PowerFlex 700 Drive - Frame 7 Components Replacement
Contents
1. Install Components 1 Clean the surface of the Heatsink mounting surface with isopropyl alcohol 2 Thoroughly clean the mounting surface of the new SCR module and apply a thin even coating of the supplied thermal grease 3 Install SCR module with supplied screws and torque using the sequence and specifications shown in the diagram below o olL o 4 f D 2 SCR Torque O SCR Torque O First Sequence Final Sequence 0 7 Nn 6 0 lb in O 5 6 N m 50 Ib in O 7 oj om 9 8 ie S 4 Install the Snubber Board Bus Bar and assembly with its lead wires and the DC cables both positive as shown below Hold the lead wires in place while you torque DC cable screws to 12 2 Nem 108 Ibein BS a Torque DC cables to 12 2 Nem 108 Ibn Shown with Phillips screws but may be hex nuts 5 Reassemble remaining components in reverse order 6 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B INO17B EN P September 2011 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At hetp www rockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools For an additiona2. Inverter Snubber Boards U V W Stackin K Main Cont Inverter Power Module IGBTs U V W under Inverter Snubber Board under Main Control Panel Bus Fuse Motor Bus Bars Communications Module Balancing Resistors B11 Inverter Snubber Resistors Switch Mode Power Supply Board under Power Interface Board Main Control Panel Converter Snubber Boards 3 with Converter Power SCR Modules underneath v So Yad a Precharge Board N Assembly s AC Bus Bars R S T F lt Capacitor ss forfan sS sS Transformer MOV Location Power Terminal Block AC Power Input Connections Connections E Rockwell Automation
3. Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Remove safety shields as needed 3 Test all Snubber Resistors a Using pliers remove the push on J1 connector from the Inverter Snubber Board Place one probe of a volt ohm meter inside the connector b At the bottom right of the DC capacitor bank under the Transitional Bus Bar locate the screw with several connections typically three with one for each Snubber Resistor Place the other probe of the volt ohm meter on that screw The reading should be 8 ohms Shown with Transitional Bus Bar and other components removed Inverter ee Snubber Resistors Test Screw common point c Ifthe reading is 8 ohms the Inverter Snubber Resistor does not need to be replaced and this test and this procedure are complete do not perform the remainder of this procedure d Ifthe reading is other than 8 ohms continue with the instructions in Step 4 Step 10 to replace any faulty Resistor Rockwell Automation Publication 20B INO17B EN P September 2011 Component Replacement Procedures Chapter 3 4 Perform Remove Main Control Panel Assembly on page 21 5 Perform Remove Stacking Panel on page 22 6 Perform Remove Transitional Bus Bar on page 23 7 Using pliers remove the wire with push on connector from the Snubber Board associated with the Resistor to be replaced To locate its Resistor follow
4. Inverter Power Module IGBTs lt Current Transducers behind Mounting Clamps 3 lt Motor Bus Bars lt lt Inverter Snubber Boards lt _ GBT Bus Bars lt Gate Interface Boards a Inverter Power Module IGBTs Rockwell Automation Publication 20B INO17B EN P September 2011 15 Chapter1 Component Diagrams and Torque Specs Main Control Panel Assembly Bottom of Drive Top of Drive Components are listed left to right for each level lt HIM lt Communications Panel lt 17B11and Main Control Board lt lt Main Control Panel Switch Mode Power Supply Board and Power Interface Board lt Stacking Panel md ar Note Components are shown as seen from right side without drive covers Fastener Torque Torque Sequence Specifications ATTENTION When mounting components to a drive s heat sink AN component fastener torque sequences and tolerances are crucial to component to heat sink heat dissipation Components can be damaged if initial tightening procedure is not performed to specification The following illustrates initial and final tightening sequences for components fastened to a heat sink using two four and six screws Initial torque is 1 3 33 of final torque except six point mountings which require 0 7 Nem 6 lbein The numeric illustration labels are for your assistance Drive components do not carry these labels Figure 1 Two Point Mounting
5. been removed before proceeding In addition 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 DC amp DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements i ATTENTION To avoid an electric shock hazard ensure that all power has ATTENTION Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by sending an erroneous signal to your system s field devices causing unintended machine motion causing an explosion in a hazardous environment ATTENTION Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance 1 Turn off and lock out input power Wait five minutes 2 Verify that there is no voltage at the drive s input power terminals 3 Check the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements sensitive to electrostatic discharge Static control precautions are required when
6. 8 For the W Phase Snubber Board follow the sub steps in Step 7 above to remove the V Phase Motor Bus Bar 9 Use needle nose pliers to remove the wire at J1 from Snubber Board to be replaced 10 Remove the ten 10 T30 hex screws that secure the Snubber Board Remove the board and discard Install Components 1 Install the new Snubber Board with the J1 terminal lug towards the right side of the drive Torque screws to 5 6 Nem 50 Ibein Reconnect wire at jl 2 Reposition any Motor Bus Bars that were removed but do Not tighten screws at this time 3 Position the CT assembly and bus bar into place Tighten its three screws and torque to 1 6 Nem 14 lbein Use a colored marker or torque seal to mark each screw after torquing so you know when all are done and to indicate signs of any tampering 4 Torque screws for any Motor Bus Bars that were removed to 9 0 Nem 80 lbein 5 Reassemble remaining components in reverse order 6 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B INO17B EN P September 2011 39 Chapter3 Component Replacement Procedures Inverter Snubber Resistor 40 Important The Inverter Snubber Board and its associated Resistor do not need to be replaced at the same time Test the Resistor as instructed below before replacing it Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions
7. CaaS Initial Sequence Clg Final Sequence 16 Rockwell Automation Publication 20B INO17B EN P September 2011 Component Diagrams and Torque Specs Chapter 1 Figure 2 Four Point Mounting ee 4 e n O a Final Sequence Figure 3 Six Point Mounting N B 0 O me a S Initial Sequence Do not exceed 0 7 Newton meters 6 Ib in on initial torque of all six screws C ere aa ma u Final Sequence Rockwell Automation Publication 20B IN017B EN P September 2011 17 Chapter1 Component Diagrams and Torque Specs Torque Specifications The following table lists fastener locations by component how the fasteners are 18 used and torque specifications Refer to Torque Sequence in this chapter for fastening two point four point and six point components to the heat sink Torque Torque Component Fastener Application Ib in Nem Fan Motor Motor to Fan Cover Assembly 14 2 Fan Cover Assembly Assembly to chassis 26 3 Fan Transformer Transformer to chassis 26 3 Fan Capacitor Capacitor to chassis Hand tighten MOV Surge Suppressor MOV to chassis 14 2 Resistor to heat sink Initial sequence 6 0 7 Inverter Snubber Resistor Final sequence 26 3 Inverter Snubber Resistor Wires to Capacitor Bus Bar Assembly 50 6 Inverter Snubber Bracket Bracket to Power Module 80 9 Inverter Snubber
