Rockwell powerflex 700s, powerflex 700h Service Manual

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Page 1

FRAME 10 HARDWARE SERVICE MANUAL

200-250 kW, 400V

300-450 HP, 480V 250-450 HP, 600V

250-400 kW, 690V

PowerFlex® 700S / 700H Adjustable Frequency AC Drives

Page 2

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

http://

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, DriveExplorer, DriveExecutive, DPI, and SCANport are either trademarks or registered trademarks of Rockwell Automation, Inc.

WARNING: 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 identify a hazard, avoid a hazard, and recognize 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.

Page 3

Summary of Changes

Manual Updates

Current Revision

This information summarizes the changes made to the PowerF lex® 700S and 700H Drives Frame 10 - Hardware Service Manual, publication

PFLEX-TG002..., since the April 2007 release.

Previous Revision

This information summarizes the changes made to the PowerF lex® 700S and 700H Drives Frame 10 - Hardware Service Manual, publication

PFLEX-TG002..., since the July 2005 release.

Change See Page...

Updated the 700S and 700H faults. 1-2

Removed the “Diagnostic Procedures by Symptom” diagrams and replaced them with the new “Common Drive Conditions and Corrective Actions” tables.

1-17

Added the “Technical Support Options” section. 1-19

Removed the “Active” Gate Driver Board measurements procedures from Chapter 2.

Updated the “Checking the Rectifying Module” procedures to include the new Series B Rectifying board.

2-9

Added procedure for removing the precharging resistors on series B rectifiers. 3-32

Updated the “Start-Up After Repair” procedures. 4-1

Updated the “Right-Hand Side” and “Left-Hand Side Power Structure” spare parts lists. C-4

Change See Page...

Updated the 700S hardware faults 1-2

Removed references to brake option in the “Conducting Forward and Reverse Biased Diode Tests for Major Power Components” (brake option not available on PowerFlex 700H/S Frame 10 drives)

2-3

Added Removal of PowerFlex 700S Phase II Control 3-6

Added the Removal of the Common Mode Filter Board 3-9

Updated the Circuit Board Connections Schematics to include the X50 Terminal Block and Common Mode Filter circuit board

B-1

Updated the Spare Parts Lists for the Disassembly / Assembly Drawings C-1

Added an Index Index-1

Page 4

soc-ii Summary of Changes

Notes:

Page 5

Table of Contents

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

Summary of

Changes

Manual Updates

Current Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-i

Previous Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-i

Preface Overview

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

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

What is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2

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

Understanding Manual Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3

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

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

Chapter 1 Troubleshooting and Error Codes

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

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

Addressing 700H Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Common Drive Conditions and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Technical Support Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Chapter 2 Component Test Procedures

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

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

Conducting Forward and Reverse Biased Diode Tests for Major Power Components. . . 2-3

Conducting Gate Driver Board Gate Interface Resistance Measurements . . . . . . . . . . . . 2-7

Checking the Rectifying Module (on AC Input Drives Only) . . . . . . . . . . . . . . . . . . . . . 2-9

Checking the Fan Inverters and Main Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Page 6

Chapter 3 Access Procedures

Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

Removing the DPI / HIM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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

Removing the 700S Phase I Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Installing the 700S Phase I Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

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

Installing the 700S Phase II Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Removing the Common Mode Filter Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Installing the Common Mode Filter Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Removing the 700S High Power Fiber Optic Interface Circuit Board . . . . . . . . . . . . . . 3-11

Installing the 700S High Power Fiber Optic Interface Circuit Board . . . . . . . . . . . . . . . 3-12

Removing the 700H I/O Circuit Boards and Control Assembly . . . . . . . . . . . . . . . . . . . 3-12

Installing the 700H I/O Circuit Boards and Control Assembly. . . . . . . . . . . . . . . . . . . . 3-13

Removing the 700H Fiber Optic Adapter Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Installing the 700H Fiber Optic Adapter Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

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

Installing the Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Removing the 700S Voltage Feedback Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Installing the 700S Voltage Feedback Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Removing the Gate Driver and Adapter Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Installing the Gate Driver and Adapter Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Removing the Power Structure from the Drive Enclosure . . . . . . . . . . . . . . . . . . . . . . . 3-27

Installing the Power Structure in the Drive Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Removing the Main Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Installing the Main Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Removing the ASIC Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Installing the ASIC Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Removing the Rectifying Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Installing the Rectifying Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Removing the Precharging Resistors from Series B Drives . . . . . . . . . . . . . . . . . . . . . . 3-32

Installing the Precharging Resistors on Series B Drives . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Removing the Left-Side Output Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Installing the Left-Side Output Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Removing the Right-Side Output Power Module and Rectifying Module . . . . . . . . . . . 3-36

Installing the Right-Side Output Power Module and Rectifying Module . . . . . . . . . . . . 3-40

Removing the Fan Inverters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Installing the Fan Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Removing the DC Bus Capacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Installing the DC Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Chapter 4 Start-Up After Repair

Loading the 700H EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Before Applying Power to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Testing Without the Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

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

Testing With the Motor Without a Mechanical Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Page 7

Appendix A Service Tools and Equipment

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

Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B Schematics

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

Appendix C Disassembly / Assembly Diagrams

Disassembly/Assembly Diagrams and Spare Parts Numbers . . . . . . . . . . . . . . . . . . . . . . C-1

Index

Page 8

Page 9

Preface

Overview

Who Should Use this Manual?

This manual is intended for qualified service personnel responsible for troubleshooting and repairing high power PowerFlex 700S and 700H 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 10 PowerFlex 700S and 700H drives only. Verify that you are working on a Frame 10 drive by checking the data nameplate on the Control Frame. The frame number is printed just above the serial number.

Cat No.

20DJ300 N 0 NNNBNNNN

UL Open Type/IP00

540V 650V

Normal Duty Power

160 kW 132 kW

250 kW 200 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

300/245 330/368

1 Min Overload Amps 2 Sec Overload Amps

450/490 450/490

MFD. in 1989 on Nov 9

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

Cat No.

20DJ500 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

1 Min Overload Amps 2 Sec Overload Amps

840/630 840/630

MFD. in 1989 on Nov 9 Frame #: 10

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

ahw0981.eps

Page 10

p-2 Overview

What is Not in this Manual

This manual does not contain in depth installation and fault information for troubleshooting. Troubleshooting information is available in publications 20C-PM001…, Programming Manual - PowerFlex 700H Adjustable

Frequency AC Drive, 20D-UM001…, User Manual - PowerFlex 700S Drive with Phase I Control, or 20D-UM006…, User Manual - PowerFlex 700S Drive with Phase II Control. Complete installation information is available in publication PFLEX-IN006…, Installation Instructions PowerFlex 700S and 700H Adjustable Frequency AC Drive.

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.

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 100-2.10

Guarding Against Electrostatic Damage 8000-4.5.2

Title Publication

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

User Manual - PowerFlex 700S Drive with Phase I Control 20D-UM001...

User Manual - PowerFlex 700S Drive with Phase II Control 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 - PowerFlex 700S /700H High Power Maintenance Stand

20D-IN014...

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

Reference Manual - PowerFlex Adjustable Frequency Drive with Phase I Control

PFLEX-RM002...

Reference Manual - PowerFlex Adjustable Frequency Drive with Phase II Control

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 (Catalog Numbers 1788-CNC and 1788-CNCR)

1788-IN002...

ControlNet Daughtercard Installation Instructions (Catalog Numbers 1788-CNF and 1788-CNFR)

1788-IN005...

Page 11

Overview p-3

Understanding Manual Conventions

Ter ms

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

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/).

Word Meanin g

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

Page 12

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 completely before servicing. 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.

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.

Page 13

Chapter 1

Troubleshooting and Error Codes

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

ATTENTION: Only qualified personnel familiar with high

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

input power has been removed from the drive and the voltage on the bus capacitors has discharged completely before servicing. 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.

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, isolated 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.

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.

Page 14

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:

• Record the contents of the fault queue (faults and times of occurrence)

• Make 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

• Make record of any liquid and condensation marks on printed circuit boards, components and mechanical parts

• Make record of the amount of dust and other additional particles on drive and drive components

• Make record of any mechanical damage to the drive and drive components

• Record the size and type of main fuses

• Record any other important marks and damage

Addressing 700S Faults

No. Name Description Action (if appropriate)

1 Abs Ovespd Det Motor speed has exceeded the limits

set in parameters 75 [Rev Speed Limit], 76 [Fwd Speed Limit] and 335 [Abs OverSpd Lim]

• Check to see if the encoder

feedback polarity is correct.

• Check to see if the drive is in

torque mode, selected in parameter 110 [Speed/ TorqueMode] value 2 “Torque Ref”. If the drive is in torque mode, verify that there is a load present.

• Verify min./max. settings in

parameters 75 [Rev Speed Lim] and Par 76 [Fwd Speed Lim]. Check to see if the load is overhauling. If it is overhauling, turn the bus regulator off using parameter 414 [Brake/Bus Cnfg] bit 2 “BusRef High”.

2 Vref Decel Fail The value of parameter 301 [Motor

Spd Ref] has failed to decrease during a ramp to zero speed stop.

• This may be due to a speed trim

from parameters 21 [Speed Trim 1], 22 [Speed Trim 2] or 23 [Speed Tr i m 3 ] .

3 Encoder 0 Loss One of the following has occurred on

encoder 0:

• missing encoder (broken wire)

• quadrature error

• phase loss

• Reconnect encoder or replace

encoder.

• Configured with parameters 365

[Fdbk LsCnfg Pri], 366 [Fdbk LsCnfg Alt], and 367 [Fdbk LsCnfgPosit]

4 Encoder 1 Loss One of the following has occurred on

encoder 1:

• missing encoder (broken wire)

• quadrature error

• phase loss

• Reconnect encoder or replace

encoder.

• Configured with parameters 365

[Fdbk LsCnfg Pri], 366 [Fdbk LsCnfg Alt], and 367 [Fdbk LsCnfgPosit]

Page 15

Troubleshooting and Error Codes 1-3

5 Opt Port 0 Loss A fault on port 0 of the Hi-Resolution

Encoder Feedback Option Card, MDI Option Card, Heidenhain, or Resolver Feedback Option Card has occurred.

• Parameter 260 [Stegmann0

Status] displays the fault status for port 0 of the Hi-Resolution Encoder Feedback Option Card.

• Parameter 264 [Heidenhain0 Stat]

displays the fault status for port 0 of the Heidenhain Feedback Option Card.

• Parameter 269 [Resolver0 Status]

displays the fault status for port 0 of the Resolver Feedback Option Card.

• Reconnect encoder or replace

encoder

• Reconnect option feedback card

• Configured with parameters 365

[Fdbk LsCnfg Pri], 366 [Fdbk LsCnfg Alt], and 367 [Fdbk LsCnfgPosit]

6 Opt Port 1 Loss The Linear sensor por tion of the MDI

feedback option card has detected a fault condition.

• Parameter 286 [Linear1 Status]

displays the fault status for linear portion of the MDI feedback Option Card.

• Reconnect encoder or replace

encoder

• Reconnect option feedback card

• Configured with parameters 365

[Fdbk LsCnfg Pri], 366 [Fdbk LsCnfg Alt], and 367 [Fdbk LsCnfgPosit]

7 Params Defaulted All parameters are reset to default by

user.

(Informational only.)

8 SLink HW Fail A fault on loading SynchLink

firmware into FPGA on Main Control Board at power up.

• Replace Main Control Board

9 SLink Comm Fail A SynchLink communication fault has

occurred.

• Parameter 902 [SL Error Status]

displays SynchLink errors.

• Verify the SynchLink configuration

in parameters:

• 904 [SL Node Cnfg]

• 905 [SL Rx CommFormat], and

• 910 [SL Tx CommFormat]

•

Reconnect SynchLink communication fibers

• Configured with parameter 384

[SL CommLoss Cnfg]

10 Drive Power Loss • DC Bus voltage has fallen below

the minimum value

• Parameter 306 [DC Bus Voltage]

displays bus voltage

• Parameter 330 [Fault TP Data]

displays the minimum value when parameter 329 [Fault TP Sel] is set to five

• The drive must first complete

precharge before this check is made

• Verify AC line power

No. Name Description Action (if appropriate)

Page 16

1-4 Troubleshooting and Error Codes

11 Motor OLoad Trip A motor overload trip has occurred.

Parameter 308 [Output Current] is squared, scaled and integrated over time. When this integrated value exceeds 1.0, this Exception Event occurs.

