700S High Performance AC

Drives
and
700H Adjustable Frequency
AC Drives

Frame 9 (132 -160 KW / 200-250 HP)

Hardware Service Manual

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.ab.com/manuals/gi) 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.

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.

Important: Identifies information that is critical for successful application and

understanding of the product.

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 the hazard
• 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.

PowerFlex is a registered trademark of Rockwell Automation, Inc.

DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.
PLC is a registered trademark of Rockwell Automation, Inc.
 Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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 Hardware Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Addressing 700H Hardware Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Diagnostic Procedures by Symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Chapter 2 Component Test Procedures

Forward Biased Diode Tests for Major Power Components. . . . . . . . . . . . . . . . . . . . . . . 2-1
Checking Rectifying Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Checking the Main Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Checking Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Checking AC-Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Checking Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Chapter 3 Access Procedures

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Opening Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Removing the DPI / HIM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Removing 700S Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Removing the 700S Voltage Feedback Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Removing the 700S Power Interface Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Removing the 700H I/O Boards and Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Removing the 700H Fiber Optic Adapter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Removing the Control Frame and Cross Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Removing the EMC-Protection Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Removing the Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Removing the Rectifying Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Removing the Main Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Removing the Fan Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Removing Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Removing the AC-Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Chapter 4 Start-Up After Repair

Loading the 700H EEPROM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Before Applying Power to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Testing with the External DC Power Supply Without Load (Optional) . . . . . . . . . . . . . . 4-4
Testing Without a Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Performing the Power Circuit Diagnostic Test on a 700S. . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Testing With the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
2

Appendix A Service Tools and Equipment

Software Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Service tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B Schematics
put Conditioning Circuitry for Drives with AC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Power Circuitry for 700S Drives with AC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Power Circuitry for 700S Drives with DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Power Circuitry for 700H Drives with AC Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Power Circuitry for 700H Drives with DC Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Circuit Board Connections for 700S Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Circuit Board Connections for 700H Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Fan Power Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

Appendix C Disassembly / Assembly Diagrams

700S 261A / 300A Mechanical Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
700H 261A / 300A Mechanical Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Cross Plate (terminals) and Internal Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
EMC-Protection Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Capacitor Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Fan Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Control Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
Rectifying Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
Key to ID Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11
 Preface

Overview

Who Should Use this This manual is intended for qualified service personnel responsible for
Manual? 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 9 PowerFlex
700S and 700H drives only. Verify that you are working on a Frame 9 drive
by checking the data nameplate on the Control Frame. The frame number is
printed just above the serial number.

Cat No. 20D J 300 N 0 NNNBNNNN

UL Open Type/IP00
540V 650V Series: A
Standard I/O: NONE
Normal Duty Power 160 kW 250 kW Original Firmware No. 2.04
Heavy Duty Power 132 kW 200 kW
Input: DC, C UL
Æ US
DC Voltage Range 462 - 594 583 - 713 LISTED
Amps 350 350 IND CONT EQ
9D42
Cat No. 20D
UL Open Type/IP00

Normal Duty Power

Heavy Duty Power
J 300 N 0 NNNBNNNN

540V
160 kW
132 kW
650V
250 kW
200 kW
Series: A
Standard I/O: NONE
Original Firmware No. 2.04

UL
Output: 3 Phase, 0 - 320Hz
AC Voltage Range
Input: DC, C Æ US
DC Voltage Range 462 - 594 583 - 713

0 - 400 0 - 460
LISTED
Amps 350 350
IND CONT EQ
Output: 3 Phase, 0 - 320Hz
AC Voltage Range 0 - 400 0 - 460 9D42
Base Hz (default) 50 Hz 60 Hz
Continuous Amps 300/245 300/245
1 Min Overload Amps 330/368 330/368
2 Sec Overload Amps 450/490 450/490
MFD. in 1989 on Nov 9 Frame #: 9
Serial Number: 2622381652

2622381652

Base Hz (default)
MADE IN THE USA (FAC 1B)

50 Hz 60 Hz
Continuous Amps 300/245 300/245
1 Min Overload Amps 330/368 330/368
2 Sec Overload Amps 450/490 450/490
L1 L2 L3 L1 L2 L3 U/T1 V/T2 W/T3 U/T1 V/T2 W/T3 MFD. in 1989 on Nov 9 Frame #: 9
Serial Number: 2622381652

MADE IN THE USA (FAC 1B) 2622381652

p-2 Overview

What is Not in this Manual This manual does not contain in depth fault information for troubleshooting.
That information is available in publications 20C-PM001, Programming
Manual - PowerFlex 700H Adjustable Frequency AC Drive, PFLEX-IN006,
Installation Instructions - PowerFlex 700S and 700H Adjustable Frequency
AC Drive and 20D-UM001, User Manual - PowerFlex 700S High
Performance AC Drive.

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

www.rockwellautomation.com/literature.

The following publications provide general drive information.

Title Publication
Wiring and Grounding Guide, (PWM) AC Drives DRIVES-IN001...
Safety Guidelines for the Application, Installation and Maintenance of SGI-1.1
Solid State Control
A Global Reference Guide for Reading Schematic Diagrams 0100-2.10
Guarding Against Electrostatic Damage 8000-4.5.2

The following publications provide specific PowerFlex drive information.

Title Publication
Programming Manual - PowerFlex 700H AC Drive 20C-PM001...
User Manual - PowerFlex 700S High Performance Drive 20D-UM001...
Installation Instructions - Hi-Resolution Feedback Option Card for 20D-IN001...
PowerFlex 700S Drives
Installation Instructions - Multi Device Interface Option for PowerFlex 20D-IN004...
700S Drives
Installation Instructions - Main Control Board PowerFlex 700S Drives 20D-IN005...
Installation Instructions - Control Assembly Cover for PowerFlex 700S 20D-IN006...
Drives
Installation Instructions - PowerFlex 700S and 700H Drives PFLEX-IN006...
Reference Manual - PowerFlex Adjustable Frequency Drive, (Volume PFLEX-RM001...
1 - 70 & 700)
Reference Manual - PowerFlex Adjustable Frequency Drive, (Volume PFLEX-RM002...
2 - 700S)

The following publications provide information that is necessary when

applying the DriveLogix Controller.
Title Publication
User Manual - DriveLogix System 20D-UM002...
Installation Instructions - DriveLogix Controller 20D-IN002...
Installation Instructions - Memory Expansion for DriveLogix Controller 20D-IN007...
ControlNet Daughtercard Installation Instructions 1788-IN002...
ControlNet Daughtercard Installation Instructions 1788-IN005...
 Overview p-3

Understanding Manual Terms

Conventions
The following words are used throughout the manual to describe an action:
Word Meaning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Must Unavoidable, you must do this
Shall Required and necessary
Should Recommended
Should Not Not recommended

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 Additional troubleshooting information and software tools are available on
Available on Internet the Allen-Bradley Drives Support Website (http://www.ab.com/support/
abdrives/).
p-4 Overview

General Precautions Class 1 LED Product

ATTENTION: Hazard of permanent eye damage exists when

! using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into module ports or
fiber-optic cable connectors.

ATTENTION: This drive contains ESD (Electrostatic

! Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with
static control procedures, reference A-B publication 8000-4.5.2,
“Guarding Against Electrostatic Damage” or any other applicable
ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can
! result in component damage or a reduction in product life. Wiring
or application errors, such as, undersizing the motor, incorrect or
inadequate AC supply, or excessive ambient temperatures may
result in malfunction of the system.
ATTENTION: Only qualified personnel familiar with high
! power PowerFlex 700S and 700H Drives and associated
machinery should plan or implement the installation, start-up and
subsequent maintenance of the system. Failure to comply may
result in personal injury and/or equipment damage.
ATTENTION: To avoid an electric shock hazard, verify that the
! voltage on the bus capacitors has discharged before performing
any work on the drive. Measure the DC bus voltage at the DC+ &
DC- terminals. The voltage must be zero.
ATTENTION: Potentially fatal voltages may result from
! improper usage of an oscilloscope and other test equipment. The
oscilloscope chassis may be at a potentially fatal voltage if not
properly grounded. If an oscilloscope is used to measure high
voltage waveforms, use only a dual channel oscilloscope in the
differential mode with X 100 probes. It is recommended that the
oscilloscope be used in the A minus B Quasi-differential mode
with the oscilloscope chassis correctly grounded to an earth
ground.
 Chapter 1

Troubleshooting and Error Codes

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

! power to the drive has been removed before performing the
following.
ATTENTION: To avoid an electric shock hazard, verify that the
! voltage on the bus capacitors has discharged before performing
any work on the drive. Measure the DC bus voltage at the DC+ &
DC- terminals. The voltage must be zero.
ATTENTION: HOT surfaces can cause severe burns. Do not
! touch the heatsink surface during operation of the drive. After
disconnecting power allow time for cooling.
ATTENTION: This drive contains ESD (Electrostatic
! Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with
static control procedures, reference A-B publication 8000-4.5.2,
“Guarding Against Electrostatic Damage” or any other
applicable ESD protection handbook.
1-2 Troubleshooting and Error Codes

Creating Fault Reports Clear and complete fault reports are critical for analysis and repair of
modules returned to the factory.

