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.

Troubleshooting and Error Codes 1-3
HiHp Drv OvrLoad 71 Drive Overload - the circuit board on
the Power Module has detected an
overload.
Measure output current of the
drive. If the level is ever greater
than the maximum drive rated
output current level reduce the
load. If the levels are always
well below the drive rated
levels, then replace the power
module.
HiHp PwrBd PrcEr 72 Power Board Processor Error - a
microprocessor on the Power Board
has detected a communication error.
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 PrChrg Cntc 73 Precharge Contactor Fault - proper
contactor feedback has not occurred.
The precharge contactor has probably
failed to pick up or the feedback signal
has failed. This fault only applies to
DC input drives.
xCheck precharge circuit
wiring.
xCheck for loose connections
on X50 terminal block and/or
the X9 and X15 connectors
on the ASIC Board.
HiHp PwrEE Error 74 Power EEPROM Error - the rating of
the drive and data in the Power
EEPROM on the Power Board do not
match.
Replace output power module
or program a new power board.
HiHP PwrBd OTemp 75 Power Board Over-Temperature -
temperature of the Power Board on
has exceeded 85qC.
Check the main cooling fan and
fan power supply, replace if
necessary.
HiHP HardwareVer 76 (High Horse Power Star-coupler board
frame 12 drives only) The left side and
right side inverter units have different
current ratings, or the ASIC on power
board is not functioning.
Check the version of each
inverter (left and right units),
then replace the units in pairs.
HiHP CurrUnblnce 77 (High Horse Power Star-coupler board
- frame 12 drives only) The output
current between the left side and right
side inverter units are unbalanced
(20% of current feedback rating, e.g.
184A = 920A * 0.2).
Check motor wiring for each
unit.
HiHP VoltUnblnce 78 (High Horse Power Star-coupler board
- frame 12 drives only) The bus
voltage for the left and right side
inverter units is unbalanced (6% of
normal bus voltage, e.g. 41Vdc =
675Vdc * 0.06).
Check input power and wiring
for each unit.
Fault No. Description Action (if appropriate)

1-4 Troubleshooting and Error Codes
Addressing 700H Hardware
Faults Name No. Description Action (if appropriate)
Auxiliary In 2 Auxiliary input interlock is open. Check remote wiring.
Power Loss 3 DC bus voltage remained below
parameter 186 [Power Loss Volts] for
longer than parameter 185 [Power
Loss Time]. Enable/Disable with
parameter 238 [Fault Config 1]. For
more information refer to publication
20C-PM001, Programming Manual -
PowerFlex 700H.
Monitor the incoming AC line for
low voltage or line power
interruption.
UnderVoltage 4 DC bus voltage fell below the
minimum value of 333V for 400/480V
drives and 461V for 600/ 690V drives.
Enable/Disable with parameter 238
[Fault Config 1]. For more information
refer to publication 20C-PM001,
Programming Manual - PowerFlex
700H.
Monitor the incoming AC line for
low voltage or power
interruption.
OverVoltage 5 DC bus voltage exceeded maximum
value.
Monitor the AC line for high line
voltage or transient conditions.
Bus overvoltage can also be
caused by motor regeneration.
Extend the decel time or install
and external dynamic brake
option.
Input Phase 17 One input line phase missing. Check user-supplied fuses
Check AC input line voltage.
OutPhasMissng 21 Zero current in one output motor
phase.
Check motor wiring.
Check motor for open phase.
Ground Fault 13 A current path to earth ground greater
than 25% of drive rating. Ground fault
level is 50% of the drive's heavy duty
current rating. The current must
appear for 800ms before the drive will
fault.
Check the motor and external
wiring to the drive output
terminals for a grounded
condition.
InverterFault 14 Hardware problem in the power
structure.
Cycle power.
Replace drive.
System Fault 10 Hardware problem exists in the power
structure.
Cycle power.
Replace drive.
Load Loss 15 Do not use this fault in 700H
applications
Check that parameter 238
[Fault Config 1] / bit 0 “Power
Loss” and parameter 259
[Alarm Config 1] / bit 13 “Load
Loss” are set to zero.
Precharge Error 31 The precharge function has failed to
complete within 30 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” to be off.
Verify the value in parameter
410 [PreChrg TimeOut]
Verify the bit value in parameter
411 [PreChrg Control] / bit 01
“PreChrg Enable”.
Power Unit 70 One or more of the output transistors
were operating in the active region
instead of desaturation. This can be
caused by excessive transistor current
or insufficient base drive voltage.
Clear fault.