The integrator's output can be viewed in parameter 330 [Fault TP Data] when parameter 329 [Fault TP Sel] is set to 13 “Mtr OL Outpt”. The overload integration rate is affected by parameters 336 [Motor OL Factor], 337 [Mtr I2T Curr Min], 338 [Mtr I2T Spd Min] and 339 [Mtr I2T Calibrat].

• Reduce the mechanical load

• Enter the correct motor nameplate

full load amps in parameter 2 [Motor NP FLA]

• Configure with parameter 371 [Mtr

OL Trip Cnfg]

12 Motor OLoad Pend A motor overload is pending.

Parameter 308 [Output Current] is squared, scaled and integrated over time. When this integrated value exceeds 0.5, this exception event occurs.

• Reduce the mechanical load

• Enter the correct motor nameplate

full load amps in parameter 2 [Motor NP FLA]

• Configure with parameter 372 [Mtr

OL Pend Cnfg]

13 Motor Stalled The motor has stalled. These three

conditions have occurred at the same time for the amount of time specified in parameter 373 [Motor Stall Time]:

1.) Drive is not stopped (parameter 150 [Logic State Mach] not equal to zero)

2.) Drive is on limit (parameter 304 [Limit Status] not equal to zero)

3.) Drive is at zero speed (parameter 155 [Logic Status] / bit 13 “At Zero Spd” is set).

• Increase torque limit

• Reduce mechanical load

• Configured with parameter 374

[Motor Stall Cnfg]

14 Inv OTemp Pend Parameter 313 [Heatsink Temp] is

within 10°C of the maximum value.

View the maximum heat sink temperature in parameter 348 [Drive OL TP Data] when parameter 347 [Drive OL TP Sel] is set to 30 “fMaxHsDegc”.

• Reduce the mechanical load

• Lower the ambient temperature

• Configured with parameter 375

[Inv OT Pend Cnfg]

15 Inv OTemp Trip Parameter 313 [Heatsink Temp] is

above the maximum limit or temperature sensor has failed (shorted or open).

See parameter 346 [Drive OL Status] / bit 0 “NTC Shorted” and bit 1 “NTC Open”.

• Reduce the mechanical load

• Lower the ambient temperature

• Verify that the cooling fan(s) and

fan inverter(s) are running and functioning properly.

• Check the heatsink for blockage or

excessive dirt and clear/clean as necessary.

• Check the air filters (if present) for

blockage and replace as necessary.

No. Name Description Action (if appropriate)

Page 17

Troubleshooting and Error Codes 1-5

16 Inv OLoad Pend The drive's operating point is

approaching the intermittent current rating limitation. If output current remains at or above present levels, an inverter overload condition will occur.

• Reduce the load on the drive

• Configured with parameter 376

[Inv OL Pend Cnfg]

17 Inv OLoad Trip The drive's operating point has

exceeded the intermittent current rating and a foldback to the continuous rating in parameter 400 [Rated Amps] has occurred.

• Reduce the mechanical load

• Configured with parameter 377

[Inv OL Trip Cnfg]

18 Ext Fault Input A digital input has detected an

external fault.

Enter a value of 3 “Ext Fault” or 38 “ExtFault Inv” in one of the [Digin x Sel] parameters to configure an input to detect an external fault.

Configured with parameter 379 [Ext Flt/Alm Cnfg]

19 DSP Memory Error Flash memory does not match the

SRAM memory

• Cycle the drive power

• If the fault remains, replace the

Main Control Board

20 DSP Device Error A DSP (Velocity Position Loop)

interrupt task has not been completed in the allotted time.

• Cycle the drive power

• If the fault remains, replace the

Main Control Board

22 Over Frequency Encoderless algorithm fails to

converge on correct speed. Two possible causes:

1.) Velocity regulator is attempting to run below motor’s slip speed.

2.) Frequency regulator “pulls out” and commanded motor frequency slows to maximum frequency limit.

23 MC Commissn Fail The drive has failed to complete

either the Motor Autotuning procedure or the Power Circuits Diagnostics test. Parameters 463 [MC Diag Error 1], 464 [MC Diag Error 2] and 465 [MC Diag Error 3] display Motor Autotuning and Power Circuit Diagnostic faults. Parameter 465 [MC Diag Error 3] Drive current, inductance, voltage and speed are not within motor nameplate specifications. This fault occur most frequently on low horsepower motors.

• Verify that motor nameplate data is

entered correctly into the drive.

• Verify the motor is wired for the

correction voltage entering into the drive.

• Verify the encoder (if used) and

velocity feedback is correct.

• Change tuning mode in to

parameter 515 [FVC Tune Config] to 9 “NoRotate Tune”.

24 DC Bus Overvolt Refer to “Protection” in Appendix A in

the PowerFlex 700S Phase II Drive - User Manual, publication 20D-UM006…, for DC Bus Overvoltage Trip levels.

• Verify the AC Line.

• Verify that either the brake or bus

regulator is enabled (parameter 414 [Brake/Bus Cnfg], bit 0 “Brake Enable” or bit 3 “Bus Reg Enable”, respectively).

• Verify that parameter 128 [Regen

Power Lim] is set properly.

• If [Brake/Bus Cnfg] bit 0 “Brake

Enable” is set, verify braking resistor is properly sized.

25 Inv Trans Desat The IGBT detects a transistor failure

(Desat).

No. Name Description Action (if appropriate)

Page 18

1-6 Troubleshooting and Error Codes

26 Ground Fault A current to ear th exceeds 35% of

the peak drive rating.

• Check the motor and external

wiring to the drive output terminals for a grounded condition.

27 Inst Overcurrent Instantaneous motor current exceeds

214% of rating

• Reduce mechanical load.

• Check the motor and external

wiring to the motor.

28 VPL/MC Comm

Fail

A communication failure has occurred between the Velocity Position Loop (VPL) processor and the Motor Control (MC) processor on the main control board. Possible causes are:

• VPL is flashing MC fir mware into

the MC processor when HIM indicates "Loading Config".

• MC has failed to complete or pass

diagnostic tests.

• MC has not detected VPL

handshake activity for over 32 ms.

• VPL has not detected MC

handshake activity for over 32 ms. This is indicated when Fault Test Point 15 or 16 equals 1. This test point is viewed in parameter 330 [Fault TP Data] when parameter 329 [Fault TP Select] is set to value 15 or 16.

• Cycle power

• Reflash firmware

• Replace Main Control Board

29 PWM Signal Short This fault is detected when ever the

actual IGBT gate is different than the commanded IGBT states. This fault is detected by the Motor Control (MC) processor.

30 MC Firmware One of the following Motor Control

(MC) firmware errors has occurred:

• MC Task Over Run

• Illegal Interrupt

• Self Diagnostic Fault

• Data Error

• Cycle power

• Reflash firmware

• Replace Main Control Board

31 Precharge Error The precharge function has failed to

complete within 30 seconds (default) of the precharge request. The precharge time out can be configured in parameter 410 [PreChrg TimeOut]. A precharge request is initiated when the DC Bus voltage is above the Undervoltage Trip level and the precharge input is high (the requirement for the precharge being high can be bypassed by setting parameter 411 [PreChrg Control] bit 01 “PreChrg Enable” off).

• Verify the value in parameter 410

[PreChrg TimeOut].

• Verify the bit value in parameter

411 [PreChrg Control] = 1 “Enbl PrChrg”.

• Configured with parameter 381

[PreChrg Err Cnfg]

32 PWM Asynch The Motor Control Processor is not

synchronized with SynchLink.

33 +/- 15volt Power The12V DC control voltage is outside

the tolerance range. The positive voltage power must be within the band from +17.00 to +11.61V DC. The negative voltage power must be within the band from -17.00 to

-11.61V DC.

• Replace switch mode power

supply. For smaller frames, replace drive.

No. Name Description Action (if appropriate)

Page 19

Troubleshooting and Error Codes 1-7

35 Parameter

Chksum

The checksum read from the EEPROM does not match the checksum calculated

• Cycle power

• Replace Main Control Board

38 Brake OL Trip The calculated temperature of the

dynamic braking resistor is too high. The temperature is calculated by a thermal model. If the resistor is internal, the model uses resistor characteristic stored in the power structure EEPROM memory. If the resistor is external, the model uses values of parameters 416 [Brake PulseWatts] and 417 [Brake Watts].

• Verify actual temperature of

brake:

• If hot, wait for brake to cool

• If cold, cycle power to the drive

• If cold, verify [Brake PulseWatts]

and [Brake Watts] are correct.

• Configured with parameter 369

[Brake OL Cnfg]

39 PowerEE CRC Fail The CRC of the data stored in the

Power Board EEPROM does not match the stored CRC.

• Cycle power

• In High Horse Power units, check

communication bus lines - 10 pin connector in Main Control Board, High Horse Power interface board, and fiber optic cable connections.

40 SLink Mult Oflow A SynchLink Multiplier Overflow has

occurred. Parameter 927 [SL Mult State] displays SynchLink multiplier overflow errors.

Configured with parameter 390 [SL MultErr Cnfg]

41 Ridethru Timeout The drive has been in a bus loss

ride-through condition for more than two seconds (default). The ride-through timeout can be configured in parameter 407 [Power Loss Time].

• Verify the AC Line.

• Verify the value in [Power Loss

Time].

42 DC Bus Undervolt Bus voltage has fallen below the level

configured in parameter 409 [Line Undervolts].

• Verify the AC Line.

• In frames 1-4, and 9 - 13 verify

the precharge resistor is present. (With power off, there should be a resistance between DC+ and BR+).

• In frames 5 & 6, check the

precharge board for errors. See the precharge board LED for fault sequence.

• Configured with parameter 393

[BusUndervoltCnfg]

43 VoltageFdbk Loss Loss of Motor or DC Bus Voltage

Feedback has occurred because of a communication failure between Motor Control and Voltage Feedback board.

• Check the communication line

between Motor Control (MC) and Voltage Feedback board.

• Replace the Voltage Feedback

board.

• Configured with parameter 394

[VoltFdbkLossCnfg]

44 Runtime Data Rst Runtime data (hours, energy) has

been reset to zero due to a checksum error.

45 Enable Health Safety circuit is active. • Check input signal to the Safety

circuit.

46 Interp Out Synch Interpolator for position feedback lost

synchronization with Velocity Position Loop (VPL).

Configured with parameter 378 [Interp Flt Cnfg]

No. Name Description Action (if appropriate)

Page 20

1-8 Troubleshooting and Error Codes

47 MC CML Task Fail Current Minor Loop (CML) task has

been delayed or run with incorrect interval.

• Cycle power.

48 No Ctrl Device The controlling device (HIM or

controller) has been disconnected while the drive was running.

• Reconnect the controlling device.

49 DPI Loss Port 1 The device at DPI port 1 has stopped

communicating with the drive.

A SCANport device is connected to a drive operating DPI devices at 500k Baud

• Verify DPI device is present and

functional at port 1.

• Configured with parameter 391

[DPI CommLoss Cfg]

50 DPI Loss Port 2 The device at DPI port 2 has stopped

communicating with the drive.

A SCANport device is connected to a drive operating DPI devices at 500k Baud

• Verify DPI device is present and

functional at port 2.

• Configured with parameter 391

[DPI CommLoss Cfg]

51 DPI Loss Port 3 The device at DPI port 3 has stopped

communicating with the drive.

A SCANport device is connected to a drive operating DPI devices at 500k Baud

• Verify DPI device is present and

functional at port 3.

• Configured with parameter 391

[DPI CommLoss Cfg]

52 DPI Loss Port 4 The device at DPI port 4 has stopped

communicating with the drive.

A SCANport device is connected to a drive operating DPI devices at 500k Baud

• Verify DPI device is present and

functional at port 4.

• Configured with parameter 391

[DPI CommLoss Cfg]

53 DPI Loss Port 5 The device at DPI port 5 has stopped

communicating with the drive.

A SCANport device is connected to a drive operating DPI devices at 500k Baud

• Verify DPI device is present and

functional at port 5.

• Configured with parameter 391

[DPI CommLoss Cfg]

54 DPI Loss Port 6 The device at DPI port 6 has stopped

communicating with the drive.

A SCANport device is connected to a drive operating DPI devices at 500k Baud

• Verify DPI device is present and

functional at port 6.

