Allen-Bradley PowerFlex 700H User manual

Installation Instructions
PowerFlex®700S and 700H Frame 10
Replacement Power Structures
Introduction Use this document to install a replacement power structure on a PowerFlex
700S or 700H frame 10 drive. This document covers the following
replacement power structures:
Spare Module Catalog
String
PowerFlex 700H
AC Input
PowerFlex 700H
DC Input
PowerFlex 700S
AC Input
PowerFlex 700S
DC Input
SK-H1-PWRMOD-D385 20CC385 20CH385 20DC385 20DH385
20CD385 20CJ385 20DD385 20DJ385
SK-H1-PWRMOD-D460 20CC460 20CH460 20DC460 20DH460
20CD460 20CJ460 20DD460 20DJ460
SK-H1-PWRMOD-D500 20CC500 20CH500 20DC500 20DH500
20CD500 20CJ500 20DD500 20DJ500
SK-H1-PWRMOD-E261 20CE261 20CK261 20DE261 20DK261
20CF261 20CM261 20DF261 20DM261
SK-H1-PWRMOD-E325 20CE325 20CK325 20DE325 20DK325
20CF325 20CM325 20DF325 20DM325
SK-H1-PWRMOD-E385 20CE385 20CK385 20CF385 20DK385
20CF385 20CM385 20DF385 20DM385
SK-H1-PWRMOD-E416 20CE416 20CK416 20DE416 20DK416
20CF416 20CM416 20DF416 20DM416

2PowerFlex® 700S and 700H Frame 10 Replacement Power Structures
What You Need to Do ❐ Step 1: Configure new power structure
❐ Step 2: Remove power from existing drive
❐ Step 3: Remove old power structure
❐ Step 4: Install new power structure
❐ Step 5: Connect power structure to components in drive
❐ Step 6: Install product identification label on new power structure
❐ Step 7: Start drive
!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 servicing the
drive. Check the DC bus voltage at the Power Terminal Block by
measuring between the +DC & -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: 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: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into SynchLink
fiber-optic ports or SynchLink fiber-optic cable connectors.
!ATTENTION: This drive contains ESD (Electrostatic
Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with
static control procedures, reference A-B publication 8000-4.5.2,
“Guarding Against Electrostatic Damage” or any other
applicable ESD protection handbook.
!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 in contact with the assembly.

PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 3
Step 1: Configuring the
New Power Structure
Before configuring the new power structure you must remove the protective
covers. Refer to the Installation Instructions - PowerFlex 700S and 700H
High Power Drives, publication PFLEX-IN006…for instructions on
removing these covers.
Configuring a DC Input Drive
Power structures are shipped from the factory pre-configured for DC input
operation.
Connecting an AC Input Drive
Power structures are shipped from the factory pre-configured for DC input
operation. When installing a replacement power structure on a drive with
AC input, you must remove the X2 plug from it’s protective sleeve and plug
the cable into the ASIC and Rectifier board.
Figure 1 ASIC Board Connections
Task Description
Remove the screw that secures the X6 connector wire to the ASIC cover and remove the
wire.
Remove the remaining screws that secure the cover to the ASIC assembly and remove the
cover.
Disconnect the ASIC fan from the assembly by unplugging the cable from X1 on the ASIC
board (see Figure 1 below for location).
Remove the cover from the connector on the loose cable (bundled with the flat gate driver
board cables) and connect the cable to the X2 connector on the ASIC board (see Figure 1
below for location).
Connect the other end of the cable connected to X2 on the ASIC board to the X13
connector for the Rectifier board on the upper right side of the power structure.
Connect the fan cable to the X1 connector on the ASIC board.
Install the cover on the ASIC board assembly.
A
B
C
D
E
F
G
H11
H12
H13
H8
H9
H10
X6
X9
X15
X3
X4
X5
X2
X1 H4
H5
H6
H1
H2
H3
H7
Connect cable to
X2 connector X1 connector