At a minimum perform, and record the following:

• 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 Hardware

Fault No. Description Action (if appropriate)
Faults HiHp In PhaseLs 65 AC Input Phase Loss - AC voltage is 1. Check for voltage on each
not present on one or two input input phase
phases. 2. Check the status of each
external input fuses
HiHp Bus Com Dly 66 Bus Communication Time Delay - the Check fiber-optic connections
processor has not received proper between the Power Interface
periodic feedback information. Circuit Board and Voltage
Feedback Circuit Board
HiHp Bus Link LS 67 Bus Communication Link Loss - bus Check fiber-optic connections
communication between the Power between the Power Interface
Interface Circuit Board and Voltage Circuit Board and Voltage
Feedback Circuit Board has halted. Feedback Circuit Board
HiHp Bus CRC Er 68 Bus Communication CRC Error - too Check fiber-optic connections
many Cycling Ring Checksum (CRC) between the Power Interface
errors have occurred in the Circuit Board and Voltage
communication bus. Feedback Circuit Board
HiHp Bus WtchDog 69 Bus Communication Watchdog Error - 1. Check fiber-optic
communication has halted in the connections between the
communication bus, causing the Power Interface Circuit Board
watch dog timer to expire. and Voltage Feedback Circuit
Board
2. Check connections between
the Main Control Board and
the Power Interface Circuit
Board
3. Replace the Voltage
Feedback Circuit Board
4. Replace the Power Interface
Circuit Board
5. Replace the Main Control
Board
HiHp Fan Fdbk Ls 70 Fan Feedback Loss - a fan feedback 1. Check the main cooling fan
signal has been lost. 2. Check the Main Control
Board cooling fan
 Troubleshooting and Error Codes 1-3

Fault No. Description Action (if appropriate)

HiHp Drv OvrLoad 71 Drive Overload - the circuit board on Measure output current of the
the Power Module has detected an drive. If the level is ever greater
overload. than the maximum drive rated
output current level reduce the
load. If the levels are always
well below the drive rated
levels, then replace the power
module
HiHp PwrBd PrcEr 72 Power Board Processor Error - a 1. Check fiber-optic
microprocessor on the Power Board connections between the
has detected a communication error. Power Interface Circuit Board
and Voltage Feedback Circuit
Board
2. Check connections between
the Main Control Board and
the Power Interface Circuit
Board
3. Replace the Voltage
Feedback Circuit Board
4. Replace the Power Interface
Circuit Board
5. Replace the Main Control
Board
HiHp PrChrg Cntc 73 Precharge Contactor Fault - proper • Check precharge circuit
contactor feedback has not occurred. wiring
The precharge contactor has probably • Check for loose connections
failed to pick up or the feedback signal on X50 terminal block
has failed. This fault only applies to
DC input drives.
HiHp PwrEE Error 74 Power EEPROM Error - the rating of Replace output power module
the drive and data in the Power or program a new power board
EEPROM on the Power Board do not
match.
HiHP PwrBd OTemp 75 Power Board Over-Temperature - Check the main cooling fan and
temperature of the Power Board on fan power supply, replace if
has exceeded 85° C. necessary

Addressing 700H Hardware

Name No. Description Action (if appropriate)
Faults Power Loss 3 DC bus voltage remained below Monitor the incoming AC line for
[Power Loss Volts] for longer than low voltage or line power
[Power Loss Time]. Enable/Disable interruption.
with [Fault Config 1]. For more
information refer to publication
20C-PM001, Programming Manual -
PowerFlex 700H.
UnderVoltage 4 DC bus voltage fell below the Monitor the incoming AC line for
minimum value of 333V for 400/480V low voltage or power
drives and 461V for 600/ 690V drives. interruption.
Enable/Disable with [Fault Config 1].
For more information refer to
publication 20C-PM001,
Programming Manual - PowerFlex
700H.
1-4 Troubleshooting and Error Codes

Name No. Description Action (if appropriate)

OverVoltage 5 DC bus voltage exceeded maximum Monitor the AC line for high line
value. voltage or transient conditions.
Bus overvoltage can also be
caused by motor regeneration.
Extend the decel time or install
and external dynamic brake
option.
Input Phase 10 One input line phase missing. Check user-supplied fuses
Check AC input line voltage.
OutPhasMissng 11 Zero current in one output motor Check motor wiring.
phase. Check motor for open phase.
Ground Fault 13 A current path to earth ground greater Check the motor and external
than 25% of drive rating. Ground fault wiring to the drive output
level is 50% of the drive's heavy duty terminals for a grounded
current rating. The current must condition.
appear for 800ms before the drive will
fault.
InverterFault 14 Hardware problem in the power Cycle power.
structure. Replace drive.
System Fault 16 Hardware problem exists in the power Cycle power.
structure. Replace drive.
Load Loss 46
Power Unit 70 One or more of the output transistors Clear fault.
were operating in the active region
instead of desaturation. This can be
caused by excessive transistor current
or insufficient base drive voltage.
 Troubleshooting and Error Codes 1-5

Diagnostic Procedures by The following charts list drive symptom, symptom descriptions and
Symptom recommended actions.

Blown Input Fuses

Use this procedure when a drive clears any of its external circuit breaker or
power fuses:

Perform Forward Replace

Disconnect Motor Rectifying Rectifying
Leads Diode Tests on No
Module Module
Rectifying Module
OK?

Yes

Perform Forward Replace

Power
Diode Tests on No Power
Module
Power Module Module
OK?

Yes

Examine Bus
Capacitors for Capacitors Replace
No Capacitors
Charring and OK?
Damaged Reliefs

Yes

Check Motor and Motor and Remedy Motor

Lead Resistances Lead Resistances No and Lead
at 1000V > 1 Mohm? Problems

Yes

Disconnect AC Are There Replace

Choke from Any Line to Yes AC
Rectifying Module Load Shorts? Choke

No

Are There
Any Line to Yes
Line Shorts?

Reconnect Reconnect
No AC Motor
Choke Leads
1-6 Troubleshooting and Error Codes

No Output Voltage
Use this procedure when there is not voltage present at the drive output
terminals, even though the drive indicates the motor is running:

DC Bus Perform forward

Measure DC Bus Voltage within Rectifying Replace Rectifying
No diode tests on No
Voltage Specification? Module OK? Module
Rectifying Module

Yes

Examine Bus
Capacitors for Capacitors Replace
Yes No
Charring and OK? Capacitors
Damaged Reliefs

Yes

Measure Power Voltages within Replace Power

No
Supply Voltages Specification? Supply

Yes

Check Board Does Drive

Connections Run?

No

Replace Main Does Drive

Control Board Run?

No

Replace Power Does Drive

Interface Board Run?
(on 700S)

No

Replace Voltage
Feedback Board
(on 700S)
 Troubleshooting and Error Codes 1-7

No HIM Display
Use this procedure when the HIM does not function:

DC Bus Perform forward

Measure DC Bus Voltage within Rectifying Replace Rectifying
No diode tests on No
Voltage Specification? Module OK? Module
Rectifying Module

Yes

Examine Bus
Capacitors for Capacitors Replace
Yes No
Charring and OK? Capacitors
Damaged Reliefs

Yes
Yes

Measure Power Voltage Replace Voltage

Supply on X4 of Equal 12V dc? No
Feedback Board
DPI Circuit Board
(on 700S)

Yes

Replace Output
Power Module
(on 700H)

Check DPI and Does HIM

Power Supply Function?
Connections

No

Replace HIM
1-8 Troubleshooting and Error Codes

Over-Temperature Faults
Use this procedure to troubleshoot drive over-temperature faults (14 - Inv
Otemp Pend and 15 - Inv Otemp Trip in 700S or 8 - Heatsink OvrTemp and
9 - Trnsistr OvrTemp in 700H):

Temperature Provide
Check Surrounding
Exceeds Yes Additional Airflow
Air Temperature Specification? or Air Conditioning

No

Current Reduce Load or

Check Motor
Exceeds Yes Procure a Drive
Current and Load
Specification? With a Higher
Levels
Rating

No

Frequency Too
Check PWM High for Lead Length Lower PWM
Yes
Frequency and Surrounding Frequency
Temp?

No

Check Fan and Remedy

Air Flow Proper Space No Spacing at
Through the Drive At Inlet? Inlet

Yes

Remove
Airlflow
Yes Air Flow
Blockages?
Blockages

No

Fan
Running Yes
Properly?

No

Check Power Power Voltage

Voltage on Fan Check Fan Inverter
Equals Bus No
Inverter Fuses (F1 and F2)
Voltage?

Yes

Check Connection
Between Power Repair
Module Circuit Connection No
Good? Connection
Board and Fan
Inverter
Yes

Check Fan Output Equals Replace

Inverter Output on 50 Hz / 220V rms? No
Fan Inverter
X1, X4 and X5

Yes

Check Fan Motor Fan Motor has Replace

for Short and Open or Short Yes
Fan Motor
Open Circuits Circuits?

No

Contact
Allen-Bradley
Drives
Technical
Support
 Chapter 2

Component Test 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
! voltage on the bus capacitors has discharged before performing
any work on the drive. Measure the DC bus voltage at the DC+ &
DC- terminals. The voltage must be zero.
ATTENTION: HOT surfaces can cause severe burns. Do not
! touch the heatsink surface during operation of the drive. After
disconnecting power allow time for cooling.
ATTENTION: This drive contains ESD (Electrostatic
! Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with
static control procedures, reference A-B publication 8000-4.5.2,
“Guarding Against Electrostatic Damage” or any other
applicable ESD protection handbook.

Forward Biased Diode Tests A forward biased diode test checks the semiconductor junctions between
for Major Power Components the terminals and measures the voltage drop across those junctions. To pass
each test, the meter must beep once and display a voltage within the
specification shown in the table. If the test finds a short, the meter will
display.000 and beep continuously. If the test finds an open circuit or
reversed polarity, the meter will display “.0L” (zero load).
2-2 Component Test Procedures

1. Remove power from the drive

2. Check for zero volts between DC+ an DC-

3. Remove the Connection cover, while referring to Opening Drive on
page 3-4.

4. Disconnect the motor leads from the drive

Forward Biased Diode Tests for Rectifying Module

Figure 2.1 Measurement Points for Forward Biased Diode Tests on Major Power
Components

DC- DC+/R+ R-

L1 L2 L3 L1 L2 L3 U/T1 V/T2 W/T3 U/T1 V/T2 W/T3

 Component Test Procedures 2-3

5. Perform forward biased diode tests, using a digital multimeter, on the

points listed in Table 2.A on page 2-3 (on AC Three-Phase drives). If the
Rectifying Module fails any of these tests, replace it (See Removing
the Rectifying Module on page 3-27).
Table 2.A Forward Biased Diode Tests for Rectifying Module
Meter Leads
+ - Nominal meter reading
L1 DC-
L2 DC- Value should gradually rise to 1.8V
L3 DC-
L1 DC+/R+(1)
L2 DC+/R+ 0.450V ± 0.075V
L3 DC+/R+
DC- L1
DC- L2 0.335V ± 0.075V
DC- L3
DC+/R+(1) L1
DC+/R+ L2 Value should gradually rise to 1.8V
DC+/R+ L3
(1) If the drive does not contain the brake chopper option, the DC+/R+
terminal will be labeled DC+.