• Configured with parameter 391

[DPI CommLoss Cfg]

55 Net Loss DPI P1 A communications fault has occurred

between the communication adapter at DPI port 1 and the network.

• Verify network connection.

• Verify status of network.

• Configured with parameter 392

[NetLoss DPI Cnfg]

56 Net Loss DPI P2 A communications fault has occurred

between the communication adapter at DPI port 2 and the network.

• Verify network connection.

• Verify status of network.

• Configured with parameter 392

[NetLoss DPI Cnfg]

57 Net Loss DPI P3 A communications fault has occurred

between the communication adapter at DPI port 3 and the network.

• Verify network connection.

• Verify status of network.

• Configured with parameter 392

[NetLoss DPI Cnfg]

58 Net Loss DPI P4 A communications fault has occurred

between the communication adapter at DPI port 4 and the network.

• Verify network connection.

• Verify status of network.

• Configured with parameter 392

[NetLoss DPI Cnfg]

No. Name Description Action (if appropriate)

Page 21

Troubleshooting and Error Codes 1-9

59 Net Loss DPI P5 A communications fault has occurred

between the communication adapter at DPI port 5 and the network.

• Verify network connection.

• Verify status of network.

• Configured with parameter 392

[NetLoss DPI Cnfg]

60 Net Loss DPI P6 A communications fault has occurred

between the communication adapter at DPI port 6 and the network.

• Verify network connection.

• Verify status of network.

• Configured with parameter 392

[NetLoss DPI Cnfg]

61 Logix Out of Run The DriveLogix controller is in a

Non-Run mode. Non-Run modes include program, remote-program and faulted modes.

• Clear fault

• Configured with parameter 386

[Lgx OutOfRunCnfg]

62 Logix Timeout The communication connection to the

DriveLogix controller has timed out.

Configured with parameter 387 [Lgx Timeout Cnfg]

63 Logix Closed The DriveLogix controller has closed

the Controller to Drive connection.

• Verify drive is present in I/O

• Configured with parameter 388

[Lgx Closed Cnfg]

64 Logix Link Chng A required link in the Controller to

Drive Communication Format has been modified.

• Clear fault

• Configured with parameter 389

[Lgx LinkChngCnfg]

65 HiHp In PhaseLs AC Input Phase Loss - the AC input

phase voltage has fallen.

1. Check for voltage on each AC input phase.

2. Check the status of each external AC input fuse.

3. Check the Rectifying board and Rectifying Modules for each AC input phase.

4. Configured with parameter 370 [HiHp InPhsLs Cfg]

66 HiHp Bus Com Dly (High Horse Power Only)

Bus Communication Time Delay - the communication bus has delayed feedback, or bad communication quality.

Check the communication bus lines:

• 10 pin connector between the

Main Control board and High Power Fiber Optic Interface board.

• Fiber-optic connections between

the High Power Fiber Optic Interface Circuit board and the ASIC board.

• Fiber-optic connections between

the High Power Fiber Optic Interface board and Voltage Feedback board

67 HiHp Bus Link Ls Bus Communication Link Loss - bus

communication between the High Power Fiber Optic Interface circuit board and the Voltage Feedback circuit board has stopped.

Check the communication bus lines:

• Fiber-optic connections between

the High Power Fiber Optic Interface board and Voltage Feedback board

• 10 pin connector between the

Main Control board and High Power Fiber Optic Interface board

• Fiber-optic connections between

the High Power Fiber Optic Interface Circuit board and the ASIC board

No. Name Description Action (if appropriate)

Page 22

1-10 Troubleshooting and Error Codes

68 HiHp Bus CRC Er Bus Communication CRC Error - too

many 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 the communication bus lines

• 10 pin connector between the

Main Control board and High Power Fiber Optic Interface board

• Fiber-optic connections between

the High Power Fiber Optic Interface board and the ASIC board

• Fiber-optic connections between

the High Power Fiber Optic Interface board and Voltage Feedback board

69 HiHp Bus

WtchDog

Bus Communication Watchdog Error

- no message (packets) came through in the communication bus - a watchdog error was detected.

Check the communication bus lines:

1. 10 pin connector between the Main Control board and High Power Fiber Optic Interface board

2. Fiber-optic connections between the High Power Fiber Optic Interface board and Voltage Feedback board

3. Replace the Voltage Feedback board

4. Replace the High Power Fiber Optic Interface board

5. Replace the ASIC board

6. Replace the Main Control board

70 HiHp Fan Fdbk Ls Fan Feedback Loss - an inverter

cooling fan did not send active feedback, or did not work.

1. Check the 10 pin connector between the Main Control board and High Power Fiber Optic Interface board

2. Check the fiber-optic connections between the High Power Fiber Optic Interface Circuit board and the ASIC board

3. Verify that the inverter cooling fans are running

71 HiHp Dr v OvrLoad Drive Overload - the drive's operating

point has exceeded the intermittent current rating and a foldback to the continuous rating in parameter 400 [Rated Amps] has occurred.

1. Reduce the mechanical load.

2. If after reducing the load the output current levels are well below the drive rated levels, replace the power module.

72 HiHp PwrBd PrcEr A processor on the High Power Fiber

Optic Interface circuit board has detected a self diagnostic problem.

Check the communication bus lines:

1. 10 pin connector between the Main Control board and High Power Fiber Optic Interface board

2. Fiber-optic connections between the High Power Fiber Optic Interface board and ASIC board

3. Replace the High Power Fiber Optic Interface board

No. Name Description Action (if appropriate)

Page 23

Troubleshooting and Error Codes 1-11

73 HiHp PrChrg Cntc Precharge Contactor Fault - the

precharge contactor did not send back the active feedback.

On drives with DC input:

• Check for loose or incorrect

connections from the external precharge circuit to the X50 terminal block and to the ASIC board (X9 and X15)

On drives with AC input:

• Check the precharge resistors

and relays on the Rectifier board

74 HiHp PwrEE Error Power EEPROM Error - the CRC of

the data stored in the High Power Fiber Optic Interface circuit board EEPROM does not match the stored CRC.

1. Cycle power.

2. Check the communication bus lines:

• 10 pin connector between the

Main Control board and High Power Fiber Optic Interface board

• Fiber-optic connections

between the High Power Fiber Optic Interface board and ASIC board

3. Replace the High Power Fiber Optic Interface board

4. Replace the ASIC board

75 HiHP PwrBd

Otemp

Power Board Over Temperature - the temperature of the High Power Fiber Optic Interface circuit board has exceeded 85° C.

• Verify that the ambient

temperature is within the specification.

• Check the main cooling fan and

fan power supply, replace if necessary

• Replace the Power modules if the

ambient temperature is within specification and the cooling fans are operating properly

81 + Soft Over Trvl (Motion Only)

Position feedback exceeds the maximum positive travel setting, parameter 694 [Motn Mx Pos Trvl].

Configured with parameter 395 [+Sft OvrTrvlCnfg]

82 - Soft Over Trvl (Motion Only)

Position feedback, exceeds the maximum negative travel setting, parameter 695 [Motn Mx Neg Trvl].

Configured with parameter 396 [-Sft OvrTrvlCnfg]

83 + Hard Over Trvl (Motion Only)

Signal for the hardware positive over travel appears on a digital input.

Configured with parameter 397 [+Hrd OvrTrvlCnfg]

84 - Hard Over Trvl (Motion Only)

Signal for the hardware negative over travel appears on a digital input.

Configured with parameter 398 [-Hrd OvrTrvlCnfg]

85 Position Error (Motion Only)

Parameter 769 [Position Error] exceeded parameter 696 [Motn PositErrTol].

• Verify the value in [Motn

PositErrTol].

• Configured with parameter 399

[Position ErrCnfg]

86 Drive Homing When the drive is in Drive Homing

mode (parameter 740 [Position Control], bit 24 or bit 27 is On), the Drive Homing Alarm triggers and the drive moves to a home position automatically.

• Check parameter 740 [Position

Control], bit14 “Find Home” or bit 27 “Return Home”.

No. Name Description Action (if appropriate)

Page 24

1-12 Troubleshooting and Error Codes

88 Stahl Optics Linear Stahl Encoder detected a

fault. Parameter 291 [Lin1Stahl Status] shows the details of the fault.

• Reconnect encoder or replace

encoder.

• Reconnect option feedback card.

93 +/- 12volt Power

Alarm

The12V DC control voltage is outside the tolerance range (Alarm). The positive voltage power exceeds +15.50 V DC. The negative voltage power exceeds -15.50V DC.

• Check the power supply on the

High Power Fiber Optic Interface and Voltage Feedback boards

94 Analog In 1 Loss Analog Input channel 1 is lost. For

configuration of Analog Input channel 1, see parameter 1093 [Anlg In1LossCnfg].

• Check condition of Analog Input

channel 1.

• Change configuration for [Anlg

In1LossCnfg].

95 Analog In 2 Loss Analog Input channel 2 is lost. For

configuration of Analog Input channel 2, see parameter 1094 [Anlg In2LossCnfg].

• Check condition of Analog Input

channel 2.

• Change configuration for [Anlg

In2LossCnfg].

96 Analog In 3 Loss Analog Input channel 3 is lost. For

configuration of Analog Input channel 3, see parameter 1095 [Anlg In3LossCnfg].

• Check condition of Analog Input

channel 3.

• Change configuration for [Anlg

In3LossCnfg].

129 Faults Cleared Indicates that all faults have been

cleared.

*Informational only.

130 Fault Q Cleared Indicates that the fault queue has

been cleared.

*Informational only.

131 Alarm Cleared Indicates that all alarms have been

cleared.

*Informational only.

132 Alarm Q Cleared indicates that the alarm queue has

been cleared.

*Informational only.

No. Name Description Action (if appropriate)

Page 25

Troubleshooting and Error Codes 1-13

Addressing 700H Faults

No. Name Description Action (if appropriate)

2 Auxiliary In The auxiliary input interlock is open. Check all remote wiring.

3 Power Loss The DC bus voltage remained below

the value set in parameter [Power Loss Volts] for longer than the time specified in parameter [Power Loss Time]. You can enable/disable this fault with parameter 238 [Fault Config 1].

Monitor the incoming AC line for low voltage or line power interruption.

4 UnderVoltage The DC bus voltage fell below the

minimum value of 333V for 400/480V drives and 461V for 600/ 690V drives. You can enable/disable this fault with parameter 238 [Fault Config 1].

Monitor the incoming AC line for low voltage or power interruption.

5 OverVoltage The DC bus voltage exceeded the

maximum value.

Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install a dynamic brake option.

6 Motor Stall The motor is operating at high current

and low frequency and is not accelerating.

1. Run an Autotune.

2. Reduce the Load.

7 MotorOverload Internal electronic overload trip. You

can enable/disable this with parameter 238 [Fault Config 1].

1. Run an Autotune.

2. Verify the settings of parameters 48 [Motor OL Factor] and 47 [Motor OL Hertz].

3. Reduce the load so that the drive output current does not exceed the current set by the value in parameter 42 [Motor NP FLA].

8 HeatsinkOvrTp The heatsink temperature has

exceeded the maximum allowable value.

85 degrees C = Alarm 90 degrees C = Fault

1. Verify that the maximum ambient temperature has not been exceeded.

2. Check the fan(s).

3. Check for an excess load.

4. Check the carrier frequency.

9 IGBT OverTemp The output transistors have exceeded

their maximum operating temperature due to an excessive load.

1. Verify that the maximum ambient temperature has not been exceeded.

2. Check the fan(s).

3. Check for an excess load.

10 System Fault A hardware problem exists in the

power structure.

1. Cycle the power.

2. Verify the fiber optic connections.

3. Contact Technical Support. See

Technical Support Options on page 1-19 for more information.

4. If the problem persists, replace the drive.

12 OverCurrent The drive output current has

exceeded the hardware current limit.

Check programming for an excess load, improper DC boost setting, DC brake voltage set too high or other causes of excess current. Check for shorted motor leads or a shor ted motor.

13 Ground Fault A current path to earth ground exists

that is greater than 25% of the drive rating. The current must appear for 800ms before the drive will fault.

Check the motor and external wiring to the drive output terminals for a grounded condition.

Page 26

1-14 Troubleshooting and Error Codes

14 InverterFault A hardware problem exists in the

power structure.

