Rockwell Automation PowerFlex 700S User manual

Installation Instructions
PowerFlex®700S and 700H Frame 14
Replacement Power Structures
Introduction Important:The Power Modules on PowerFlex 700S Phase II and 700H
frame 14 drives are matched at the factory and cannot be paired
with any other Power Modules. Therefore, when a Power
Module fails, you must replace both power structures on a
frame 14 drive.
Use this document to install replacement power structures on a frame 14
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 structures
❐ Step 3: Install the new power structures
❐ Step 4: Connect the new power structures to the components in the
drive
❐ Step 5: Install the product identification label on the new power
structures
❐ 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-D1K7 20CC1K7 20CH1K7 na na
20CD1K7 20CJ1K7 na na
SK-H1-PWRMOD-D2K1 20CC2K1 20CH2K1 na na
20CD2K1 20CJ2K1 na na
SK-H1-PWRMOD-D2K7 20CC2K7 20CH2K7 na na
20CD2K7 20CJ2K7 na na
600/690V AC
(810/932V DC)
SK-H1-PWRMOD-E1K5 20CE1K5 20CK1K5 20DE1K5 20DK1K5
20CF1K5 20CM1K5 20DF1K5 20DM1K5
SK-H1-PWRMOD-E1K9 20CE1K9 20CK1K9 na na
20CF1K9 20CM1K9 na na
SK-H1-PWRMOD-E2K2 20CE2K2 20CK2K2 na na
20CF2K2 20CM2K2 na na

2PowerFlex® 700S and 700H Frame 14 Replacement Power Structures
Power Structure Locations in Frame 14 Drives
Step 1: Removing Power
from the Drive
Above 1500A Drive 1500A Drive
Rectifying
Structure
Rectifying
Structure
Rectifying
Structure
Power
Structure
Power
Structure
Power
Structure
Power
Structure
Note: Shown with doors and control frames removed for clarity only.
!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.

PowerFlex® 700S and 700H Frame 14 Replacement Power Structures 3
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.
Step 2: Removing the Old
Power Structures
Before you can remove the old power structures from the drive, you must
remove the protective screens, protective covers and air flow plates from the
drive.
Note: The following steps must be completed for both power structures in
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 enclosures and remove the screens.
2. Remove the four M5 POZIDRIV screws that secures each of the three
pairs of protective covers to the drive power structures and remove the
protective covers.
L1 L2 L3
O
I
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 14 Replacement Power Structures
Removing the Air Flow Plates
3. Remove the four T8 Torx-head screws that secure each airflow plate to
the drive.
4. Slide each airflow plate off of the drive.
4
3

PowerFlex® 700S and 700H Frame 14 Replacement Power Structures 5
Important:Mark all connections and wires before removal to avoid
incorrect wiring during assembly.
5. Remove the motor connections from the output power terminals on both
of the power structures. Note: The terminals are located in different
positions, depending on whether du/dt filters are installed or not.
6. Remove the ground connections from the bottom of the power structure
enclosures.
7. Remove the input connections from the incoming DC bus terminals at
the top of both power structures.
U/T1 V/T2 W/T3
Side View
U/T1 V/T2 W/T3
ASIC Board Assembly
Power Supply Voltage
Feedback Board Assembly
Ground Terminals
DC Bus Terminals
Output Power Terminals
without du/dt Filters
Output Power Terminals
with du/dt Filters
DC–
(Front Terminals)
DC+
(Back Terminals)

6PowerFlex® 700S and 700H Frame 14 Replacement Power Structures
8. Remove the four screws that secure the cover to the ASIC assembly on
each power structure and remove the -DC bus connection from the
cover.
Remove –DC bus
connection

PowerFlex® 700S and 700H Frame 14 Replacement Power Structures 7
9. Disconnect the cable to the cooling fan, mounted on the ASIC assembly
cover, from connector X1 on the ASIC board and remove the ASIC
assembly cover from each power structure.
10. Disconnect the fiber optic cables (H1 - H7) from each ASIC board.
11. Disconnect the cable from connector H903 on each ASIC Feedback
board.
12. For drives with 700H control, disconnect the +24V supply cable from
connector X10 on ASIC board #1.
13. For drives with DC input, disconnect the external precharge circuitry
from connectors X9 and X15 from each 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 14 Replacement Power Structures
14. 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 away from the frame of the
power structures.
15. Disconnect the fan control cables and, for drives with AC input,
disconnect the precharge cable from the Rectifying modules located to
the left of the ASIC board.
Rubber grommet and
wire bundles
Fan control cables -
Shown disconnected
Precharge cables -
Shown disconnected

