Allen-Bradley PowerFlex 700H User manual

Hardware Service Manual

700S High Performance

AC Drive

and

700H Adjustable Frequency

AC Drive

Frame 12

450-560kW, 400V

700-900HP, 480V

630-800kW, 690V

700-900HP 600V

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety

Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available

from your local Rockwell Automation sales office or online at www.rockwellautomation.com/literature) describes

some important differences between solid state equipment and hard-wired electromechanical devices. Because of

this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for

applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting

from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many

variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume

responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment,

or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell

Automation, Inc. is prohibited.

Throughout this manual, when necessary we use notes to make you aware of safety considerations.

Important: Identifies information that is critical for successful application and understanding of the product.

PowerFlex is a registered trademark of Rockwell Automation, Inc.

DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.

PLC is a registered trademark of Rockwell Automation, Inc.

WA R N I N G : Identifies information about practices or

circumstances that can cause an explosion in a hazardous

environment, which may lead to personal injury or death, property

damage, or economic loss.

ATTENTION: Identifies information about practices or

circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you:

xidentify a hazard

xavoid the hazard

xrecognize the consequences

Shock Hazard labels may be located on or inside the equipment

(e.g., drive or motor) to alert people that dangerous voltage may be

present.

Burn Hazard labels may be located on or inside the equipment

(e.g., drive or motor) to alert people that surfaces may be at

dangerous temperatures.

Table of Contents

Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Preface Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

What is in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

What is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2

Understanding Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2

Additional Support Available on Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4

Chapter 1 Creating Fault Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Addressing 700S Hardware Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Addressing 700H Hardware Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Diagnostic Procedures by Symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Chapter 2 Viewing the 700H Diagnostic LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Viewing the 700S Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Performing Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Conducting Forward and Reverse Biased Diode Tests for Major Power Components. . . 2-4

Checking Fiber Optic Connections to the Gate Driver Boards . . . . . . . . . . . . . . . . . . . . . 2-8

Conducting Gate Driver Board Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Checking Rectifying Module (on AC Input Drives Only) . . . . . . . . . . . . . . . . . . . . . . . 2-14

Checking the DC Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Checking the Main Fan Inverters and Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Chapter 3 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Removing Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Removing the DPI / HIM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Removing the 700S Phase II Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Removing the 700S High Power Fiber Optic Interface Circuit Board . . . . . . . . . . . . . . . 3-8

Removing the 700S Control Assembly Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Removing the 700H I/O Boards and Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Removing the 700H Star Coupler Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Removing the Covers from the Power Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Removing the 700S Voltage Feedback Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Removing the Gate Driver and Adapter Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Removing the Power Structures from the Drive Enclosure . . . . . . . . . . . . . . . . . . . . . . 3-25

Removing the Main Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Removing the ASIC Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Removing the Rectifying Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Removing the Left-Side Output Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Removing the Right-Side Output Power Modules and Rectifying Modules . . . . . . . . . 3-33

Removing the Fan Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Removing the DC Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Chapter 4 Before Applying Power to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Testing with the External DC Power Supply Without Load (Optional) . . . . . . . . . . . . . . 4-2

Testing Without a Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Performing the Power Circuit Diagnostic Test on a 700S. . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Testing With the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Appendix A Software Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Service tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Appendix B List of Schematic Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Appendix C Circuit Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Hardware Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10

Appendix D Disassembly/Assembly Diagrams and Spare Parts Numbers . . . . . . . . . . . . . . . . . . . . . . D-1

Preface

Overview

Who Should Use this

Manual?

This manual is intended for qualified service personnel responsible for

troubleshooting and repairing high power PowerFlex 700H and 700S AC

Drives. You should have previous experience with, and basic understanding

of electrical terminology, procedures, required troubleshooting equipment,

equipment protection procedures and methods, and safety precautions.

What is in this Manual This manual contains hardware service information for Frame 12

PowerFlex 700H and 700S drives only. Verify that you are working on a

Frame 12 drive by checking the data nameplate on the Control Frame. The

frame number is printed just above the serial number.

What is Not in this Manual This manual does not contain in depth fault information for troubleshooting.

That information is available in publications 20C-PM001, Programming

Manual - PowerFlex 700H Adjustable Frequency AC Drive, PFLEX-IN006,

Installation Instructions - PowerFlex 700S and 700H Adjustable Frequency

AC Drive and 20D-UM006, User Manual - PowerFlex 700S with Phase II

Control High Performance AC Drive.