Forward Biased Diode Tests for Output Power Module

6. Perform forward biased diode tests, using a digital multimeter, on the
points listed in Table 2.B on page 2-3. If the Output Power Module
fails any of these tests, replace it (See Removing the Power
Module on page 3-23).
Table 2.B Forward Biased Diode Tests for Output Power Module
Meter Leads
+ - Nominal meter reading
T1 DC-
T2 DC- Value should gradually rise to 1.8V
T3 DC-
T1 DC+/R+
T2 DC+/R+
T3 DC+/R+
0.290V ± 0.075V
DC- T1
DC- T2
DC- T3
DC+/R+ T1
DC+/R+ T2 Value should gradually rise to 1.8V
DC+/R+ T3
2-4 Component Test Procedures

Forward Biased Diode Tests for Brake Chopper

7. Perform forward biased diode tests, using a digital multimeter, on the
points listed in Table 2.C on page 2-4 (on drives with Brake Choppers).
If the Brake Chopper Assembly fails any of these tests, replace it.
Table 2.C Forward Biased Diode Tests for Brake Chopper Assembly
Meter Leads
+ - Nominal meter reading
R- DC- Value should gradually rise to 1.8V
R- DC+/R+ 3.15V ± 0.075V
DC- R- 0.36V ± 0.75V
DC+/R+ R- Value should gradually rise to 1.8V

Checking Rectifying Module 1. Remove power from the drive

2. Check for zero volts between DC+ an DC-

3. Remove the Connection cover, while referring to Opening Drive on

page 3-4.

4. Remove the DPI/HIM Assembly, while referring to Removing the DPI /

HIM Assembly on page 3-6.

5. Remove the 700S Control Assembly (on a 700S drive), while referring to
Removing 700S Control Assembly on page 3-8.
6. Remove the 700S Voltage Feedback circuit board (on a 700S drive),
while referring to Removing the 700S Voltage Feedback Circuit
Board on page 3-10.
7. Remove the 700S Power Interface circuit board (on a 700S drive), while
referring to Removing the 700S Power Interface Circuit Board on
page 3-12.
8. Remove the 700H Main Control board and enclosure (on a 700H drive),
while referring to Removing the 700H Fiber Optic Adapter Board on
page 3-15.
9. Referring to Removing the Control Frame and Cross Plate on page 3-17,
remove the Control Frame and Cross Plate.

10.Referring to Removing the EMC-Protection Plate on page 3-20, remove

the EMC-Protection Plate.

11.Visually inspect the pre-charging resistors. If pre-charging resistors are

damaged:
A. Replace the Rectifying Module (See Removing the Rectifying
Module on page 3-27).

B. Check capacitors, rectifiers and external connections for

short-circuits. Referring to Forward Biased Diode Tests for Output
Power Module on page 2-3, check the Output Power Module.
 Component Test Procedures 2-5

Measurement of Rectifying Module

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

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

points listed in Table 2.D on page 2-5 (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 (See Removing the Rectifying Module on
page 3-27).
Table 2.D Rectifying Module Measurements
Measurement points Resistance
X10: red to X10: black
X11: red to X11: black 18Ω ± 1Ω
X12: red to X12: black

Checking the Rectifier Circuit Board

14.Connect 24V power (from the test power supply) to X13: Pin 5 and 24V
Common to X13: Pin 1
15.Perform “DC Test Power Supply ON” tests in Table 2.E on page 2-6.

16.De-energize test power supply. Perform “DC Test Power Supply OFF”
tests in Table 2.E on page 2-6.
17.If the results differ from measurements shown in Table 2.E on page 2-6,
replace the Rectifying Module (See Removing the Rectifying Module on
page 3-27).
2-6 Component Test Procedures

Figure 2.2 Rectifying board layout and measurement points

Precharging
Resistors

J9

J5
J1

X13 X6 X10 X11

X12

X13: Pin 1 X13: Pin 5

(24V dc Common) (24V dc Power)
X10: Pin 1 X11: Pin 1 X12: Pin 1

Table 2.E Rectifying Board Forward Biased Diode Test Results

Meter Leads DC Test Power DC Test Power
+ - Supply ON Supply OFF
J1 X10:PIN1 ~ 0.5V OL
J5 X11:PIN1 ~ .5V OL
J9 X12:PIN1 ~ .5V OL

Important: Power supply polarity is critical during these tests. Reversing

the polarity will damage components on the circuit board.
 Component Test Procedures 2-7

Checking the Brake Chopper

These tests require a recommended multi-meter capable of measuring
capacitance.

18.Disconnect the cable which connects the brake chopper to the Output
Power Module connector X11.

19.Measure gate capacitance (gate to emitter) between the grey and white
wires on the X11 plug.
20.Measure gate capacitance (gate to emitter) between the red and black
wires on the X11 plug.

Important: Use correct polarity when you measure gate capacitance.

21.If measurement results are not similar to values in Table 2.F on page 2-7,
replace both brake chopper and rectifying module (See Removing the
Rectifying Module on page 3-27).
Table 2.F Proper Brake Chopper Measurements
Meter Leads
+ - Capacitance (+/- 20%)
X11-grey X11-white 50nF
X11-red X11-black 50nF

Checking the Main Fan 1. Remove power from the drive

2. Check for zero volts between DC+ an DC-

3. Remove the Connection cover, while referring to Opening Drive on
page 3-4.

4. Remove the fan power supply cover, while referring to Removing the
Fan Power Supply on page 3-34

5. Disconnect the fan motor from the output filter transformer (Refer to Fan
Power Supply Connections on page B-8).

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

measurements are not similar to those in Table 2.G on page 2-8, replace
the fan (See Removing the Main Fan on page 3-32).
2-8 Component Test Procedures

Table 2.G Correct Fan Measurements

Connection Wires Resistance ± 5%
Black-Brown 62
Brown-Blue 36
Blue-Black 27

7. Disconnect capacitor from fan power supply.

8. Measure value of the start capacitor. If the resulting value does not equal
7μF, replace the capacitor (See Removing the Fan Power Supply on
page 3-34).

Checking Capacitors Important: This procedure requires special equipment and training. Only
qualified and trained personnel should perform these
procedures.

These tests require the recommended high voltage DC-power supply.

1. Test each capacitor with a DC-power supply. Recommended is to set DC

power supply current limit < 50mA.

2. Connect the power supply’s DC+ to the drive’s DC+ terminal and the
power supply’s DC- to the drive’s DC- terminal.

3. Set power supply voltage setting to zero.

4. Switch on the external DC power supply.

5. Slowly increase the external DC power supply output voltage to the

drive’s nominal DC bus voltage (1.35 x Unity)

Example: 480v AC Nominal Voltage

1.35 x 480v = 648v

6. Monitor the current while testing.

7. Leakage current should be less than 3mA when voltage has stabilized.

8. Abort test if current leakage is significantly higher when voltage has

stabilized.

9. Decrease the DC power supply output voltage to zero. Wait until DC bus
voltage has decreased to zero. Switch off the external DC power supply.

10.As a precaution, use a resistor to discharge each capacitor after testing.

Use a proper resistor that can handle the discharging current.

11.If any capacitor has failed. Replace all the capacitors in the same series
connection (See Removing Capacitors on page 3-38).
 Component Test Procedures 2-9

Checking AC-Choke 1. Visually inspect the AC-Choke for burn marks.

2. Measure the resistance between and across each phase and from each
phase to ground to verify that each phase is intact and not shorted to
ground.

3. If the AC-Choke fails either inspection or tests, replace it (See Removing

the AC-Choke on page 3-40).
2-10 Component Test Procedures

Checking Terminals Check that cables L1 and L3 do not touch the ferrite ring.

If cables are touching the ferrite ring:

1. Loosen terminals L1 and L3.

2. Push cables L1 and L3 towards cable L2.

3. Tighten terminals, using torques specified in Torque Specifications on

page 3-1.
 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
! voltage on the bus capacitors has discharged before performing
any work on the drive. Measure the DC bus voltage at the DC+ &
DC- terminals. The voltage must be zero.
ATTENTION: HOT surfaces can cause severe burns. Do not
! touch the heatsink surface during operation of the drive. After
disconnecting power allow time for cooling.
ATTENTION: 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
! 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.

