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

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

Three covers

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.

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+

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

X15

X3X4X5

H4H5H6 H1H2H3

X10

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.

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

Disconnect cable

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