Cat No. 20D J500 N 0 NNNBNNNN

UL Open Type/IP00

540V 650V

Normal Duty Power 250 kW

200 kW

450 kW

500 kW

Heavy Duty Power

DC Voltage Range 462 - 594

350

583 - 713

350

Amps

Input: DC,

AC Voltage Range 0 - 400

50 Hz

0 - 460

60 Hz

Base Hz (default)

Output: 3 Phase, 0 - 320Hz

Continuous Amps 420/500

630/550

420/500

630/550

1 Min Overload Amps

2 Sec Overload Amps 840/630 840/630

MFD. in 1989 on Nov 9 Frame #: 12

Serial Number: 2622381652

2622381652

MADE IN THE USA (FAC 1B)

Series: A

Standard I/O: NONE

Original Firmware No. 2.04

USC

LISTED

IND CONT EQ

9D42

Frame#:10

Cat No.

20D

300N 0 NNNBNNNN

ULOpen Type/IP00

540V 650V

Normal Duty Power

160kW

132kW

250kW

200kW

HeavyDuty Power

DCVoltage Range

462- 594

350

583- 713

350

Amps

Input:DC,

ACVoltage Range

0- 400

50Hz

0- 460

60Hz

BaseHz (default)

Output:3 Phase, 0 - 320Hz

ContinuousAmps

300/245

330/368

300/245

330/368

1Min Overload Amps

2Sec Overload Amps

450/490 450/490

MFD.in2005 on Feb 29

Serial Number: 2622381652

2622381652

MADEIN THE USA (FAC1B)

Series:A

StandardI/O: NONE

OriginalFirmware No. 2.04

USC

LISTED

INDCONT EQ

P-2 Overview

Reference Materials Allen-Bradley publications are available on the internet at

www.rockwellautomation.com/literature.

The following publications provide general drive information.

The following publications provide specific PowerFlex drive information.

The following publications provide information that is necessary when

applying the DriveLogix Controller.

Understanding Manual

Conventions

Terms

The following words are used throughout the manual to describe an action:

Title Publication

Wiring and Grounding Guide, (PWM) AC Drives DRIVES-IN001…

Safety Guidelines for the Application, Installation and Maintenance of

Solid State Control

SGI-1.1

A Global Reference Guide for Reading Schematic Diagrams 0100-2.10

Guarding Against Electrostatic Damage 8000-4.5.2

Title Publication

Programming Manual - PowerFlex 700H AC Drive 20C-PM001…

User Manual - PowerFlex 700S with Phase II Control High

Performance Drive

20D-UM006…

Installation Instructions - Hi-Resolution Feedback Option Card for

PowerFlex 700S Drives

20D-IN001…

Installation Instructions - Multi Device Interface Option for PowerFlex

700S Drives

20D-IN004…

Installation Instructions - Main Control Board PowerFlex 700S Drives 20D-IN005…

Installation Instructions - Control Assembly Cover for PowerFlex 700S

Drives

20D-IN006…

Installation Instructions - PowerFlex 700S /700H High Power

Maintenance Stand

20D-IN014…

Installation Instructions - PowerFlex 700S and 700H Drives PFLEX-IN006…

Reference Manual - PowerFlex 700S with Phase II Control Adjustable

Frequency Drives

PFLEX-RM003…

Title Publication

User Manual - DriveLogix System 20D-UM002…

Installation Instructions - DriveLogix Controller 20D-IN002…

Installation Instructions - Memory Expansion for DriveLogix Controller 20D-IN007…

ControlNet Daughtercard Installation Instructions 1788-IN002…

ControlNet Daughtercard Installation Instructions 1788-IN005…

Word Meaning

Can Possible, able to do something

Cannot Not possible, not able to do something

May Permitted, allowed

Must Unavoidable, you must do this

Shall Required and necessary

Should Recommended

Should Not Not recommended

Overview P-3

Cross References

“Figure 2.2 on page 2-6” is a cross reference to figure 2.2 on page 5 of

Chapter 2.

“Figure C.1 on page C-2” is a cross reference to figure C.1 on page 2 of

Appendix C.

