to gain access to the Inverters 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Re
166. the motor and external wiring to the drive output terminals for a grounded condition 27 Inst Overcurrent Instantaneous motor current exceeds 214 of rating 1 Reduce mechanical load 2 Check the motor and external wiring to the motor 28 VPL MC Comm Fail communication failure has occurred between the Velocity 1 Cycle power Position Loop VPL processor and the Motor Control MC 2 Reflash firmware processor on the main control board Possible causes are 3 Replace Main Control board e VPLis flashing MC firmware into the MC processor when gt P ace Main poar HIM indicates Loading Config e MC has failed to complete or pass diagnostic tests e MC has not detected VPL handshake activity for over 32 ms e VPL has not detected MC handshake activity for over 32 ms This is indicated when Fault Test Point 15 or 16 equals 1 This test point is viewed in Par 330 Fault TP Data when Par 329 Fault TP Select is set to value 15 or 16 29 PWM Signal Short This fault is detected when ever the actual IGBT gate is different than the commanded IGBT states This fault is detected by the Motor Control MC processor PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO006A EN P July 2009 Troubleshooting and Error Codes 1 7 Name Description Action 30 MC Firmware One of the following Motor Control MC firmware errors has 1 Cycle power occurred 2
167. the protective screens Refer to Removing the Protective Screens from the Power Structure Enclosure on page 3 48 3 Remove the four T8 Torx head screws that secure the Air Flow Plate to the enclosure frame 4 Slide the Air Flow Plate off of the enclosure frame Remove screws Remove screws L Installing the Air Flow Plate on the Power Structure Enclosure Install the Air Flow Plate in reverse order of removal PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 57 Removing the Inverter Unit from the Enclosure 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 Remove the protective covers Refer to Removing the Protective Covers from the Inverters on page 3 42 Remove the ASIC boards from the drive Refer to Removing the ASIC Circuit Boards on page 3 44 Note It is not necessary to remove the ASIC board assembly from the Inverter Only disconnect the fiber optic cables and other wires from the board that connect to boards in the Rectifying structure If present remove the protective screens Refer to Removing the Protective Screens from the Power Structure Enclosure on page 3 48 If necessary remove the Voltage Feedback board from the drive Refer to Removin
168. tifying Structure Enclosure on page 3 19 5 Remove the NFE Converter Unit Refer to Removing the NFE Converter Unit from the Enclosure on page 3 27 6 Remove the screws that secure the NFE Converters to the frame Two socket extensions are stored on the underside of the NFE Converter frame for use when removing the screws at the back of the enclosure Remove screws Remove screws Remove screws 22 Remove screws E gt 20 Nem 177 Ibein 7 Lift the NFE Converters off of the frame Installing the NFE Converters Install the NFE Converters in reverse order of removal PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 32 Access Procedures Removing the Rectifying Circuit Board There is a Rectifying board for each NFE Converter in the drive 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 Move the control frame Refer to Moving the Control Frame on page 3 17 Remove the protective covers Refer to Removing the Protective Covers from the NFE Converters on page 3 18 If present remove the protective screens Refer to Removing the Protective Screens from the Rectifying Structure Enclosure on page 3 19 Remove the NFE Converter Unit Refer to Removing the NFE Converter Unit from the Enclosure on page 3 27 Remove the NFE Converters Refer to Removing
