Installation Instructions
PowerFlex® 700S and 700H Frame 12
Replacement Power Structures
Introduction
Important: The Power Modules on PowerFlex 700S and 700H frame 12
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 12 drive.
Use this document to install the replacement power structures on a frame 12
drive. This document covers the following replacement power structures:
Spare Module Catalog String
SK-H1-PWRMOD-F12D
SK-H1-PWRMOD-F12E
PowerFlex 700H AC Input
20CC820
20CD820
20CC920
20CD920
20CC1K0
20CD1K0
20CE650
20CF650
20CE750
20CF750
20CE820
20CF820
PowerFlex 700H DC Input
20CH820
20CJ820
20CH920
20CJ920
20CH1K0
20CJ1K0
20CK650
20CM650
20CK750
20CM750
20CK820
20CM820
PowerFlex 700S AC Input
20DC820
20DD820
20DC920
20DD920
20DC1K0
20DD1K0
20DE650
20DF650
20DE750
20DF750
20DE820
20DF820
PowerFlex 700S DC Input
20DH820
20DJ820
20DH920
20DJ920
20DH1K0
20DJ1K0
20DK650
20DM650
20DK750
20DM750
20DK820
20DM820
Note: The frame 12 power structure kit does not contain the drive-rated
ASIC boards. You must either use the existing ASIC boards or order
replacement ASIC boards in order to complete this installation. Please refer
to the Spare Parts and Options List for PowerFlex Architecture (7) Class
Low Voltage AC Drives for part catalog numbers. This list is located at:
www.ab.com/support/abdrives/powerflex700s/phase2/index.html
From this page, click on the “Parts List” link to view a PDF of the parts list
for both 700S and 700H drives.
2
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
What You Need to Do
This document contains directions for replacing one power structure
mounted in a Rittal TS8 drive enclosure. These steps must be repeated for
the installation of the second power structure.
❐ Step 1: Remove power from existing drive
❐ Step 2: Remove protective covers from existing drive
❐ Step 3: Prepare old power structure for removal
❐ Step 4: Remove old power structure from drive
❐ Step 5: Remove existing ASIC board from old power structure
(optional)
❐ Step 6: Install ASIC board on new power structure
❐ Step 7: Configure EMC filter
❐ Step 8: Install new power structure
❐ Step 9: Connect power structure to components on drive
❐ Step 10: Install product identification label on new power structure
❐ Step 11: Start drive
Step 1: Removing Power
from the Existing Drive
!
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 12 Replacement Power Structures
3
1. Turn off and lock out input power and 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.
L1
L2
L3
I
O
Step 2: Removing the
Protective Covers from the
Existing Drive
1. Open the enclosure door and loosen the T8 Torx-head screws that hold
the control frame to the drive enclosure.
2. Swing the control frame out and away from the power structure.
Loosen screws
Control assembly not
shown for clarity only.
4
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
3. Remove the T8 Torx-head screws which secure the airflow plate to the
drive.
4. Slide airflow plate off the enclosure frame.
Remove screws
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
5
5. Remove the four M5 POZIDRIV screws that hold the top and bottom
protective covers to the main front protective cover, then remove the top
and bottom protective covers.
6. Remove the four M5 POZIDRIV screws that hold the main front
protective cover to the drive, then remove the protective cover.
7. remove the side protective covers.
Screws
Screws
Screws
6
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
Step 3: Preparing the Old
Power Structure for
Removal
1. Remove the motor wiring from the power structure at the front of the
power structure.
2. Remove the ground connection from the lower right rear corner of the
power structure.
3. Remove the input (AC or DC) from the incoming terminals at the top of
the power structure.
ASIC board
AC Power connection
terminals
Power Supply Voltage
Feedback board
Motor connection
terminals
Drive frame ground
connection
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
7
4. Carefully disconnect the fiber-optic cables from sockets along the front
of the ASIC board, and carefully set them aside.
!
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.
!
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.
5. Disconnect the other cables from the sockets on the front of the ASIC
board, and set them aside.