Torque Specifications The following table lists fastener torque specifications:

Item Screw Torque Final
Connection Cover (mounting) M4 x 8 Pozidrive® 3 N-m
(27 lb.-in.)
Power Cover (mounting) MM4 x 8 Pozidrive 3 N-m
(27 lb.-in.)
Conduit Cover (mounting) M4 x 8 Pozidrive 3 N-m
(27 lb.-in.)
DPI / HIM Assembly Door M3 x 6 Phillips® 0.9 N-m
(8 lb.-in.)
DPI / HIM Assembly (mounting) M3 x 6 Phillips 0.9 N-m
(8 lb.-in.)
Shield for 700S Voltage Feedback M3 x 6 Phillips 0.9 N-m
Circuit Board (mounting) (8 lb.-in.)
700S Voltage Feedback Circuit Board M3 x 0.5 thread - 37 mm x 0.9 N-m
(mounting) 37 mm hex standoff (8 lb.-in.)
3-2 Access Procedures

Item Screw Torque Final

700S Power Interface Circuit Board M3 x 6 Phillips 0.9 N-m
(mounting) (8 lb.-in.)
700H Control Board (mounting) M3 x 5 Pozidrive 0.9 N-m
(8 lb.-in.)
700H Control Board enclosure M4 x 8 Pozidrive 3 N-m
(mounting) M4 x 40 Pozidrive (27 lb.-in.)
700H Fiber Optic Adapter bracket M4 x 8 Pozidrive 3 N-m
(mounting) (27 lb.-in.)
700H Fiber Optic Adapter Board M4 x 8 Pozidrive 0.9 N-m
(mounting) (8 lb.-in.)
Control Frame (mounting) M4 x 8 Pozidrive 3 N-m
(27 lb.-in.)
Conduit (mounting) M4 x 8 Pozidrive 3 N-m
(27 lb.-in.)
MOV (mounting) M4 x 30 Phillips 3 N-m
(27 lb.-in.)
Ground Wire on Cross Plate M6 x 14 hexagonal screw 4 N-m
(35 lb.-in.)
Cross Plate (mounting) M4 x 8 Pozidrive 3 N-m
(27 lb.-in.)
DC+, DC- and brake cable to DC-link M8 nut 14 N-m
(124 lb.-in.)
AC-choke (terminals) L1, L2, L3, A, M8 x 25 hexagonal screw 17 N-m
B, C (151 lb.-in.)
IGBT (terminals) M8 x 20 hexagonal screw 9 N-m
(80 lb.-in.)
DC+, DC-, and brake cable to top M8 x 20 hexagonal screw 20 N-m
terminals (177 lb.-in.)
EMI Protection Plate (mounting) M4 x 8 Pozidrive 3 N-m
(27 lb.-in.)
DC- Bus Bars to rectifier/power M6 x 14 Pozidrive 5 N-m
busbars (44 lb.-in.)
Rectifier/Power Module (upper M5 x 10 Pozidrive 4 N-m
mounting) (35 lb.-in.)
Rectifier/Power Module (lower M5 x 10 Pozidrive 4 N-m
mounting) (35 lb.-in.)
Rectifier (terminals) M8 x 20 hexagonal screw 9 N-m
(80 lb.-in.)
Fan Power Supply Plate (mounting) M4 x 8 Pozidrive 3 N-m
(27 lb.-in.)
Fan Assembly (top mounting) M4 x 8 Pozidrive 3 N-m
(27 lb.-in.)
Fan Assembly (bottom mounting) M4 x 8 Pozidrive 3 N-m
(27 lb.-in.)
Fan Power Supply Capacitor Bracket M4 x 8 Pozidrive 3 N-m
(mounting) (27 lb.-in.)
Fan Power Supply (mounting) M4 x 8 Pozidrive 1.8 N-m
(15 lb.-in.)
Capacitor (-) Bus Bar M6 x 16 Pozidrive 4 N-m
(35 lb.-in.)
Capacitor (+) Bus Bar M6 x 14 Pozidrive 4 N-m
(35 lb.-in.)
Capacitor (+) Bus Bar with bush ring M6 x 20 Pozidrive 4 N-m
(35 lb.-in.)
DC+ and DC- cables to Bus Bars M8 x 20 hexagonal screw 10 N-m
(89 lb.-in.)
 Access Procedures 3-3

Item Screw Torque Final

Brake chopper (terminals) M5 x 12 Pozidrive 4 N-m
(35 lb.-in.)
Brake chopper Bus Bar (terminal) M8 x 20 hexagonal screw 10 N-m
(89 lb.-in.)
Rectifier (mounting) M6 x 20 Pozidrive 5 N-m
(44 lb.-in.)
Brake chopper (mounting) M6 x 14 Pozidrive 5N-m
(44 lb.-in.)
Rectifying board M4 x 8 Pozidrive 1.5 N-m
(13 lb.-in.)
AC-choke (upper plate mounting) M8 x 8 Pozidrive 3 N-m
(27 lb.-in.)
Control Bracket (mounting) M4 x 8 Pozidrive 3 N-m
(27 lb.-in.)
AC-choke (mounting) M5 x 10 Pozidrive 4 N-m
(35 lb.-in.)
Motor and AC Line Terminals M8 nut 20 N-m
(177 lb.-in.)
Terminal Strip Assembly (mounting) M5 x 10 Pozidrive 4 N-m
(35 lb.-in.)

Pozidrive® is a registered trademark of the Phillips Screw Company

Phillips® is a registered trademark of Phillips Screw Company

Understanding Torque Figures in Assembly Diagrams

Icons and numbers in the assembly diagrams indicate how to tighten
hardware:
Tool Type and Size
PZ indicates Pozidrive screwdriver bit
P indicates Phillips screwdriver bit
Fastener Type
Pozidrive Screw

Phillips Screw
PZ2
Hexagonal Bolt 4 N-m Tightening Torque
or Standoff (35 lb.-in.)
Hexagonal
Screw
Hexagonal Nut
3-4 Access Procedures

Opening Drive Opening

1. Remove power from drive.

2. Check for zero volts between DC+ and DC-.

3. Remove Connection cover

L1 L2 L3 L1 L2 L3 U/T1 V/T2 W/T3 U/T1 V/T2 W/T3

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

4. Remove Power cover

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

L1 L2 L3 L1 L2 L3 U/T1 V/T2 W/T3 U/T1 V/T2 W/T3

 Access Procedures 3-5

5. Remove Conduit Cover

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

L1 L2 L3 L1 L2 L3 U/T1 V/T2 W/T3 U/T1 V/T2 W/T3

Closing
The covers may be replaced and removed in any order.
3-6 Access Procedures

Removing the DPI / HIM Removal

Assembly
1. Remove power from drive.

2. Check for zero volts between DC+ and DC-.

3. Referring to Opening Drive on page 3-4, remove the Power Cover from
the drive.

Important: Before removing connections and wires, mark the connections

and wires to avoid incorrect wiring during assembly.
4. Remove two screws from front of DPI / HIM assembly.
Screws

P1
0.9 N-m
(8 lb.-in.)

5. Open the door, which holds the DPI interface and HIM.

6. Unplug the DPI cable from X2 connector on the DPI Interface Circuit
Board.
X2 X4

Back View of DPI

Circuit Board which
should remain mounted
on the back of
the assembly

7. Unplug the cable from X4 connector on the circuit board (on 700S drives
only).
 Access Procedures 3-7

8. Remove four mounting screws and the assembly from the Control
Frame.
Mounting Screws

P1
0.9 N-m
(8 lb.-in.)

Installation
Install the DPI / HIM Assembly in reverse order of removal, while referring
to Torque Specifications on page 3-1.
3-8 Access Procedures

Removing 700S Control Removal

Assembly
J2

J7

Captive Screw

1. Remove power from drive.

2. Check for zero volts between DC+ and DC-.

3. Referring to Opening Drive on page 3-4, remove the Power Cover from
the drive.
Important: Before removing connections and wires, mark the connections
and wires to avoid incorrect wiring during assembly.

4. On the 700S control assembly, unplug I/O and SynchLink cables from
the Main Control Board, unplug feedback wiring from feedback option
card and unplug communication cables from 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 SynchLink
fiber-optic ports or SynchLink fiber-optic cable connectors.

Important: Minimum inside bend radius for SynchLink fiber-optic cable is

25.4 mm (1 in.). Any bends with a shorter inside radius can
 Access Procedures 3-9

permanently damage the fiber-optic cable. Signal attenuation

increases with decreased inside bend radii.

5. Unplug J2 and J7 ribbon cables from the Main Control Board.

6. Loosen captive screw.

7. Swing Control Assembly away from drive.

8. Lift Control Assembly up and off of hinge.

Installation
Install the 700S Control Assembly in reverse order of removal, while
referring to Torque Specifications on page 3-1.
3-10 Access Procedures

Removing the 700S Voltage Removal

Feedback Circuit Board
J2

J1

J4

J5

Shield

Standoffs Screws
(5) (4)

3 mm P1
0.9 N-m 0.9 N-m
(8 lb.-in.) (8 lb.-in.)

1. Remove power from drive.

2. Check for zero volts between DC+ and DC-.

3. Referring to Opening Drive on page 3-4, remove the Power Cover from
the drive.

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

Voltage Feedback Circuit Board, and carefully set them aside.

ATTENTION: Hazard of permanent eye damage exists when

! using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber-optic ports or
fiber-optic cable connectors.

Important: Minimum inside bend radius for fiber-optic cable is 25.4 mm (1

in.). Any bends with a shorter inside radius can permanently
 Access Procedures 3-11

damage the fiber-optic cable. Signal attenuation increases with

decreased inside bend radii.

5. Disconnect feedback cables from sockets J1 and J2 of the Voltage

Feedback Circuit Board.

6. Remove the four screws which secure the clear plastic shield to the
standoffs and remove the shield.

7. Remove the five standoffs which support the clear plastic shield and
secure the Voltage Feedback Circuit Board to its mounting plate.

8. Remove the Voltage Feedback Circuit Board from its mounting plate.

Installation
Install the Voltage Feedback Circuit Board in reverse order of removal,
while referring to Torque Specifications on page 3-1.
3-12 Access Procedures

Removing the 700S Power Removal

Interface Circuit Board

Screws
(5)

P1
0.9 N-m
(8 lb.-in.)

Fiber-Optic
Sockets

1. Remove power from drive.

2. Check for zero volts between DC+ and DC-.

3. Referring to Opening Drive on page 3-4, remove the Power Cover from
the drive.
4. Carefully disconnect the ribbon cables from sockets along the top side of
the Power Interface Circuit Board, and carefully set them aside.