1. Cycle the power.

2. Contact Technical Support. See

Technical Support Options on page 1-19 for more information.

3. If the problem persists, replace the drive.

15 Load Loss Do not use this fault in 700H

applications

Check that parameter 238 [Fault Config 1] / bit 0 “Power Loss” and parameter 259 [Alarm Config 1] / bit 13 “Load Loss” are set to zero.

16 Motor Therm The option board thermistor input is

greater than the limit.

1. Check to ensure that the motor is cooling properly.

2. Check for an excess load.

3. Verify the thermistor connection. If the thermistor connection on the option board is not used, it must be shorted.

17 Input Phase One input line phase is missing.

Configured in parameter 238 [Fault Config 1]

1. Check all user-supplied fuses

2. Check the AC input line voltage.

21 OutPhasMissng There is zero current in one of the

output motor phases.

1. Check the motor wiring.

2. Check the motor for an open phase.

24 Decel Inhibit The drive cannot follow the

commanded decel due to bus limiting.

1. Verify that the input voltage is within the specified limits.

2. Verify that the system ground impedance follows the proper grounding techniques.

3. Disable bus regulation and/or add a dynamic brake resistor and/or extend the deceleration time.

25 OverSpd Limit Functions such as Slip

Compensation or Bus Regulation have attempted to add an output frequency adjustment greater than the value programmed in parameter 83 [Overspeed Limit].

Remove the excessive load or overhauling conditions or increase the value in parameter 83 [Overspeed Limit].

28 BrakResMissing No brake resistor has been detected. 1. Program parameter [Bus Reg

Mode x] to not use the brake option.

2. Install a brake resistor.

29 Anlg In Loss An analog input is configured to fault

on a signal loss. A signal loss has occurred. Configure this fault with [Anlg In x Loss].

1. Check parameter settings.

2. Check for broken/loose connections at the inputs.

30 MicroWatchdog A microprocessor watchdog timeout

has occurred.

1. Cycle the power.

2. Replace the Main Control board.

31 IGBT Temp HW The drive output current has

exceeded the instantaneous current limit.

1. Check for an excess load.

2. Raise the value set in [Accel Time x].

3. Parameter 53 [Motor Cntl Sel] may need to be set to “Custom V/Hz”.

4. Verify the values set in parameters 62 [IR Voltage Drop] and 63 [Flux Current Ref].

5. Contact Technical Support. See

Technical Support Options on page 1-19 for more information.

No. Name Description Action (if appropriate)

Page 27

Troubleshooting and Error Codes 1-15

32 Fan Cooling Fan is not energized at start

command.

1. Check the status LEDs on the fan inverter(s).

2. Verify that the fan(s) and fan inverter(s) are running.

33 AutoReset Lim The drive unsuccessfully attempted

to reset a fault and resumed running for the programmed number of [Flt RstRun Tries]. you can enable/ disable this fault with parameter 238 [Fault Config 1].

Correct the cause and manually clear the fault.

34 CAN Bus Flt A sent message was not

acknowledged.

1. Cycle the power.

2. Replace the Main Control board.

37 HeatsinkUndTp The ambient temperature is too low. Raise the ambient temperature.

44 Device Change The new power unit or option board

installed is a different type.

Clear the fault and reset the drive to the factory defaults.

45 Device Add A new option board was added. Clear the fault.

47 NvsReadChksum There was an error reading

parameters 9 [Elapsed MWh] and 10 [Elapsed Run Time] from EEPROM.

1. Cycle the power.

2. Replace the Main Control board.

48 ParamsDefault The drive was commanded to write

default values to EEPROM.

1. Clear the fault or cycle power to the drive.

2. Program the drive parameters as needed.

50 MotorCalcData The motor nameplate data is

incorrect.

Check the motor nameplate data and verify the proper entry in the “Motor Data” parameters.

54 Zero Divide This event occurred because a

mathematical function had a dividend of zero.

1. Cycle the power.

2. Replace the main control board.

59 Gate Disable Both of the digital gate disable inputs

(SD-1 and SD-2) are not enabled on the 20C-DG1 option board.

1. Check the motor.

2. Verify that the option board is properly wired.

3. Replace the option board. Refer to Appendix E -“Instructions for ATEX Approved PowerFlex 700H Drives in Group II Category (2) Applications with ATEX Approved Motors” in the PowerFlex 700H/S High Power Drives Installation Manual, publication PFLEX-IN006… for information on installing this option board.

60 Hrdwr Therm The thermistor input is activated

(>4kΩ) on the 20C-DG1 option board.

1. Check the motor.

2. The resistance of the thermistor input must go below 2kΩ before the drive can be reset.

63 Shear Pin The value programmed in parameter

148 [Current Lmt Val] has been exceeded. You can enable/disable this fault with parameter 238 [Fault Config 1].

Check the load requirements and the value in [Current Lmt Val].

65 I/O Removed An I/O option board has been

removed.

Clear the fault.

70 Power Unit One or more of the output transistors

were operating in the active region instead of desaturation. This can be caused by excessive transistor current or insufficient base drive voltage.

Clear the fault.

No. Name Description Action (if appropriate)

Page 28

1-16 Troubleshooting and Error Codes

71 Periph Loss The communications card has a fault

on the network side.

1. Check the DPI device event queue and corresponding fault information for the device.

81 Port DPI Loss The DPI port has stopped

communicating.

A SCANport device was connected to a drive operating DPI devices at 500k baud.

1. If the adapter was not intentionally disconnected, check the wiring to the port. Replace the wiring, port expander, adapters, Main control board or complete drive as required.

2. Check the HIM connection.

3. If an adapter was intentionally disconnected and the bit for that adapter in parameter 276 [Logic Mask] is set to “1”, this fault will occur. To disable this fault, set the [Logic Mask] bit for the adapter to “0.”

95 AutoT Rs Stat The Autotune Rs Static Test has

failed.

1. Verify that the motor is not rotating when autotune is enabled.

2. Check the motor connections.

96 AutoT Lm Rot The Autotune Lm rotate test has

failed.

1. Check the motor nameplate data.

2. Check the motor connections.

3. Verify that the Accel Time < (Base Speed/40) x 33 sec. Note: 33 sec. = time limit to bring motor to 40 Hz.

97 AutoT MagRot The Autotune magnetizing current

rotate test has failed.

1. Check the motor nameplate data.

2. Check the motor connections.

3. Verify that the Accel Time < (Base Speed/40) x 33 sec. (see above).

98 AutoT Saturat The Autotune saturation curve test

has failed.

1. Check the motor nameplate data.

2. Check the motor connections.

99 UserSet Timer A User Set load or save was not

completed in less than 5 seconds.

Replace the Main Control board.

100 Param Chksum The checksum read from the Main

Control board does not match the checksum calculated.

1. Restore the drive to the factory defaults.

2. Cycle the power.

3. Reload User Set if used.

104 PwrBrd Chksum The checksum read from the

EEPROM does not match the checksum calculated from the EEPROM data.

1. Cycle the power.

2. Contact Technical Support. See

Technical Support Options on page 1-19 for more information.

3. If the problem persists, replace the drive.

106 MCB-PB Config The drive rating information stored on

the power board is incompatible with the Main Control board.

1. Reset the fault or cycle the power.

2. Replace the Main Control board.

107 New IO Option A New option board was added to the

Main Control board.

1. Restore the drive to the factory defaults.

2. Reprogram parameters as necessary.

113 Fatal App A Fatal Application error has

occurred.

1. Replace the Main Control board.

No. Name Description Action (if appropriate)

Page 29

Troubleshooting and Error Codes 1-17

Common Drive Conditions and Corrective Actions

No Output Voltage

The drive has no output voltage to the motor, even though the drive indicates that the motor is running.

114 AutoT Enable Autotune is enabled but has not

started.

Press the Start key within 20 seconds of enabling autotune.

120 I/O Change An option board has been replaced. Reset the fault.

121 I/O Comm Loss An I/O Board lost communications

with the Main Control board.

1. Check the connector.

2. Check for induced noise.

3. Replace I/O board or Main Control board.

No. Name Description Action (if appropriate)

Diagnostic Procedure Corrective Action

1. Measure the DC bus voltage. If the DC bus is not within specification, repair or replace the Rectifying module as needed.

Otherwise, continue with step 2.

2. Measure the AC output voltage at the motor

terminals using a VAC RMS meter and compare the measurement to the AC output voltage displayed on the HIM (Par 307 [Output Voltage] for 700S drives, Par 6 [Output Voltage] for 700H drives).

If the AC output voltage at the motor terminals does not match the output voltage displayed on the HIM, repair or replace the Output Power modules as needed.

Otherwise, continue with step 3.

3. Verify that there are no loose or missing

connections between the Gate Driver board and ASIC board and the Gate Driver board and Adapter board.

If there are loose or missing connections, or a board has been damaged, replace the loose or missing connections, or repair or replace any of the boards as needed.

Otherwise, continue with step 4.

4. Complete the “Conducting Forward and

Reverse Biased Diode Tests for Major Power Components” on page 2-3

for the Output Power

modules.

If the test is not completed successfully, replace the Output Power modules.

Otherwise, continue with step 5.

5. Check the motor windings and motor cables

with a high resistance DVM (megger).

Repair or replace the motor as needed.

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.

Page 30

1-18 Troubleshooting and Error Codes

Blown Input Fuse

If the drive causes the AC input line fuse to open, complete the following tests to verify that the power structure is functioning properly before replacing the AC input line fuse and reapplying power to the drive.

No HIM Display

If the HIM does not display, complete the following procedure to verify that power is available.

Diagnostic Procedure Corrective Action

1. Disconnect the motor leads. Continue with step 2.

2. Complete the “Conducting Forward and Reverse Biased Diode Tests for Major Power Components” on page 2-3

for the Rectifier

module.

If the test is not completed successfully, replace the Rectifying module.

Continue with step 3.

3. Complete the “Conducting Forward and Reverse Biased Diode Tests for Major Power Components” on page 2-3

for the Output Power

modules.

If the test is not completed successfully, replace the Output Power modules.

Continue with step 4.

4. Examine the DC bus capacitors. If there is evidence of charring and damaged

reliefs, replace the DC bus capacitors.

Otherwise, continue with step 5.

5. Check the motor windings and motor cables with a high resistance DVM (megger).

Repair or replace the motor as needed.

Otherwise, continue with step 6.

6. Disconnect and check the AC choke with a high resistance DVM (megger).

• Verify that the line to line is open

• Verify that the line to ground is open

• Verify that the input to output is low

resistance, but not shorted

Repair or replace the AC choke as needed.

Continue with step 7.

7. Reconnect the AC choke and motor leads.

Diagnostic Procedure Corrective Action

1. Measure the DC bus voltage. If the DC bus is not within specification, repair or

replace the Rectifying module as needed.

Otherwise, continue with step 2.

2. Measure the DC voltage supply at connector X4 on the DPI circuit board on the back of the HIM cradle. The voltage should be approximately 12V DC.

If the DC voltage is incorrect:

• PowerFlex 700S drives - Replace the High

Power Fiber Optic Interface circuit board

• PowerFlex 700H drives - Replace the output

power modules

Otherwise, continue with step 3.

3. Check for loose or missing connections between the DPI circuit board and the High Power Fiber Optic Interface circuit board.

If there are loose or missing connections, or a board has been damaged, replace the loose or missing connections, or repair or replace any of the boards as needed.

Otherwise, Replace the HIM.

Page 31

Troubleshooting and Error Codes 1-19

Technical Support Options

Technical Support Wizards

If you are connected to a drive via DriveExplorer™ or DriveExecutive™, you can run a Tech Support wizard to gather information that will help diagnose problems with your drive and/or peripheral device. The information gathered by the wizard is saved as a text file and can be emailed to your remote technical support contact. (See What You Need When You

Call Tech Support on page 1-20 for more information.)

To run a Tech Support wizard in DriveExplorer, select Wizards from the Actions menu. In DriveExecutive, select Wizards from the Too ls menu. Or, click the button. Follow the prompts to complete the wizard.

Page 32

1-20 Troubleshooting and Error Codes

What You Need When You Call Tech Support

When you contact Technical Support, please be prepared to provide the following information:

• Order number

• Product catalog number and drives series number (if applicable)

• Product serial number

• Firmware revision level

• Most recent fault code

• Your application

The data contained in the following parameters will help in initial troubleshooting of a faulted PowerFlex 700H drive. You can use the table below to record the data provided in each parameter listed.