H8
Connects to X50
terminal block for
pre-charge circuitry on
DC Input drives
X2
X11
X9
H9
H10
H11
X15
X26
H12
H1
H13
H2
H3
X3
Fiber Optic ports
H4
X1
H5
H6
X4
H7
X6
X5
Connects to DC Bus
6. If you are replacing a power structure on a PowerFlex 700S drive,
disconnect the cable from connector J8 and the fiber optic connections,
J4 and J5, from the Power Supply Voltage Feedback board on the power
structure in the left-hand enclosure.
J4 J5
J8
8
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
Step 4: Removing the Old
Power Structure from the
Drive
1. 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). Slide
the power structure out of the enclosure 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.
2. Remove the old power structure from the maintenance stand using the
following lifting instructions:
Note: Frame 12 power structures weight approximately 120 kg (265
lbs.).
a. Attach the lifting hardware to the power structure. The lifting
hardware must be fastened symmetrically to at least two of the
lifting holes on the unit.
Lifting points
b. Lift the power structure off of the maintenance stand and place the
back side of the unit onto a sturdy palette.
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
Step 5: Removing the
Existing ASIC Board from
the Old Power Structure
9
Important: If you are installing a new ASIC board, continue with Step 6
“Installing the ASIC Board on the New Power Structure” on
page 10. If you are installing the existing ASIC board, continue
with step 1 below.
!
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.
!
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.
1. Carefully disconnect the remaining fiber-optic cables from sockets of
the ASIC board, and carefully set them aside.
Figure 1 Termination Points on the ASIC Board
Connects X13 to Rectifying board on AC drives
X2
X11
H8
X9
H9
Fiber Optic ports
H10
H11
X15
X26
H12
H1
H13
H2
H3
X3
X1
Connects to Gate
Driver board
X4
H4
H5
H6
H7
X5
X6
2. Disconnect the remaining cables from sockets on the front of the ASIC
board, and set them aside.
3. Remove the screws that secure the ASIC assembly to the drive and set
the assembly aside.
10
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
Step 6: Installing the ASIC Connecting a DC Input Drive
Board on the New Power
Power structures are shipped from the factory pre-configured for DC input
Structure
operation.
Connecting an AC Input Drive
If you are installing an existing ASIC board on the new power structure,
continue with step 11 on page 12. If you are installing a new ASIC board on
the new power structure, continue with step 1 below.
1. Remove the cover from the existing ASIC assembly and the DC- bus
connection from the cover.
2. Unplug the fan that mounts on the ASIC assembly cover from
connector X1 of the ASIC board.
3. Disconnect the Feedback board that mounts on the ASIC assembly
cover from connector X26 on the ASIC board.
X26 Feedback board connection
X2
X11
H8
X1 Fan connection
X9
H9
H10
H11
X15
X26
H12
H1
H13
H2
H3
X3
X1
X4
H4
H5
H6
H7
X5
X6
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
11
4. Slide the old ASIC board out of its chassis.
5. Slide the new ASIC board into the chassis.
ASIC Board
6. If you are installing a replacement power structure on a drive with AC
input, remove the X2 plug from its protective sleeve and plug the cable
into the X2 socket on the ASIC board.
X26 Feedback
board connection
To X13 connection on Rectifying board
X2
X11
H8
X9
H9
H10
H11
X1 Fan connection
X15
X26
H12
H1
H13
H2
H3
X3
X1
X4
H4
H5
H6
H7
X5
X6
7. Connect the other end of the cable connected to X2 on the ASIC board
to X13 on the Rectifier circuit board on the upper right side of the
power structure.
8. Connect the cable from the Feedback board to the X26 connector on the
ASIC board.
9. Plug the fan that mounts on the ASIC assembly cover into the X1
connector on the ASIC board.
12
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
10. Secure the cover of the ASIC assembly and reconnect the DC- bus cable
to the cover.
11. Secure the ASIC board and assembly to the new power structure.
!
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.