4PowerFlex® 700S and 700H Frame 10 Replacement Power Structures
Configuring the EMC Filter
Frame 10 size drives are equipped with common mode capacitors and
capacitors that are connected to the input terminals. To guard against drive
damage, these capacitors should be disconnected depending upon the type
of ground system on which the drive is installed.
Installation on an Ungrounded Distribution System or High Resistive Ground
If you are installing a 400/480V AC input drive on an ungrounded
distribution system or high resistive ground, you:
•Must move the common mode jumper to the disconnected position -
refer to Move the Common Mode Jumper to the Disconnected
Position on page 6.
•Should insulate terminal X4 on the Rectifier circuit board- refer to
Insulate Terminal X4 on the Rectifier Circuit Board on page 7.
•Must disconnect the small capacitors from the input terminals - refer to
Disconnect the Small Capacitors from the Input Terminals on page 8.
If you are installing a 600/690V AC input drive on an ungrounded
distribution system or high resistive ground you:
•Must move the common mode jumper to the disconnected position -
refer to Move the Common Mode Jumper to the Disconnected
Position on page 6.
•Must insulate terminal X4 on the Rectifier circuit board- refer to Insulate
Terminal X4 on the Rectifier Circuit Board on page 7.
•Must disconnect the small capacitors from the input terminals - refer to
Disconnect the Small Capacitors from the Input Terminals on page 8.
Installation on a Grounded B Phase Delta System
If you are installing a drive on a grounded B phase Delta system you:
•Must move the common mode jumper to the disconnected position -
refer to Move the Common Mode Jumper to the Disconnected
Position on page 6.
•Must insulate terminal X4 on the Rectifier circuit board- refer to Insulate
Terminal X4 on the Rectifier Circuit Board on page 7.
•Must disconnect the small capacitors from the input terminals - refer to
Disconnect the Small Capacitors from the Input Terminals on page 8.
Note: Refer to the Wiring and Grounding Guidelines for Pulse Width
Modulated (PWM) AC Drives - Installation Instructions,
publication DRIVES-IN001…, for additional information on an
ungrounded distribution system or high resistive ground
installation.

PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 5
Figure 2 Common Mode Jumper and Rectifier Circuit Board Location
Common
Mode jumper
Rectifier Circuit Board
Front View
of Assembly
There is one common
mode jumper located on
the upper-right side of the
power structure.

6PowerFlex® 700S and 700H Frame 10 Replacement Power Structures
Move the Common Mode Jumper to the Disconnected Position
Follow the lettered steps below to move the common mode jumper to the
disconnected position (refer to Figure 2 on page 5 for jumper location):
Task Description
Loosen the upper screw.
Remove the lower screw.
Move the jumper to the horizontal position.
Install and tighten the screws.
A
B
C
D
A
B
C
D
Rectifier Circuit Board
Front View of
Power Structure

PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 7
Insulate Terminal X4 on the Rectifier Circuit Board
Follow the lettered steps below to insulate terminal X4 on the Rectifier
circuit board (refer to Figure 2 on page 5 for Rectifier board location):
Important:Do not install the screw and washer that was removed from this
connection.
Task Description
Remove the screw from the X4 connection on the Rectifier circuit board.
Insulate the top and bottom of the X4 connection on the Rectifier circuit board.
A
B
X1
X4
X41
X1
X4
X41
Rectifier Circuit Board
AB
Side View of Power Structure

8PowerFlex® 700S and 700H Frame 10 Replacement Power Structures
Disconnect the Small Capacitors from the Input Terminals
Follow the lettered steps below to disconnect the small capacitors from the
input terminals:
Important:Do not re-install the capacitor leads.
Task Description
Remove the screws and lock washers that secure each of the three capacitor supply wires
to the input power terminals.
Insulate the capacitor leads and leave disconnected.
Install and tighten the screws and lock washers only.
A
B
C
L1 L2 L3
Capacitor
Insulator
Capacitor lead -
leave disconnected
Input power terminal
A
B
C
Front View of Input
Power Terminals
Side View of Input
Power Terminals

PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 9
Step 2: Removing Power
From the Existing Drive
1. Turn off and lock out input power. Wait five minutes.
2. Verify that there is no voltage at the drive’s input power terminals.
3. Check the DC bus voltage at the Power Terminal Block by measuring
between the +DC & -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.
Step 3: Removing the Old
Power Structure
Refer to the PowerFlex 700H/S Frame 10 Hardware Service Manual,
publication PFLEX-TG002…, for information about removing the old
power structure.
Step 4: Installing the New
Power Structure
Refer to the PowerFlex 700H/S Frame 10 Hardware Service Manual,
publication PFLEX-TG002…, for information about installing the new
power structure.
!ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged before servicing the
drive. Check the DC bus voltage at the Power Terminal Block by
measuring between the +DC & -DC terminals, between the +DC
terminal and the chassis, and between the -DC terminal and the
chassis. The voltage must be zero for all three measurements.
Remove power before making or breaking cable connections.
When you remove or insert a cable connector with power
applied, an electrical arc may occur. An electrical arc can cause
personal injury or property damage by:
•sending an erroneous signal to your system’s field devices,
causing unintended machine motion
•causing an explosion in a hazardous environment
Electrical arcing causes excessive wear to contacts on both the
module and its mating connector. Worn contacts may create
electrical resistance.
L1 L2 L3
O
I