Param(s) Name Description Parameter Data

224 Fault Frequency Captures and displays the output speed of

drive at time of last fault.

225 Fault Amps Captures and displays motor amps at time

of last fault.

226 Fault Bus Volts Captures and displays the DC bus voltage

of drive at time of last fault.

227 Status 1 @ Fault Captures and displays [Drive Status 1] bit

pattern at time of last fault.

228 Status 2 @ Fault Captures and displays [Drive Status 2] bit

pattern at time of last fault.

229 Alarm 1 @ Fault Captures and displays [Drive Alarm 1] bit

pattern at time of last fault.

230 Alarm 2 @ Fault Captures and displays [Drive Alarm 2] bit

pattern at time of last fault.

243 Fault 1 Code A code that represents the fault that tripped

the drive.

245 Fault 2 Code

247 Fault 3 Code

249 Fault 4 Code

251 Fault 5 Code

253 Fault 6 Code

255 Fault 7 Code

257 Fault 8 Code

244 Fault 1 Time Time stamp of the fault occurrence.

246 Fault 2 Time

248 Fault 3 Time

250 Fault 4 Time

252 Fault 5 Time

254 Fault 6 Time

256 Fault 7 Time

258 Fault 8 Time

262-269 Alarm Code 1-8 A code that represents a drive alarm. No

time stamp available.

Page 33

Chapter 2

Component Test Procedures

Viewing the 700H Diagnostic LED

The Control Assembly on 700H drives contains a diagnostic LED which is visible through the cover of the Control Assembly.

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

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: 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

ATTENTION: The Control Assembly LED is only operational

when the drive is energized, and only visible with the covers removed from the power structure. Servicing energized equipment can be hazardous. Severe injury or death can result from electrical shock, burn or unintended actuation of controlled equipment. Follow Safety related practices of NFPA 70E, ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES. DO NOT work alone on energized equipment!

Page 34

2-2 Component Test Procedures

Performing Visual Inspections

Visually inspect the cooling tunnels and power structure before energizing the drive.

Inspecting the Cooling Tunnels

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the main cooling fans from the bottom of the power structure.

Refer to Removing the Main Fans on page 3-28

3. Inspect the tunnels. Clean the heatsinks and tunnels if necessary.

LED Indication

Steady The drive is operational and has

no faults

Flashing Quickly • Switching power supply

overload

• Rectifier Board fault

• Fan or fan inverter fault

• Brake Chopper fault

• Fiber Optic Adapter Board Fault

Flashing Slowly Bad connection between circuit

boards, check all connections

LED visible through

this hole

ahw1016.eps

Page 35

Component Test Procedures 2-3

Inspecting the Power Structure

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Check components for burn marks, breakage or foil delamination on

circuit boards. Check all the boards on the power structure, including those on the Output Power Modules and the Rectifying Module (if present).

Replace any of these components without further testing if they show evidence of burn marks, breakage or foil delamination.

Conducting Forward and Reverse Biased Diode Tests for Major Power Components

A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions. A reverse biased diode test should find an open circuit, and the meter should display a value close to zero (Ex. “.0L” = zero load).

Important: The actual voltage readings may vary depending upon your

equipment. If your readings are not near the indicated values in the tables below, verify that the actual voltage measured is consistent for the Rectifying module and Output Power modules.

There is a series A and series B Rectifying circuit board. The tests you can perform and the results of those tests vary depending on which series of board is in your drive.

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Disconnect the motor leads from the drive.

4. Conduct forward and reverse biased diode tests on the Rectifying

Module (if present) and the Output Power Modules.

Voltage Class

Rectifying Circuit Board Catalog String

Series A Series B

400/480V AC 20-VB00459 20-VB00461

600/690V AC 20-VB00460 20-VB00462

Page 36

2-4 Component Test Procedures

Figure 2.1 Measurement Points for Forward and Reverse Diode Tests

Series A Rectifying Circuit Board - Rectifying Module Tests

Table 2.A Forward Biased Diode Tests on Rectifying Module

Meter Leads

Nominal meter reading-+

DC+ L1

The value should gradually rise to about 0.5V

(1)

The actual voltage reading may vary depending upon your equipment. If your readings are not near 0.5V, verify

that the actual voltage measured is consistent for the Rectifying module and the Output Power modules.

DC+ L2

DC+ L3

L1 DC-

L2 DC-

L3 DC-

Table 2.B Reverse Biased Diode Tests on Rectifying Module

Meter Leads

Nominal meter reading+-

L1 DC-

Meter should display “.0L” (zero load).

L2 DC-

L3 DC-

DC+ L1

DC+ L2

DC+ L3

DANGER DANGER

DC BUS CONDUCTORS AND CAPACITORS OPERATE AT HIGH VOLTAGE. REMOVE POWER AND WAIT 5 MINUTES BEFORE SERVICING

Cat No.

1234567890-*

FIELD INSTALLED OPTIONS:FIELD INSTALLED OPTIONS:

DC-

DC+

U/T1

V/T2

W/T3

Page 37

Component Test Procedures 2-5

Series B Rectifying Circuit Board - Rectifying Module Tests

Important: If the drive fails any of these measurements, replace the

Rectifying Module.

Series A Rectifying Circuit Board - Output Power Module Tests

Table 2.C Forward Biased Diode Tests on Rectifying Module

Meter Leads

Nominal meter reading-+

DC+ L1

The value should gradually rise to about 1.0V

(1)

The actual voltage reading may vary depending upon your equipment. If your readings are not near 1.0V, verify

that the actual voltage measured is consistent for the Rectifying module and the Output Power modules.

DC+ L2

DC+ L3

L1 DC-

The value should gradually rise to about 0.35V

(2)

The actual voltage reading may vary depending upon your equipment. If your readings are not near 0.35V,

verify that the actual voltage measured is consistent for the Rectifying module and the Output Power modules.

L2 DC-

L3 DC-

Table 2.D Reverse Biased Diode Tests on Rectifying Module

Meter Leads

Nominal meter reading+-

L1 DC-

Meter should display “.0L” (zero load) and rises to the meter battery voltage.

L2 DC-

L3 DC-

DC+ L1

DC+ L2

DC+ L3

Table 2.E Forward Biased Diode Tests on Output Power Modules

Meter Leads

Nominal meter reading+-

DC- T1

The value should gradually rise to about 0.5V

(1)

The actual voltage reading may vary depending upon your equipment. If your readings are not near 0.5V, verify

that the actual voltage measured is consistent for the Rectifying module and the Output Power modules.

DC- T2

DC- T3

T1 DC+

T2 DC+

T3 DC+

Table 2.F Reverse Biased Diode Tests on Output Power Modules

Meter Leads

Nominal meter reading+-

T1 DC-

Meter should display “.0L” (zero load)

T2 DC-

T3 DC-

DC+ T1

DC+ T2

DC+ T3

Page 38

2-6 Component Test Procedures

Series B Rectifying Circuit Board - Output Power Module Tests

If the drive fails any of these measurements, replace both Output Power Modules.

Table 2.G Forward Biased Diode Tests on Output Power Modules

Meter Leads

Nominal meter reading+-

DC- T1

The value should gradually rise to about 1.0V

(1)

The actual voltage reading may vary depending upon your equipment. If your readings are not near 1.0V, verify

that the actual voltage measured is consistent for the Rectifying module and the Output Power modules.

DC- T2

DC- T3

T1 DC+

The value should gradually rise to about 0.35V

(2)

The actual voltage reading may vary depending upon your equipment. If your readings are not near 0.35V,

verify that the actual voltage measured is consistent for the Rectifying module and the Output Power modules.

T2 DC+

T3 DC+

Table 2.H Reverse Biased Diode Tests on Output Power Modules

Meter Leads

Nominal meter reading+-

T1 DC-

Meter should display “.0L” (zero load) and rises to the meter battery voltage.

T2 DC-

T3 DC-

DC+ T1

DC+ T2

DC+ T3

Page 39

Component Test Procedures 2-7

Conducting Gate Driver Board Gate Interface Resistance Measurements

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Locate the Gate Driver Board on the front of the power structure.

H5H7H9H4H6H8

X10

X11

X12

X13

X14

X15

ahw1009.eps

Page 40

2-8 Component Test Procedures

4. Measure the gate interface resistance for each output power transistor.

The resistance from each gate and collector pin to the branch emitter pin should be about 500 ohms. If any of the gate interfaces fails this test, replace both Output Power modules.

H5H7H9H4H6H8

X3X4X5

X10

X11

X12

X13

X14

X15

~500 ohms

Emitter

Gate Interface for W High (WH)

in Left Power Output Module

~500 ohms

Emitter

Gate Interface for V High (VH)

in Left Power Output Module

~500 ohms

Emitter

Gate Interface for U High (UH)

in Left Power Output Module

~500 ohms

Gate Interface

for W Low (WL)

in Left Power

Output Module

Gate Interface

for U Low (UL)

in Left Power

Output Module

Gate Interface

for V Low (VL)

in Left Power

Output Module

~500 ohms

Emitter

Gate Interface for W High (WH)

in Right Power Output Module

~500 ohms

Emitter

Gate Interface for V High (VH)

in Right Power Output Module

X10

~500 ohms

Emitter

Gate Interface for U High (UH)

in Right Power Output Module

X11

~500 ohms

Gate Interface

for W Low (WL)

in Right Power

Output Module

Gate Interface

for U Low (UL)

in Right Power

Output Module

Gate Interface

for V Low (VL)

in Right Power

Output Module

Page 41

Component Test Procedures 2-9

Checking the Rectifying Module (on AC Input Drives Only)

Important: This procedure requires special equipment and training. Only

qualified and trained personnel should perform these procedures.

There is a series A and series B Rectifying circuit board. The tests you can perform and the results of those tests vary depending on which series of board is in your drive.

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Remove the Power Structure from the enclosure. Refer to Removing the

Power Structure from the Drive Enclosure on page 3-27.

4. Visually inspect the pre-charging resistors. If the pre-charging resistors

are damaged:

A. Replace the Rectifying Module (Refer to Removing the

Right-Side Output Power Module and Rectifying Module on page 3-36).

B. Check the rectifiers and external connections for short-circuits.

C. Check the Output Power Modules (Refer to Conducting

Forward and Reverse Biased Diode Tests for Major Power Components on page 2-3).

5. Verify that the plugs on the cable that connects X13 on the Rectifying

Board to X2 on the ASIC Board are properly seated.

6. Verify that the jumper at X50 on the Rectifying board is in place.

Taking Measurements on Rectifying Module

7. Disconnect connectors X13, X12, X11 and X10.

8. Perform resistance measurements, using a digital multimeter, on the

points listed in Table 2.I on page 2-10

or Table 2.J on page 2-10 (on AC

Three-Phase drives). These points are on the back of the X10, X11 and X12 plugs which you have disconnected from the board. If the Rectifying Module fails any of these tests, replace it (Refer to

Removing the Right-Side Output Power Module and Rectifying Module on page 3-36).

Voltage Class

Rectifying Circuit Board Catalog String

Series A Series B

400/480V AC 20-VB00459 20-VB00461

600/690V AC 20-VB00460 20-VB00462

Page 42

2-10 Component Test Procedures

Table 2.I Series A Rectifying Circuit Board Resistance Measurements

Table 2.J Series B Rectifying Circuit Board Resistance Measurements

Drives with Series A Rectifying Circuit Boards Only

9. Without applying power to X13, verify that there is no resistance

between the following points: J3 and X9, J7 and X9, and J11 and X9. Refer to Rectifying Board Charge Relay Test Results on page 2-11

. If

the Rectifying Module fails any of these tests, replace it (Refer to

Removing the Right-Side Output Power Module and Rectifying Module on page 3-36).

Figure 2.2 Rectifying Board Layout and Measurement Points

Measurement points Resistance

X10: red to X10: black

18Ω ± 1ΩX11: red to X11: black

X12: red to X12: black

Measurement points Resistance

X10: red to X10: black

47Ω ± 4. 7 ΩX11: red to X11: black

X12: red to X12: black

X13X6

X10X11

X12

X9 X100

X41

X101

X50

J11

Jumpers for the Precharging ResistorsX9

Page 43

Component Test Procedures 2-11

Table 2.K Rectifying Board Charge Relay Test Results

No Power on X13

Meter Leads

Results+-

J3 X9

0ΩJ7 X9

J11 X9

Page 44

2-12 Component Test Procedures

Checking the Fan Inverters and Main Fans

Checking the Fan Inverter LEDs

A frame 10 drive has two fans and two fan inverters. Each fan inverter has a red and a green diagnostic LED.