12. Connect the remaining cables and fiber-optic cables to the ASIC board
in the reverse order of Step 5: "Removing the Existing ASIC Board
from the Old Power Structure" on page 9.
Step 7: Configuring the
EMC Filter
Frame 12 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 14.
• Should insulate terminal X4 on the Rectifier circuit board- refer to
Insulate Terminal X4 on the Rectifier Circuit Board on page 15.
• Must disconnect the small capacitors from the input terminals - refer to
Disconnect the Small Capacitors from the Input Terminals on page 16.
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 14.
• Must insulate terminal X4 on the Rectifier circuit board- refer to Insulate
Terminal X4 on the Rectifier Circuit Board on page 15.
• Must disconnect the small capacitors from the input terminals - refer to
Disconnect the Small Capacitors from the Input Terminals on page 16.
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
13
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 14.
• Must insulate terminal X4 on the Rectifier circuit board- refer to Insulate
Terminal X4 on the Rectifier Circuit Board on page 15.
• Must disconnect the small capacitors from the input terminals - refer to
Disconnect the Small Capacitors from the Input Terminals on page 16.
Note: Refer to 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.
Figure 2 Common Mode Jumper and Rectifier Circuit Board Location
Common
Mode jumper
There is one jumper located on
each Rectifying Module. The
Rectifying Modules are located on
the upper-right side of the right side
power stack of in each enclosure of
the drive’s power structure.
Front View
of Assembly
Rectifier Circuit Board
DANGER
DC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE. REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
DANGER
DC BUS CONDUCTORS AND CAPACITORS
OPERATE AT HIGH VOLTAGE. REMOVE POWER
AND WAIT 5 MINUTES BEFORE SERVICING
Control Frame not shown for clarity only
14
PowerFlex® 700S and 700H Frame 12 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 13 for jumper location):
Task
A
Description
Loosen the upper screw.
B
Remove the lower screw.
Move the jumper to the horizontal position.
C
Install and tighten the screws.
D
A
Front View of
Power Structure
D
C
B
Rectifier Circuit Board
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
15
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 13 for Rectifier board location):
Task
A
Description
Remove the screw from the X4 connection on the Rectifier circuit board.
B
Insulate the top and bottom of the X4 connection on the Rectifier circuit board.
Important: Do not install the screw and washer that was removed from this
connection.
A
Side View of Power Structure
B
X4
X4
X1
X1
X41
X41
Rectifier Circuit Board
16
PowerFlex® 700S and 700H Frame 12 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:
Task
A
B
C
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.
Important: Do not re-install the capacitor leads.
Important: It is not necessary to remove the power
wiring from the terminals in order to
insulate the capacitor leads.
L1
L2
L3
Input power terminal
Insulator
B
A
Capacitor
Capacitor lead
C
Step 8: Installing the New
Power Structure
Install the new power structure in the reverse order of Step 4: "Removing
the Old Power Structure from the Drive" on page 8 and make the motor,
ground, input power and Power Supply Voltage Feedback board (for
PowerFlex 700S installations) connections in the reverse order of Step 3:
"Preparing the Old Power Structure for Removal" on page 6.
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
Step 9: Connecting the
Power Structure to
Components on the Drive
17
You must connect the power structure to control components on the control
frame. If the drive has DC input, you must also connect the precharge
circuit.
