Allen-Bradley PowerFlex 700H User manual

Hardware Service Manual
700S High Performance
AC Drive
and
700H Adjustable Frequency
AC Drive
Frame 12
450-560kW, 400V
700-900HP, 480V
630-800kW, 690V
700-900HP 600V

Important User Information
Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available
from your local Rockwell Automation sales office or online at www.rockwellautomation.com/literature) describes
some important differences between solid state equipment and hard-wired electromechanical devices. Because of
this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for
applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting
from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many
variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume
responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of 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.
Important: Identifies information that is critical for successful application and understanding of the product.
PowerFlex is a registered trademark of Rockwell Automation, Inc.
DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.
PLC is a registered trademark of Rockwell Automation, Inc.
!
WA R N I N G : Identifies information about practices or
circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property
damage, or economic loss.
!
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you:
xidentify a hazard
xavoid the hazard
xrecognize the consequences
Shock Hazard labels may be located on or inside the equipment
(e.g., drive or motor) to alert people that dangerous voltage may be
present.
Burn Hazard labels may be located on or inside the equipment
(e.g., drive or motor) to alert people that surfaces may be at
dangerous temperatures.

Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Preface Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
What is in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
What is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Understanding Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Additional Support Available on Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Chapter 1 Creating Fault Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Addressing 700S Hardware Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Addressing 700H Hardware Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Diagnostic Procedures by Symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Chapter 2 Viewing the 700H Diagnostic LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Viewing the 700S Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Performing Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Conducting Forward and Reverse Biased Diode Tests for Major Power Components. . . 2-4
Checking Fiber Optic Connections to the Gate Driver Boards . . . . . . . . . . . . . . . . . . . . . 2-8
Conducting Gate Driver Board Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Checking Rectifying Module (on AC Input Drives Only) . . . . . . . . . . . . . . . . . . . . . . . 2-14
Checking the DC Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Checking the Main Fan Inverters and Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Chapter 3 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Removing Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Removing the DPI / HIM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Removing the 700S Phase II Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Removing the 700S High Power Fiber Optic Interface Circuit Board . . . . . . . . . . . . . . . 3-8
Removing the 700S Control Assembly Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Removing the 700H I/O Boards and Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Removing the 700H Star Coupler Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Removing the Covers from the Power Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Removing the 700S Voltage Feedback Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Removing the Gate Driver and Adapter Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Removing the Power Structures from the Drive Enclosure . . . . . . . . . . . . . . . . . . . . . . 3-25
Removing the Main Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Removing the ASIC Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Removing the Rectifying Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Removing the Left-Side Output Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Removing the Right-Side Output Power Modules and Rectifying Modules . . . . . . . . . 3-33
Removing the Fan Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Removing the DC Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Chapter 4 Before Applying Power to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Testing with the External DC Power Supply Without Load (Optional) . . . . . . . . . . . . . . 4-2
Testing Without a Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Performing the Power Circuit Diagnostic Test on a 700S. . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Testing With the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

2
Appendix A Software Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Service tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Appendix B List of Schematic Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Appendix C Circuit Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Hardware Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
Appendix D Disassembly/Assembly Diagrams and Spare Parts Numbers . . . . . . . . . . . . . . . . . . . . . . D-1