5. Carefully disconnect the fiber-optic cables from sockets along the right
side of the circuit board, and carefully set them aside.

ATTENTION: Hazard of permanent eye damage exists when

! using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber-optic ports or
fiber-optic cable connectors.

Important: Minimum inside bend radius for fiber-optic cable is 25.4 mm (1

in.). Any bends with a shorter inside radius can permanently
 Access Procedures 3-13

damage the fiber-optic cable. Signal attenuation increases with

decreased inside bend radii.

6. Disconnect other cables from sockets of the circuit board, and set them
aside.

7. Remove the five screws which secure the Power Interface Circuit Board
to the Control Frame.

8. Remove the circuit board from the Control Frame.

Installation
Install the 700S Power Interface Circuit Board in reverse order of removal,
while referring to Torque Specifications on page 3-1.
3-14 Access Procedures

Removing the 700H I/O Removal

Boards and Control
1. Remove power from drive.
Assembly
2. Check for zero volts between DC+ and DC-.

3. Referring to Opening Drive on page 3-4, remove the Power Cover,

Connection Cover and Conduit Cover from the drive.

4. Open the enclosure that contains the Control and I/O Boards and
carefully unplug the DPI cable and any I/O cables.
5. Remove the I/O Boards from the Control Board and enclosure. Note the
order of the boards and the keys which prevent placement of boards in
incorrect slots.
Do not remove enclosure cover.
Enclosure is illustrated without
the cover for clarity.

Keys

6. Unplug the serial connection from X7 of the Control Board.

X7
Serial Port

X2 X3 X4 X5 X6
(Slot A) (Slot B) (Slot C) (Slot D) (Slot E)
 Access Procedures 3-15

7. Remove the three screws which secure the Control Assembly to the
drive.
Do not remove enclosure cover.
Enclosure is illustrated without
the cover for clarity.

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

8. Remove the Control Assembly.

Installation
Install the 700H Control and I/O Boards in reverse order of removal, while
referring to Torque Specifications on page 3-1.

Removing the 700H Fiber Removal

Optic Adapter Board
1. Remove power from drive.
2. Check for zero volts between DC+ and DC-.

3. Referring to Opening Drive on page 3-4, remove the Power Cover,

Connection Cover and Conduit Cover from the drive.
4. Referring to Removing the 700H I/O Boards and Control Assembly on
page 3-14, remove the I/O boards and Control Assembly.

5. Remove the Control Frame while referring to Removing the Control

Frame and Cross Plate on page 3-17.
3-16 Access Procedures

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

PZ2
0.9 N-m
PZ3 (8 lb.-in.)
3 N-m
(27 lb.-in.)

7. Remove the Fiber Optic Adapter bracket.

8. Disconnect the control power cable from X2 of the Fiber Optic Adapter
Board.

5 -H1 through -H7

X7
Sockets for
Connects to Fiber-Optic
4
Main Control Cables
Board 3

X2
Connects to
24V dc Power
 Access Procedures 3-17

9. Carefully disconnect the fiber-optic cables from right side of the circuit
board, and carefully set them aside.

ATTENTION: Hazard of permanent eye damage exists when

! using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber-optic ports or
fiber-optic cable connectors.

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.

10.Remove the four screws which secure the Fiber Optic Adapter Board to
the bracket.
11.Remove the Fiber Optic Adapter Board from the bracket.

Installation
Install the 700H Fiber Optic Adapter Board in reverse order of removal,
while referring to Torque Specifications on page 3-1.

Removing the Control Removal

Frame and Cross Plate
1. Remove power from drive.

2. Check for zero volts between DC+ and DC-.

3. Referring to Opening Drive on page 3-4, remove the Power Cover,
Connection Cover and Conduit Cover from the drive.

4. Referring to Removing the DPI / HIM Assembly on page 3-6, remove

the DPI / HIM assembly.

5. If removing a Control Frame from a DC input drive with precharge

interlock, disconnect the wiring from terminal strip X50.

Important: Before removing connections and wires, mark the connections

and wires to avoid incorrect wiring during assembly.
3-18 Access Procedures

6. If removing a Control Frame from a 700S drive, remove the Power

Interface and Voltage Feedback circuit boards (refer to Removing the
700S Voltage Feedback Circuit Board on page 3-10 and Removing the
700S Power Interface Circuit Board on page 3-12).

7. If removing a Control Frame from a 700H drive, carefully disconnect the

connections to the I/O boards and Control Assembly, and carefully set
aside

8. Remove the DPI / HIM Assembly, while referring to Removing the DPI /
HIM Assembly on page 3-6.

9. Remove eight screws which secure the Control Frame to the drive.
10.Remove the six screws which secure the Conduit to the drive.

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

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

11.Remove the Conduit from the drive.

12.Remove the Control Frame from the drive while carefully routing the
cables and wires through the access hole of the Control Frame.
 Access Procedures 3-19

13.Disconnect the Cross Plate Fan (if present), MOV and ground wires.

P2
3 N-m
(27 lb.-in.)

6 mm
4 N-m
(35 lb.-in.)

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

14.Remove three screws which hold Cross Plate to the drive.

15.Remove the Cross Plate.

3-20 Access Procedures

Installation
Install the Control Frame and Cross Plate in reverse order of removal, while
referring to Torque Specifications on page 3-1.

Removing the Removal

EMC-Protection Plate
1. Remove power from drive.

2. Check for zero volts between DC+ and DC-.

3. Referring to Opening Drive on page 3-4, remove the Power Cover,
Connection Cover and Conduit Cover from the drive.

4. Referring to Removing the DPI / HIM Assembly on page 3-6, remove

the DPI / HIM assembly.

5. Referring to Removing the Control Frame and Cross Plate on page 3-17,
remove the Control Frame and Cross Plate.

6. Disconnect the internal DC Bus wires from the DC Bus terminals at the
top of the drive.

Note the sequence of

hardware and the orientation
of the Belleville (cupped)
washer.

13 mm
14 N-m
(124 lb.-in.)
 Access Procedures 3-21

7. Disconnect the internal three-phase wiring from the AC choke (if

present).

6 mm
17 N-m
(151 lb.-in.)

Important: Be careful not to damage filter

capacitors on AC Choke terminals.

8. Disconnect the output cables from the top of the Power Module.

Note the sequence of

hardware and the orientation
of the Belleville (cupped)
washer.

6 mm
9 N-m
(80 lb.-in.)

Note the colors of the feedback wires, and

make sure you re-install the wires on the
proper motor phases.
Phase Feedback Wire Color
U (T1) Black
V (T2) Grey
W (T3) White
3-22 Access Procedures

9. Remove four screws which secure the EMI-Protection Plate to the drive.
Also remove the two screws which secure the common mode inductors.

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

10.Disconnect the fan which is mounted on the EMI-Protection Plate.

11.Remove the EMI-Protection Plate.

 Access Procedures 3-23

Installation

Install the EMC-Protection Plate in reverse order of removal, while

referring to Torque Specifications on page 3-1.

Removing the Power Module Removal

1. Remove power from drive.

2. Check for zero volts between DC+ and DC-.

3. Referring to Opening Drive on page 3-4, remove the Power Cover,
Connection Cover and Conduit Cover from the drive.

4. Referring to Removing the DPI / HIM Assembly on page 3-6, remove

the DPI / HIM assembly.

5. Referring to Removing the Control Frame and Cross Plate on page 3-17,
remove the Control Frame and Cross Plate.

6. Referring to Removing the EMC-Protection Plate on page 3-20, remove

the EMC-Protection Plate.
3-24 Access Procedures

7. Disconnect all of the cables from the Power Module circuit board.

X6

X11

X9

X10

1 2 3 4 5 6 7
X5 X8 X15 X1 X7
 Access Procedures 3-25

8. Remove the six screws which connect the Power Module to the DC Bus
bars.

Remove

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

PZ3
5 N-m
(44 lb.-in.)

Remove

Loosen but do not remove

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

9. Remove the three fastening screws at the top of the Power Module.

10.Loosen (4-5 turns), but do not remove the three fastening screws at the
bottom of the Power Module.
3-26 Access Procedures

11.Install the RT1 tool on the Power Module and remove the module from
the drive.
 Access Procedures 3-27

Installation

Install the Power Module in reverse order of removal, while referring to

Torque Specifications on page 3-1.

Removing the Rectifying Removal

Module
1. Remove power from drive.

2. Check for zero volts between DC+ and DC-.

3. Referring to Opening Drive on page 3-4, remove the Power Cover,

Connection Cover and Conduit Cover from the drive.

4. Referring to Removing the DPI / HIM Assembly on page 3-6, remove

the DPI / HIM assembly.
5. Referring to Removing the Control Frame and Cross Plate on page 3-17,
remove the Control Frame and Cross Plate.

6. Referring to Removing the EMC-Protection Plate on page 3-20, remove

the EMC-Protection Plate.
7. Remove the three-phase AC wiring from the Rectifying Module. Also
remove the Brake Chopper Cable, if present.

AC Wiring

J9

Note the sequence of

hardware and the orientation
of the Belleville (cupped)
J5
washer.

J1

6 mm
9 N-m
(80 lb.-in.)

Brake Chopper
Cable
3-28 Access Procedures

8. Disconnect the cables from connectors on the Rectifying Module circuit

board.

J9

J5
J1

X13 X6 X10 X11

X12
 Access Procedures 3-29

9. Remove the three screws which secure Rectifying Module circuit board
to the Rectifying Module sub-assembly. Do not remove the screws at the
top of the module which secure the conducting straps (that connect the
circuit board to AC power from the AC Choke).

J9

J5

J1

PZ2
1.5 N-m
(13 lb.-in.)