8. labeled and then disconnect wiring from TB2 4 Using pliers if needed remove the three 3 wiring harnesses J1 J2 J3 at the top of the board Note Some connectors may not be properly labeled Be sure to label them appropriately 5 Remove the Precharge Board mounting star screw located at the lower left corner of the Precharge Board 6 For AC input Using your fingers or needle nose pliers squeeze the wings of each of the three spacers and separate the Precharge Board from the mounting plate 7 For DC input Turn each of the six 6 lock screws 1 4 turn counterclockwise to unlock Screw Spacers 8 Remove the Precharge Board ACInput Shown Install Components 1 Install the new Precharge Board 2 Reconnect wiring 3 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B INO17B EN P September 2011 25 Chapter3 Component Replacement Procedures Main Control Board Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Remove safety shields as needed Communications Panel Located over Main Control Panel Screws and Washers Ground Wire Release Cable from Clamp Main Control Board Shown larger than in image above Ribbon Cables To 1811 3 Unscrew the green yellow groun
9. 1 vee oe o a Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 Perform Remove Main Control Panel Assembly on page 21 Perform Remove Stacking Panel on page 22 Perform Remove Precharge Board Assembly on page 23 Locate the Inverter Snubber Board to be replaced Remove the Current Transducer assembly mounted over the board to be replaced a Disconnect the wiring harness from the transducer board Clip the wire tie and remove the wiring harness b Remove the three button head screws that secure the bus bar Move the bus bar and transducer to an ESD safe flat surface 38 Rockwell Automation Publication 20B INO17B EN P September 2011 Component Replacement Procedures Chapter 3 7 For all Snubber Boards remove the U Phase Motor Bus Bar to gain access to the board being replaced TIP Depending on spacing it may be required that all three CTs and Bus Bars be removed before the U Phase Bus Bar can be removed a Remove the top nut at the U Phase output terminal block b rnor already removed disconnect the U Phase Current Transducer at its top end c Slide the Motor Bus Bar out of the notch at the top d Slide the bar out of the enclosure if possible or at least down and out of the way To do so move the top end of the bar to the right and the bottom end of the bar to the left pull down on a angle then rotate the bar 180 and fully remove the bar
10. Board Board to Brackets 50 6 Converter Snubber Board Board to Input Rectifier 50 6 Resistor to heat sink Initial sequence 6 0 7 Balancing Resistor Final sequence 26 3 Balancing Resistor Wires to Capacitor Bus Bar Assembly 50 6 Heatsink Thermal Sensor Thermistor to heatsink 14 2 Bus Capacitor Holder Holder to Bus Capacitors 26 3 Capacitor Bus Bar Assembly Assembly to Bus Capacitors 50 6 Gate Interface Board Board to Power Modules 14 2 Inverter Power Module IGBT Bus Bus Bar to Power Modules 80 9 Bar Module to heat sink Initial sequence 6 0 7 Inverter Power Module IGBT Final sequence 32 3 6 DIN Rail TB1 Rail to chassis 50 6 PE Shortening Bar Bar to TB1 80 9 SCR to heat sink Initial sequence 6 0 7 Converter Power Module SCR Final sequence 50 6 Transitional Bus Bar Assembly Assembly to Power Module Bus Bar Assembly 80 9 Bus Fuse F1 Fuse to Transitional Bus Bar 80 9 DC Bus Inductor L1 Inductor to chassis 50 6 Bus Bar Cable Adaptor Adaptor to Transitional Bus Bar and DC Bus 80 9 Inductor Converter Bus and Motor Bus Bars Bus Bars to all connections 80 9 Wires PE Wires to Ground Stud 80 9 Wires Wires to TB1 80 9 Wire TE Wire to TB1 50 6 Rockwell Automation Publication 20B IN017B EN P September 2011 Component Diagrams and Torque Specs Chapter 1 Torque Torque Component Fastener Application Ib in Nem Wires Wires to TB2 7 0 8 Wires Wires to TB3 8 10 0 9 1 1 CT Mounting Plate Mount
11. Components 1 Perform the following steps for one IGBT module at a time a Using isopropyl alcohol thoroughly clean the surface of the Heatsink Important The replacement IGBT modules are supplied with a conductive tape across the terminals Do Not remove the tape until instructed b Verify that the mounting surface of the new IGBT module is clean If not clean with isopropyl alcohol c Using a3 putty knife or similar tool apply a thin even coating of the supplied thermal grease to the mounting surface of the IGBT module Use enough thermal grease to create a conductive coating but not so much that the two surfaces can rock Important In the next step take care to not disturb any of the thermal grease on the IGBT module d Place the IGBT module on the Heatsink and install with supplied screws and tighten using this torque sequence IGBT Torque Sequence First Sequence 0 7 N m 6 0 lb in Final Sequence 3 6 N m 32 Ib in Rockwell Automation Publication 20B INO17B EN P September 2011 43 Chapter3 Component Replacement Procedures e Remove the conductive tape from the IGBT module and immediately install a new Gate Interface Board After the conductive tape is removed the IGBT module s gate terminals must not be exposed longer than one minute 2 Repeat Step 1 for the second IGBT module 3 Reconnect the Gate Interface Board connections 4 Place the
12. IGBT Bus Bar on the IGBT modules over the Gate Interface Boards with its flanges fitting over and under the Transitional Bus Bar IGBT Bus Bar Flanges Transitional Bus Bar fits here Step 4 Step 5 IGBT Bus Bar Inverter Snubber Brackets screws Be sure to orient brackets as shown 5 Install M6 screws for the IGBT module Bus Bar but do not torque at this time 6 Install the Inverter Snubber Brackets parallel to each other but do not torque at this time 7 Install remaining M6 screws for the IGBT module and Bus Bar Step 8 Step 6 Step 7 DC Remaining IGBT Bus L Bar screws DC 8 Torque all screws on the Inverter Snubber Brackets and on the IGBT module Bus Bar to 9 0 Nem 80 Ibein 9 Torque DC and DC M6 screws to 5 9 Nem 52 Ibein 10 Install the new Snubber Board with the terminal lug towards the outside of the drive Torque screws to 5 6 Nem 50 bein 11 Position each Motor Bus Bar but do not torque mounting screws yet 12 Position each Current Transducer and install screws but do not torque yet 44 Rockwell Automation Publication 20B INO17B EN P September 2011 Main Control Panel Thermal Sensor Component Replacement Procedures Chapter 3 13 Torque the left screws for each Current Transducer to 5 9 Nem 52 Ibein 14 Set each Motor Bus Bar in final position and torque the remaining Current Transducer screw to 5 9 Nem 52 lbein 15 Torque each Motor Bus Bar mounting screw at