10 PowerFlex® 700S and 700H Frame 10 Replacement Power Structures
Step 5: Connecting the
Power Structure to
Components in the Drive
You must connect the new power structure to the components in the drive. If
the drive has DC input, you must also connect the pre-charge circuit.
Connections to the 700S Control
When installing a power structure in a PowerFlex 700S drive, you must
make the following connections between the ASIC board and the Fiber
Optic Interface, Power Supply Voltage Feedback, Common Mode Filter and
Rectifier boards.
Connect this component: termination point in
the Power Structure to …
…this component : termination point on the
Control Frame
ASIC Board: H1 (fiber optic connector) Fiber Optic Interface Board: J8 (fiber optic
connector)
ASIC Board: H2 (fiber optic connector) Fiber Optic Interface Board: J9 (fiber optic
connector)
ASIC Board: H3 (fiber optic connector) Fiber Optic Interface Board: J10 (fiber optic
connector)
ASIC Board: H4 (fiber optic connector) Fiber Optic Interface Board: J11 (fiber optic
connector)
ASIC Board: H5 (fiber optic connector) Fiber Optic Interface Board: J12 (fiber optic
connector)
ASIC Board: H6 (fiber optic connector) Fiber Optic Interface Board: J14 (fiber optic
connector)
ASIC Board: H7 (fiber optic connector) Fiber Optic Interface Board: J13 (fiber optic
connector)
ASIC Board: X10 Insulate and do not connect
ASIC Board: X2 Rectifier Board: X13
Power Supply Voltage Feedback Board: J8 Common Mode Filter Board: J5
Power Supply Voltage Feedback Board: J4
(fiber optic connector)
Fiber Optic Interface Board: J6
Power Supply Voltage Feedback Board: J6
(fiber optic connector)
Fiber Optic Interface Board: J7

PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 11
Figure 3 Connections Between the Power Structure and the 700S Phase I Control
Figure 4 Connections Between the Power Structure and the 700S Phase II Control
Fiber Optic
Interface
Board
ASIC
Board
X2
H1
H2
H3
H4
H5
H6
H7
Fiber Optic Cables
J8 J9 J10 J11 J12 J14 J13
J3
J17
Fan
Power
J8 J15
J5
J6 TX
J7 RX
J4
J16
J8
+24v
RX J5
TX J4
J2
U-
V-
W-
J1
80W
Power
Supply
Power Supply
Voltage Feedback
Fiber 98
Fiber 89
2
DPI
DPI
COMM
(Option)
X2
X4
DPI
Interface
X1
2
20
J2
HIM
Bezel J1 HIM
X3 J3
HIM
DPI Assembly
PWR
STS
PORT
MOD
NET A
NET B
J10
J35 700S
Main
Control
Board
(Phase I)
J2
TB1
J7
72
10
J1
J11
J34
J8 J9
SynchLink TB2
TX RX
P2
P3
P5
P4
P6
DriveLogix
Controller
(Option)
P2
P3
P1 Feedback
Option
Card
RS-232
Flex I/O
Communication
Daughtercard
(Option)
P1
700S Control Assembly (Phase I)
Auxiliary
Power
24 V dc
Inside Power Structure
Make and verify these connections
J5
J1
2
Common Mode Filter Board
To X13 Connector for Rectifier Board (AC Input Drives Only)
X10
HIM
P10
P12
P6
P21
P2
P3
80
P1
Comm
Input
P1
Feedback
Inputs
P2
P3
P11
J1
2
9
20
10
120
34
Compact I/O
P1
34
J2
-U
-V
-W
DC-
DC+
J8
+24V
J4 Tx
J5 Rx
X3 J3
J2 J1
X2
X1
HIM
DOOR
EXTERNAL DPI
X4
2
PWR
STS
PORT
MOD
NET A
NET B
DPI Assembly
EXAMPLE:
20-HIM-A3
20-VB00601
2
Main
Control
Board
Feedback
Option
Board
Logix
Expansion
Board
NetLinx
Daughtercard
M6
J17
J18 J15
External
24V DC
1 = 24V
3 = Common
(75W min)
J5
J6 Tx
J7 Rx
J4
2
2
+24 V Iso
+12 V
-12 V
+5V
Pan Fan
Control
J16
Fiber Optic
Interface Board
80W
Power
Supply
Power Supply
Voltage
Feedback
DPI
Interface
Board
DPI
Comm
Option
DPI
Bezel
Fiber Optic Cables
J8 J9 J10 J11 J12 J14 J13
M
Fiber
8
9
9
ASIC Board
H1 (Gate Enable)
H2 (U Gate)
H3 (V Gate)
H4 (W Gate)
H5 (ADconv)
H6 (Vbus Tx)
H7 (Vbus Rx)
X2
DriveLogix
Battery
J3
P1
40
J2
P2
30
J1
P5P4
TB2TB1
P3
RS232
P2
CompactFlash
Memory
P13
P3 16
Second Encoder
or
Safe Off Option Board
P3
P1
SynchLink
Option Board
RX
TX
P2
Embedded
EtherNet I/P
Option Board
RJ45
Connector
P1
P7 P9
8
Inside Power Structure
Make and verify these connections
700S Control Assembly (Phase II)
J5
J1
2
Common Mode Filter Board
To X13 Connector for Rectifier Board (AC Input Drives Only)
X10