Troubleshooting and Error Codes 1-5
Diagnostic Procedures by
Symptom
The following charts list drive symptoms, symptom descriptions and
recommended actions.
Blown Input Fuses
Use this procedure when a drive clears any of its external circuit breaker or
power fuses:
Rectifying
Module
OK?
No
Ye s
No
No
Ye s
Ye s
No
Ye s
No
Ye s
Ye s
No
Disconnect Motor
Leads
Perform Forward
Diode Tests on
Rectifying Module
Perform Forward
Diode Tests on
Output Power
Modules
Examine Bus
Capacitors for
Charring and
Damaged Reliefs
Check Motor and
Lead Resistances
at 1000V
Disconnect AC
Choke from
Rectifying Module
Replace
Rectifying
Module
Replace
Power
Modules
Replace
Capacitors
Remedy Motor
and Lead
Problems
Replace
AC
Choke
Reconnect
AC
Choke
Reconnect
Motor
Leads
Power
Modules
OK?
Capacitors
OK?
Motor and
Lead Resistances
> 1 Mohm?
Are There
Any Line to
Load Shorts?
Are There
Any Line to
Line Shorts?

1-6 Troubleshooting and Error Codes
No Output Voltage
Use this procedure when there is no voltage present at the drive output
terminals, even though the drive indicates the motor is running:
Measure DC Bus
Voltage
Perform forward
diode tests on
Rectifying Module
Rectifying
Module OK?
Replace Rectifying
Module
No
Examine Bus
Capacitors for
Charring and
Damaged Reliefs
Capacitors
OK?
Replace
Capacitors
No
Measure Power
Supply Voltages
Replace Power
Supply
Check Board
Connections
Does Drive
Run?
Does Drive
Run?
Replace Power
Interface Board
(on 700S)
Does Drive
Run?
Replace Voltage
Feedback Board
(on 700S)
No
Ye s
Ye s
No
Ye s
No
No
DC Bus
Voltage within
Specification?
Voltages within
Specification?
Replace Main
Control Board
Ye s
No

Troubleshooting and Error Codes 1-7
No HIM Display
Use this procedure when the HIM does not function:
Perform forward
diode tests on
Rectifying Module
Rectifying
Module OK?
Replace Rectifying
Module
No
Examine Bus
Capacitors for
Charring and
Damaged Reliefs
Capacitors
OK?
Replace
Capacitors
No
No
Ye s
Ye s
No
Ye s
Measure DC Bus
Voltage
Measure Power
Supply on X4 of
DPI Circuit Board
Check DPI and
Power Supply
Connections
Replace HIM
Does HIM
Function?
DC Bus
Voltage within
Specification?
Voltage
Equal 12V dc?
Replace Power
Interface Board
(on 700S)
Replace Output
Power Module
(on 700H)
Ye s
Ye s
No
Check HIM
Connection
and Seating
Properly
Connected?
Reseat or
reconnect
HIM
No
Ye s

1-8 Troubleshooting and Error Codes
Over-Temperature Faults
Use this procedure to troubleshoot drive over-temperature faults (14 - Inv
Otemp Pend and 15 - Inv Otemp Trip in 700S or 8 - Heatsink OvrTemp and
9 - Trnsistr OvrTemp in 700H):
Check Surrounding
Air Temperature
Temperature
Exceeds
Specification?
Provide
Additional Airflow
or Air Conditioning
Contact
Allen-Bradley
Drives
Technical
Support
Ye s
No
Ye s
No
Ye s
No
No
Ye s
No
Ye s
No
Ye s
Ye s
No
Current
Exceeds
Specification?
Frequency Too
High for Lead Length
and Surrounding
Te m p ?
Proper Space
At Inlet?
Power Voltage
Equals Bus
Voltage?
Connection
Good?
Output Equals
50 Hz / 220V rms?
Fan Motor has
Open or Short
Circuits?
Check Motor
Current and Load
Levels
Check PWM
Frequency
Check Fans and
Air Flow
Through the Drive
Check Power
Voltage on Fan
Inverters
Check Connection
Between ASIC
Board and Fan
Inverters
Check Fan
Inverter Outputs
on X1, X4 and X5
Check Fan Motors
for Short and
Open Circuits
Reduce Load or
Procure a Drive
With a Higher
Rating
Lower PWM
Frequency
Remedy
Spacing at
Inlet
Check Fan Inverter
Fuses (F1 and F2)
Repair
Connection
Replace
Fan Inverter(s)
Replace
Fan Motor(s)
Airlflow
Blockages? Ye s
Remove
Air Flow
Blockages
Ye s
No
No
Fans
Running
Properly?
No
Ye s

