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