Figure 3 700S Connections
6
H903
1
X900
H900
H901
H902
25
26
M
2
3
Sample Pre-Charge
Connection Shown
in Dashed Lines
CR1
1
Fiber Optic
2
4
6
X6
+24V
0EVA
DC+
1
2
3
3
5
7
From DC Bus
in Power Circuitry
DC-
To Rectifying Board X13
To Gate Driver Board X13
To Gate Driver Board X14
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
X2
X3
X4
X5
H8
H9
H10
X10 24V Power
H11
H12
H1
H13
H2
X600
H3
X11
H4
Fan
H5
Control
H6
H7
X50
PS #1
CR2
M
ASIC
Board #1
X15
21
Charge
22
23
Relay
X1
+24VDC
1
2
DC-
4
M
CR1
X26
X9
3
On Power Structure #1 (Left)
Feedback
Board #1
To Left Fan X8
External Wiring
Shown as Dashed
Lines
6
X900
1
M
Feedback
Board #2
25
26
2
3
X26
X9
ASIC
Board #2
+24V
0EVA
X15
21
Charge
22
23
Relay
X1
+24VDC
1
2
DC-
4
X50
PS #2
X10 24V Power
1
2
4
6
Fiber Optic
Fiber Optic
Fan
Power
J18
J15
J6
J7
DPI J4
LED J16
Status
External 24V DC
1=24V
3=Common
(75W min)
700S Phase II Control Assembly
8
X2
X3
X4
X5
H8
H9
H10
H11
H12
H13
X600
X11
Fan
Control
DC+
1
2
3
From DC Bus
in Power Circuitry
DC-
To Rectifying Board X13
To Gate Driver Board X13
To Gate Driver Board X14
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
3
To Left Fan X8
DC- From Power Structure
J2
80 W
J8
+24V Power -DCSupply -DC+
J1
9
-U
J4
-V
-W
8 J5
DC+ From Power Structure
U/T1 Phase from Pwr Strctr
V/T2 Phase from Pwr Strctr
W/T3 Phase from Pwr Strctr
2
J1
2
To Main Control Board
2
J5
+24 V Iso
+12 V
-12 V
+5V
Star Coupler Fiber Optic Interface Board
J2
7
Common Mode
FIlter Board
J17
J1
5
T 6 4 2
7 5 3 1
J27
J24
J25
J23
J22
J21
J20
J19
J3
J28
J13
J14
J12
J11
J10
J9
J8
T 6 4 2
7 5 3 1
H1
H2
H3
H4
H5
H6
H7
3
X6
J5
Fiber
Power Supply Voltage Feedback Board
9
9
20-VB00601
X2
2
X1
X4
HIM
Bezel
J2
DPI
Interface
J1
J3
X3
20
DPI
Comm
Option
On Power Structure #2 (Right)
H903
H900
H901
H902
9
PWR
STS
PORT
MOD
NET A
NET B
DPI Assembly
9
HIM
Door
Example:
20-HIM-A3
HIM
External
DPI
18
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
ASIC Board Connections - Power Structure #1
Connect this component : termination
point . . .
ASIC Board: H1 (fiber optic connector)
ASIC Board: H2 (fiber optic connector)
ASIC Board: H3 (fiber optic connector)
ASIC Board: H4 (fiber optic connector)
ASIC Board: H5 (fiber optic connector)
ASIC Board: H6 (fiber optic connector)
ASIC Board: H7 (fiber optic connector)
ASIC Board: X6
ASIC Board: X3
ASIC Board: X4
ASIC Board: X5
ASIC Board: H8 (fiber optic connector)
ASIC Board: H9 (fiber optic connector)
ASIC Board: H10 (fiber optic connector)
ASIC Board: H11 (fiber optic connector)
ASIC Board: H12 (fiber optic connector)
ASIC Board: H13 (fiber optic connector)
ASIC Board: X11
ASIC Board: X2
to this component : termination point
Star Coupler Fiber Optic Interface Board: J8 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: J9 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: J10 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: J11 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: J12 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: J14 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: J13 (fiber optic connector)
From DC Bus
Gate Driver Board Power Structure #2: X13
Gate Driver Board Power Structure #2: X14
Gate Driver Board Power Structure #2: X15
Gate Driver Board Power Structure #2: H4
Gate Driver Board Power Structure #2: H5
Gate Driver Board Power Structure #2: H6
Gate Driver Board Power Structure #2: H7
Gate Driver Board Power Structure #2: H8
Gate Driver Board Power Structure #2: H9
Left Fan on Power Structure #2: X8
Rectifying Board: X13
ASIC Board Connections - Power Structure #2
Connect this component : termination
point . . .