13. Replacement Procedures Table of Contents Important User Information 23s 2244253124 aed hee tee 2 New and Updated Lntormation sss eee 5 Introduction 222 ci aad Vesey dade tele paul oii 2 nee Ue oka HX 7 Component KIR a R eG Sos sass ioste eae ERN RT Kee ewe S 7 Recommended 1oolssityc5 se 8 Safety Precautions si ices desea ie A nade ee eee 9 Important Initial Steps rered eri rer e E TR e a 11 Chapter 1 Drive Components c K 0 SE e SSR RR T ER KESE EE reas 13 Inverter S Ction aR d ER eee ESTREN AR TN eke se antares acess 15 Main Control Panel Assemble 16 Fastener Torque Specifications 1 20 e e iba whe taatts wind reren 16 DOrqiie Sequence sy RA S 9 an EE EAE NRT EES da N E eee 16 Torque Speci tone css eri kenne yeep seks eerie 18 Chapter 2 Remove Main Control Panel Assembly 21 Remove Stacking Panel aaa R ER R Raa TRT 22 Remove Precharge Board Assembly 23 Remove Transitional Bus Bato ce n n neses oi enna hes 23 Chapter 3 Precharge Boardi caresme e aE E E E E E TEE 25 Main Conttol Board aaaea AAEE A a eae 26 IOT delete ERa pol acca ak eighteen ordre 27 Switch Mode Power Supply Board 30 Power Interface Board Sah aise awt aie kniwchdweeda de anew 31 Bab a a a aa a a a a e eC Cha deed lal 32 Fan Transformer orrors at ares Poet ae a En 35 Ce eT PASC ER setne e a EE UE E OR 35 Inverter Snubber Board 38 Inverter Snubber Resistoky cesar wcatadeersise ntact ounce doten 40 Inverter Power Module IGRT 42 Ma
14. servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference Allen Bradley Publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook A ATTENTION This assembly contains parts and sub assemblies that are Rockwell Automation Publication 20B IN017B EN P September 2011 9 Preface 10 gt gt D ATTENTION The information in this publication is merely a guide for proper installation Rockwell Automation Inc cannot assume responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this drive or associated equipment A hazard of personal injury and or equipment damage exists if codes are ignored ATTENTION Only qualified personnel familiar with adjustable frequency AC 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 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 Replace all protective shields before applying power to the drive Failure to replace protective shields may result in death or serious injury Rockwell Automatio
15. shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B IN017B EN P September 2011 Component Replacement Procedures Chapter 3 DC Link Choke AC Input Only Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Locate the DC Link Choke Perform Remove Main Control Panel Assembly on page 21 Pon Perform Remove Stacking Panel on page 22 5 Using the instructions in Converter Snubber Board AC Input Only on page 50 remove all three Converter Snubber Boards 6 Remove the six Snubber Board mounting brackets M6 T40 screws 7 Remove the four 4 M6 screws from the DC Link Choke terminals labeled 1 and 4 8 Remove the Converter Bus Bars DC and DC DC Choke Connectors Snubber Board Mounting Bracket Converter Bus Bars SCR module 9 Perform Remove Transitional Bus Bar on page 23 10 Remove the four 4 screws for the DC Link Choke mounting brackets 11 Remove the DC Link Choke Install Components 1 Install new DC Link Choke by screwing mounting brackets to drive 2 Torque screws to 9 0 Nem 80 bein Reassemble remaining components in reverse order n a Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publicatio
16. the wire from the Snubber Board to its Resistor carefully clipping the wire ties along the way 8 Follow the other Resistor wire going from the Resistor to the Positive Inverter Bus beneath the Negative Inverter Bus carefully clipping the wire ties along the way Remove the screw for the Resistor wire 9 Remove the Resistor to be replaced by unscrewing it from the heatsink 10 Using isopropyl alcohol clean any grease off of the location where the Resistor is to be mounted Install Components 1 Apply a thin bead of thermal grease to the full length of the metal bottom of the new Resistor Spread grease evenly 2 Align the wire with push on connector to the right and align the wire with the ring lug connector to the left 3 Mount the new Resistor on heatsink with screws Torque to 2 9 Nem 26 lbein 4 Connect the wire with the ring lug connector to the original location on the Positive Inverter Bus 5 Connect the wire with push on connector to J1 of its Inverter Snubber Board 6 Replace all wire ties 7 Reassemble remaining components in reverse order 8 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B INO17B EN P September 2011 41 Chapter3 Component Replacement Procedures Inverter Power Module Important Kit includes two 2 IGBT modules and two 2 Gate Interface IGBT Boards It is recommended that both IGBT modules for a phase be rep
17. to the right Torque to 9 0 Nem 80 lbein Snubber Board Mounting Brag 8 Install Snubber Boards oriented with the serial number as shown in the diagram to the right Torque to 2 9 Nem 26 lbein 9 Replace leads 10 Install AC Bus Bars R S T Torque both ends to 9 0 Nem 80 Ibein 11 Torque screws for Converter Bus Bars to 9 0 Nem 80 bein 12 Reassemble remaining components in reverse order 13 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B INO17B EN P September 2011 53 Chapter 3 MOV AC Input Only 54 Component Replacement Procedures Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Locate the MOV assembly 3 Perform Remove Precharge Board Assembly on page 23 4 Note wire placement and connections Disconnect the MOV ground wire and its R S and T wires at the top nut on the input power terminal block 5 Unscrew MOV mounting brackets 6 Remove the MOV assembly Install Components 1 Install the new MOV assembly Tighten the MOV mounting screw to 2 9 Nem 26 lbein 2 Reconnect all wires and connectors for the MOV 3 Torque the R S and T Phase power terminal block nuts to 9 8 Nem 80 Ibein 4 Reinstall the Precharge Board 5 Replace all safety
18. 11 Remove the IGBT module bus Important Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 one minute Do not let the gate connections remain disconnected longer A ATTENTION The IGBT gate terminals must not be exposed longer than than one minute Locate jumper wire from Step 2 before proceeding to the next step 46 Rockwell Automation Publication 20B IN017B EN P September 2011 Component Replacement Procedures Chapter 3 12 Remove the left Gate Interface Board located over the Heatsink Thermal Sensor You do not need to disconnect the connector 13 Connect the jumper wire to gate connections on the IGBT module 14 Carefully cut the wire ties securing the Heatsink Thermal Sensor Do Not cut the harness 15 Access the sensor connector to the Monitor Wire located approximately under the W Phase Current Transducer Bus Bar at the right side of the unit Disconnect the sensor connector 16 Using a 5 16 offset open end wrench remove the sensor Install Components 1 Install the new Heatsink Thermal Sensor 2 Torque sensor to 1 6 Nem 14 lbein 3 Connect the other end of the sensor wire to the Monitor Wire 4 Replace all wire ties to secure the wiring harness 5 Remove the jumper wire to gate connections on the IGBT module and immediately reinstall the left Gate Interface Board onto the IGBT module 6 Reasse