PowerFlex® 700S and 700H Frame 14 Replacement Power Structures 9
16. 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 the Power Supply Voltage Feedback board on
Power Structure #1 (see illustration below for location).
17. 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 14 Replacement Power Structures
18. 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.
19. 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

PowerFlex® 700S and 700H Frame 14 Replacement Power Structures 11
20. Remove the two hexagonal screws that secure each power structure to
the enclosure frames.
21. Follow the instructions in publication PFLEX-IN014…, Installation
Instructions - PowerFlex 700S / 700H High Power Maintenance Stand,
to install the Maintenance Stand (part number 20-MAINSTND).
Remove each power structure by sliding it onto the rails of the
Maintenance Stand.
Note: The Maintenance Stand is designed for removing power
structures from drives supplied in Rittal TS8 enclosures. Alternate
means of removal will be necessary for other types of enclosures.
22. Follow the instructions in publication PFLEX-IN005…, Installation
Instructions - Lifting & Mounting PowerFlex 700S and 700H Drives
(Frame 10 - 14), supplied with the new power structures, to lift the
power structures off of the Maintenance Stand.
Remove screws - one each side of enclosure

12 PowerFlex® 700S and 700H Frame 14 Replacement Power Structures
Step 3: Installing the New
Power Structures
Install the new power structures in reverse order of removal. Refer to the
publication PFLEX-IN006…, Installation Instructions - PowerFlex 700S
and 700H Drives Frames 9 - 14, for tightening torques of power and motor
terminations.
Step 4: Connecting the
Power Structures to
Components in the Drive
1. For drives with AC input, connect the precharge cable and remove the
jumper from the fan control connector and connect the fan control cable
from the Rectifying modules to the Power Structure.
2. Use the tables and illustrations below to make all connections between
the ASIC, ASIC Feedback, Common Mode Filter, Power Supply
Voltage Feedback and Fiber Optic Star Interface (700S) or Star Coupler
(700H) circuit boards for your installation.
–Refer to PowerFlex 700S Phase II Drives Connections: on page 16 for
a PowerFlex 700S Phase II circuit board connection diagram.
–Refer to PowerFlex 700H Connections: on page 19 for a PowerFlex
700H circuit board connection diagram.
Important:If the drive has DC input, you must also connect the
precharge circuit. Refer to Pre-Charge Connections on
Drives with DC Input on page 21.
=
Connect fan control
cables
Connect Precharge
cables

PowerFlex® 700S and 700H Frame 14 Replacement Power Structures 13
Figure 1 ASIC Board and ASIC Feedback Board
Figure 2 Power Supply Voltage Feedback Board
H11H12H13 H8 H9H10
X9
X15
X3X4X5
H4H5H6 H1H2H3
H7
X2
X10
X1
H900
H901
H902
H903
X900
ASIC Board ASIC Feedback Board
J2 J1 J4 J5
J8

14 PowerFlex® 700S and 700H Frame 14 Replacement Power Structures
Figure 3 700S Star Coupler Fiber Interface Board
J28
J13
J14
J12
J11
J10
J9
J8
J7
J6
J27
J24
J25
J23
J22
J21
J20
J19
J5

PowerFlex® 700S and 700H Frame 14 Replacement Power Structures 15
Figure 4 700H Star Coupler Fiber Optic Interface Board
Figure 5 700S Common Mode Filter Board
H8
H7
H6
H5
H4
H3
H2
H1
H18
H17
H16
H15
H14
H13
H12
H11
H23
H22
H21
X2
J5
J1