10.Remove the Rectifying Module circuit board.

3-30 Access Procedures

11.Remove the six screws which connect the Rectifying Module to the DC
Bus bars.

Remove

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

Remove

PZ3
5 N-m
(44 lb.-in.)

Loosen but do not remove

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

12.Remove the three fastening screws at the top of the Rectifying Module.

13.Loosen (4-5 turns), but do not remove the three fastening screws at the
bottom of the Rectifying Module.
 Access Procedures 3-31

14.Install the RT1 tool on the Rectifying Module and remove the module
from the drive.

Installation

Install the Rectifying Module in reverse order of removal, while referring to

Torque Specifications on page 3-1.

Important: Before installing a new Rectifying Module, be sure to remove

the circuit board. Mechanical interference with the RT1 tool
could damage the new circuit board.
3-32 Access Procedures

Removing the Main Fan Removal

1. Remove power from drive.

2. Check for zero volts between DC+ and DC-.

3. Referring to Opening Drive on page 3-4, remove the Connection Cover

from the drive.

4. Remove the four rubber bushings which cover the screws which mount
the fan assembly

Remove
 Access Procedures 3-33

5. Remove the screw which secures the fan power supply plate. Then lift
and pull the plate away from the drive.
X2

X8

S1

NO
4
3
2
1

PZ2
X7
3 N-m
X5 (27 lb.-in.)

X4
X1
X6

6. Disconnect the motor lead wires including the ground wire. Refer to
Figure B.8 on page B-8, when reconnecting these wires.

7. Check that the upper mounting bolts securely hold drive on the wall of
the system enclosure. Remove lower mounting bolts from the bottom of
the frame.

8. Loosen, but do NOT remove, four front screws (which are accessible
through the holes vacated by the rubber bushings) so that the fan
assembly can easily slide off. To loosen, but not remove these front
screws, turn them 12 times.

9. Remove four screws from bottom of the frame. The fan plate should now
easily slide down. If it does not, loosen the front screws another turn and
attempt again. Continue loosening the screws until the fan plate slides
easily from the drive.

Important: Do not attempt to force the fan plate from the drive. This may
bend the fan.

10.Remove fan from fan plate. Refer to Figure C.6 on page C-7.
3-34 Access Procedures

Installation
Install the fan in reverse order of removal, while referring to Torque
Specifications on page 3-1. Refer to Figure B.8 on page B-8, when
reconnecting the fan and fan power supply.

Removing the Fan Power Removal

Supply
1. Remove power from drive.

2. Check for zero volts between DC+ and DC-.

3. Referring to Opening Drive on page 3-4, remove the Connection Cover

from the drive.

4. Remove the screw which secures the fan power supply plate. Then lift
and pull the plate away from the drive.

X2

X8

S1

NO
4
3
2
1

PZ2
X7 3 N-m
X5 (27 lb.-in.)

X4
X1
X6
 Access Procedures 3-35

5. Disconnect the wires which run from the transformer to the power
supply (X4 and X5 on the power supply). Refer to Figure B.8 on
page B-8, when reconnecting these wires.

6. On the fuseholder/capacitor bracket disconnect the capacitor from the

transformer. Disconnect the power supply cooling fan and the fuses.
3-36 Access Procedures

7. Remove the screws which mount the fuseholder/capacitor bracket to the

drive, and remove the bracket.

X2

X8

S1

NO
4
3
2
1

X7

X5

X4
X1
X6

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

8. Disconnect the remaining cable from the power supply (X8 on the power
supply).

9. Remove the screws which mount the power supply to the drive, and
remove the power supply.
 Access Procedures 3-37

Installation
1. Install the fan power supply and fuseholder/capacitor bracket in reverse
order of removal, while referring to Torque Specifications on page 3-1.

2. Verify that dip switch S1 is properly configured.

X2

X8

ON 4
3
4
ON

2
3 2
1
1
S1

S1

S1-1 S1-2 S1-3 S1-4

X7 Off Off On Off
X5

X4
X1
X6

3. Install fan power supply plate.

3-38 Access Procedures

Removing Capacitors Removal

1. Remove power from drive.

2. Check for zero volts between DC+ and DC-.

3. Referring to Opening Drive on page 3-4, remove the Connection Cover

from the drive.

4. Referring to Removing the Control Frame and Cross Plate on page 3-17,
remove the Control Frame and Cross Plate.

5. Remove terminal sub-assembly (Number 88 in Figure C.1 on page C-2

or Figure C.2 on page C-3)

6. Disconnect fiber-optic connectors X7, X10 and internal fan cable from
power board.

7. Remove DC+ and DC- cables (Numbers 112 and 114).

8. Remove twelve (12) screws which connect the Output Power Module
and Rectifying Module (if present) to the DC+ and DC- busbars.

9. Remove sixteen (16) screws (Numbers 42, 44 and 45) from capacitor
terminals.

114 112
PZ2
4 N-m
(35 lb.-in.)

44 44 44 44

Table 3.A Capacitor Sub-assembly

Hardware
Id. No. Description
42 Screw M6 x14 Z4-1 (combination) 45 45 45
45
44 Screw M6 x16 Z4-1 (combination)
45 Screw M5x20 TX (combination)
52 Washer (straight) M8 SFS3738
53 Washer (cone) M8 DIN679
54 Screw hexagonal M8 X 20
112 Cable DC+
42 54 42 54
114 Cable DC-
53 53
52 52

6 mm
10 N-m
(89 lb.-in.)
 Access Procedures 3-39

10.Remove busbars and insulators.

11.Remove screws which secure capacitors to drive.

12.Remove capacitors from drive.

Installation
Install the capacitors in reverse order of removal, while referring to Torque
Specifications on page 3-1.
Important: The screws in this sub-assembly vary in length. It is critical that
you use the correct screws in the correct locations. Refer to
Table 3.A on page 3-38.
3-40 Access Procedures

Removing the AC-Choke Removal

1. Remove power from drive.

2. Check for zero volts between DC+ and DC-.

3. Referring to Opening Drive on page 3-4, remove the Connection Cover

from the drive.

4. Referring to Removing the Control Frame and Cross Plate on page 3-17,
remove the Control Frame and Cross Plate.

5. Disconnect the internal DC Bus wires from the DC Bus terminals at the
top of the drive.

Note the sequence of

hardware and the orientation
of the Belleville (cupped)
washer.

13 mm
14 N-m
(124 lb.-in.)
 Access Procedures 3-41

6. Remove nine (9) screws from upper plate.

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

7. Remove control bracket (Number 63 in Figure C.1 on page C-2 or Figure

C.2 on page C-3)
8. Remove all cables from AC-choke terminals.

6 mm
17 N-m
(151 lb.-in.)
3-42 Access Procedures

9. Remove eight (8) fastening screws from AC-choke.

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

Lifting Lug

10.Remove AC-choke from drive by using lifting lugs.

Installation
Install the AC-choke in reverse order of removal, while referring to Torque
Specifications on page 3-1.
 Chapter 4

Start-Up After Repair

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.

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

Phone United States/ 1.262.512.8176 (7 AM - 6 PM CST)

Canada 1.440.646.5800 (24 hour support)
Outside United You can access the phone number for your country via
States/Canada 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 ⇒ [email protected]

Be prepared to furnish the following information when you contact support:

• Product Catalog Number

• Product Serial Number
• Firmware Revision Level
4-2 Start-Up After Repair

Before Applying Power to 1. Check for zero volts between DC+ and DC-
the Drive 2. Perform forward biased diode tests, using a digital multimeter, on the

DC- DC+/R+ R-

L1 L2 L3 L1 L2 L3 U/T1 V/T2 W/T3 U/T1 V/T2 W/T3

points listed in Table 4.A on page 4-3 to test the Rectifying Module (on
AC Three-Phase drives). A forward biased diode test checks the
semiconductor junctions between the terminals and measures the voltage
drop across those junctions. To pass each test, the meter must beep(1)
once and display a voltage within the specification shown in the table. If
the test finds a short, the meter will display .000 and beep continuously.
If the test finds an open circuit or reversed polarity, the meter will display
“.0L” (zero load). If the Rectifying Module fails any of these tests,
replace it.
(1)
Not all makes and models of digital multi-meters beep, consult documentation for your meter to determine how
it indicates a positive result for the forward biased diode test and short circuit.
 Start-Up After Repair 4-3

Table 4.A Forward Biased Diode Tests for Rectifying Module

Meter Leads
+ - Nominal meter reading
L1 DC-
L2 DC- Value should gradually rise to 1.8V
L3 DC-
L1 DC+/R+
L2 DC+/R+ 0.450V ± 0.075V
L3 DC+/R+
DC- L1
DC- L2 0.335V ± 0.075V
DC- L3
DC+/R+(1) L1
DC+/R+ L2 Value should gradually rise to 1.8V
DC+/R+ L3
(1)
If the drive does not contain the brake chopper option, the DC+/R+
terminal will be labeled DC+.

3. Perform forward biased diode tests, using a digital multimeter, on the

points listed in Table 4.B to test the Output Power Module. If the
Output Power Module fails any of these tests, replace it.
Table 4.B Forward Biased Diode Tests for Output Power Module
Meter Leads
+ - Nominal meter reading
T1 DC-
T2 DC- Value should gradually rise to 1.8V
T3 DC-
T1 DC+/R+
T2 DC+/R+
T3 DC+/R+
0.290V ± 0.075V
DC- T1
DC- T2
DC- T3
DC+/R+ T1
DC+/R+ T2 Value should gradually rise to 1.8V
DC+/R+ T3

4. Perform forward biased diode tests, using a digital multimeter, on the

points listed in Table 4.C to test the Brake Chopper Assembly (on drives
with Brake Choppers). If the Brake Chopper Assembly fails any of
these tests, replace it.
Table 4.C Forward Biased Diode Tests for Brake Chopper Assembly
Meter Leads
+ - Nominal meter reading
R DC- Value should gradually rise to 1.8V
R DC+/R+ 3.15V ± 0.075V
DC- R 3.60V ± 0.75V
DC+/R+ R Value should gradually rise to 1.8V
4-4 Start-Up After Repair

Testing with the External DC This is a low current - low risk test for the Output Power Module and drive
Power Supply Without Load Control board. It requires the recommended high voltage DC-power supply.
(Optional) 1. Verify that the external DC power supply is de-energized

2. Connect the power supply’s DC+ to the drive’s DC+ terminal and the
power supply’s DC- to the drive’s DC- terminal.
3. Set power supply voltage setting to zero.