Checking the Fan Inverter Fuses

A pair of fuses (F1 and F2) are included in the circuit to feed DC Bus power to the fan inverters. The fuses are located on the left front of the drive next to the Gate Driver board. Locate these fuses and, using a multi-meter, verify that they are not open.

ATTENTION: The inverter LEDs are only operational when

the drive is energized, and only visible with the covers removed from the power structure. Servicing energized equipment can be hazardous. Severe injury or death can result from electrical shock, burn or unintended actuation of controlled equipment. Follow Safety related practices of NFPA 70E, ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES. DO NOT work alone on energized equipment!

LED

IndicationRed Green

Steady Steady Inverter Idle

Off Flashing Inverter Running

Flashing Steady Inverter Faulted

or No Control from ASIC Board

Fan Inverter Fuses

Gate Driver board

Page 45

Component Test Procedures 2-13

Isolating a Faulty Fan Inverter

The ASIC Board controls both fan inverters. A cable connects X11 on the ASIC Board to X8 on the left-hand inverter. Another cable connects X3 of the left-hand inverter to X8 on the right-hand inverter. A jumper terminates X3 on the right-hand inverter. Refer to Figure B.6 on page B-7

. Use the

following procedure to isolate a faulty inverter if the fans are not running:

1. Disconnect the cable from X3 of the left-hand inverter.

2. Remove the jumper from X3 of the right-hand inverter, and connect it to

X3 of the left-hand inverter.

3. Energize the drive. If the left-hand fan runs, then the right-hand fan

inverter is faulty.

Checking the Main Fan Motors

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Disconnect the left-hand fan motor from its inverter.

4. Measure the resistance of the fan windings. If the resulting

measurements are not similar to those in Table 2.L

below, replace the fan

(Refer to Removing the Main Fans on page 3-28

Table 2.L Correct Fan Measurements

5. Reconnect the left-hand fan motor to its inverter.

6. Repeat steps 3-5 for the right-hand fan motor.

Connection Wires Resistance ± 5%

Black-Brown 60

Brown-Blue 26

Blue-Black 34

Resistance to ground .0L (Zero Load)

Page 46

2-14 Component Test Procedures

Page 47

Chapter 3

Access Procedures

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

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: 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: 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: This drive contains ESD (Electrostatic

Page 48

3-2 Access Procedures

Torque Specifications

Understanding Torque Figures in Assembly Diagrams

Icons and numbers in the assembly diagrams indicate how to tighten hardware:

The following table lists fastener torque specifications:

POZIDRIV® is a registered trademark of the Phillips Screw Company

Phillips

is a registered trademark of Phillips Screw Company

Item Fastener Final Torque

700H Fiber Optic Adapter Board (mounting) M4 x 8 POZIDRIV

0.9 N-m (8 lb.-in.)

700H I/O and Control Assembly M4X8 self-tapping 0.8 N-m (7 lb.-in.)

700S Power Interface Circuit Board (mounting) M3 x 6 Phillips

0.9 N-m (8 lb.-in.)

700S Voltage Feedback Circuit Board (mounting) M3 x 6 Phillips 0.9 N-m (8 lb.-in.)

700S Voltage Feedback Circuit Board (mounting) M3 x 0.5 thread - 37 mm x 37

mm hex standoff

0.9 N-m (8 lb.-in.)

AC Input Terminals on Power Structure M10 nut 40 N-m (354 lb.-in.)

ASIC Fan M4 x 16 POZIDRIV 0.4 N-m (3.5 lb.-in.)

Block (Mounting) M10 x 12 hexagonal screw 20 N-m (177 lb.-in.)

Capacitor M4 x 8 self tapping 1 N-m (9 lb.-in.)

Capacitor Bus Bar M6 x 16 POZIDRIV 4 N-m (35 lb.-in.)

Capacitor Bus Bar M6 x 20 POZIDRIV 4 N-m (35 lb.-in.)

DC- / DC+ Terminals M6 x 20 POZIDRIV 5 N-m (44 lb.-in.)

DPI / HIM Assembly (mounting) M3 x 6 Phillips 0.9 N-m (8 lb.-in.)

DPI / HIM Assembly Door M3 x 6 Phillips 0.9 N-m (8 lb.-in.)

Main Fan M4 x 8 POZIDRIV 1.7 N-m (15 lb.-in.)

Main Fan (Mounting) M6 x 20 POZIDRIV 3 N-m (27 lb.-in.)

Main Fan Inverter Assembly M5 x 10 POZIDRIV 4 N-m (35 lb.-in.)

Motor Output Terminals on Power Structure M8 x 20 hexagonal screw 20 N-m (177 lb.-in.)

Output Power Module Output Terminals (U,V,W) M8 x 20 hexagonal screw 14 N-m (124 lb.-in.)

Rectifier board (Mounting) M4 x 8 POZIDRIV 1 N-m (9 lb.-in.)

Rectifying Module Input Terminals (L1,L2,L3) M10 x 20 hexagonal screw 12 N-m (106 lb.-in.)

Touch Cover (Main Fan) M5 x 16 3 N-m (27 lb.-in.)

Y-Bus Bar M10 nut 40 N-m (354 lb.-in.)

PZ2 4 N-m (35 lb.-in.)

Tool Type and Size

PZ indicates POZIDRIV screwdriver bit

P indicates Phillips screwdriver bit

Tightening Torque

Fastener Type

POZIDRIV Screw

Phillips Screw

Hexagonal Bolt or Standoff

Hexagonal Screw

Hexagonal Nut

Torx Head Screw

Page 49

Access Procedures 3-3

Removing Power from Drive

1. Turn off and lock out input power. Wait five minutes.

2. 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.

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

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

io_bd1.eps

Page 50

3-4 Access Procedures

Removing the DPI / HIM Assembly

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

Important: Before removing connections and wires, mark the connections

and wires to avoid incorrect wiring during assembly.

2. Remove the two screws from front of DPI / HIM assembly.

3. Open the panel that holds the DPI interface and HIM.

4. Unplug the DPI cable from the X2 connector on the DPI Interface

circuit board.

5. On 700S drives only, unplug the cable from the X4 connector on the

DPI circuit board.

6. Remove the four mounting screws and the assembly from the Control

Frame.

Screws

0.9 N-m (8 lb.-in.)

ahw0664.eps

ahw0665.eps

Back view of DPI circuit

board, which should remain

mounted on the back of the

assembly.

ahw0666.eps

0.9 N-m (8 lb.-in.)

Mounting screws

Page 51

Access Procedures 3-5

Installing the DPI / HIM Assembly

Install the DPI / HIM assembly in reverse order of removal, while referring to Torque Specifications on page 3-2

Removing the 700S Phase I Control Assembly

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

Important: Before removing connections and wires, mark the connections

and wires to avoid incorrect wiring during assembly.

Important: Minimum inside bend radius for SynchLink 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.

1. Loosen the captive screw and swing the Control assembly away from

drive.

2. On the Control assembly:

– Unplug the I/O and SynchLink cables from the Main Control circuit

board

– Unplug the feedback wiring from Feedback Option card

– Unplug communication cables from DriveLogix™ controller (if

present)

3. Unplug the ribbon cables from J2 and J7 on the Main Control circuit

board.

Note: If the DriveLogix option is installed, the J2 and J7 connections for the ribbon cables will be located behind the DriveLogix controller.

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.

Page 52

3-6 Access Procedures

4. Remove the three screws that hold the control bracket and Phase I Main

Control circuit board to the control frame.

5. Remove the control bracket and Phase I Main Control circuit board.

Installing the 700S Phase I Control Assembly

Install the 700S Phase I Control assembly in reverse order of removal, while referring to Torque Specifications on page 3-2

Removing the 700S Phase II Control Assembly

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

Important: Before removing connections and wires, mark the connections

and wires to avoid incorrect wiring during assembly.

2. Unplug any fiber optic ControlNet and SynchLink cables from the

Control Assembly (if present).

Important: Minimum inside bend radius for SynchLink and ControlNet

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.

J7 J2

Remove Three screws

Loosen captive

screw

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.

Page 53

Access Procedures 3-7

3. Unplug any remaining I/O and communications cables from the Control

assembly and set them aside.

4. Loosen the captive screw on the Control assembly mounting plate and

swing the Control assembly away from the drive.

Captive screw

Page 54

3-8 Access Procedures

5. Carefully disconnect the ribbon cables from the sockets on the High

Power Fiber Optic Interface circuit board on the back of the control mounting plate.

6. Loosen the two mounting screws on the front of the Control assembly

and slide the control cassette off the mounting bracket.

Installing the 700S Phase II Control Assembly

Install the 700S Phase II Control assembly in reverse order of removal.

Disconnect ribbon cables.

Note: Control mounting plate

not shown for clarity only.

Note: Ribbon cables not shown

for clarity only.

Page 55

Access Procedures 3-9

Removing the Common Mode Filter Circuit Board

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Loosen the captive screw on the control assembly mounting plate and

swing the control assembly away from the drive.

Important: Before removing connections and wires, mark the connections

and wires to avoid incorrect wiring during assembly.

3. Disconnect the 24V power supply cable from connector J5 on the

Common Mode Filter circuit board.

4. Disconnect the twisted pair wires from connector J5 on the High Power

Fiber Optic Interface circuit board.

24V Supply

cable

Page 56

3-10 Access Procedures

5. Remove the four screws that secure the Common Mode Filter circuit

board to the four standoffs on the control assembly mounting plate and remove the Common Mode Filter circuit board.

Installing the Common Mode Filter Circuit Board

Install the Common Mode Filter Circuit Board in the reverse order of removal.

Remove screws

Page 57

Access Procedures 3-11

Removing the 700S High Power Fiber Optic Interface Circuit Board

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Loosen the captive screw and swing the Control assembly away from

drive.

3. Carefully disconnect the ribbon cables from the sockets at the top of the

High Power Fiber Optic Interface circuit board, and carefully set them aside.

4. Carefully disconnect the fiber-optic cables from sockets along the right

side of the High Power Fiber Optic Interface circuit board, and carefully set them aside.

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.

ahw0985.eps

0.9 N-m (8 lb.-in.)

Ribbon cables

Screws (5)

Fiber optic cables

J5 Connector

Page 58

3-12 Access Procedures

5. Disconnect the 24V power supply cable from connector J5 on the High

Power Fiber Optic Interface circuit board.

6. Remove the five screws that secure the High Power Fiber Optic

Interface circuit board to the Control Frame and remove the circuit board from the Control Frame.

Installing the 700S High Power Fiber Optic Interface Circuit Board

Install the 700S High Power Fiber Optic Interface circuit board in reverse order of removal, while referring to Torque Specifications on page 3-2

Removing the 700H I/O Circuit Boards and Control Assembly

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Open the enclosure that contains the Control and I/O circuit boards and

carefully unplug the DPI cable and any I/O cables.

3. Remove the I/O circuit boards from the Control Board and enclosure.

Note the order of the boards and the keys which prevent placement of the boards in incorrect slots.

ahw0705.eps

Do not remove enclosure cover.

Enclosure is illustrated without

the cover for clarity.

Keys

Page 59

Access Procedures 3-13

4. Unplug the serial connection from X7 on the Control circuit board.

5. Remove the three screws that secure the Control assembly to the control

frame and remove the control assembly.

Installing the 700H I/O Circuit Boards and Control Assembly

If you replace the Control circuit board in a 700H drive, you must load information about the Control circuit board into the Power EEPROM (Refer to Loading the 700H EEPROM on page 4-1

Install the 700H Control and I/O circuit boards in reverse order of removal, while referring to Torque Specifications on page 3-2

ahw0704.eps

(Slot A)

Serial Port

(Slot B)

(Slot C)X5(Slot D)

(Slot E)

ahw0708.eps

Do not remove enclosure cover.

Enclosure is illustrated without

the cover for clarity.

PZ2 3 N-m (27 lb.-in.)