19. 20B IN017B EN P September 2011 45 Chapter3 Component Replacement Procedures Heatsink Thermal Sensor The Heatsink Thermal Sensor is located at the top of the Heatsink under the U Phase Gate Interface Board with beige insulated wiring It is connected to the Power Interface Board assembly by the Monitor Wire ak Heatsink Thermal Sensor Refer to the diagram above and to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components 1 Ny ae 9 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 Make a jumper wire consisting of wire plus two 2 10 wire lugs either fork or ring illustrated below 14 or 16 gauge wire about 10 cm 4 in Perform Remove Main Control Panel Assembly on page 21 Perform Remove Stacking Panel on page 22 Perform Remove Precharge Board Assembly on page 23 To gain access to the wire harness in a later step you must remove the Current Transducers over the U V and W Phase Bus Bars Unscrew the button head screws on each transducer bus bar Move the transducers to a safe location On the input power terminal block remove the top nuts securing the U V and W Phase Motor Bus Bars Slide the top of each bus bar to the right unlocking it from the ground and remove each bus bar from the unit Remove the U Phase Inverter Snubber Board 10 Remove the two Inverter Snubber Board brackets
20. Board panel d Remove and save the grounding wire screw connects to PE on TB11 e Remove and save the two mounting screws for the Main Control Board Rockwell Automation Publication 20B IN017B EN P September 2011 27 Chapter3 Component Replacement Procedures L Remove the Main Control Board HIM Board slot tes ae Ribbon Cable Connector TELL mn gt E Allen Bradley SN j CE Wiring Connector crounding wire Screw gt Optional 20 Comm x Board Detail Mounting Screws 4 Y Mounting Screw 3 Remove the 20 Comm x Board if used a Disconnect the ribbon cable between the 20 Comm x Board and T Comm board disconnect only from the T Comm board b Remove and save the four mounting screws 4 Ifthe 20 Comm x Board is not used remove the screw securing the T Comm grounding tab T Comm grounding tab screw T Comm grounding tab flat T Comm grounding tab upright 5 Place the tip of a flathead screwdriver between the T Comm grounding tab and screw mount Gently pry up until the grounding tab is in an upright position or about 90 degrees from the screw mount 28 Rockwell Automation Publication 20B INO17B EN P September 2011 Component Replacement Procedures Chapter 3 6 Ifneeded use the same flathead screwdriver tip to pry the seven locking tabs away from the T Comm Board Allen Bradley E T Comm Board Locking Tab Locations Five locking tabs are on the back sid
21. Components 1 Replace washers on Snubber Board Bus Bar studs 2 Replace insulation over washers 3 Place new Snubber Board over insulation 4 Install M6 nuts on studs with star washer side facing Snubber Board Do not tighten yet M Center insulation around washers so it is not pinched between the Bus Bar and any washer or nut Torque M6 nuts to 2 9 Nem 26 lbein Replace push on wire Reassemble remaining components in reverse order woe oN SD Replace all safety shields and enclosure covers before applying power to the drive Precharge SCR Module DC Refer to the figures in Component Diagrams and Torque Specs on page 13 and Input Only Figure 5 on page 56 for these instructions Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Locate the Precharge SCR module to be replaced 3 Perform Remove Main Control Panel Assembly on page 21 4 Perform Remove Stacking Panel on page 22 5 Label and remove power cables DC and DC and all connected wires from the SCR module 6 Remove the entire Snubber Board Bus Bar assembly including its lead wires and carefully set assembly aside 7 Remove the SCR module and discard Rockwell Automation Publication 20B INO17B EN P September 2011 57 Chapter 3 58 Component Replacement Procedures
22. Installation Instructions Allen Bradley PowerFlex 700 Drive Frame 7 Components Replacement ai at ut K 3 _ Allen Bradley Rockwell Software Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment o
23. Publication 20B IN017B EN P September 2011 13 Chapter1 Component Diagrams and Torque Specs AC input drive is shown Heatsink Thermal Sensor location DC Capacitor Bank Current Transducer under Transitional Bus Bar quantity 3 Transitional Bus Bar Bus Fuse Power Interface Board location under Main Control Panel Ribbon Cable Main Control Board to Power Interface Board Ribbon Cable Main Control Board to Comm Board DC Link Choke Switch Mode Power Supply Board under Main Control Panel Capacitor for Fan Transformer MOV Location Power Terminal Block AC Power Input Connections 14 Rockwell Automation Publication 20B INO17B EN P September 2011 Motor Connections Gate Interface Board Inverter Snubber Board U V and W not visible in this image Inverter Power Module IGBT U V and W below U IGBT Gate Harness and CT Harness Motor Bus Bars U V W Main Control Panel Thermal Sensor Wire HIM Blank shown on this Drive Main Control Board under HIM mounting Communications Panel Main Control Panel Precharge Board Assembly Inverter Section Note Components are shown as seen from right side without drive covers Component Diagrams and Torque Specs Chapter 1 lt Current Transducers lt Current Transducer Mounting Clamps lt lt Inverter Snubber Boards lt lt Motor Bus Bars lt Gate Interface Boards lt lt
24. Steps on page 11 2 Perform Remove Main Control Panel Assembly on page 21 3 Perform Remove Stacking Panel on page 22 4 Perform Remove Precharge Board Assembly on page 23 5 Verify that all wiring to Power Terminal Block is properly labeled and then remove all nuts and disconnect accompanying wires from the Power Terminal Block including the DC and DC Bus cables the PE jumper cable to chassis ground and the PE Bus Bar located over the third and fourth Terminal Blocks TIP For easier removal of the PE jumper cable flex the cable to relieve the strain on lug Remove these nuts and wiring Label and remove all wiring here Z 2 6 Remove the single screws on the right end of U V and W Current Transducer bus bars The Current Transducer assemblies do not need to be removed Remove the U V and W Bus Bars To do so move the top end of the bar to the right and the bottom end of the bar to the left pull down on a angle then rotate the bar 180 and fully remove the bar Rockwell Automation Publication 20B INO17B EN P September 2011 33 Chapter3 Component Replacement Procedures 8 9 TIP Label Bus Bars for correct 10 Remove the screws and accompanying wires for R S and T Bus Bars at the SCR Remove the R S T Bus Bars orientation when reinstalling later Remove at least two terminal blocks from the DIN rail by pushing down on the metal tab on top of the termina
25. age 11 2 Perform Remove Transitional Bus Bar on page 23 3 Label and remove all wires and connectors from the Bus Capacitor Bus Bar 4 Remove nuts and washers fastening the Bus Capacitor Bus Bar 5 Remove the Bus Capacitor Bus Bar 6 Remove Capacitors by pulling them out Install Components 1 Replace screw posts for each new Capacitor using a 3 mm angle hex wrench 2 Place Capacitors into position in drive 3 Place Capacitor bank bus onto Capacitors 4 Install washers and nuts onto posts Note Install all posts washers and nuts before tightening 5 Reconnect all wires and connectors 6 Reassemble remaining components in reverse order 7 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B IN017B EN P September 2011 49 Chapter3 Component Replacement Procedures Converter Snubber Board AC Refer to the figures in Component Diagrams and Torque Specs on page 13 for Input Only these instructions Remove Components 1 2 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 Locate the Converter Snubber Board to be replaced Some wires below shown disconnected Nn YR BY Perform Remove Main Control Panel Assembly on page 21 Perform Remove Stacking Panel on page 22 Perform Remove Precharge Board Assembly on page 23 For the T Phase Converter Snubber Board if the U Phase M