4. Switch on the external DC power supply.

5. Slowly increase the external DC power supply output voltage to the

drive’s nominal DC bus voltage (1.35 x Unity)

Example: 480v AC Nominal Voltage

• 2-
3---------------
• V = 1.35 × 480V = 648V
Π

6. 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)

7. Make configuration changes which allow the HIM to issue start and
speed commands.

8. Make configuration changes which allow operation without an encoder

and motor.

9. Start the drive, by pressing .

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

(the up button).

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

12.Return the configurations to suit the application.

13.Decrease the DC power supply output voltage to zero. Wait until DC bus
voltage has decreased to zero. Switch off the external DC power supply.
 Start-Up After Repair 4-5

Testing Without a Motor This test allows you to measure several operating parameters and diagnose
problems without connecting the motor.

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

1. Verify that the motor cables are disconnected.

2. Energize the drive.

3. Make configuration changes which allow the HIM to issue start and
speed commands.

4. Make configuration changes which allow operation without an encoder

and motor.

5. Start the drive, by pressing .

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

(the up button).

7. Measure the output voltage on each phase and verify that it is balanced.
If it is unbalanced troubleshoot the drive.

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

9. Return the configurations to suit the application.

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

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

2. Verify that the motor cables are connected.

3. Energize the drive.

4. From the Monitor menu on the HIM press Esc (the escape button) to
navigate to the Main menu.
5. Use (the down button) to move the cursor to the Start-Up
selection, and to select Start-Up. Then press again to verify
your intention to continue with the Start-Up menu.
6. Use (the down button) to move the cursor to Power Circuit
Diagnostics (Pwr Circuit Diag), and to select Power Circuit
Diagnostics.

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

indications and instructions on the HIM.
4-6 Start-Up After Repair

Testing With the Motor 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. Energize the drive.

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

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

– parameter 308 [Output Current] (700S)

– parameter 003 [Output Current] (700H)

7. Stop the drive.

 Appendix A

Service Tools and Equipment

Software Tools DriveTools 2000, Drive Executive, Drive Explorer and Drive Observer are
software tools for uploading, downloading and monitoring system
parameters

Service tools Service of the PowerFlex frequency converter requires certain kinds of
tools, devices and test equipment. Basic tools, devices and test equipment
have to meet requirements of professional services. The tools have to be in
good condition and have to fit how and where they are going to be used.

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 *Pozidrive 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 earthings
24 ESD-protective clothing Wrist wrap, shoes, overall clothing (coat)
25 Power supply (service) Capacity of three phase service 400/500/690Vac,
250A
A-2 Service Tools and Equipment

Item Description Details

26 CK-2 Cable kit of DC power supply for PowerFlex frame 9
units
27 RT-1 Module replacement tool for PowerFlex frame 9 units
28 Fiber-optic repair kit
 put Conditioning Circuitry for Drives with AC Input

LI/R

L2/S

L3/T
CM
REACTOR

LI'/R'
LI/R
L2'/S' To
L2/S Power
Circuitry
L3'/T'
Schematics

L3/T
CM LINE
REACTOR REACTOR

PCB

MOV
assembly

PE
PE
Appendix

Figure B.1 Input Conditioning Circuitry

for Drives with AC Input
B
 B-2

DC-
DC+/R+
Power Circuitry for 700S Drives with AC Input

R-
Schematics

K3

K2

K1

X10 X11 X12

X9

2
U/T1
V/T2

LI'/R' 4
W/T3
From AC
L2'/S' X1 U/T1
Input
Conditioning L3'/T' X2
V/T2
X3
W/T3

W/T3
V/T2
U/T1
X8

4 4 4
X6 X5

X11 X10

U_HI
V_HI
W_HI

U_LO
V_LO
W_LO
DC-
DC+

TERM A

X1
Mains Voltage
I_V

I_U
I_W

BRK
BRK
X41
TERM V

TERM U
TERM W

Suppression
X4
I_U

X9 Measurements I_V
Rectifier Board X13 I_W
Power Board
X6
DC+
IFS

X10
X7 X5 X8 X15 X4
1 2
4

M4
1 2 3 4 5 6 7 Fiber
M Cross Plate
V/T2
U/T1
W/T3

2 24 VDC Fan

To Voltage
Feedback
M3
DC-
DC+

To Fan Power Supply Board J1

M EMC Protection
Plate Fan To Voltage
2 24 VDC Feedback
Board J2

M2
To Power Interface J9 (U_Gate)

M Fan Inverter
To Power Interface J10 (V_Gate)
To Power Interface J12 (ADconv)

To Power Interface J11 (W_Gate)

To Power Interface J14 (Vbus_Tx)

To Power Interface J13 (Vbus_Rx)

Cooling Fan
2
To Power Interface J8 (Gate_Enable)

24 VDC

Figure B.2 Power Circuitry for 700S

Drives with AC Input
 R-
Power Circuitry for 700S Drives with DC Input

External Circuitry
DC+/R+
M

2
U/T1
F1 R1 CR2
V/T2

4
W/T3

DC U/T1
Source
V/T2
W/T3

W/T3
V/T2
U/T1

DC-
M
4 4 4
PE
X11 X10
X50

U_HI
PE X1
V_HI
W_HI

U_LO
V_LO
W_LO

F1 R1 CR2 1
DC-

DC Bus
DC+

TERM A

Precharge
2
I_V

Control I_U
I_W

BRK
BRK
TERM V

TERM U
TERM W

I_U

X9 Measurements I_V
CR1
Pilot Relay I_W
M 5
Power Board
CR1 M X6
6
Main DC Contactor
DC+
IFS

M CR2
X10
X7 X5 X8 X15 X4
Precharge
1 2
4

M4
1 2 3 4 5 6 7 Fiber
M Cross Plate
V/T2
U/T1
W/T3

2 24 VDC Fan

To Voltage
Feedback
M3
DC-
DC+

To Fan Power Supply Board J1

M EMC Protection
Plate Fan To Voltage
2 24 VDC Feedback
Board J2

M2
To Power Interface J9 (U_Gate)

M Fan Inverter
To Power Interface J10 (V_Gate)
To Power Interface J12 (ADconv)

To Power Interface J11 (W_Gate)

To Power Interface J14 (Vbus_Tx)

To Power Interface J13 (Vbus_Rx)

Cooling Fan
2
To Power Interface J8 (Gate_Enable)

24 VDC
Schematics

Figure B.3 Power Circuitry for 700S

Drives with DC Input
B-3
 K1
B-4

X10 X11 X12

X9 Power Circuitry for 700H Drives with AC Input

2
U/T1
V/T2

LI'/R' 4
W/T3
From AC
Schematics

L2'/S' X1 U/T1
Input
Conditioning L3'/T' X2
V/T2
X3
W/T3

X8

4 4 4
X6 X5

X11 X10

U_HI
V_HI
W_HI

U_LO
V_LO
W_LO
DC-
DC+

TERM A

X1
Mains Voltage
I_V

I_U
I_W

BRK
BRK
X41

TERM V

TERM U
TERM W

Suppression
X4
I_U

X9 Measurements I_V
Rectifier Board X13 I_W
Power Board
X6
DC+
IFS

X10
X7 X5 X8 X15 X4
1 2
4

M4
24 VDC 2 1 2 3 4 5 6 7 Fiber
M Cross Plate
24 VDC Fan

To Opto
M3 Adapter Board
To Fan Power Supply
M EMC Protection
Plate Fan
2 24 VDC
To Opto Adapter Board

M2

M Fan Inverter
Cooling Fan
2 24 VDC

Figure B.4 Power Circuitry for 700H

Drives with AC Input
 Power Circuitry for 700H Drives with DC Input

R-

External Circuitry
DC+/R+
M

2
U/T1
F1 R1 CR2
V/T2

4
W/T3

DC U/T1
Source
V/T2
W/T3

DC-
M
4 4 4
PE
X11 X10
X50
U_HI

PE X1
V_HI
W_HI

U_LO
V_LO
W_LO

F1 R1 CR2 1
DC-

DC Bus
DC+

TERM A

Precharge
2
I_V

I_U

Control
I_W

BRK
BRK
TERM V

TERM U
TERM W

I_U

X9 Measurements I_V
CR1
Pilot Relay I_W
M 5
Power Board
CR1 M X6
6
Main DC Contactor
DC+
IFS

M CR2
X10
X7 X5 X8 X15 X4
Precharge
1 2
4

M4
24 VDC 2 1 2 3 4 5 6 7 Fiber
M Cross Plate
2 24 VDC Fan

To Opto
M3 Adapter Board
To Fan Power Supply
M EMC Protection
Plate Fan
2 24 VDC
To Opto Adapter Board

M2

Fan Inverter
Schematics

M
Cooling Fan
2 24 VDC
Figure B.5 Power Circuitry for 700H
Drives with DC Input
B-5
 B-6

Circuit Board Connections for 700S Drives

Schematics

From From

From Power Board (Gate_Enable)

