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Allen-Bradley SK-H1-PWRMOD-D590 Replacement Power Structure Overview
Allen-Bradley SK-H1-PWRMOD-D590 is a replacement power structure for PowerFlex 700S and PowerFlex 700H frame 11 drives. It is a spare module catalog string that covers several 590A drive references, including 20CC590, 20CH590, 20DC590, 20DH590, 20CD590, 20CJ590, 20DD590, and 20DJ590. This power structure is used when a frame 11 drive requires replacement of its existing power structure. It supports AC input and DC input drive configurations. The module is preconfigured at the factory for DC input operation. For AC input drives, the installer must move the X2 plug from its protective sleeve and connect the cable to the ASIC and rectifier boards. This step gives the replacement power structure the correct input configuration for the drive.
Installation Overview
The replacement process includes configuring the power structure, removing power from the existing drive, removing the old power structure, installing the replacement power structure, connecting it to drive components, installing the product identification label, and starting the drive. Before configuring the power structure, protective covers must be removed from the drive. The installation instructions for PowerFlex 700S and 700H high power drives provide assistance for removing these covers.
Configuring an AC Input Drive
Power structures are preconfigured for DC input operation. When installing a replacement power structure on a drive with AC input, the X2 plug must be removed from its protective sleeve and plugged into the ASIC and rectifier boards. The cover from the ASIC board assembly is removed. The ASIC fan is disconnected by unplugging the cable from X1 on the ASIC board. The cover is removed from the connector on the loose cable bundled with the flat gate driver board cables, and the cable is connected to the X2 connector on the ASIC board. The other end of the cable connected to X2 on the ASIC board is connected to the X13 connector for the rectifier boards on the V phase and W phase power stack if present. The fan cable is reconnected to X1 on the ASIC board. The cover is installed on the ASIC board assembly.
Configuring the EMC Filter
Frame 11 size drives are equipped with common mode capacitors. To guard against drive damage, these capacitors should be disconnected depending upon the type of ground system on which the drive is installed. For installation on an ungrounded distribution system or high resistive ground with a 400 or 480V AC input drive, the common mode jumper must be moved to the disconnected position. It is recommended to insulate terminal X4 on the rectifier circuit board. For a 600 or 690V AC input drive on an ungrounded distribution system or high resistive ground, the common mode jumper must be moved to the disconnected position and terminal X4 must be insulated. For installation on a grounded B phase Delta system, the common mode jumper must be moved to the disconnected position and terminal X4 must be insulated. The jumper is located on the rectifying modules. For drives with one rectifying module, it is located on the upper right side of the middle power stack V phase. For drives with two rectifying modules, they are located on the upper right side of the middle V phase and right side W phase power stacks. The SK-H1-PWRMOD-D590 590A frame 11 power structure uses two rectifying modules in the 400 or 480V AC and 600 or 690V AC classes according to the configuration table.
Moving the Common Mode Jumper and Insulating X4
To move the common mode jumper to the disconnected position, loosen the upper screw, remove the lower screw, move the jumper to the horizontal position, and install and tighten the screws. To insulate terminal X4 on the rectifier circuit board, remove the screw from the X4 connection, insulate the top and bottom of the X4 connection, and do not install the screw and washer that was removed from this connection.
Removing Power from the Existing Drive
Before servicing, verify that the voltage on the bus capacitors has discharged. Check the DC bus voltage at the power terminal block by measuring between the positive DC and negative DC terminals, between the positive DC terminal and the chassis, and between the negative DC terminal and the chassis. The voltage must be zero for all three measurements. Remove power before making or breaking cable connections. When a cable connector is removed or inserted with power applied, an electrical arc may occur. An electrical arc can cause personal injury or property damage by sending an erroneous signal to system field devices, causing unintended machine motion, or 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. Turn off and lock out input power, wait five minutes, verify no voltage at the drive input power terminals, and measure the three voltage checks again.
Removing and Installing the Power Structure
The hardware service manual for PowerFlex 700S and 700H frame 11 drives provides information about removing the old power structure and installing the replacement power structure. Proper handling and mounting are required to maintain drive integrity.
Connections to the 700S Control Frame
When installing a power structure in a PowerFlex 700S drive, connections must be made between the ASIC and fiber optic interface, power supply voltage feedback, common mode filter, and rectifier boards. ASIC board H1 connects to fiber optic interface board J8. H2 connects to J9. H3 connects to J10. H4 connects to J11. H5 connects to J12. H6 connects to J14. H7 connects to J13. ASIC board X10 is insulated and not connected. ASIC board X2 connects to rectifier board X13 for AC input drives only. Power supply voltage feedback board J8 connects to common mode filter board J5. Power supply voltage feedback board J5 connects to fiber optic interface board J6. Power supply voltage feedback board J4 connects to fiber optic interface board J7.
Connections to the 700H Control Frame
When installing a power structure in a PowerFlex 700H drive, eight connections are made between the ASIC and fiber optic adapter and rectifier boards. ASIC board H1 through H7 connect to fiber optic adapter board H1 through H7. ASIC board X10 connects to fiber optic adapter board X2. ASIC board X2 connects to rectifier board X13.
Precharge Connections for DC Input
On drives with DC input, ASIC board connectors X9 and X15 must be connected to the X50 terminal block for the precharge circuit. The X50 terminal block is located on the control frame. ASIC board X9 terminal 25 connects to X50 terminal 1 for precharge complete signal positive 24V DC. X9 terminal 26 connects to X50 terminal 2 for precharge complete signal common. X15 terminal 21 connects to X50 terminal 3 for charge relay contact. X15 terminal 23 connects to X50 terminal 4 for charge relay contact. This connection is for DC input only. Do not install on AC input drives.
Product Identification Label
All frame 11 replacement power structures are preconfigured at the factory without a product identification label on the drive. If installing the power structure in a 700S drive, label it with the accompanying PowerFlex 700S label. If installing the power structure in a 700H drive, label it with the accompanying PowerFlex 700H label.
Starting the Drive
Install the protective covers on the drive. Start up the drive by following the start up procedures in the appropriate user manual or programming manual. The SK-H1-PWRMOD-D590 replacement power structure is designed to restore PowerFlex 700S and 700H frame 11 drives to operation when used with the correct configuration, connections, and safety steps. It provides a practical replacement path for frame 11 power structures in AC input and DC input drive systems.
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