26. age 45 4 Remove the two screws at the bottom of the Stacking Panel for the Power Interface and the Switch Mode Power Supply Boards Remove the panel by sliding it up and out 22 Rockwell Automation Publication 20B IN017B EN P September 2011 Remove Precharge Board Assembly Remove Transitional Bus Bar Basic Component Removal Procedures Chapter 2 Install Components When instructed for the component you are replacing reinstall the Stacking Panel components in the reverse order of removal Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Using pliers if needed remove the three 3 wiring harnesses J1 J2 J3 at the top of the board Note Some connectors may not be labeled Be sure to label them 3 For DC input only Verify that customer wiring to TB2 is properly labeled and then disconnect wiring from TB2 4 Unscrew the two mounting screws at the top of the mounting panel 5 Slide the board and mounting plate out by pulling down and out Install Components When instructed for the component you are replacing reinstall the Precharge Board Assembly components in the reverse order of removal Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components 1 Read and follow the Safet
27. ajor components in the PowerFlex 700 Frame 7 drive All kits include necessary components ESD wrist strap and hardware if required and thermal grease if required Description Kit Catalog No Notes Precharge Board SK G9 PRE1 V480 ACinput 1336 PB SP22C DC input Main Control Board SK G9 VMCB1 D0 115V 1 0 SK G9 VMCB1 CO 24V 1 0 T Comm Board SK G9 TCOMM Switch Mode Power Supply Board SK G9 PWRS1 D0 Power Interface Board SK G9 GDB1 D292 292A Drives SK G9 GDB1 D325 325A Drives Heatsink Fan SK G1 FAN1 F7 Heatsink Fan Transformer 1336 T SP5A 480 to 120 Auto transformer fan only Current Transducer SK G1 CT1 F7 Includes one Transducer Inverter Power Module IGBT SK G1 QOUT1 F7 Includes Two IGBTs Two Gate Interface Boards Inverter Snubber Kit SK G1 INVSNB1 F7 Includes One Snubber Board One Resistor SCR Snubber Kit SK G1 SCRSNUBRB ACinput requires three kits DC input requires one kit Converter Power Module SCR SK G1 SCR1 F7 ACinput Kit includes three SCR Modules DC Precharge SCR Module SK G1 SCR2 F7 DC input Kit includes one SCR Module Thermal Sensors SK G1 THM1 F7 Includes Main Control Panel Thermal Sensor Heatsink Thermal Sensor Bus Fuse 1336 F1 SP6A Bus Capacitor SK G1 BUSCAP1 F7 Includes one Capacitor MOV SK G1 MOV1 F7 AC input DC Link Choke SK G1 DCCHOKE1 F7 ACinput Balancing Resistor 1336 RLOAD SP4A In
28. and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 Locate the Converter SCR modules R S T to be replaced Converter SCR Modules Perform Remove Main Control Panel Assembly on page 21 Perform Remove Stacking Panel on page 22 Using the instructions in Converter Snubber Board AC Input Only on page 50 remove all three Converter Snubber Boards Label and note the position of the SCR module leads Remove the leads Remove the two 2 M6 screws that hold the AC Bus Bar to SCR one 1 screw per SCR Remove the top nut at the input power terminal block Remove the three AC Bus Bars R S T 10 Remove the six Snubber Board Mounting Brackets M6 T40 screws 11 Remove the four 4 M6 screws from the DC Link Choke terminal 1 and 4 Rockwell Automation Publication 20B INO17B EN P September 2011 51 Chapter3 Component Replacement Procedures 12 Remove the Converter Bus Bars DC and DC DC DC Choke Connectors Snubber Board Mounting Bracket Converter Bus Bars SCR module 13 Disconnect the SCR gate leads 14 Remove the four 4 Phillips screws that hold each SCR to the Heatsink 15 Remove the SCR modules Install Components 1 Using isopropyl alcohol thoroughly clean the surface of the Heatsink 2 Verify that the mounting surface of each new SCR module is clean If not clean with isopropyl alcohol 3 Using a 3 putty knife or similar too
29. ates lower phase TB2 TB11 J7 Monitor Wire to thermal sensors TB1 TB11 4 Remove the two Power Interface Board mounting star screws located at the upper right and lower left corners of the board 5 Using your fingers or needle nose pliers squeeze the wings of each of the nine 9 spacers and remove the Power Interface Board from the mounting plate Rockwell Automation Publication 20B INO17B EN P September 2011 TB2 J18 J23 31 Chapter3 Component Replacement Procedures Install Components 1 Install the new Power Interface Board Tighten board screws to 1 7 Nem 15 lbein 2 Reconnect all wiring except the ribbon cable going from the Power Interface Board J1 to the Main Control Board J2 3 Reinstall the Main Control Panel Assembly Tighten sheet metal screws to 3 2 Nem 28 lbein 4 Reconnect the ribbon cable going from the Power Interface Board J1 to the Main Control Board J2 5 Replace all safety shields and enclosure covers before applying power to the drive Fan The Fan is located behind the Main Control Panel assembly and Precharge Board Fan Assembly Refer to the figure below and the figures in Component Diagrams and Torque Specs on page 13 for these instructions 32 Rockwell Automation Publication 20B INO17B EN P September 2011 Component Replacement Procedures Chapter 3 Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial
30. cludes one Resistor Refer to the master parts list for the most up to date information http www ab com support abdrives powerflex70 PF7ReleasedParts pdf Rockwell Automation Publication 20B IN017B EN P September 2011 Preface Recommended Tools The following list of tools is provided for your reference to disassemble and assemble the drive and components This list may not be all encompassing for your situation Not all tools are needed for some components Refer to pertinent sections for details Description Notes Torque wrench metered in Ibein or N m T30 and T40 bits Torque seal or colored marker Screwdrivers standard Phillips star various sizes Magnetic screwdriver long Socket set metric Cylindrical pick up magnet Pliers regular and needle nose Wire cutters Volt ohm meter Used to test Inverter Snubber Resistors Isopropyl alcohol Nylon tie wraps Pencil 14 or 16 gauge wire about 10 cm 4 in Needed whenever IGBT gates are exposed Used to short the gates Two 2 10 wire lugs either fork or ring Rockwell Automation Publication 20B IN017B EN P September 2011 Preface Safety Precautions The precautions and general installation requirements provided in the PowerFlex 700 Frame 7 10 Installation Instructions publication 20B IN014 and the PowerFlex 700 User Manual publication 20B UM002 must be followed in addition to those included here
31. d wire from the Communications Panel 4 Remove the two nuts and two screws and washers for the Communications Panel 5 Disconnect both ribbon cables from the left side of the Main Control Board 6 Holding the Communications Panel release the cable at the bottom of the panel from its clamp and set the Communications Panel aside 7 Ifneeded unscrew and disconnect the wire set going to TB11 from the Main Control Board 8 Unscrew the six 6 screws holding the Main Control Board 9 Remove the Main Control Board 26 Rockwell Automation Publication 20B INO17B EN P September 2011 T Comm Board Component Replacement Procedures Chapter 3 Install Components 1 Install the new Main Control Board r Reassemble all components in the reverse order of removal Reconnect all cables 3 4 Replace all safety shields and enclosure covers before applying power to the drive See Component Diagrams and Torque Specs on page 13 to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Remove the Main Control Board a Remove the HIM board from its slot if used b Disconnect the ribbon cable from the Main Control Board connects to Jlon Power Interface Board c Disconnect the wiring connector from the Main Control Board connects to 8 pin serial port in the lower right corner of Main Control