From Power Board J9 (U_Gate)
From Power Board J10 (V_Gate)
From Power Board J11 (W_Gate)
From Power Board J12 (ADconv)
From Power Board J13 (Vbus_Rx)
From Power Board J14 (Vbus_Tx)
Power Power
Module Module

1 2 3 4 5 6 7 Fiber

J8 J9 J10 J11 J12 J13 J14 2 J8 80W J2

P2 50 J5
RS232 P5 72 +24 V Iso DC-
DriveLogix +24V Power
J10 J2 J3
+12 V Supply DC+
FLEX I/O P4 Controller
50 -12 V Fiber J1
80 J35 J6 Tx 8 9 J4 Rx Voltage -U
P6 +5V -V
P3 Feedback
J7 Rx 9 8 J5 Tx -W
P1 10
Comm Main J7
Board
Input NetLinx 34 J17 Power Interface Board
Daughtercard
Control
P2 J11 Board 9
X2 20-VB00601
Feedback J4
DPI DPI
Feedback P1 Option Bezel 9
34 2
Inputs Board P3 X4
Interface X1 J2 J1
J34 J1 Board
J16
SynchLink J18 J15 HIM
J8 J9 TB1 TB2 X3 J3
2
DOOR
TX RX 2 20 PWR 9
M5 2 External STS EXAMPLE:
Control M 24V DC 20-HIM-A3
1 = 24V
Chassis Fan M6 3 = Common
Control M (75W min) DPI PORT
Pan Fan Comm MOD
Option NET A
NET B
HIM
DPI Assembly
EXTERNAL DPI

Figure B.6 Circuit Board Connections for

700S Drives
 Circuit Board Connections for 700H Drives

From
From Power Board
Power Board

24 VDC 2 3 5 7 Fiber
1 2 4 6

8X

Opto Adapter External

J1 24V dc
Board
J1

37

X1 X2 20-VB00601
DPI DPI
Bezel 9
X4
Interface X1 J2 J1
Control Board Board
X3 J3
HIM
X7
(RS-232 DOOR
X2 X3 X4 X5 X6
Programming 20 PWR 9
(Slot A) (Slot B) (Slot C) (Slot D) (Slot E)
Port) STS EXAMPLE:
20-HIM-A3

20C-DA1-A X1 DPI PORT

(24V dc Digital Input Comm MOD
w/ Analog I/O) 20C-DO1 20C-DPI1 Option NET A
or (Digital Output Option Option (DPI Communications NET B
20C-DA1-B Option) Board Board Option) HIM
(115V ac Digital Input DPI Assembly
w/ Analog I/O) EXTERNAL DPI
X3 X2

10 8 / 10 3 3

Analog Digital Digital Digital

I/O Inputs Outputs Outputs
Schematics

Figure B.7 Circuit Board Connections for

700H Drives
B-7
 B-8

Fan Power Supply Connections

Schematics

From Power From Power

Board X10 Board X7

F2, 6A F1, 6A 4

Area Under Main Power Terminal Strip

+ -
Black 6
X2 X8
Black 2
Blue
S1-1 S1-2 S1-3 S1-4 X4 2.2 mf 10 MW
Black 5 M1
Fan Frequency Yellow/Green
Off Off On Off Converter Black 4 M Main Fan
X5 Black 1 Black
S1 - Setup Switch 2.2 mf 10 MW
Black 3 Brown

7 mf
Area Under Fan Power Supply Plate Fan Area
Figure B.8 Fan Power Supply
Connections
 Appendix C

Disassembly / Assembly Diagrams

Diagrams on the following pages illustrate disassembly and assembly of the

drive and its sub-systems.
C-2 Disassembly / Assembly Diagrams

700S 261A / 300A Mechanical Construction

Figure C.1 700S 261A / 300A Mechanical Construction

S
 Disassembly / Assembly Diagrams C-3

700H 261A / 300A Mechanical Construction

Figure C.2 700H 261A / 300A Mechanical Construction

S
C-4 Disassembly / Assembly Diagrams

Cross Plate (terminals) and Internal Fan

Figure C.3 Cross Plate (terminals) and Internal Fan

 Disassembly / Assembly Diagrams C-5

EMC-Protection Plate

Figure C.4 EMC-Protection Plate

C-6 Disassembly / Assembly Diagrams

Capacitor Sub-Assembly

Figure C.5 Capacitor Sub-Assembly

DC+

DC-
 Disassembly / Assembly Diagrams C-7

Fan Sub-Assembly

Figure C.6 Fan Sub-Assembly

C-8 Disassembly / Assembly Diagrams

Control Bracket

Figure C.7 Control Bracket

 Disassembly / Assembly Diagrams C-9

Rectifying Module

Figure C.8 Rectifying Module

C-10 Disassembly / Assembly Diagrams

Power Module

Figure C.9 Power Module

 Disassembly / Assembly Diagrams C-11

Key to ID Numbers The following table describes the parts identified by balloons in the
mechanical drawings:

Id. No. Description Shown in... Id. No. Description Shown in...
2 DC Bus Capacitor ELKO 3300uF 420V Figure C.5 63 Control bracket Figure C.1,
3 Fan 230W Figure C.6 Figure C.2,
Figure C.7
5 AC-choke/filter 310A Figure C.1,
Figure C.2 64 EMC-protection plate (power) Figure C.1,
Figure C.2,
6 Frame Figure C.1,
Figure C.4
Figure C.2
66 Cable lug KP40 Figure C.1,
8 Cover (power) Figure C.1,
Figure C.2
Figure C.2
68 Fan power supply
9 Cover (connection) Figure C.1,
Figure C.2 69 Internal fan Figure C.3,
Figure C.4
10 Bushing plate Figure C.1,
Figure C.2 70 Cross plate (terminals) Figure C.1,
Figure C.2,
12 Earthing plate Figure C.2
Figure C.3
15 Earthing cover 3 Figure C.1,
75 Control frame Figure C.1,
Figure C.2
Figure C.2
20 Screw M4 x 8 Figure C.3
81 Screw M4 x 8 Figure C.8
23 Upper plate Figure C.1,
83 Control cable conduit Figure C.1,
Figure C.2
Figure C.2
26 Busbar DC- and brake Figure C.1,
84 Plate gasket 52486 Figure C.1,
Figure C.2
Figure C.2
28 Rectifying board Figure C.8
85 Bushing rubber 52515 Figure C.1,
29 Diode mod SKKH 330/16 Figure C.8 Figure C.2
30 IGBT/Diode SKM 195GAL123D (brake) Figure C.8 86 Cover (control cable conduit) Figure C.1,
31 Stand-off insulator M6*25 (brake) Figure C.1, Figure C.2
Figure C.2 88 Terminal sub-assembly H Figure C.1,
32 Busbar DC connection Figure C.5 Figure C.2
34 Busbar DC+ Figure C.5 88 Terminal sub-assembly T/L Figure C.1,
35 Insulator DC+/- Figure C.5 Figure C.2
36 Busbar DC- Figure C.5 89 Fan sub-assembly Figure C.1,
38 Capacitor 220nF/1250V 500V 6mm Figure C.8 Figure C.2
39 Discharging resistor 2x8k Figure C.6 90 Stop plate 34 Figure C.1,
Figure C.2
40 Rectifying module sub-as. Figure C.1,
Figure C.2 91 Bushing rubber GD9 Figure C.1,
Figure C.2
40 Rectifying module sub-as. (brake) Figure C.1,
Figure C.2 92 Capacitor sub-Assembly Figure C.1,
Figure C.2
41 Fan plate Figure C.6
93 Heat sink (rectifying module) Figure C.8
42 Screw M6 x14 Z4-1 (combination) Figure C.5,
Figure C.8, 94 Frame (heat sink, rectifier) Figure C.8
Figure C.9 95 Busbar rectifying board Figure C.8
44 Screw M6 x16 Z4-1 (combination) Figure C.5 96 Busbar rectifier + Figure C.8
45 Screw M5x20 TX (combination) Figure C.5, 97 Insulator, rectifier Figure C.8
Figure C.8 98 Busbar rectifier - Figure C.8
52 Washer (straight) M8 SFS3738 Figure C.5, 99 Busbar brake Figure C.8
Figure C.8, 100 Bushing rubber GD16 Figure C.6
Figure C.9
102 Clamp for ferrite ring Figure C.4
53 Washer (cone) M8 DIN679 Figure C.5,
103 Ferrite ring packet Figure C.1,
Figure C.8,
Figure C.2,
Figure C.9
Figure C.4
54 Screw hexagonal M8 X 20 Figure C.5,
104 VaconBus adapter Figure C.7
Figure C.8,
Figure C.9 105 Finger proof shield Figure C.3
55 Screw M4 x 8 Figure C.6 109 Insulator capacitor Figure C.5
59 Bushing rubber GD21 Figure C.1, 110 Insulator DC-/connection Figure C.5
Figure C.2
C-12 Disassembly / Assembly Diagrams

Id. No. Description Shown in...

112 Cable DC+ Figure C.5
114 Cable DC- Figure C.5
115 Screw M5 x 10 Figure C.9
116 Fan power supply cover Figure C.1,
Figure C.2
117 Power module sub-as. 261A Figure C.1,
Figure C.2,
Figure C.9
117 Power module sub-as. 300A Figure C.1,
Figure C.2,
Figure C.9
118 Bushing rubber GD48 Figure C.1,
Figure C.2
200 700S Control Assembly Figure C.1,
201 700S Voltage Feedback Circuit Board Figure C.1,
202 700S Power Interface Circuit Board Figure C.1,
203 DPI / HIM Assembly Figure C.1,
Figure C.2
204 MOV Figure C.1,
Figure C.2
205 Fan (Control frame) Figure C.1
206 700H Control Assembly Figure C.2
Publication PFLEX-TG001A-EN-P – July 2004
Copyright © 2004 Rockwell Automation, Inc. All rights reserved. Printed in USA.