169. tings Am Per 509 Voltage Class Rating Drive n ti SA 13 te ON OFF 100 400V 480V AC 1770 4 0 76 3s S 15 015 OFF na 2150 4 0 92 35 S 1 5 0 1s OFF na 600V 690V AC 1500 3 0 88 3s S 1 10 15 OFF na 1900 4 0 84 3s S 1 0 1s OFF na 2250 4 0 96 3s S 1 5 0 1s OFF na Figure E 2 Circuit Breaker Switch Locations D I L nca u u ay tnr eng DISCHARGED SPRING PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 MCCB Circuit Breakers E 3 Trip Curves Figure E 3 L S Functions N _ 48 3 p a a M TTE Note For In 600 A gt lomax 9 5 x In PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 E 4 MCCB Circuit Breakers Notes PowerFlex 700S 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Index Numerics Digln CnflctA Fault 1 14 700H Faults 1 11 Digln CnflctB Fault 1 15 7005 Digln CnflctC Fault 1 15 Drive Status Indicators 1 2 Diode Tests Faults 1 4 Forward Biased 2 2 Reverse Biased 2 2 A Anlg In Loss Fault 1 12 F ASIC Feedback Board Fan Cooling Fault 1 12 Connectors
170. tion Title Publication Wiring and Grounding Guide PWM AC Drives DRIVES IN001 Safety Guidelines for the Application Installation and Maintenance of SGI 1 1 Solid State Control A Global Reference Guide for Reading Schematic Diagrams 100 2 10 Guarding Against Electrostatic Damage 8000 4 5 2 The following publications provide specific PowerFlex drive information Title Publication Installation Instructions PowerFlex 700S and 700H Drives PFLEX INOOG Programming Manual PowerFlex 700H Adjustable AC Drive 20C PM001 User Manual PowerFlex 7005 High Performance Drive Phase Il 20D UM006 Control Installation Instructions Hi Resolution Feedback Option Card for 20D IN001 PowerFlex 700S Drives Installation Instructions Multi Device Interface Option for PowerFlex 20D INO04 7008 Drives Installation Instructions Main Control Board PowerFlex 7005 Drives 20D IN005 Installation Instructions Control Assembly Cover for PowerFlex 7005 20D INOO6 Drives Installation Instructions SynchLink Board for PowerFlex 700S Drives 20D INO10 with Phase II Control Installation Instructions PowerFlex 7005 700H High Power 20D INO014 Maintenance Stand Reference Manual PowerFlex 700 Adjustable Frequency Drive PFLEX RMO003 Phase Control The following publications provide information that is necessary when applying the DriveLogix Controller for PowerFlex 700
171. tructure 1 Structure 2 Structure 1 Structure 1 Structure 2 Structure 2 2700A Drive Rectifying Power Power Rectifying Structure 1 Structure 1 Structure 2 Structure 2 Note Shown with doors and control frames removed for clarity only PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGOO6A EN P July 2009 3 4 Access Procedures Removing Power from the Drive ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by 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 1 Turn off and lock out input power Wait five minutes 2 Verify that there is no voltage at the drive s input power te
172. ucture Install the Air Flow Plate in reverse order of removal PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 21 Removing the Main Cooling Fans from the NFE Converters There is a Main Cooling Fan on each of the NFE Converters 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Move the control frame Refer to Moving the Control Frame on page 3 17 3 Remove the protective covers Refer to Removing the Protective Covers from the NFE Converters on page 3 18 4 If present remove the protective screens Refer to Removing the Protective Screens from the Rectifying Structure Enclosure on page 3 19 5 Remove the screw located directly in front of the Main Cooling Fan housing that secures the NFE Converter module to the drive frame Remove screws PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TGO06A EN P July 2009 3 22 Access Procedures 6 Disconnect the Main Cooling Fan cable connector on the NFE Converters see illustration below for location 7 Remove the four screws that secure the fan housing to the frame Then remove the fan from the frame Disconnect fan able PZ2 4 Nem 35 Ibein Remove screws 8 Repeat steps 5 7 for each remaining fan Installing the Main Cooling Fans on th