32. e of the Main Control Board above two are on the front side in the area between the optional HIM and 20 Comm x board slots upper right NOTE Use a flathead screwdriver tip to pry the locking tabs away from the T Comm Board lower right 7 Remove the T Comm Board from the Main Control Board return or dispose of it properly Install Components 1 Install the new T Comm Board 2 Verify the board is locked into all seven locking tabs 3 Carefully bend the T Comm grounding tab until it is flush with the screw mount on the Main Control Board 4 Reassemble all components in the reverse order of removal 5 Reconnect all cables safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B INO17B EN P September 2011 29 Chapter3 Component Replacement Procedures Switch Mode Power Supply Refer to the figures in Component Diagrams and Torque Specs on page 13 for Board these instructions Remove Components 1 Perform Remove Main Control Panel Assembly on page 21 2 Disconnect all cables J2 J4 J3 J1 from the Switch Mode Power Supply Board 3 Remove the Switch Mode Power Supply Board mounting star screw located at the lower right corner of the board Spacers 4 Using your fingers or needle nose pliers squeeze the wings of each of the Screw three spacers and separate the Switch Mode Power Supply Board from the mounting plate 5 Remove the Swi
33. e wiring harness Remove the three button head screws that secure the bus bar Move the bus bar and transducer to an ESD safe flat surface for working with it Using your fingers or needle nose pliers squeeze the wings of each of the four spacers and separate the transducer and board from the mounting clamp Loosen the two screws that hold the two sections of the CT mounting clamp but do not take the screws completely out Only loosen them so that the end is flush with the bottom of the CT mounting clamp Remove mounting clamp from the bus bar by sliding the gentle bend of the bus bar the end with only one screw hole through the assembly taking care not to Spacers damage the transducer or the insulation on the bus bar Component Replacement Procedures Chapter 3 9 Remove transducer assembly transducer and board from the bus bar by sliding the gentle bend of the bus bar the end with only one screw hole through the assembly taking care not to damage the insulation on the bus bar or loosen the wiring Discard old transducer Install Components 1 Position the mounting bar with the end with two screw holes to your right 2 Orient the transducer with the wiring socket away from you and its board to your left Slide transducer onto the bus bar by sliding the gentle bend of the bus bar through the assembly taking care not to damage the insulation on the bus bar and not to loos
34. en the wiring Wiring Socket 3 Orient the transducer mounting clamp with the smaller section on the bottom and the notch toward you 4 Slide the mounting clamp onto the bus bar by sliding the gentle bend of the bus bar the end with only one screw hole through the assembly taking care not to damage the insulation on the bus bar or loosen the wiring 5 Attach the new transducer to the spacers Verify that each spacer locks Tighten the clamp screws of the mounting bracket finger tight 6 Position the CT assembly and bus bar into place Tighten its three screws and torque to 1 6 Nem 14 Spacers Ibein Use a colored marker or torque seal to mark each screw after torquing so you know when all are done and to indicate signs of any tampering Rockwell Automation Publication 20B INO17B EN P September 2011 37 Chapter3 Component Replacement Procedures 7 Loosen the mounting bracket screws and align the CT assembly on the bus bar with the remaining transducers 8 Torque the mounting bracket screws to 5 9 Nem 52 lbein 9 Reconnect the wiring harness Secure with a wire tie 10 Replace all safety shields and enclosure covers before applying power to the drive Inverter Snubber Board Important The Inverter Snubber Board and its associated Resistor do not need to be replaced at the same time Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components
35. in Control Panel Thermal Sensor 0 cece cece ene enes 45 Heatsink Thermal Sensor ote tele nerne rererere erroreen 46 Biis Ps Z A A A 48 DUS T ON ap ccroaevacie nite Rana a eidean ana E Baath ea 49 Converter Snubber Board AC Input Only 0 02 00 ee eee 50 Converter Power Module SCR AC Input Only 51 MOV AC Input On 54 DC Link Choke AC Input On vanhiuoncaeaceedene dt 55 Precharge SCR Module Snubber Board DC Input Only 56 Precharge SCR Module DC Input Only eee eee e 57 Rockwell Automation Publication 20B INO17B EN P September 2011 3 Table of Contents Notes 4 Rockwell Automation Publication 20B IN017B EN P September 2011 Summary of Changes This manual contains new and updated information New and Updated This table contains the changes made to this revision Information Topic Page Added Heatsink Fan Transformer kit 1336 T SP5A to table of component kits 7 Instructions were already in this manual but the kit was not listed in the table Added T Comm Board kit SK G9 TCOMM to table of component kits IN S Added T Comm Board removal and installation instructions Rockwell Automation Publication 20B IN017B EN P September 2011 5 Summary of Changes Notes 6 Rockwell Automation Publication 20B IN017B EN P September 2011 Introduction Component Kits Preface This publication provides guidelines for replacing the m
36. ing Plate to CT Clamping Plate 14 2 CT Camping Plate Clamping Plate to Bus Bar 26 3 Power Cables Cables to terminals 80 9 Main Control Gate Driver Precharge Plates to chassis 26 3 Board Mounting Plates High Voltage Guard Guard to chassis 26 3 Rockwell Automation Publication 20B INO17B EN P September 2011 19 Chapter1 Component Diagrams and Torque Specs Notes 20 Rockwell Automation Publication 20B IN017B EN P September 2011 Remove Main Control Panel Assembly Chapter 2 Basic Component Removal Procedures The procedures in this section are required by many of the replacement procedures described in this manual in addition to replacement of these components themselves DO NOT perform any of the procedures in this section unless specified by the instructions for the component you are replacing Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 Remove safety shields as needed Remove the ribbon cable going from the Main Control Board J2 to the Power Interface Board J1 I Remove the two screws on the Main Control Panel below TB11 for the Main Control Board Verify that all wiring to lower side of TB11 is properly labeled and then disconnect wiring from TB11 Rockwell Automation Publication 20B IN017B EN P September 2011 21 Chapter2 Basic C