ASIC Board: H1 (fiber optic connector)
ASIC Board: H2 (fiber optic connector)
ASIC Board: H3 (fiber optic connector)
ASIC Board: H4 (fiber optic connector)
ASIC Board: H5 (fiber optic connector)
ASIC Board: H6 (fiber optic connector)
ASIC Board: H7 (fiber optic connector)
ASIC Board: X6
ASIC Board: X3
ASIC Board: X4
ASIC Board: X5
ASIC Board: H8 (fiber optic connector)
ASIC Board: H9 (fiber optic connector)
ASIC Board: H10 (fiber optic connector)
ASIC Board: H11 (fiber optic connector)
ASIC Board: H12 (fiber optic connector)
ASIC Board: H13 (fiber optic connector)
ASIC Board: X11
ASIC Board: X2
to this component : termination point
Star Coupler Fiber Optic Interface Board: J19 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: J20 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: J21 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: J22 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: J23 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: J25 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: J24 (fiber optic connector)
From DC Bus
Gate Driver Board Power Structure #1: X13
Gate Driver Board Power Structure #1: X14
Gate Driver Board Power Structure #1: X15
Gate Driver Board Power Structure #1: H4
Gate Driver Board Power Structure #1: H5
Gate Driver Board Power Structure #1: H6
Gate Driver Board Power Structure #1: H7
Gate Driver Board Power Structure #1: H8
Gate Driver Board Power Structure #1: H9
Left Fan on Power Structure #1: X8
Rectifying Board: X13
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
19
Figure 4 Termination Points on the ASIC Boards
Connects to X13 on Rectifying
circuit board on AC Input drives
X2
X11
H8
Connects to fan on ASIC
assembly cover
X9
H9
H10
X15
X26
H11
H12
H1
H13
H2
Connect to X50 terminal block
for Pre-charge circuitry on DC
Input drives
H3
X3
H4
X1
H5
H6
ahw0994.eps
X4
H7
Connects to DC Bus
X6
X5
Figure 5 Termination Points on the Gate Driver Board
Fiber Optic Connections to ASIC Board
H8 H6 H4 H9 H7 H5
X3
X8
X4
X9
X5
X10
X6
X11
X12
X7
X13
X14
X15
X1
Connect to ASIC Board
20
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
ASIC Feedback Board Connections - Power Structure #1
Connect this component :
termination point . . .
ASIC Feedback Board: X900
ASIC Feedback Board: H903
to this component : termination point
ASIC Board Power Structure #1: X26
Star Coupler Fiber Optic Interface Board: J28
ASIC Feedback Board Connections - Power Structure #2
Connect this component :
termination point . . .
ASIC Feedback Board: X900
ASIC Feedback Board: H903
to this component : termination point
ASIC Board Power Structure #2: X26
Star Coupler Fiber Optic Interface Board: J27
Figure 6 Termination Points on ASIC Feedback Boards
H900
X900
H901
H902
Fiber Optic
Ports
H903
Power Supply Voltage Feedback Board Connections
Connect this component :
termination point . . .