16 PowerFlex® 700S and 700H Frame 14 Replacement Power Structures
PowerFlex 700S Phase II Drives Connections:
Figure 6 Connections Between the Power Structure and 700S Phase II Control
Fiber Optic 1
23
45
67
X3
X2
X6
ASIC
Board #1
X9
X15
Charge
Relay
Fan
Control
25
26
21
22
23
1
2
3
W/T3 Phase from Pwr Strctr
V/T2 Phase from Pwr Strctr
U/T1 Phase from Pwr Strctr
DC+ From Power Structure
Star Coupler Fiber Optic Interface Board
J18 J15
J28
J13
-12 V
+12 V
+24 V Iso
+5V
Fiber Optic
NET B
DPI Assembly
20-VB00601
DPI
Option
Comm
Interface
DPI
2
9
J16
J4
X4
X3
X2
NET A
PORT
MOD
20 PWR
STS
9
HIM
X1 J2
J3
J1 9
Bezel
External
DPI
HIM
20-HIM-A3
Example:
Door
HIM
Power Supply Voltage Feedback Board
Supply
Power
2
J7
J6
J5
J4
J5
+24V
J8 J2
80 W
-W
-V
-U
-DC+
-DC-
J1
DC- From Power Structure
2
LED
DPI
Status
X10
H1
H2
H3
H4
H5
H6
H7
+24V
0EVA
Fiber
9
8
8
9
24V Power
X4
X5
H8
H11
H12
H9
H10
X11
X600
H13
X26
1
2
+24VDC
DC-
X1
DC-
DC+
H903
H901
H900
H902
X900
6
X3
H7
H6
H5
H4
H3
H2
H1
X10 24V Power
1
2
23
22
+24VDC
DC-
X1
Relay
Charge
H13
X11
X600
Fan
Control
H10
H11
H12
H9
X5
H8
X4
ASIC
Board #2
H902
H901
H900
H903
X900
X15
26
21
25
0EVA
+24V
X9
X26
6
2
X6
X2
3
1
3
3
J1
J2
J17
J3
J27
From DC Bus
in Power Circuitry
To Gate Driver Board X14
To Gate Driver Board X13
To Gate Driver Board X15
To Gate Driver Board H4
To Gate Driver Board H5
To Gate Driver Board H6
To Gate Driver Board H7
To Gate Driver Board H8
To Gate Driver Board H9
To Rectifying Board X13
DC-
DC+
From DC Bus
in Power Circuitry
To Gate Driver Board X14
To Gate Driver Board X13
To Gate Driver Board X15
To Gate Driver Board H4
To Gate Driver Board H5
To Gate Driver Board H6
To Gate Driver Board H7
To Gate Driver Board H8
To Gate Driver Board H9
To Rectifying Board X13
1
23
45
67
1
Fiber Optic
23
45
67
Board #1
Feedback
Board #2
Feedback
External 24V DC
1=24V
3=Common
(75W min)
Fan
Power
1
2
3
4
57
6T
1
2
3
4
57
6T
To Main Control Board
700S Phase II Control Assembly
J14 J12 J11 J10
J9 J8
J24 J25 J23 J22
J21
J20 J19
To Left Fan X8
On Power Structure #1 (Left)On Power Structure #2 (Right)
To Left Fan X8
CR1
MCR1
CR2
M
M
M
Sample Pre-Charge
Connection Shown
in Dashed Lines
2
1
4
3
2
1
4
3
X50
PS #2
X50
PS #1
External Wiring
Shown as Dashed
Lines
2
Common Mode
FIlter Board
J5
J1