173. ve screws PZ2 27 lbein 10 Repeat steps 6 9 for each of the remaining Fan Inverters PowerFlex 7008 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 Access Procedures 3 27 Installing the Fan Inverters on the NFE Converters Install the Fan Inverters in reverse order of removal Removing the NFE Converter Unit from the Enclosure Note The NFE Converters are secured to a frame that is removed from the enclosure as a single unit This unit must be removed from the enclosure before the individual NFE Converters and or Rectifying modules can be removed 1 Remove power from the drive Refer to Removing Power from the Drive on page 3 4 2 Move the control frame Refer to Moving the Control Frame on page 3 17 3 Remove the protective covers Refer to Removing the Protective Covers from the NFE Converters on page 3 18 4 If present remove the protective screens Refer to Removing the Protective Screens from the Rectifying Structure Enclosure on page 3 19 Important Before removing connections and wires mark the connections and wires to avoid incorrect wiring during assembly PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 3 28 Access Procedures 5 Disconnect the Fan Inverter cables from connector X1 on the NFE Converters and the pre c
174. wer module Locate the Gate Driver boards on the front of the Inverter units YQ Co O CO coco Note One Inverter unit shown for clarity only O k ame Gate Driver Boards PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 0 5 ohms DC DC DC U T1 V T2 W T3 aie ale 0 5 ohms Component Test Procedures 2 7 5 Measure the gate interface resistance for each U V and W phase Output Power transistor The resistance from each extinguishing pin to the branch emitter pin connectors X10 and X11 should be approximately 166 Q The resistance from the X10 branch emitter pin to the same branch output power terminal U T1 V T2 and W T3 should be approximately 0 5 Q The resistance from the X11 branch emitter to the same branch DC bus terminal should be approximately 0 5 Q Gate Interfac
175. werFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publication PFLEX TG006A EN P July 2009 1 22 Troubleshooting and Error Codes Subcode Description There is saturation in power unit 2 typical of frame 12 and 14 drives 304 305 307 There is saturation in the U phase of power unit 2 typical of frame 14 drives 308 There is saturation in the V phase of power unit 2 typical of frame 14 drives 309 There is saturation in the W phase of power unit 2 typical of frame 14 drives Table 1 Y Subcode 338 Table 1 2 Hardware Enable Fault F94 Subcode Description An hardware enable signal is missing from the control terminal block Parameter Checksum Fault F100 Subcodes Subcode 322 Description A firmware interface powerdown variable checksum error has occurred on the Control board 578 A firmware interface variable checksum error has occurred on the Control board 834 A system powerdown variable checksum error panel menu index fault history pointer has occurred on the Control board 1090 A system parameter checksum error multimonitor panel default pages has occurred on the Control board 1346 An application defined powerdown variable checksum error has occurred on the Control board 1602 An application defined powerdown variable checksum error has occurred on the Control board 2626 A system parameter check
176. ying Circuit board 11 Perform gate resistance measurements using a digital multimeter on the points listed in Table 2 F below These points are on the back of the gate leads that you have disconnected from the board Table 2 F Rectifying Module Gate Lead Resistance Measurements Measurement points on Gate Leads Resistance X10 gate lead red to X10 gate lead black X11 gate lead red to X11 gate lead black 18 Q I Q X12 gate lead red to X12 gate lead black Important If the Rectifying module fails any of these tests replace it Refer to Removing the Rectifying Modules from the NFE Converters on page 3 34 Checking the Main Fan Checking the Fan Inverter LEDs Inverters and Fans Each fan inverter has a red and a green diagnostic LED ATTENTION The inverter LEDs are only operational when AN 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 alone on energized equipment LED Red Green Indication Steady Steady Inverter Idle Off Flashing Inverter Running Flashing Steady Inverter Faulted or No Control from ASIC board PowerFlex 7005 700H High Performance AC Drive Frame 14 Hardware Service Manual Publicat

Download Pdf Manuals

Related Search

Related Contents

  Philips 8718291126027 energy-saving lamp    L-PRO 4000 Manual - ERLPhase Power Technologies Ltd.  D-Link Medialounge Wless Media Player    descargar - quideva.com    Fusion F300S Light Therapy Device User Manual  

Copyright © All rights reserved. Failed to retrieve file