Power Supply Voltage Feedback
Board: J8
Power Supply Voltage Feedback
Board: J5 (fiber optic connector)
Power Supply Voltage Feedback
Board: J4 (fiber optic connector)
to this component : termination point
Common Mode Filter Board: J5
Star Coupler Fiber Optic Interface Board: J7
Star Coupler Fiber Optic Interface Board: J6
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
21
Figure 7 Termination Points on 700S Boards
Star Coupler Fiber Optic Interface Board
Power Supply Voltage Feedback Board
J4 J5
J28
J13
J14
J12
J11
J10
J9
J8
J8
J7
J6
J27
J24
700S Common Mode FIlter Board
J25
J23
J22
J1
J21
J20
J19
J5
J5
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
Figure 8 700H Connections
Feedback
Board #1
X26
X9
1
25
M
26
2
3
Sample
Pre-Charge
Connection
Shown in
Dashed Lines
4
M
CR1
X1
2
2
X10 24V Power
H1
H2
H3
H4
H5
H6
H7
2
3
4
5
6
7
6
X900
X9
1
M
26
+24V
0EVA
21
22
23
X15
Charge
Relay
25
2
3
4
X1
X50
PS #2
1
2
X10
Fiber Optic
H1
H2
H3
H4
H5
H6
H7
1
2
3
4
5
6
7
2
1
2
1
2
+24VDC
GND
5
7
T
6
3
4
1
2
X2
X3
X4
X5
+24VDC
H8
DCH9
24V Power
H10
H11
H12
H13
X600
Fan X11
Control
22
23
21
Star Coupler Fiber
Optic Interface Board
DPI
Interface
X1
37
20-VB00601
X2
X1
Control Board
Programming
X2
(slot A)
Analog I/O
Plus Digital In
24V Or 115V
20C-DA1-A
2OC-DA1-B
Analog I/O Digital In
(10) (8/10)
X3
(slot B)
X4
(slot C)
X5
(slot D)
X6
(slot E)
20C-D01
3
Option
Board
Option
Board
DPI Option
20C-DPI1
X2
X3
3
700H Control Assembly
X1
X4
X3
X7
X1
Digital Out
Option
To Rectifying Board X13
To Gate Driver Board X13
To Gate Driver Board X14
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
3
To Left Fan X8
9
20
DPI
Comm
Option
20C-DPI1
HIM
Bezel
J2
J1
J3
9
PWR
PORT
MOD
NET A
NET B
DPI Assembly
DC+
1
2
3
DC-
H23
H22
H21
X2
3
4
H18
H17
H16
H15
H14
H13
H12
H11
5
X6
Fiber Optic
Fiber
Optic
6
ASIC
Board
#2
X26
3
7
From DC Bus
in Power Circuitry
Fiber Optic
H903
T
DC-
External Wiring
Shown as Dashed
Lines
Feedback
Board #2
H900
H901
H902
DC+
1
2
3
X5
H8
H9
H10
H11
H12
H13
X600
X11
Fan
Control
+24VDC
DC-
CR1
1
X6
X2
X3
X4
X15
Charge
Relay
1
X50
PS #1
CR2
M
21
22
23
+24V
0EVA
ASIC
Board
#1
On Power Structure #1
6
X900
9
HIM
Door
Example:
20-HIM-A3
HIM
External DPI
From DC Bus
in Power Circuitry
To Rectifying Board X13
To Gate Driver Board X13
To Gate Driver Board X14
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
3
To Left Fan X8
On Power Structure #2
H903
H900
H901
H902
3
H8
H7
H6
H5
H4
H3
H2
H1
22
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
23
ASIC Board Connections - Power Structure #1
Connect this component : termination
point . . .
ASIC Board: H1 (fiber optic connector)
ASIC Board: H2 (fiber optic connector)
ASIC Board: H3 (fiber optic connector)
ASIC Board: H4 (fiber optic connector)
ASIC Board: H5 (fiber optic connector)
ASIC Board: H6 (fiber optic connector)
ASIC Board: H7 (fiber optic connector)
ASIC Board: X6
ASIC Board: X3
ASIC Board: X4
ASIC Board: X5
ASIC Board: H8 (fiber optic connector)
ASIC Board: H9 (fiber optic connector)
ASIC Board: H10 (fiber optic connector)
ASIC Board: H11 (fiber optic connector)
ASIC Board: H12 (fiber optic connector)
ASIC Board: H13 (fiber optic connector)
ASIC Board: X11
ASIC Board: X2
to this component : termination point
Star Coupler Fiber Optic Interface Board: H1 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: H2 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: H3 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: H4 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: H5 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: H6 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: H7 (fiber optic connector)
From DC Bus
Gate Driver Board Power Structure #2: X13
Gate Driver Board Power Structure #2: X14
Gate Driver Board Power Structure #2: X15
Gate Driver Board Power Structure #2: H4
Gate Driver Board Power Structure #2: H5
Gate Driver Board Power Structure #2: H6
Gate Driver Board Power Structure #2: H7
Gate Driver Board Power Structure #2: H8
Gate Driver Board Power Structure #2: H9
Left Fan on Power Structure #2: X8
Rectifying Board: X13
Note: Refer to page 19for ASIC Board and Gate Driver Board termination
points.
