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