12 PowerFlex® 700S and 700H Frame 10 Replacement Power Structures
Figure 5 Termination Points on the ASIC Board
H11
H12
H13
H8
H9
H10
X6
X9
X15
X3
X4
X5
X2
X1 H4
H5
H6
H1
H2
H3
H7
Connects to X13 connector for the
Rectifier board on AC input drives
Connect to Pre-charge circuitry
on DC Input drives
Connects to fan on ASIC
Cassette cover
Fiber Optic connections to the
Fiber Optic Interface Board

PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 13
Figure 6 Termination Points on 700S Boards
Connections to the 700H Control
When installing a power structure in a PowerFlex 700H drive, you must
make the following connections between the ASIC and Fiber Optic Adapter
and Rectifier boards:
J4 J5
J8
J8
J10
J12
J6
J5
J9
J11
J14
J7
J13
J5
J1
Power Supply Voltage Feedback Board
Fiber Optic Interface Board
Common Mode Filter Board
Connect this component: termination point in
the Power Structure to …
…this component : termination point on the
Control Frame
ASIC Board : H1 (fiber optic connector) Fiber Optic Adapter Board : H1
(fiber optic connector)
ASIC Board : H2 (fiber optic connector) Fiber Optic Adapter Board : H2
(fiber optic connector)
ASIC Board : H3 (fiber optic connector) Fiber Optic Adapter Board : H3
(fiber optic connector)
ASIC Board : H4 (fiber optic connector) Fiber Optic Adapter Board : H4
(fiber optic connector)
ASIC Board : H5 (fiber optic connector) Fiber Optic Adapter Board : H5
(fiber optic connector)
ASIC Board : H6 (fiber optic connector) Fiber Optic Adapter Board : H6
(fiber optic connector)

14 PowerFlex® 700S and 700H Frame 10 Replacement Power Structures
Figure 7 Connections Between the Power Structure and 700H Control
Figure 8 Termination Points on Fiber Optic Adapter Board (700H Drives)
ASIC Board : H7 (fiber optic connector) Fiber Optic Adapter Board : H7
(fiber optic connector)
ASIC Board : X10 Fiber Optic Adapter Board : X3
ASIC Board: X2 Rectifier Board: X13
Connect this component: termination point in
the Power Structure to …
…this component : termination point on the
Control Frame
Fiber Optic Adapter Board
ASIC
Board
X10
H1
H2
H3
H4
H5
H6
H7
Fiber Optic Cables
H1 H2 H3 H4 H5 H6 H7 X3
DPI
COMM
(Option)
X2
X4
DPI
Interface
X1
20
J2
HIM
Bezel
J1
HIM
X3 J3
HIM
DPI Assembly
PWR
STS
PORT
MOD
NET A
NET B
700H Control Assembly
Inside Power Structure
Make and verify these connections
+24V
Common
1
2
X2
X1
37
X2
(Slot A)
20C-DA1-A
(24V dc Digital Input
w/ Analog I/O)
or
20C-DA1-B
(115V ac Digital Input
w/ Analog I/O)
10
Analog
I/O
8 / 10
Digital
Inputs
X3
(Slot B)
20C-DO1
(Digital Output
Option)
3
Digital
Outputs
3
Digital
Outputs
X4
(Slot C)
Option
Board
X5
(Slot D)
Option
Board
X6
(Slot E)
20C-DPI1
(DPI Communications
Option)
X1
X3 X2
X7
(RS-232
Programming
Port)
X1
700H Control Board
X2
(AC Input Drives Only) To X13 Connector for Rectifier Board(s)
H1
H2
H3
H4
H5
H6
H7
X2
Back View

PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 15
Pre-Charge Connections on Drives with DC Input
You must connect the ASIC board connectors X9 and X15 to the X50
terminal block for the pre-charge circuit. The X50 terminal block is located
on the Control Frame. Refer to publication PFLEX-IN006…, Installation
Instructions - PowerFlex 700S and 700H High Power Drives, for
information regarding the pre-charge circuit.
X50 Terminal Block Connections
Figure 9 Sample Pre-charge Wiring Diagram
ASIC Board Charge Relay Contact Ratings
ASIC Board
Connector Terminal to X50 Terminal Pre-Charge Circuit Connection Description
X9 25 . . . 1 Pre-charge Complete Signal (+24V DC)
26 . . . 2 Pre-charge Complete Signal (Common)
X15 21 . . . 3 Charge Relay Contact
23 . . . 4 Charge Relay Contact
M
F2 R2 CR2
DC+
DC Source
DC-
CR2R1F1
M
CR1
Pilot Relay
CR1 M
Main DC Contactor
M
CR2
Precharge
M
Precharge
Complete
1
2
3
4
25
26
21
23
X15
X9
ASIC Board
X50
Charge
Relay*
*Refer to the “ASIC Board
Charge Relay Contact
Ratings” table below.
Customer Connections - External precharge
circuitry is shown as dashed lines.
Drive ConnectionsTerminal Block
Important: For DC Input Only.
Do Not Install on AC Input Drives
Load Resistance load (cos φ = 1)
Rated load 8 A at 250 VAC: 5 A at 30 VDC
Rated carry current 8 A
Max. switching voltage 250 VAC; 30 VDC, (400 VAC)
Max. switching current AC 8 A; DC 5 A
Max. switching power 2,000 VA; 150 W
Failure rate (reference value) 5 VDC 10 mA (for gold plating 0.35 µ min.)

16 PowerFlex® 700S and 700H Frame 10 Replacement Power Structures
Step 6: Installing the
Product Identification Label
on the New Power Structure
All frame 10 replacement power structures are shipped form the factory
without a product identification label on the drive. If you are installing the
power structure in a 700S drive, you should label it with the accompanying
PowerFlex 700S label. If you are installing the power structure in a 700H
drive, you should label it with the accompanying PowerFlex 700H label.
Step 7: Starting the Drive 1. Install the protective covers on the drive. Refer to publication
PFLEX-IN006…, Installation Instructions - PowerFlex 700S and 700H
High Power Drives, for assistance in installing these covers.
2. Start up the drive. Refer to the Start Up procedures in the appropriate
publication:
–User Manual - PowerFlex 700S Drives with Phase I Control,
20D-UM001
–User Manual - PowerFlex 700S Drives with Phase II Control,
20D-UM006
–Programming Manual - PowerFlex 700H Drives, 20C-PM001.
DCBUSCONDUCTORSANDCAPACITORS
OPERATEATHIGHVOLTAGE.REMOVEPOWER
ANDWAIT5MINUTESBEFORESERVICING
DANGER!
DCBUSCONDUCTORS AND CAPACITORS
OPERATE AT HIGHVOLTAGE. R EMOVEPOWER
AND WAIT 5 MINUTESBEFORE SERVICING
DANGER
!
OR

PowerFlex® 700S and 700H Frame 10 Replacement Power Structures 17
Reference Materials Allen-Bradley publications are available on the internet at
www.rockwellautomation.com/literature.
The following manuals are recommended for general drive information:
The following manuals are recommended for detailed PowerFlex 700H and
700S information:
For Allen-Bradley Drives Technical Support and access to the proper
Hardware Service Manual:
Title Publication
Industrial Automation Wiring and Grounding Guidelines 1770-4.1
Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001…
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
PowerFlex 700S Reference Manual - Phase I Control PFLEX-RM002…
PowerFlex 700S Reference Manual - Phase II Control PFLEX-RM003…
PowerFlex 700H Programming Manual 20C-PM001…
PowerFlex 700S User Manual - Phase I Control 20D-UM001…
PowerFlex 700S User Manual - Phase II Control 20D-UM006…
Installation Instructions - PowerFlex 700S and 700H High Power Drives PFLEX-IN006…
Hardware Service Manual - PowerFlex 700S and 700H Frame 10 Drives PFLEX-TG002…
Title Online at...
Allen-Bradley Drives Technical Support www.ab.com/support/abdrives

www.rockwellautomation.com
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Power, Control and Information Solutions Headquarters
Publication PFLEX-IN008D-EN-P - August 2008 18 351483-P04
Supersedes PFLEX-IN008C-EN-P - August 2006 Copyright © 2008 Rockwell Automation. All rights reserved. Printed in the U.S.A.