Chapter 2
Component Test Procedures
Viewing the 700H Diagnostic
LED
The Control Assembly on 700H drives contains a diagnostic LED which is
visible through the cover of the Control Assembly. the Control Assembly is
located in the upper, left-hand drive enclosure.
!
ATTENTION: 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.
!
ATTENTION: The Control Assembly LED is only operational
when the drive is energized, and only visible with the door of the
drive enclosure is open. Servicing energized equipment can be
hazardous. Severe injury or death can result from electrical
shock, burn or unintended actuation of controlled equipment.
Follow Safety related practices of NFPA 70E, ELECTRICAL
SAFETY FOR EMPLOYEE WORKPLACES. DO NOT work
alone on energized equipment!

2-2 Component Test Procedures
Viewing the 700S Diagnostic
LEDs
The PowerFlex 700S contains a Run LED, controller LEDs, and SynchLink
LEDs. These LEDs are only operational when the drive is energized and are
only visible when the drive door is open. The status of these LEDs can also
be viewed from the HIM or from an application program (e.g.,
DriveExplorer™) in parameter 554 [LED Status]. This feature is only
available with DriveLogix version 15.03 or later.
LED Indication
Steady The drive is operational and has
no faults
Flashing Quickly xSwitching power supply
overload
xRectifier Board fault
xFan or fan inverter fault
xBrake Chopper fault
xFiber Optic Adapter Board Fault
Flashing Slowly Bad connection between circuit
boards, check all connections
LED visible through
this hole
!
ATTENTION: The RUN LED and the controller LEDs are only operational when the drive is energized.
Servicing energized equipment can be hazardous. Severe injury or death can result from electrical shock, burn
or unintended actuation of controlled equipment. Follow Safety related practices of NFPA 70E, ELECTRICAL
SAFETY FOR EMPLOYEE WORKPLACES. DO NOT work alone on energized equipment!

Component Test Procedures 2-3
Table C Drive Status Indicator Descriptions
➋
➊
➌
# Name Color State Description
DRIVE
Power Structure
➊PWR
(Power)
Green Steady Illuminates when power is applied to the drive.
➋STS
(Status)
Green Flashing Drive ready, but not running & no faults are present.
Steady Drive running, no faults are present.
Yellow Flashing When running, a type 2 (non-configurable) alarm condition
exists, drive continues to run. When stopped, a start inhibit
exists and the drive cannot be started.
Steady A type 1 (user configurable) alarm condition exists, but
drive continues to run.
Red Flashing A fault has occurred.
Steady A non-resettable fault has occurred.
Red /
Ye l l o w
Flashing
Alternately
The drive is in flash recovery mode. The only operation
permitted is flash upgrade.
Control Assembly
Communications
➌PORT Refer to the
Communication
Adapter User Manual
Status of DPI port internal communications (if present).
MOD Status of communications module (when installed).
NET A Status of network (if connected).
NET B Status of secondary network (if connected).
Control
(1) SYNCHLINK Green Steady The module is configured as the time keeper.
or
The module is configured as a follower and
synchronization is complete.
Green Flashing The follower(s) are not synchronized with the time keeper.
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 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.

2-4 Component Test Procedures
Performing Visual Inspections Visually inspect the cooling tunnels and power structures before energizing
the drive.
Inspecting the Cooling Tunnels
1. Remove the main cooling fans from the bottom of the power structures.
Refer to Removing the Main Fans on page 3-26.
2. Inspect the tunnels. Clean the heatsinks and tunnels if necessary.
Inspecting the Power Structures
1. Remove the covers from the power structures. Refer to Removing the
Covers from the Power Structures on page 3-15.
2. Check components for burn marks, breakage or foil delamination on
circuit boards. Check all the boards on the power structures, including
those on the Output Power Modules and the Rectifying Modules (if
present).
Replace any of these components without further testing if they show
evidence of burn marks, breakage or foil delamination.
Conducting Forward and
Reverse Biased Diode Tests
for Major Power Components
A forward biased diode test checks the semiconductor junctions between
the terminals and measures the voltage drop across those junctions. To pass
each test, the meter must display a voltage near 0.5V. If the test finds a
short, the meter will display “.000.” If the test finds an open circuit or
reversed polarity, the meter will display “.0L” (zero load).
A reverse biased diode test should find an open circuit, and the meter should
display “.0L” (zero load).
~.0L
+
-
~0.5V
+
-
Forward biased test
on PN-junction
Reverse biased test
on PN-junction