Preface
Overview
Who Should Use this
Manual?
This manual is intended for qualified service personnel responsible for
troubleshooting and repairing high power PowerFlex 700H and 700S AC
Drives. You should have previous experience with, and basic understanding
of electrical terminology, procedures, required troubleshooting equipment,
equipment protection procedures and methods, and safety precautions.
What is in this Manual This manual contains hardware service information for Frame 12
PowerFlex 700H and 700S drives only. Verify that you are working on a
Frame 12 drive by checking the data nameplate on the Control Frame. The
frame number is printed just above the serial number.
What is Not in this Manual This manual does not contain in depth fault information for troubleshooting.
That information is available in publications 20C-PM001, Programming
Manual - PowerFlex 700H Adjustable Frequency AC Drive, PFLEX-IN006,
Installation Instructions - PowerFlex 700S and 700H Adjustable Frequency
AC Drive and 20D-UM006, User Manual - PowerFlex 700S with Phase II
Control High Performance AC Drive.
Cat No. 20D J500 N 0 NNNBNNNN
UL Open Type/IP00
540V 650V
Normal Duty Power 250 kW
200 kW
450 kW
500 kW
Heavy Duty Power
DC Voltage Range 462 - 594
350
583 - 713
350
Amps
Input: DC,
AC Voltage Range 0 - 400
50 Hz
0 - 460
60 Hz
Base Hz (default)
Output: 3 Phase, 0 - 320Hz
Continuous Amps 420/500
630/550
420/500
630/550
1 Min Overload Amps
2 Sec Overload Amps 840/630 840/630
MFD. in 1989 on Nov 9 Frame #: 12
Serial Number: 2622381652
2622381652
MADE IN THE USA (FAC 1B)
Series: A
Standard I/O: NONE
Original Firmware No. 2.04
UL
USC
Æ
LISTED
IND CONT EQ
9D42
Frame#:10
Cat No.
20D
J
300N 0 NNNBNNNN
ULOpen Type/IP00
540V 650V
Normal Duty Power
160kW
132kW
250kW
200kW
HeavyDuty Power
DCVoltage Range
462- 594
350
583- 713
350
Amps
Input:DC,
ACVoltage Range
0- 400
50Hz
0- 460
60Hz
BaseHz (default)
Output:3 Phase, 0 - 320Hz
ContinuousAmps
300/245
330/368
300/245
330/368
1Min Overload Amps
2Sec Overload Amps
450/490 450/490
MFD.in2005 on Feb 29
Serial Number: 2622381652
2622381652
MADEIN THE USA (FAC1B)
Series:A
StandardI/O: NONE
OriginalFirmware No. 2.04
UL
USC
Æ
LISTED
INDCONT EQ

P-2 Overview
Reference Materials Allen-Bradley publications are available on the internet at
www.rockwellautomation.com/literature.
The following publications provide general drive information.
The following publications provide specific PowerFlex drive information.
The following publications provide information that is necessary when
applying the DriveLogix Controller.
Understanding Manual
Conventions
Terms
The following words are used throughout the manual to describe an action:
Title Publication
Wiring and Grounding Guide, (PWM) AC Drives DRIVES-IN001…
Safety Guidelines for the Application, Installation and Maintenance of
Solid State Control
SGI-1.1
A Global Reference Guide for Reading Schematic Diagrams 0100-2.10
Guarding Against Electrostatic Damage 8000-4.5.2
Title Publication
Programming Manual - PowerFlex 700H AC Drive 20C-PM001…
User Manual - PowerFlex 700S with Phase II Control High
Performance Drive
20D-UM006…
Installation Instructions - Hi-Resolution Feedback Option Card for
PowerFlex 700S Drives
20D-IN001…
Installation Instructions - Multi Device Interface Option for PowerFlex
700S Drives
20D-IN004…
Installation Instructions - Main Control Board PowerFlex 700S Drives 20D-IN005…
Installation Instructions - Control Assembly Cover for PowerFlex 700S
Drives
20D-IN006…
Installation Instructions - PowerFlex 700S /700H High Power
Maintenance Stand
20D-IN014…
Installation Instructions - PowerFlex 700S and 700H Drives PFLEX-IN006…
Reference Manual - PowerFlex 700S with Phase II Control Adjustable
Frequency Drives
PFLEX-RM003…
Title Publication
User Manual - DriveLogix System 20D-UM002…
Installation Instructions - DriveLogix Controller 20D-IN002…
Installation Instructions - Memory Expansion for DriveLogix Controller 20D-IN007…
ControlNet Daughtercard Installation Instructions 1788-IN002…
ControlNet Daughtercard Installation Instructions 1788-IN005…
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

Overview P-3
Cross References
“Figure 2.2 on page 2-6” is a cross reference to figure 2.2 on page 5 of
Chapter 2.
“Figure C.1 on page C-2” is a cross reference to figure C.1 on page 2 of
Appendix C.
Additional Support
Available on Internet
Additional troubleshooting information and software tools are available on
the Allen-Bradley Drives Support Website (http://www.ab.com/support/
abdrives/).