Page 60

3-14 Access Procedures

Removing the 700H Fiber Optic Adapter Circuit Board

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the I/O circuit boards and Control assembly. Refer to

Removing the 700H I/O Circuit Boards and Control Assembly on page 3-12,

3. Move the Control Frame to expose its back. Refer to Removing the

Covers from the Power Structure on page 3-15.

4. Disconnect the control power cable from X2 on the Fiber Optic Adapter

circuit board.

5. Carefully disconnect the fiber-optic cables from right side of the circuit

board, and carefully set them aside.

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.

ahw0707.eps

H1 through H7 sockets

for Fiber Optic cables

X2 connects to

24V dc power

X7 connects to Main

Control circuit board.

Note: Disconnects

when you remove

the circuit board from

the control frame.

Page 61

Access Procedures 3-15

6. Remove the four screws which secure the Fiber Optic Adapter bracket

to the stand-offs on the back of the Control Frame.

7. Remove the Fiber Optic Adapter Board from the Control Frame.

Installing the 700H Fiber Optic Adapter Circuit Board

Install the 700H Fiber Optic Adapter circuit board in reverse order of removal, while referring to Torque Specifications on page 3-2

Removing the Covers from the Power Structure

You must remove the protective covers to gain access to the power structure.

Moving the Control Frame

You must first move the Control Frame in order to remove the protective covers from the drive.

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Loosen the T8 Torx-head screws that secure the Control Frame to the

drive enclosure (remove screws on early frame 10 drives).

3. Swing the Control Frame out and away from the power structure.

ahw1033.eps

PZ2

0.9 N-m (8 lb.-in.)

Remove 4 screws

Page 62

3-16 Access Procedures

ahw0730.eps

Frame 10 drives, from early production runs, have

holes instead of slots for these screws. You must

completely remove the screws from these drives in

order to swing-open the control frame.

Screws

Page 63

Access Procedures 3-17

Removing the Airflow Plate

The drive is equipped with a plate, just above the Control Frame, that manages airflow through the drive. You must remove this plate in order to remove the protective covers.

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Move the Control Frame away from the power structure. Refer to

Removing the Covers from the Power Structure on page 3-15

3. Remove the T8 Torx-head screws that secure the airflow plate to the

drive and remove the air flow plate from the drive enclosure.

ahw0731.eps

Screws

Page 64

3-18 Access Procedures

Removing the Protective Covers from Power Structure

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Move the Control Frame away from the power structure. Refer to

Removing the Covers from the Power Structure on page 3-15

3. Remove the Airflow Plate. Refer to Removing the Airflow Plate on

page 3-17.

4. Remove the four M5 POZIDRIV screws that secure the top and bottom

protective covers to the main front protective cover, then remove the top and bottom protective covers.

Note: you only need to remove the top and bottom covers to gain access to the power terminals. You can remove the other covers without removing the top and bottom covers.

5. Remove the four M5 POZIDRIV screws that secure the main front

protective cover to the drive, then remove the protective cover.

Page 65

Access Procedures 3-19

6. Remove the side protective covers.

Installing the Protective Covers

Install the Protective Covers in reverse order of removal, while referring to

Torque Specifications on page 3-2

ahw0732.eps

Page 66

3-20 Access Procedures

Removing the 700S Voltage Feedback Circuit Board

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Carefully disconnect the fiber-optic cables from the J4 and J5 sockets

along the top of the Voltage Feedback circuit board, and carefully set them aside.

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.

4. Disconnect the cable from the J8 socket of the Voltage Feedback circuit

board, and set it 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.

J4 J5

ahw0995.eps

Page 67

Access Procedures 3-21

5. Remove the five screws that secure the Voltage Feedback circuit board

to the drive and remove the circuit board from the drive.

Installing the 700S Voltage Feedback Circuit Board

Install the 700S Voltage Feedback circuit board in reverse order of removal, while referring to Torque Specifications on page 3-2

Screws

(5)

0.9 N-m (8 lb.-in.)

ahw0731.eps

Page 68

3-22 Access Procedures

Removing the Gate Driver and Adapter Circuit Boards

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Disconnect the wires from the fuse block that holds the fuses for the

Fan Inverters and remove the fuses.

4. Remove the four screws that secure the fuse block to the bracket

beneath it and remove the fuse block.

Remove fuse wires

Remove fuses

Remove screws and

fuse block

Page 69

Access Procedures 3-23

5. Carefully disconnect the fiber-optic cables from sockets along the top of

the Gate Driver circuit board and carefully set them aside.

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.

6. Disconnect the other cables from the sockets of the Gate Driver board

and 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.

Remove fiber optic cables

Page 70

3-24 Access Procedures

7. Remove the six screws that secure the brackets to the drive and remove

the brackets.

gate_driver_bracket01.jpg

gate_driver_bracket02.jpg

Page 71

Access Procedures 3-25

8. Remove eight of the stacker connectors from the Gate Driver board,

leaving the two smaller ones which are third from the top.

9. Carefully remove the Gate Driver board and the remaining connectors.

10. Remove the cable ties that secure the Adapter board to the circuit

boards on the Output Power Modules and remove the Adapter board.

gate_driver.jpg

Page 72

3-26 Access Procedures

Installing the Gate Driver and Adapter Circuit Boards

1. Replace the Adapter board and install the cable ties that secure it to the

circuit boards on the Output Power Modules.

2. Plug the old stacker connectors into the new Gate Driver board so the

pins do not protrude through the connectors on the back of the board.

3. Align the Gate Driver board so that its connectors align with the mating

connectors on the Adapter board.

4. While supporting the Adapter board from behind, press the Gate Driver

board onto it.

5. Verify the proper alignment of the mounting with a mirror. Verify that

none of the pins in the stacker connectors have missed the mating connectors.

6. Install the brackets and install and tighten the mounting screws.

7. Connect all of the cables on the Gate Driver board.

Page 73

Access Procedures 3-27

Removing the Power Structure from the Drive Enclosure

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Remove the motor wiring from the power structure at the front of the

power structure.

4. Remove the ground connection from the lower right rear corner of the

power structure.

5. Remove the AC power wiring from the incoming terminals at the top of

the power structure.

6. Follow the instructions in publication PFLEX-IN014…, Installation

Instructions - PowerFlex 700S /700H High Power Maintenance Stand,

to install the Maintenance Stand. Remove the power structure by sliding it onto the rails of the Maintenance Stand.

Installing the Power Structure in the Drive Enclosure

Install the power structure in reverse order of removal, while referring to

Torque Specifications on page 3-2

. Refer to the publication PFLEX-IN006…, Installation Instructions - PowerFlex 700S and 700H High Power Drives, for tightening torques of motor terminations.

Motor Connection

Terminals

AC Power Connection

Te r mi n a l s

Ground

Connection

bare_frame 10.eps

Page 74

3-28 Access Procedures

Removing the Main Fans

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Disconnect the fan cable connectors under the power structure.

4. Remove the two screws that secure each fan to the drive (there are two

fans and four screws). Then remove the fans.

Installing the Main Fans

Install the fans in reverse order of removal, while referring to Torque

Specifications on page 3-2.

Disconnect connectors

from fan inverters

Remove screws

Page 75

Access Procedures 3-29

Removing the ASIC Circuit Board

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Remove the power structure for the drive. Refer to Removing the Power

Structure from the Drive Enclosure on page 3-27.

4. Carefully disconnect the fiber-optic cables from sockets (H1 - H7)

along the front of the ASIC board, and carefully set them aside.

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.

5. Disconnect the other cables from sockets on the front of the ASIC board

and set them aside.

6. Disconnect the wire connected to the cover of the ASIC board.

7. Remove the fan from the ASIC board.

ATTENTION: The sheet metal cover and mounting screws on

the ASIC circuit 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: 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.

asic01.jpg

asic02.jpg

Page 76

3-30 Access Procedures

8. Slide the ASIC board assembly out of its chassis.

9. Remove the plastic board holder.

10. Carefully disconnect the fiber-optic cables from sockets (H8, - H13)

along the back of the ASIC board and carefully set them aside.

11. Disconnect the other cables from sockets on the ASIC board and set

them aside.

Installing the ASIC Circuit Board

Install the ASIC board in reverse order of removal, while referring to

Torque Specifications on page 3-2

. Reconnect the cables to ASIC board,

while referring to Figure B.3 on page B-4

, Figure B.4 on page B-5 or Figure

B.5 on page B-6.

Page 77

Access Procedures 3-31

Removing the Rectifying Circuit Board

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Remove the power structure for the drive. Refer to Removing the Power

Structure from the Drive Enclosure on page 3-27.

4. Disconnect all the wiring from connectors X10, X11, X12, X13 the

Rectifying board and carefully set it aside.

5. Remove the screws that secure the circuit board to the Rectifying

Module and remove the board.

Installing the Rectifying Circuit Board

Install the Rectifying circuit board in reverse order of removal, while referring to Torque Specifications on page 3-2

X13X6

X10X11

X12

X9 X100

X41

X101

X50

J11

Series A Rectifying Board Shown

Page 78

3-32 Access Procedures

Removing the Precharging Resistors from Series B Drives

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Remove the power structure for the drive. Refer to Removing the Power

Structure from the Drive Enclosure on page 3-27.

4. Disconnect the wiring from connectors X21 and X31, X22 and X32,

and X23 and X33 on the Rectifying board.

X13X6

X10X11

X12

X9 X100

X41

X101

X50

X33 X23 X32 X22 X31 X21

Page 79

Access Procedures 3-33

5. Remove the two screws that secure each of the Precharging Resistors to

the drive frame and remove the Precharging Resistors.

Installing the Precharging Resistors on Series B Drives

Install the Precharging Resistors in reverse order of removal.

Remove screws

from resistors

6-Pulse Drive

12-Pulse Drive

Remove screws

from resistors

Page 80

3-34 Access Procedures

Removing the Left-Side Output Power Module

Important: Do not attempt to disassemble the Output Power Module.

Important: Always replace the Output Power Modules in pairs (do not

replace just one module).

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Remove the power structure from the drive cabinet. Refer to Removing

the Power Structure from the Drive Enclosure on page 3-27.

4. Remove the cable-tie that secures the Power Module circuit board to the

Adapter board.

5. Disconnect the output leads from the bottom of the Output Power

Module.

6. Remove the Y bus bars.

Y Bus Bars

Page 81

Access Procedures 3-35

7. Remove the balancing resistor wires from the bus bars.

8. Remove the screws that secure the Snubber Capacitors and remove the

Snubber Capacitors from the power structure.

9. Remove the screws that secure the DC bus bars to the left side of the

power structure and remove the DC bus bars.

10. Remove the screws that secure the Output Power Module to the drive.

11. Disconnect the Power Module circuit board from the Adapter board.

Balancing Resistors

Balancing Resistor Wires

Snubber Capacitors

Snubber Capacitor

Fastening Screws

Page 82

3-36 Access Procedures

12. Remove the Output Power Module from the drive.

Installing the Left-Side Output Power Module

Important: If you replace the Output Power Modules in a 700H drive, you

must load information about the Power Modules into the Power EEPROM (refer to Loading the 700H EEPROM on page 4-1

Install the Output Power Module in reverse order of removal, while referring to Torque Specifications on page 3-2

Removing the Right-Side Output Power Module and Rectifying Module

Important: Do not attempt to disassemble the Output Power Module.

Important: Always replace the Output Power Modules in pairs (do not

replace just one module).

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Remove the power structure from the drive cabinet. Refer to Removing

the Power Structure from the Drive Enclosure on page 3-27.

Page 83

Access Procedures 3-37

4. Carefully disconnect the fiber-optic cables from the Gate Driver board

and carefully set them aside.

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.

5. Remove the cables from X13, X14 and X15 sockets on the Gate Driver

board and carefully set them aside.

6. Disconnect the DC Bus wiring from the Gate Driver board.

7. Remove the cable-tie that secures the Power Module circuit board to the

Adapter board.

8. Disconnect the output leads from the bottom of the Output Power

Module.

9. Remove the Y bus bars.

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.

Y Bus Bars

Page 84

3-38 Access Procedures

10. Remove the balancing resistor wires from the bus bars.

11. Disconnect all wiring from the circuit board on the Rectifying Module.

12. Disconnect the cables from the AC input terminals on the Rectifying

Module.

