Frames 7, 8, 9, 10 In
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1. CR cs Nuts ooooo f r sunraces s 3 A Remove Main Control Panel support Q O 6 Q O B 000 000 00 6 O Disconnect wire harnesses from TB11 to the Switch Mode Power Supply Board J4 connector and at TB1 and TB2 on the Power Interface Board Label and disconnect all customer wiring from TB11 10 Carefully set the Main Control Panel aside Chapter 2 Component Replacement Procedures Power Interface Board Remove Components 1 Perform Remove Main Control Panel Assembly on page 13 2 Remove all remaining wiring and cabling from the Power Interface Board as indicated in the table below Frame Connector Connected Components 7 8 9 10 J1 X X X X Main Control Board J10 X X Precharge Board only on DC input systems J8 X X X U Phase Gate Interface Board J9 X X 24V Power Supply Board J16 X X X X WPhase CT J15 X X X X VPhaseCT J14 X X X X UPhaseCT J24 X X X X Bus IN of Power Interface Board to J1 of Precharge Board J13 X X X X Switch Mode Power Supply Board J12 X X X X Switch Mode Power Supply Board J23 X X X X U V W positive gates upper phase J18 X X X X U V W negative gates lower phase TB2 X X X X TBI J7 X Monitor Wire to thermal sensors J6 X X2. 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 Vorstlaan Boulevard du Souverain 36 1170 Brussels 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 IN22B EN P December 2009 Supersedes Publication 20B IN22A EN P August 2009 Copyright 2009 Rockwell Automation Inc All rights reserved Printed in the U S A
3. GDB1 D875 875A Drives X Switch Mode Power Supply Board SK G9 PWRS1 DO X X X X 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 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 e Screwdrivers standard Phillips star various sizes e Socket set metric e Cylindrical pick up magnet e Pliers needle nose e Nylon tie wraps 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 ATTENTION To avoid an electric shock hazard ensure that all power has 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 and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must
4. X Monitor Wire to thermal sensors TB1 X X X X TBI J2 X X X Switch Mode Power Supply Board Frame 9 J2 DC input i TB1 shown Ji J6 J7 J10 TB2 J8 J9 J18 J16 J15 J14 J24 J23 J13 J12 14 Publication 20B IN22B EN P December 2009 Publication 20B IN22B EN P December 2009 3 Component Replacement Procedures Chapter 2 Remove the two Power Interface Board mounting star screws located at the upper right and lower left corners of the board Using your fingers or needle nose pliers squeeze the wings of each of the nine 9 spacers and separate the Power Interface Board from the mounting plate Frame 7 shown Remove the Power Interface Board Install Components 1 Install the new Power Interface Board Tighten board screws to 1 7 N m 15 Ib in Reconnect all wiring except the ribbon cable going from the Power Interface Board J1 to the Main Control Board J2 Reinstall the Main Control Panel Assembly Tighten sheet metal screws to 3 2 N m 28 lb in Reconnect the ribbon cable going from the Power Interface Board J1 to the Main Control Board J2 Replace all safety shields and enclosure covers before applying power to the drive Chapter 2 Component Replacement Procedures Switch Mode Power Supply Refer to the figures in Component Diagrams on page 9 for these Board instructions Remove Components 1 2 Perform Remove Main Control Panel Assembly on page 1
5. be zero for all three measurements Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by e sending an erroneous signal to your system s field devices causing unintended machine motion e 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 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 Publication 20B IN22B EN P December 2009 Preface ATTENTION l ATTENTION ATTENTION ATTENTION ATTENTION als Na el Publication 20B IN22B EN P December 2009 This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference
6. 3 Disconnect all cables J2 J4 J3 J1 from the Switch Mode Power Supply Board Remove the Switch Mode Power Supply Board mounting star screw located at the lower right corner of the board Using your fingers or needle nose pliers squeeze the wings of each of the three spacers and separate the Switch Mode Power Supply Board from the mounting plate Spacers Remove the Switch Mode Power Supply Board Install Components 1 Install the new Switch Mode Power Supply Board Tighten board screws to 1 7 N m 15 Ib in Reconnect all cables Reassemble all components in the reverse order of removal Tighten sheet metal screws to 3 2 N m 28 lb in Reconnect the ribbon cable going from the Power Interface Board J1 to the Main Control Board J2 Replace all safety shields and enclosure covers before applying power to the drive Publication 20B IN22B EN P December 2009 Component Replacement Procedures Chapter 2 Notes Publication 20B IN22B EN P December 2009 17 Chapter 2 Component Replacement Procedures Notes 18 Publication 20B IN22B EN P December 2009 Rockwell Automation Rockwell Automation provides technical information on the Web to assist you in using its products At http support rockwellautomation com you can Support find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport f