37. l apply a thin even coating of the supplied thermal grease to the mounting surface of each SCR module Use enough thermal grease to create a conductive coating but not so much that the two surfaces can rock Important In the next step take care to not disturb any of the thermal grease on the SCR module 4 Install each new SCR module with supplied screws and tighten using this torque sequence o olo OB ol o SCR Torque O SCR Torque O First Sequence Final Sequence 0 7 N m 6 0 lb in O 5 6 N m 50 Ib in O 4 O 0 YS Q 9 O 52 Rockwell Automation Publication 20B IN017B EN P September 2011 Component Replacement Procedures Chapter 3 5 Install the SCR module leads from the Precharge Board J2 and J3 For each SCR module the left connection is for the J3 lead and the right connection is for the J2 lead Note J3 has its red wire on the left and white wire on the right while J2 has its red wire on the right and white wire on the left J3 Lead J2 Lead Connection C Connection peu O O o Q O O 6 Install the Converter Bus Bars DC and DC per the diagram in Step 12 on page 52 but do not torque screws at this time 7 Install the Snubber Board Mounting Brackets oriented as in the diagram
38. l block while lifting the bottom of the terminal block out toward you and up R S T Bus Bars at SCR TIP If desired for ease of access to individual terminal blocks 11 TIP Slide remaining 12 13 14 15 16 Install Components 1 2 remove barriers between terminal blocks by pulling out on a slight down or upward angle Remove the three screws for the DIN rail two toward the left end and one at the right end terminal blocks sideways as needed to access screws Screws at Left End of DIN Rail Remove the DIN rail Unplug Fan wire Remove the 12 screws at the exterior of fan cover Do not remove screws near Fan cable at this time Remove the Fan cover and the Fan You may need to pry the cover from the drive enclosure Remove the four screws near Fan cable that hold the Fan and cover together If needed remove the old gasket from Fan cover and replace gasket Mate cover and new Fan positioning Fan cable in notch of opening in cover 34 Rockwell Automation Publication 20B INO17B EN P September 2011 Component Replacement Procedures Chapter 3 3 Install the four screws that hold the Fan and cover together 4 Place Fan unit in position locating Fan wire in bottom left corner 5 Install the 12 screws at the exterior of fan cover 6 Reconnect Fan wire 7 Reassemble remaining components in reverse order TIP When replacing Motor Bus Bars remove nearby ter
39. l level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document c
40. laced at the same time Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Locate the Inverter Power Module to be replaced 3 Perform Remove Transitional Bus Bar on page 23 4 Perform Remove Components on page 38 for the Inverter Snubber Board over the IGBT modules to be replaced but do not discard the Inverter Snubber Board 5 Remove the two Inverter Snubber brackets two screws each for each board Set aside Inverter Snubber Brackets 6 Disconnect the positive and negative IGBT bus bars four T40 screws each 7 Using a pencil mark the sides of the IGBT Bus Bar to note location for later installation Exact positioning is critical for alignment of other components especially the Transitional Bus Bar unit 8 Remove the IGBT Bus Bar from the modules Set aside 9 Disconnect connections for the Gate Interface Boards 42 Rockwell Automation Publication 20B INO17B EN P September 2011 Component Replacement Procedures Chapter 3 10 Remove the Gate Interface Boards three 3 screws and discard 11 Remove the six 6 screws for the IGBT modules 12 Remove the IGBT modules by tipping the top edge out first Discard Note Picture shows new IGBT modules with conductive tape but existing modules will not have conductive tape Install
41. mble remaining components in reverse order 7 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B INO17B EN P September 2011 47 Chapter3 Component Replacement Procedures Bus Fuse The Bus Fuse is located on the Transitional Bus Bar Refer to the figure here and the figures in Component Diagrams and Torque E Specs on page 13 for these instructions amp x A us 3 Fuse Remove Components E 1 Read and follow the Safety Sa roun Precautions on page 9 and Cable Important Initial Steps on page 11 TIP When you remove the screws in the next step you will remove the Bus Fuse as well There is a plate over the top end of the Bus Fuse that will be free upon removal of the screws Do not let the plate fall 2 Remove the four screws noted in diagram above for the Bus Fuse 3 Remove Fuse Install Components 1 Install new Bus Fuse 2 Torque screws to 9 0 Nem 80 lbein 3 Reassemble remaining components in reverse order 4 Replace all safety shields and enclosure covers before applying power to the drive 48 Rockwell Automation Publication 20B INO17B EN P September 2011 Component Replacement Procedures Chapter 3 Bus Ca pacitor Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on p
42. minal block barriers to provide additional maneuvering space 8 Replace all safety shields and enclosure covers before applying power to the drive Fan Transformer Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Perform Remove Precharge Board Assembly on page 23 3 Label and unscrew or disconnect wires for the Transformer 4 Unscrew Transformer mounting brackets Install Components 1 Install new Transformer by screwing mounting brackets to drive 2 Reconnect all wires and connectors for the Transformer 3 Reassemble remaining components in reverse order 4 Replace all safety shields and enclosure covers before applying power to the drive Current Transducer Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Remove the safety cover Rockwell Automation Publication 20B INO17B EN P September 2011 35 Chapter3 Component Replacement Procedures 3 36 Rockwell Automation Publication 20B INO17B EN P September 2011 Locate the Current Transducer to be replaced W Phase V Phase U Phase Disconnect the wiring harness from the transducer board Clip the wire tie and remove th
43. n 20B INO17B EN P September 2011 55 Chapter3 Component Replacement Procedures Precha rge SCR Module Figure 5 Precharge SCR Module Location DC Input Drive Shown Snubber Board DC Input Only Precharge SCR Module and Snubber Refer to the figures in Component Diagrams and Torque Specs on page 13 and Figure 5 above for these instructions Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Locate the Precharge SCR module Snubber Board to be replaced 3 Remove the upper and lower safety shields 4 Perform Remove Main Control Panel Assembly on page 21 5 Perform Remove Stacking Panel on page 22 6 Remove the push on lead from the Snubber Board 7 Unscrew and remove the Snubber Board from its bus bar Set aside 56 Rockwell Automation Publication 20B INO17B EN P September 2011 Component Replacement Procedures Chapter 3 Install
44. n Publication 20B IN017B EN P September 2011 Preface Important Initial Steps Read and follow these statements before performing any service on the drive Read and follow the precautions in Safety Precautions on page 9 Identify components to be replaced using the figures in Component Diagrams and Torque Specs on page 13 Remove protective shields only as necessary Before disconnecting any wire or cable verify that it is labeled Also when removing components note hardware type and location When torquing any fasteners use a colored marker or torque seal to mark each screw after torquing so you know when all are done and to indicate signs of any subsequent tampering Refer to the product installation documentation for startup and other instructions after servicing Rockwell Automation Publication 20B IN017B EN P September 2011 11 Preface Notes 12 Rockwell Automation Publication 20B INO17B EN P September 2011 Chapter 1 Component Diagrams and Torque Specs Drive Components AC input drive is shown Transitional Bus Bar DC Capacitor Bank Heatsink Thermal under Transitional Bus Bar Sensor location Main Control Panel Assembly Gate Interface Board U Vand W not shown Main Control Panel Thermal Sensor N O Current Transducer underneath anel WA nel p 7 o 1