13. Remove the circuit board from the Rectifying Module (refer to

Removing the Rectifying Circuit Board on page 3-31

14. Remove the screws that secure the Snubber Capacitors and remove the

Snubber Capacitors.

right_modules01.jpg

AC Input

Te r mi n a l s

(L1, L2, L3)

Balancing Resistors

Balancing Resistor Wires

right_modules02.jpg

Snubber Capacitors

Snubber Capacitor

Fastening Screws

Page 85

Access Procedures 3-39

15. Remove the screws that secure DC bus bars to right side of power

structure and remove the DC bus bars.

16. Remove the screws that secure the Rectifying Module to the power

structure and remove the Rectifying Module.

right_modules03.jpgright_modules04.jpg

Page 86

3-40 Access Procedures

17. Remove the screws that secure the Output Power Module to the power

structure and remove the Output Power Module.

Installing the Right-Side Output Power Module and Rectifying Module

Important: If you replace the Output Power Modules in a 700H drive, you

must load information about the Power Modules into the Power EEPROM (Refer to Loading the 700H EEPROM on page 4-1

Install the Output Power Module in reverse order of removal, while referring to Torque Specifications on page 3-2

Removing the Fan Inverters

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Remove the power structure from the drive cabinet. Refer to Removing

the Power Structure from the Drive Enclosure on page 3-27.

right_modules05.jpg

Page 87

Access Procedures 3-41

4. Prepare the Power Structure for Inverter assembly removal.

Task Description

Remove the cable-ties that secure the cables with orange insulation (on both left-hand and right-hand sides). This will allow you to move the cables while removing the inverter assemblies.

Left-hand

Side

View

Left-hand

Inverter

Fron t View

on Left-hand Side

fm10_front.jpg

prepare_left.jpg

prepare_right.jpg

Right-hand

Inverter

Page 88

3-42 Access Procedures

5. Remove the Inverter assemblies.

Task Description

Remove the two M5 POZIDRIV screws that secure the front of the fan inverter to the drive.

Disconnect the fan motor cable under the inverter.

Remove the four M5 POZIDRIV screws that secure the bottom of the fan inverter to the drive.

Disconnect the cables at X2, X8 and X3 (on left-hand and center inverters); and X2 and X8 (on right-hand inverter).

Carefully remove the inverters by sliding them out towards the front of the drive.

Important: Take care to not damage the output transformer when removing

or installing the inverter.

Bottom View

of Power Structure

removing_assy.jpg

C C

Page 89

Access Procedures 3-43

6. Remove the Inverter from the old Inverter assembly.

Installing the Fan Inverters

Install the fan inverters in reverse order of removal, while referring to

Torque Specifications on page 3-2

Tas k D esc ri pt ion

Disconnect the cables at connectors X4 (Blue) and X5 (Black).

Task Description

Remove two M5 POZIDRIV screws that secure the inverter board and heatsink to the assembly carriage.

Carefully remove the inverter board and heatsink from the assembly carriage.

Right-hand Inverter Shown

right_assy_upright.jpg

right_assy_underside.jpg

Page 90

3-44 Access Procedures

Removing the DC Bus Capacitors

1. Remove power from the drive. Refer to Removing Power from Drive on

page 3-3.

2. Remove the covers from the power structure. Refer to Removing the

Covers from the Power Structure on page 3-15.

3. Remove the power structure from the drive cabinet. Refer to Removing

the Power Structure from the Drive Enclosure on page 3-27.

4. Remove the balancing resistor wires from bus bars.

5. Remove the screws that secure DC bus bars to right side of power

structure and remove the DC bus bars.

right_modules01.jpg

AC Input

Te r mi n a l s

(L1, L2, L3)

Balancing Resistors

Balancing Resistor Wires

right_modules03.jpg

Page 91

Access Procedures 3-45

6. Remove the four screws that secure the capacitor to the power structure

and remove the capacitor.

Installing the DC Bus Capacitors

Install the DC bus capacitors in reverse order of removal, while referring to

Torque Specifications on page 3-2

removing_caps.jpg

Page 92

3-46 Access Procedures

Notes:

Page 93

Chapter 4

Start-Up After Repair

Loading the 700H EEPROM

If you replace the Output Power Modules or Control Board in a 700H drive you must load information about the Power Modules or Control Board into the Power EEPROM. Contact Allen-Bradley Drives Technical Support for instructions and software tools for performing this operation.

Be prepared to provide the following information when you contact technical support:

• Product Catalog Number

• Product Serial Number

• Firmware Revision Level

ATTENTION: Power must be applied to the drive to perform

the following start-up procedure. Some of the voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, only qualified service personnel should perform the following procedure. Thoroughly read and understand the procedure before beginning. If an event does not occur while performing this procedure, Do Not Proceed. Remove Power including user supplied control voltages. User supplied voltages may exist even when main AC power is not applied to then drive. Correct the malfunction before continuing.

Phone United States/

Canada

1.262.512.8176 (7 AM - 6 PM CST)

1.440.646.5800 (24 hour support)

Outside United States/Canada

You can access the phone number for your country via the Internet: Go to http://www.ab.com Click on Support (http:// support.rockwellautomation.com/) Under Contact Customer Support, click on Phone

Support

Internet ⇒ Go to http://www.ab.com/support/abdrives/

E-mail ⇒ support@drives.ra.rockwell.com

Page 94

4-2 Start-Up After Repair

Before Applying Power to the Drive

1. 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.

2. Perform the forward and reverse biased diode tests using a digital

multimeter. Refer to Conducting Forward and Reverse Biased Diode

Tests for Major Power Components on page 2-3.

Testing Without the Motor

This test allows you to measure several operating parameters and diagnose problems without connecting the motor to the drive.

1. Verify that the input power wiring and grounding is connected.

2. Verify that the motor cables are disconnected.

3. Energize the drive.

4. Measure the DC bus voltage and verify that the value is reflected in:

– parameter 306 [DC Bus Voltage] (700S)

– parameter 012 [DC Bus Voltage] (700H)

5. Make configuration changes that allow the HIM to issue start and speed

commands.

6. Make configuration changes that allow operation without an encoder

and motor.

7. Start the drive, by pressing (the start button).

8. Increase the speed command from zero to base speed, by pressing

(the up button).

9. Measure the output voltage on each phase and verify that it is balanced.

If it is unbalanced troubleshoot the drive.

10. Stop the drive, by pressing (the stop button).

11. Re-configure the drive to suit the application.

Page 95

Start-Up After Repair 4-3

Performing the Power Circuit Diagnostic Test on a 700S Drive

The Power Circuit Diagnostic Test on the 700S drive allows you to diagnose problems in the drive’s power structure without applying large amounts of power.

1. Verify that input power wiring and grounding is connected.

2. Verify that the motor cables are connected.

3. Energize the drive.

4. Measure the DC bus voltage and verify that the value is reflected in:

– parameter 306 [DC Bus Voltage]

5. From the Monitor menu on the HIM press (the escape button) to

navigate to the Main menu.

6. Use (the down button) to move the cursor to the Start-Up

selection, and press to select Start-Up. Then press again to verify your intention to continue with the Start-Up menu.

7. Use (the down button) to move the cursor to Power Circuit

Diagnostics (Pwr Circuit Diag), and press to select Power Circuit Diagnostics.

8. Press to begin the Power Circuit Diagnostic routine. Follow the

indications and instructions on the HIM.

Esc

Page 96

4-4 Start-Up After Repair

Testing With the Motor Without a Mechanical Load

This test allows you to measure several operating parameters and diagnose problems without connecting the motor to its mechanical load.

1. Verify that input power wiring and grounding is connected.

2. Verify that the motor cables are connected.

3. Verify that the motor load is disconnected.

4. Measure the DC bus voltage and verify that the value is reflected in:

– parameter 306 [DC Bus Voltage] (700S)

– parameter 012 [DC Bus Voltage] (700H)

5. Energize the drive.

6. Start the drive and increase the speed from zero to base speed.

7. Measure the drive output current and verify that the value is reflected in:

– parameter 308 [Output Current] (700S)

– parameter 003 [Output Current] (700H)

8. Stop the drive.

Page 97

Appendix A

Service Tools and Equipment

Software Tools

DriveTools™ SP, DriveExecutive, DriveExplorer™ and DriveObserver™ are software tools for uploading, downloading and monitoring system parameters.

Service Tools

This list of basic service tools which will cover needs of tools for repair and maintenance measurements.

Item Description Details

1 Oscilloscope Portable, digitizing, dual channel scope, with isolation

2 Current clamp 1000A(ac, rms), signal output

3 Soldering station Soldering / de soldering

4 Adjustable power supply 0...1300Vdc, 1A, adjustable current limit. Efore LPS

750-HV or equivalent.

5 Adjustable power supply 0...690Vac (+10%), 10A, three phase, galvanic

isolation

6 Multi meter Digital multi meter, capable of ac and dc voltage,

continuity, resistance, capacitance measurements, and forward diode bias tests. Fluke model 87 III or equivalent.

7 Insulation tester 1000Vdc

8 Torque wrench 1...12Nm

9 Torque wrench 6...50Nm

10 Box wrench 7mm, 8mm, 10mm, 13mm, 17mm, 19mm, 22mm

11 Socket extension 230mm

12 Wrench 7mm, 8mm, 10mm, 13mm, 17mm, 19mm, 22mm

13 Wire cutter

14 Nose pliers

15 Crimping tools For cable terminals 1,5...240

16 Angle wrench

17 Screw driver

18 *Flat nose 7*2(mm)

19 *POZIDRIV #1, 2, 3

20 *Phillips #1, 2, 3

21 *Torx #25

22 Hexagonal wrench #4, 5, 6

23 ESD-protected place of work Working surface, Floor covering, seat and ground

connections

24 ESD-protective clothing Wrist wrap, shoes, overall clothing (coat)

25 20-MAINSTND maintenance stand Maintenance stand for removing power structure from

drive cabinet

26 Fiber-optic repair kit Agilent HFBR-4593 Polishing Kit, consisting of a

Polishing Fixture, 600 grit abrasive paper and 3 mm pink lapping film (3M Company, OC3-14).

For Agilent HFBR-4532 latching connectors and HFBR-RL cable. Refer to Agilent publications 5988-9777EN and 5988-3625EN.

Page 98

A-2 Service Tools and Equipment

Notes:

Page 99

Appendix B

Schematics

List of Schematic Diagrams

For a Schematic Diagram on… See...

Power Circuitry for Drives with AC Input

page B-2

Power Circuitry for Drives with DC Input page B-3

Circuit Board Connections for 700S Drives with Phase I Control page B-4

Circuit Board Connections for 700S Drives with Phase II Control page B-5

Circuit Board Connections for 700H Drives page B-6

Fan Power Supply Connections page B-7

Page 100

B-2 Schematics

Power Circuitry for Drives with AC Input

W_LO

W_HI

TERM W

TERM V

V_HI

V_LO

TERM U

U_LO

U_HI

I_V

I_W

I_U

Power Board

4 4 4

X41

Mains Voltage

Suppression

Rectifier Board

X13

X10

X11

X12

X2X1X4

Right-Hand Output Power Module

W_LO

W_HI

TERM W

TERM V

V_HI

V_LO

TERM U

U_LO

U_HI

I_V

I_W

I_U

Power Board

4 4 4

X3X2X1X4X5

Left-Hand Output Power Module

X14

X15

X16

X18

X20

X4X5X6

X10

Adapter

Board

Fiber Optic Cables

H4 (UH)

H5 (UL)

H6 (VH)

H7 (VL)

H8 (WH)

H9 (WL)

From ASIC Board H8

From ASIC Board H9

From ASIC Board H10

From ASIC Board H11

From ASIC Board H12

From ASIC Board H13

X10

X11

X12

X3X4X5X6X7

Driver

Board

X11

X12

X13

X17

X19X1X2X3X7

From ASIC Board X2

DC+

DC-

To ASIC Board X6

X1 X2X3X1 X2X3X1 X2

Line Reactor

L1 / R

L2 / S

L3 / T

X50

T1/ U

T2 / V

T3 / W

DC+

DC-

To Voltage Feedback Board J2

(On 700S Only)

To Voltage Feedback Board J1

(On 700S Only)

400V drives have

2 DC Bus Capacitors

in series and

and 3 in parallel.

600V drives have

3 DC Bus Capacitors

in series and

and 2 in parallel.

Figure B.1 Power Circuitry for Drives

with AC In

ahw1020.eps