PowerFlex® 700S and 700H Frame 14 Replacement Power Structures 17
ASIC Board Connections - Power Structure #1
ASIC Board Connections - Power Structure #2
Connect this component :
termination point . . . to this component : termination point
ASIC Board: H1 (fiber optic connector) Star Coupler Fiber Optic Interface Board: J8 (fiber optic
connector)
ASIC Board: H2 (fiber optic connector) Star Coupler Fiber Optic Interface Board: J9 (fiber optic
connector)
ASIC Board: H3 (fiber optic connector) Star Coupler Fiber Optic Interface Board: J10 (fiber optic
connector)
ASIC Board: H4 (fiber optic connector) Star Coupler Fiber Optic Interface Board: J11 (fiber optic
connector)
ASIC Board: H5 (fiber optic connector) Star Coupler Fiber Optic Interface Board: J12 (fiber optic
connector)
ASIC Board: H6 (fiber optic connector) Star Coupler Fiber Optic Interface Board: J14 (fiber optic
connector)
ASIC Board: H7 (fiber optic connector) Star Coupler Fiber Optic Interface Board: J13 (fiber optic
connector)
Connect this component :
termination point . . . to this component : termination point
ASIC Board: H1 (fiber optic connector) Star Coupler Fiber Optic Interface Board: J19 (fiber optic
connector)
ASIC Board: H2 (fiber optic connector) Star Coupler Fiber Optic Interface Board: J20 (fiber optic
connector)
ASIC Board: H3 (fiber optic connector) Star Coupler Fiber Optic Interface Board: J21 (fiber optic
connector)
ASIC Board: H4 (fiber optic connector) Star Coupler Fiber Optic Interface Board: J22 (fiber optic
connector)
ASIC Board: H5 (fiber optic connector) Star Coupler Fiber Optic Interface Board: J23 (fiber optic
connector)
ASIC Board: H6 (fiber optic connector) Star Coupler Fiber Optic Interface Board: J25 (fiber optic
connector)
ASIC Board: H7 (fiber optic connector) Star Coupler Fiber Optic Interface Board: J24 (fiber optic
connector)

18 PowerFlex® 700S and 700H Frame 14 Replacement Power Structures
ASIC Feedback Board Connections - Power Structure #1
ASIC Feedback Board Connections - Power Structure #2
Power Supply Voltage Feedback Board Connections
Connect this component :
termination point . . . to this component : termination point
ASIC Feedback Board: H903 Star Coupler Fiber Optic Interface Board: J28
Connect this component :
termination point . . . to this component : termination point
ASIC Feedback Board: H903 Star Coupler Fiber Optic Interface Board: J27
Connect this component :
termination point . . . to this component : termination point
Power Supply Voltage Feedback
Board: J8
Common Mode Filter Board: J5
Power Supply Voltage Feedback
Board: J5
(fiber optic connector)
Star Coupler Fiber Optic Interface Board: J7
Power Supply Voltage Feedback
Board: J4
(fiber optic connector)
Star Coupler Fiber Optic Interface Board: J6

PowerFlex® 700S and 700H Frame 14 Replacement Power Structures 19
PowerFlex 700H Connections:
Figure 7 Connections Between the Power Structure and 700H Control
X3
X2
X6
ASIC
Board
X9
X15
Charge
Relay
Fan
Control
25
26
21
22
23
1
2
3
X10
H1
H2
H3
H4
H5
H6
H7
Analog I/O
(8/10)
Digital In
(10) 33
2OC-DA1-B
24V Or 115V
20C-DA1-A
Plus Digital In
Analog I/O
(slot A)
X2
Digital Out
Option
20C-D01
(slot B)
X3
Control Board
Option
Board
X4
(slot C) (slot D)
X5 (slot E)
20C-DPI1
DPI Option
X1
X3
X6
X2
9
Programming
X7
X1
37
X1
X2
X4
J3
DPI Assembly
Option
20C-DPI1
Comm
DPI
X3
PORT
NET A
NET B
MOD
20
PWR Example:
20-HIM-A3
External DPI
HIM
9Door
HIM
Bezel
HIM
Interface
DPI
20-VB00601
X2
X1
J2 J1 9
+24V
0EVA
24V Power
X4
X5
H8
H11
H12
H9
H10
X11
X600
H13
X26
#1
1
2
+24VDC
DC-
X1
DC-
DC+
Board #1
Feedback
H903
H901
H900
H902
X900
6
X3
Fiber Optic
H7
H6
H5
H4
H3
H2
H1
X10 24V Power
1
2
23
22
+24VDC
DC-
X1
Relay
Charge
H13
X11
X600
Fan
Control
H10
H11
H12
H9
X5
H8
X4
ASIC
Board
H902
H901
Feedback
H900
H903
Board #2
X900
X15
26
21
25
0EVA
+24V
X9
X26
6
2
X6
#2
X2
3
1
DC-
DC+
3
3
2
1
+24VDC
GND
2
M
M
H8
H18
Star Coupler Fiber
Optic Interface Board
3
Fiber Optic
3
Option
Board
From DC Bus
in Power Circuitry
To Gate Driver Board X14
To Gate Driver Board X13
To Gate Driver Board X15
To Gate Driver Board H4
To Gate Driver Board H5
To Gate Driver Board H6
To Gate Driver Board H7
To Gate Driver Board H8
To Gate Driver Board H9
From DC Bus
in Power Circuitry
To Gate Driver Board X14
To Gate Driver Board X13
To Gate Driver Board X15
To Gate Driver Board H4
To Gate Driver Board H5
To Gate Driver Board H6
To Gate Driver Board H7
To Gate Driver Board H8
To Gate Driver Board H9
1
2
3
4
5
6
7
1
2
3
4
5
6
7
T
7
6
5
4
3
2
1
T
7
6
5
4
3
2
1
23
22
21
To Rectifying Board X13
To Rectifying Board X13
700H Control Assembly
H7 H6 H5 H4 H3 H2 H1
H17 H16 H15 H14 H13 H12 H11 H23 H22 H21
To Left Fan X8
On Power Structure #1On Power Structure #2
To Left Fan X8
Fiber
Optic
Sample
Pre-Charge
Connection
Shown in
Dashed Lines
External Wiring
Shown as Dashed
Lines
2
Fiber Optic
2
1
4
3
2
1
4
3
X50
PS #2
X50
PS #1
CR1
MCR1
CR2
M