Additional Support

Available on Internet

Additional troubleshooting information and software tools are available on

the Allen-Bradley Drives Support Website (http://www.ab.com/support/

abdrives/).

P-4 Overview

General Precautions Class 1 LED Product

ATTENTION: Hazard of permanent eye damage exists when

using optical transmission equipment. This product emits intense

light and invisible radiation. Do not look into module 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 into contact with the assembly.

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: An incorrectly applied or installed drive can

result in component damage or a reduction in product life. Wiring

or application errors, such as, undersizing the motor, incorrect or

inadequate AC supply, or excessive ambient temperatures may

result in malfunction of the system.

ATTENTION: Only qualified personnel familiar with high

power PowerFlex 700S and 700H Drives and associated

machinery should plan or implement the installation, start-up and

subsequent maintenance of the system. Failure to comply may

result in personal injury and/or equipment damage.

ATTENTION: To avoid an electric shock hazard, verify that the

voltage on the bus capacitors has discharged before performing

any work on the drive. Measure the DC bus voltage at the DC+ &

DC- terminals. The voltage must be zero.

ATTENTION: Potentially fatal voltages may result from

improper usage of an oscilloscope and other test equipment. The

oscilloscope chassis may be at a potentially fatal voltage if not

properly grounded. If an oscilloscope is used to measure high

voltage waveforms, use only a dual channel oscilloscope in the

differential mode with X 100 probes. It is recommended that the

oscilloscope be used in the A minus B Quasi-differential mode

with the oscilloscope chassis correctly grounded to an earth

ground.

Chapter 1

Troubleshooting and Error Codes

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 performing

any work on the drive. Measure the DC bus voltage at the DC+ &

DC- terminals. The voltage must be zero.

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: 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.

1-2 Troubleshooting and Error Codes

Creating Fault Reports Clear and complete fault reports are critical for analysis and repair of

modules returned to the factory.

At a minimum, perform and record the following:

xRecord the contents of the fault queue (faults and times of occurrence)

xMake record of any burn marks on the rectifying module, DC-capacitors,

inverter bridge, charging resistors, balancing/precharging resistors,

printed circuit boards, bus bars, cabling and fiber-optic cabling

xMake record of any liquid and condensation marks on printed circuit

boards, components and mechanical parts

xMake record of the amount of dust and other additional particles on drive

and drive components

xMake record of any mechanical damage to the drive and drive

components

xRecord the size and type of main fuses

xRecord any other important marks and damage

Addressing 700S Hardware

Faults Fault No. Description Action (if appropriate)

HiHp In PhaseLs 65 AC Input Phase Loss - AC voltage is

not present on one or two input

phases.

1. Check for voltage on each

input phase.

2. Check the status of each

external input fuses.

HiHp Bus Com Dly 66 Bus Communication Time Delay - the

processor has not received proper

periodic feedback information.

Check fiber-optic connections

between the Power Interface

Circuit Board and Voltage

Feedback Circuit Board.

HiHp Bus Link LS 67 Bus Communication Link Loss - bus

communication between the Power

Interface Circuit Board and Voltage

Feedback Circuit Board has halted.

Check fiber-optic connections

between the Power Interface

Circuit Board and Voltage

Feedback Circuit Board.

HiHp Bus CRC Er 68 Bus Communication CRC Error - too

many Cycling Ring Checksum (CRC)

errors have occurred in the

communication bus.

A fast power cycle may cause the

700S Main Control Board to attempt

to communicate with the ASIC Board

before the ASIC Board is energized.

Check fiber-optic connections

between the Power Interface

Circuit Board and Voltage

Feedback Circuit Board.

Wait five minutes before

re-energizing the drive.

HiHp Bus WtchDog 69 Bus Communication Watchdog Error -

communication has halted in the

communication bus, causing the

watch dog timer to expire.

1. Check fiber-optic

connections between the

Power Interface Circuit Board

and Voltage Feedback Circuit

Board.

2. Check connections between

the Main Control Board and

the Power Interface Circuit

Board.

3. Replace the Voltage

Feedback Circuit Board.

4. Replace the Power Interface

Circuit Board.

5. Replace the Main Control

Board.

HiHp Fan Fdbk Ls 70 Fan Feedback Loss - a fan feedback

signal has been lost.

1. Check the main cooling fan.

2. Check the Main Control

Board cooling fan.

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