P-4 Overview
General Precautions Class 1 LED Product
!
ATTENTION: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into module ports or
fiber-optic cable connectors.
!
ATTENTION: The sheet metal cover and mounting screws on
the ASIC Board located on the power structure are energized at
(-) DC bus potential high voltage. Risk of electrical shock, injury,
or death exists if someone comes into contact with the assembly.
!
ATTENTION: This drive contains ESD (Electrostatic
Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with
static control procedures, reference A-B publication 8000-4.5.2,
“Guarding Against Electrostatic Damage” or any other applicable
ESD protection handbook.
!
ATTENTION: An incorrectly applied or installed drive can
result in component damage or a reduction in product life. Wiring
or application errors, such as, undersizing the motor, incorrect or
inadequate AC supply, or excessive ambient temperatures may
result in malfunction of the system.
!
ATTENTION: Only qualified personnel familiar with high
power PowerFlex 700S and 700H Drives and associated
machinery should plan or implement the installation, start-up and
subsequent maintenance of the system. Failure to comply may
result in personal injury and/or equipment damage.
!
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged before performing
any work on the drive. Measure the DC bus voltage at the DC+ &
DC- terminals. The voltage must be zero.
!
ATTENTION: Potentially fatal voltages may result from
improper usage of an oscilloscope and other test equipment. The
oscilloscope chassis may be at a potentially fatal voltage if not
properly grounded. If an oscilloscope is used to measure high
voltage waveforms, use only a dual channel oscilloscope in the
differential mode with X 100 probes. It is recommended that the
oscilloscope be used in the A minus B Quasi-differential mode
with the oscilloscope chassis correctly grounded to an earth
ground.

Chapter 1
Troubleshooting and Error Codes
!
ATTENTION: To avoid an electric shock hazard, ensure that all
power to the drive has been removed before performing the
following.
!
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged before performing
any work on the drive. Measure the DC bus voltage at the DC+ &
DC- terminals. The voltage must be zero.
!
ATTENTION: HOT surfaces can cause severe burns. Do not
touch the heatsink surface during operation of the drive. After
disconnecting power allow time for cooling.
!
ATTENTION: This drive contains ESD (Electrostatic
Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with
static control procedures, reference A-B publication 8000-4.5.2,
“Guarding Against Electrostatic Damage” or any other
applicable ESD protection handbook.

1-2 Troubleshooting and Error Codes
Creating Fault Reports Clear and complete fault reports are critical for analysis and repair of
modules returned to the factory.
At a minimum, perform and record the following:
xRecord the contents of the fault queue (faults and times of occurrence)
xMake record of any burn marks on the rectifying module, DC-capacitors,
inverter bridge, charging resistors, balancing/precharging resistors,
printed circuit boards, bus bars, cabling and fiber-optic cabling
xMake record of any liquid and condensation marks on printed circuit
boards, components and mechanical parts
xMake record of the amount of dust and other additional particles on drive
and drive components
xMake record of any mechanical damage to the drive and drive
components
xRecord the size and type of main fuses
xRecord any other important marks and damage
Addressing 700S Hardware
Faults Fault No. Description Action (if appropriate)
HiHp In PhaseLs 65 AC Input Phase Loss - AC voltage is
not present on one or two input
phases.
1. Check for voltage on each
input phase.
2. Check the status of each
external input fuses.
HiHp Bus Com Dly 66 Bus Communication Time Delay - the
processor has not received proper
periodic feedback information.
Check fiber-optic connections
between the Power Interface
Circuit Board and Voltage
Feedback Circuit Board.
HiHp Bus Link LS 67 Bus Communication Link Loss - bus
communication between the Power
Interface Circuit Board and Voltage
Feedback Circuit Board has halted.
Check fiber-optic connections
between the Power Interface
Circuit Board and Voltage
Feedback Circuit Board.
HiHp Bus CRC Er 68 Bus Communication CRC Error - too
many Cycling Ring Checksum (CRC)
errors have occurred in the
communication bus.
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.
Check fiber-optic connections
between the Power Interface
Circuit Board and Voltage
Feedback Circuit Board.
Wait five minutes before
re-energizing the drive.
HiHp Bus WtchDog 69 Bus Communication Watchdog Error -
communication has halted in the
communication bus, causing the
watch dog timer to expire.
1. Check fiber-optic
connections between the
Power Interface Circuit Board
and Voltage Feedback Circuit
Board.
2. Check connections between
the Main Control Board and
the Power Interface Circuit
Board.
3. Replace the Voltage
Feedback Circuit Board.
4. Replace the Power Interface
Circuit Board.
5. Replace the Main Control
Board.
HiHp Fan Fdbk Ls 70 Fan Feedback Loss - a fan feedback
signal has been lost.
1. Check the main cooling fan.
2. Check the Main Control
Board cooling fan.