20 PowerFlex® 700S and 700H Frame 14 Replacement Power Structures
ASIC Board Connections - Power Structure #1
ASIC Board Connections - Power Structure #2
ASIC Feedback Board Connections - Power Structure #1
ASIC Feedback Board Connections - Power Structure #2
Connect this component :
termination point . . . to this component : termination point
ASIC Board: H1 (fiber optic connector) Star Coupler Fiber Optic Interface Board: H1 (fiber optic
connector)
ASIC Board: H2 (fiber optic connector) Star Coupler Fiber Optic Interface Board: H2 (fiber optic
connector)
ASIC Board: H3 (fiber optic connector) Star Coupler Fiber Optic Interface Board: H3 (fiber optic
connector)
ASIC Board: H4 (fiber optic connector) Star Coupler Fiber Optic Interface Board: H4 (fiber optic
connector)
ASIC Board: H5 (fiber optic connector) Star Coupler Fiber Optic Interface Board: H5 (fiber optic
connector)
ASIC Board: H6 (fiber optic connector) Star Coupler Fiber Optic Interface Board: H6 (fiber optic
connector)
ASIC Board: H7 (fiber optic connector) Star Coupler Fiber Optic Interface Board: H7 (fiber optic
connector)
Connect this component :
termination point . . . to this component : termination point
ASIC Board: H1 (fiber optic connector) Star Coupler Fiber Optic Interface Board: H11 (fiber optic
connector)
ASIC Board: H2 (fiber optic connector) Star Coupler Fiber Optic Interface Board: H12 (fiber optic
connector)
ASIC Board: H3 (fiber optic connector) Star Coupler Fiber Optic Interface Board: H13 (fiber optic
connector)
ASIC Board: H4 (fiber optic connector) Star Coupler Fiber Optic Interface Board: H14 (fiber optic
connector)
ASIC Board: H5 (fiber optic connector) Star Coupler Fiber Optic Interface Board: H15 (fiber optic
connector)
ASIC Board: H6 (fiber optic connector) Star Coupler Fiber Optic Interface Board: H16 (fiber optic
connector)
ASIC Board: H7 (fiber optic connector) Star Coupler Fiber Optic Interface Board: H17 (fiber optic
connector)
Connect this component :
termination point . . . to this component : termination point
ASIC Feedback Board: H900, H901,
H902 (fiber optic bundle)
Star Coupler Fiber Optic Interface Board: H21, H22, H23
ASIC Feedback Board: H903 Star Coupler Fiber Optic Interface Board: H8
Connect this component :
termination point . . . to this component : termination point
ASIC Feedback Board: H903 Star Coupler Fiber Optic Interface Board: H18