ASIC Board Connections - Power Structure #2
Connect this component : termination
point . . .
ASIC Board: H1 (fiber optic connector)
ASIC Board: H2 (fiber optic connector)
ASIC Board: H3 (fiber optic connector)
ASIC Board: H4 (fiber optic connector)
ASIC Board: H5 (fiber optic connector)
ASIC Board: H6 (fiber optic connector)
ASIC Board: H7 (fiber optic connector)
ASIC Board: X6
ASIC Board: X3
ASIC Board: X4
ASIC Board: X5
ASIC Board: H8 (fiber optic connector)
ASIC Board: H9 (fiber optic connector)
ASIC Board: H10 (fiber optic connector)
ASIC Board: H11 (fiber optic connector)
ASIC Board: H12 (fiber optic connector)
ASIC Board: H13 (fiber optic connector)
ASIC Board: X11
ASIC Board: X2
to this component : termination point
Star Coupler Fiber Optic Interface Board: H11 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: H12 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: H13 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: H14 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: H15 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: H16 (fiber optic connector)
Star Coupler Fiber Optic Interface Board: H17 (fiber optic connector)
From DC Bus
Gate Driver Board Power Structure #1: X13
Gate Driver Board Power Structure #1: X14
Gate Driver Board Power Structure #1: X15
Gate Driver Board Power Structure #1: H4
Gate Driver Board Power Structure #1: H5
Gate Driver Board Power Structure #1: H6
Gate Driver Board Power Structure #1: H7
Gate Driver Board Power Structure #1: H8
Gate Driver Board Power Structure #1 : H9
Left Fan on Power Structure #1 : X8
Rectifying Board: X13
24
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
ASIC Feedback Board Connections - Power Structure #1
Connect this component :
termination point . . .
ASIC Feedback Board: X900
ASIC Feedback Board: H900, H901,
H902 (fiber optic bundle)
ASIC Feedback Board: H903
to this component : termination point
ASIC Board Power Structure #1: X26
Star Coupler Fiber Optic Interface Board: H21, H22, H23
Star Coupler Fiber Optic Interface Board: H8
Note: Refer to page 20for ASIC Feedback Board termination points.
ASIC Feedback Board Connections - Power Structure #2
Connect this component :
termination point . . .
ASIC Feedback Board: X900
ASIC Feedback Board: H903
to this component : termination point
ASIC Board Power Structure #2: X26
Star Coupler Fiber Optic Interface Board: H18
Figure 9 Termination Points on the 700H Star Coupler Fiber Optic Interface Board
H8
H7
H6
H5
H4
H3
H2
H1
H18
H17
H16
H15
H14
X2
H13
H12
H11
H23
H22
H21
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
25
DC Input Precharge Control Wiring
If you are installing a DC input drive with a precharge interlock you must
make the following connections on the X50 terminal block from the
precharge circuit. Refer to Figure 10 below for additional information.
Frame 12 - X50 Terminal Block Connections
X50 Terminal Block Terminal Description
Power Module 1
3
Charge Relay Contact (Jumper to Power Module 2 Terminal 4)
4
Charge Relay Contact
1
1
Precharge Complete Signal (+24V DC)
2
Precharge Complete Signal (Common)
Power
Module
2
2
3
Charge Relay Contact
3
4
Charge Relay Contact (Jumper to Power Module 1 Terminal 21)
1
Precharge Complete Signal (+24V DC)
2
Precharge Complete Signal (Common)
4
Figure 10 Sample Precharge Wiring Diagram
External precharge circuitry is shown as dashed lines.
