Rockwell Automation PowerFlex 700S User manual

Installation Instructions
PowerFlex®700S and 700H Frame 13
Replacement Power Structures
Introduction Use this document to install a replacement power structure on a PowerFlex
700S or 700H frame 13 drive. This document covers the following
replacement power structures:
What You Need to Do ❐ Step 1: Remove power from the drive
❐ Step 2: Remove the old power structure
❐ Step 3: Install the new power structure
❐ Step 4: Connect the new power structure to the components in the
drive
❐ Step 5: Install the product identification label on the new power
structure
❐ Step 6: Start the drive
Voltage Class
Spare Module Catalog
String
PowerFlex
700H AC Input
PowerFlex
700H DC Input
PowerFlex
700S AC Input
PowerFlex
700S DC Input
400/480V AC
(540/650V DC)
SK-H1-PWRMOD-D1K1 20CC1K1 20CH1K1 20DC1K1 20DH1K1
20CD1K1 20CJ1K1 20DD1K1 20DJ1K1
SK-H1-PWRMOD-D1K3 20CC1K3 20CH1K3 20DC1K3 20DH1K3
20CD1K3 20CJ1K3 20DD1K3 20DJ1K3
SK-H1-PWRMOD-D1K4 20CC1K4 20CH1K4 20DC1K4 20DH1K4
20CD1K4 20CJ1K4 20DD1K4 20DJ1K4
600/690V AC
(810/932V DC)
SK-H1-PWRMOD-E920 20CE920 20CK920 20DE920 20DK920
20CF920 20CM920 20DF920 20DM920
SK-H1-PWRMOD-E1K0 20CE1K0 20CK1K0 20DE1K0 20DK1K0
20CF1K0 20CM1K0 20DF1K0 20DM1K0
SK-H1-PWRMOD-E1K1 20CE1K1 20CK1K1 20DE1K1 20DK1K1
20CF1K1 20CM1K1 20DF1K1 20DM1K1

2PowerFlex® 700S and 700H Frame 13 Replacement Power Structures
Step 1: Removing Power
From the 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. Measure 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 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 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:
•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

PowerFlex® 700S and 700H Frame 13 Replacement Power Structures 3
Step 2: Removing the Old
Power Structure
Before you can remove the old power structure from the drive, you must
remove the protective screens, protective covers and air flow plate from the
drive.
Removing the Protective Screens and Covers
1. For NEMA/UL Type 1 enclosures, remove the screws that secure the
protective screens to the enclosure and remove the screens.
2. Remove the four M5 POZIDRIV screws that secure each of the three
protective covers to the power structure and remove the protective
covers.
DC BUS CONDUCTORS AND CAPACITORS
OPERATEAT HIGH VOLTAGE.REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER
!
1
Three covers
2

4PowerFlex® 700S and 700H Frame 13 Replacement Power Structures
Removing the Air Flow Plate
3. Remove the four T8 Torx-head screws that secure the airflow plate to
the drive.
4. Slide the airflow plate off of the drive.
3
4

PowerFlex® 700S and 700H Frame 13 Replacement Power Structures 5
Important:Before removing connections and wires, mark the connections
and wires to avoid incorrect wiring during assembly.
5. Remove the motor wiring from the output power terminals on the power
structure.
6. Remove the ground connection from the lower right corner of the power
structure.
7. Remove the input connections from the incoming DC bus terminals at
the top of the power structure.
DC-
DC+ DC- DC+ DC- DC+
U/T1 V/T2 W/T3
U/T1 V/T2 W/T3
Output Power Terminals
DC Bus Terminals
ASIC Board
Assembly
Power Supply Voltage
Feedback Board Assembly
Ground Terminals

6PowerFlex® 700S and 700H Frame 13 Replacement Power Structures
8. Remove the four screws that secure the cover to the ASIC assembly and
remove the -DC bus connection from the cover.
9. Unplug the cooling fan that mounts to the ASIC assembly cover from
connector X1 on the ASIC board and remove the ASIC assembly cover.
=
Remove -DC bus
connection.

PowerFlex® 700S and 700H Frame 13 Replacement Power Structures 7
10. Disconnect the fiber optic cables (H1 - H7) from the ASIC board.
11. For drives with 700H control, disconnect the +24V supply cable from
connector X10 on ASIC board #1.
12. For drives with DC input, disconnect the external precharge circuitry
from connectors X9 and X15 from the ASIC board.
H11H12H13 H8 H9H10
X9
X15
X3X4X5
H4H5H6 H1H2H3
H7
X2
X10
X1
Disconnect fiber optic
cables (H1 - H7)
DC precharge
connections
Disconnect
cables

8PowerFlex® 700S and 700H Frame 13 Replacement Power Structures
13. Pull the rubber grommet, through which the ASIC board and Power
Supply Voltage Feedback board wire bundles are routed, out of the
drive frame and secure the wire bundles in the left-hand enclosure of the
drive.
14. For drives with AC input, disconnect the precharge cable from the
Rectifying modules and the fan control cables, located in the power
structure to the left of the ASIC board.
Rubber grommet and
wire bundles.
Important: Move wire
bundles to left-hand
enclosure.
Fan control cables.
Shown disconnected.
Precharge cables.
Shown disconnected.

PowerFlex® 700S and 700H Frame 13 Replacement Power Structures 9
15. For drives with 700H control, continue with step 19 on page 11. For
drives with 700S control, disconnect the DC bus connection cable from
the connector J2 and the motor feedback connection cable from
connector J1 at the top of each the Power Supply Voltage Feedback
boards (see illustration below for location).
16. Carefully disconnect the fiber-optic cables from sockets J4 and J5 on
the side of each of the Power Supply Voltage Feedback boards and
carefully set them aside (see illustration below for location).
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.
!ATTENTION: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber-optic ports or
fiber-optic cable connectors.
J2
J1
J4
J5
Disconnect:

10 PowerFlex® 700S and 700H Frame 13 Replacement Power Structures
17. Remove the four screws that secure each of the Power Supply Voltage
Feedback board assemblies to the fan housing on the power structures
and carefully remove the Power Supply Voltage Feedback board
assemblies.
18. Disconnect the cable from connector J8 on each of the Power Supply
Voltage Feedback boards, and set the cable aside.
Remove screws
J2 J1 J4 J5
J8
Disconnect cable