45. omplete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Otomasyon Ticaret A S Kar Plaza Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 20B IN017B EN P September 2011 Supersedes Publication 23P UM001A EN P March 2010 Copyright 2011 Rockwell Automation Inc All rights reserved Printed in the U S A
46. omponent Removal Procedures 6 Remove the two nuts at the top of the Main Control Panel lt 6 o o ZX CAUTION HOT SURFACES a 7 Remove Main Control Panel support 8 Disconnect wire harnesses from TB11 to the Switch Mode Power Supply Board J4 connector and at TB1 and TB2 on the Power Interface Board 9 Label and disconnect all customer wiring from TB11 10 Carefully set the Main Control Panel aside Install Components When instructed for the component you are replacing reinstall the Main Control Panel Assembly components in the reverse order of removal Remove Stacking Panel Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components 1 Perform Remove Main Control Panel Assembly on page 21 2 Remove remaining wiring harnesses from the Power Interface Board Do not disconnect the wiring between the Power Interface Board and the Switch Mode Power Supply Board Connector Connected Components J14 J15 J16 U V W Phase CT J24 Bus IN of Power Interface Board to J1 of Precharge Board J7 Main Control Panel Thermal Sensor J18 U V W negative gates J23 U V W positive gates 3 Disconnect the Main Control Panel Assembly Thermal Sensor wire from the Monitor Wire See diagram at the start of Main Control Panel Thermal Sensor on p
47. otor Bus Bar must be removed for space considerations then e If space allows remove the U Phase Current Transducer and then disconnect both ends of the U Phase Motor Bus Bar and remove it to gain access to the Converter Snubber Board e Otherwise if space does vot allow using the instructions in Step 2 Step 5 in Component Replacement Procedures on page 25 remove all three Current Transducer assemblies and move them to a safe location but do not disassemble them Label and disconnect any push on wire connector from the Converter Snubber Board to be replaced Remove the two 2 T30 screws that secure the board Remove the board and discard Install Components 1 2 3 Install the new Snubber Board Torque screws to 2 9 Nem 26 lbein Reconnect all wires If removed reinstall the U Phase Motor Bus Bar and torque screws to 9 0 Nem 80 bein Reassemble remaining components in reverse order Replace all safety shields and enclosure covers before applying power to the drive 50 Rockwell Automation Publication 20B INO17B EN P September 2011 Converter Power Module SCR AC Input Only Component Replacement Procedures Chapter 3 Important Ifany SCR module fails all three SCR modules should be replaced Kit includes all three modules Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components 1 2 i yi x 8 9 Read
48. r 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 ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures gt eee IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes Preface Component Diagrams and Torque Specs Basic Component Removal Procedures Component
49. tch Mode Power Supply Board Install Components 1 Install the new Switch Mode Power Supply Board Tighten board screws to 1 7 Nem 15 lbein 2 Reconnect all cables 3 Reassemble all components in the reverse order of removal Tighten sheet metal screws to 3 2 Nem 28 lbein 4 Reconnect the ribbon cable going from the Power Interface Board J1 to the Main Control Board J2 5 Replace all safety shields and enclosure covers before applying power to the drive 30 Rockwell Automation Publication 20B INO17B EN P September 2011 Power Interface Board Component Replacement Procedures Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components Chapter 3 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Perform Remove Main Control Panel Assembly on page 21 3 Remove remaining wiring harnesses from the Power Interface Board including the wiring between the Power Interface Board and the Switch Mode Power Supply Board Connector Connected Components J1 Jn Main Control Board J10 Precharge Board only on DC input systems J16 W Phase CT J15 V Phase CT J14 U Phase CT J24 Bus IN of Power Interface Board to J1 of Precharge Board J13 Switch Mode Power Supply Board J12 Switch Mode Power Supply Board J23 U V W positive gates upper phase J18 U V W negative g
50. the bottom to 9 0 Nem 80 lbein 16 Reassemble remaining components in reverse order 17 Replace all safety shields and enclosure covers before applying power to the drive The Main Control Panel Thermal Sensor is located at the upper left of the Main Control Panel Assembly and is connected to the Heatsink Thermal Sensor by the Monitor Wire Refer to the diagram below and to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Main Control Panel Thermal Sensor To E p S oJ Stacking C Panel To Power S To Interface Heatsink Board Thermal Monitor Wire Sensor Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Perform Remove Main Control Panel Assembly on page 21 3 Perform Remove Stacking Panel on page 22 4 Unscrew one end of the sensor from the Stacking Panel Note This screw and nut are small Take care that they do not drop 5 Disconnect the other end from the Monitor Wire Install Components 1 Apply thermal grease to the metal side of the new Main Control Panel Thermal Sensor and install it with supplied screw with star washer toward the panel Torque screw to 1 7 Nem 15 lbein 2 Reconnect the Monitor Wire 3 Reinstall the Main Control Panel Assembly 4 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication
51. y Precautions on page 9 and Important Initial Steps on page 11 2 Remove the upper safety cover four screws 3 Locate the Transitional Bus Bar Rockwell Automation Publication 20B IN017B EN P September 2011 23 Chapter2 Basic Component Removal Procedures Figure 4 Screws on Panel over Transitional Bus Bar Remove these screws TIP When you remove the screws in the next step you will remove the Bus Fuse as well There is a plate over the top end of the Bus Fuse which will be free upon removal of the screws Do not let the plate fall 4 Using Figure 4 remove the seventeen 17 screws for the Transitional Bus Bar 5 Slide the Transitional Bus Bar to the left and out This allows access to the wire connections below it if needed Install Components When instructed for the component you are replacing reinstall the Transitional Bus Bar components in the reverse order of removal Only torque screws after all components are in place 24 Rockwell Automation Publication 20B INO17B EN P September 2011 Precharge Board Chapter 3 Component Replacement Procedures Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions Remove Components 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Remove the safety cover over the Precharge Board 3 For DC input only Verify that customer wiring to TB2 is properly
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