DC+
M
PU1
X50
1
F1
M
R1 CR2
2
X9
25
26
CR1
4
M
Precharge
Complete*
ASIC
Board
#2
X15
3
DC Source
Precharge
Complete*
ASIC
Board
#1
21
22
23
CR2
M
CR1
M
PU2
X50
DC-
1
M
2
F2
R2 CR2
X9
25
26
X15
3
4
21
22
23
*Refer to the “ASIC Board
Charge Relay Contact
Ratings” table below.
ASIC Board Charge Relay Contact Ratings
Load
Rated load
Rated carry current
Max. switching voltage
Max. switching current
Max. switching power
Failure rate (reference value)
Resistance load (cos φ = 1)
8 A at 250 VAC: 5 A at 30 VDC
8A
250 VAC; 30 VDC, (400 VAC)
AC 8 A; DC 5 A
2,000 VA; 150 W
5 VDC 10 mA (for gold plating 0.35 µ min.)
26
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
Step 10: Installing the
Product Identification Label
on the New Power
Structures
All frame 12 replacement power structures are shipped form the factory
without a product identification label on the drive. If you are installing the
power structures in a 700S drive, you should label it with the accompanying
PowerFlex 700S label. If you are installing the power structures in a 700H
drive, you should label it with the accompanying PowerFlex 700H label.
GER
! DAN
TORS
CAPACI
E POWER
ING
AND
REMOV
SERVIC
CTORS E.
CONDU VOLTAG
S BEFORE
BUS HIGH
DC E AT MINUTE
5
OPERAT
WAIT
AND
R
GE
AN
! D
TORS
PACI POWER
G
D CA
AN MOVE ICIN
E. RE SERV
TORS
AG
UC
ND VOLT FORE
S COHIGH TES BE
BU
DC E AT MINU
AT T 5
ER
OP D WAI
AN
OR
Step 11: Starting the Drive
1. Replace the protective covers in the reverse order of Step 2: "Removing
the Protective Covers from the Existing Drive" on page 3.
2. Start up the drive. Refer to the Start Up procedures in the appropriate
publication:
–
User Manual - PowerFlex 700S Drives with Phase II Control,
20D-UM006
–
Programming Manual - PowerFlex 700H Drives, 20C-PM001
PowerFlex® 700S and 700H Frame 12 Replacement Power Structures
Reference Materials
27
Allen-Bradley publications are available on the internet at
www.rockwellautomation.com/literature.
The following manuals are recommended for general drive information:
Title
Industrial Automation Wiring and Grounding Guidelines
Preventive Maintenance of Industrial Control and Drive System
Equipment
Safety Guidelines for the Application, Installation and Maintenance
of Solid State Control
A Global Reference Guide for Reading Schematic Diagrams
Guarding Against Electrostatic Damage
Publication
1770-4.1
DRIVES-TD001…
SGI-1.1
0100-2.10
8000-4.5.2
The following manuals are recommended for detailed PowerFlex 700H and
700S information:
Title
Reference Manual - PowerFlex 700S Drives with Phase II Control
User Manual - PowerFlex 700S Drives with Phase II Control
Programming Manual - PowerFlex 700H Drives
Installation Instructions - PowerFlex 700S and 700H High Power Drives
Installation Instructions - PowerFlex® 700S and 700H High Power Maintenance
Stand
Publication
PFLEX-RM003…
20D-UM006…
20C-PM001…
PFLEX-IN006…
PFLEX-IN014…
For Allen-Bradley Drives Technical Support and access to the proper
Hardware Service Manual:
Title
Allen-Bradley Drives Technical Support
Online at...
www.ab.com/support/abdrives
www.rockwellautomation.com
Power, Control and Information Solutions Headquarters
Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA,Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
Europe/Middle East/Africa: Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium,Tel: (32) 2 663 0600, Fax: (32) 2 663 0640
Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong,Tel: (852) 2887 4788, Fax: (852) 2508 1846
Publication PFLEX-IN012B-EN-P - August 200828
Supersedes PFLEX-IN012A-EN-P - March 2006
360403-P02
Copyright © 2008 Rockwell Automation. All rights reserved. Printed in the U.S.A.