7. Allen Bradley Publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook 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 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 HOT surfaces can cause severe burns Do not touch the heatsink surface during operation of the drive After disconnecting power allow time for cooling Replace all protective shields before applying power to the drive Failure to replace protective shields may result in death or serious injury NN Preface Important Initial Steps Read and follow these statements before performing any service on the drive e Read and follow the precautions in Safety Precautions on page 6 e Identify components to be replaced using the figures in Component Diagrams on page 9 e Remove protective shields only as necessary e Before disconnecting any wire or cable verify that it is labeled Also wh
8. PowerFlex 700 Drive Power Interface 2 Board and Switch Mode Power Supply 45 Aren 3ramey Board Replacement Frames 7 8 9 10 Installation Instructions Allen Bradley Rockwell Software Automation Important User Information Solid state equipment has operational charactetistics 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 literature rockwellautomation com 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 informat
9. Table of Contents Preface TOTL UCHONA coa EEE dou 5 Recommended Tools 14 es rer 5 Safety Precautlons ses Mr nee 6 Important Initial Steps as ee ae 8 Chapter 1 Dive Components 5454 ers ke Weta wa EE dE 9 Main Control Panel Assembly 2 steak RW ELE ee 10 Circ it DOGS ama aud ue decer DE wate eee ee ACE 10 Chapter 2 Remove Main Control Panel Assembly 522a ds 13 Power Interf ce BOard soins ee ad tea des utei d 14 Remove Components oce i ve TEE AERE ERR ERI ERE 14 Install Components aaa Queso ca ae Ia 4h eoo mre es e 15 Switch Mode Power Supply Board eei Re Ra 16 Remove Components er EE queries sr Odes 16 InsallCompenene nur neat Riu span aes Ren 16 Table of Contents Notes 4 Publication 20B IN22B EN P December 2009 Introduction Recommended Tools Publication 20B IN22B EN P December 2009 Preface This publication provides guidelines for replacing installing Power Interface Boards and Switch Mode Power Supply Boards in the PowerFlex 700 drive for Frames 7 8 9 and 10 All kits include the board wrist strap and hardware if required Frame Description Kit Catalog No Notes 7 8 9 10 Power Interface Board SK G9 GDB1 D292 292A Drives X SK G9 GDB1 D325 325A Drives X SK G9 GDB1 D365 365A Drives X SK G9 GDB1 D415 415A Drives X SK G9 GDB1 D481 481A Drives X SK G9 GDB1 D535 535A Drives X SK G9 GDB1 D600 600A Drives X SK G9 GDB1 D700 730A Drives X SK G9
10. eature that you can customize to make the best use of these tools For an additional 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 support rockwellautomation com Installation Assistance If you experience a problem with a hardware module within the first 24 hours of installation please review the information that s contained in this manual You can also contact a special Customer Support number for initial help in getting your module up and running United States 1 440 646 3434 Monday Friday 8 a m 5 p m EST Outside United Please contact your local Rockwell Automation representative for any States technical support issues New Product Satisfaction Return Rockwell tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility Howevet if your product is not functioning it may need to be returned United States Contact your distributor You must provide a Customer Support case number see phone number above to obtain one to your distributor in order to complete the return process Outside United Please contact your local Rockwell Automation representative for States return procedure www rockwellautomation com Power Control and Information Solutions Headquarters Americas
11. en removing components note hardwate type and location e When torquing any fasteners use a colored marker or torque seal to mark each fastener after torquing so you know when all are done and to indicate signs of any subsequent tampering e Refer to the product installation documentation for startup and other instructions after servicing Publication 20B IN22B EN P December 2009 Chapter 1 Component Diagrams Drive Components Figure 1 Main Control Panel Assembly Relative Location Frame 7 shown Main Control Panel Thermal Sensor HIM Main Control Panel hel Power Interface Board under Main Control Panel Pr ge Switch Mode Power Supply Board under Main Control Panel a Oe A l mi TB11 Precharge Board Assembly ECT ECT A e E 3 L9 F Publication 20B IN22B EN P December 2009 Chapter 1 Component Diagrams Main Control Panel Assembly Figure 2 Main Control Panel Assembly Frame 7 AC input drive shown Bottom of Drive Top of Drive Compone
12. ferent from that on Frames 7 9 Precharge Board See Figure 4 for location of boards i other than Precharge Board d mid g 12 Publication 20B IN22B EN P December 2009 Remove Main Control Panel Assembly Publication 20B IN22B EN P December 2009 Chapter 2 Component Replacement Procedures Read and follow the Safety Precautions on page 6 and Important Initial Steps on page 8 for all these instructions Refer to the figures in Component Diagrams on page 9 as needed for these instructions Perform this procedure only when instructed for the component you are replacing 1 2 9 Remove safety shields as needed Remove the ribbon cable going from the Main Control Board J2 to the Power Interface Board J1 Remove the two screws and washers on the Main Control Panel below TB11 For Frames 9 and 10 Remove the two screws on the left side of the Main Control Panel assembly These screws are larger than those below TB11 Do not mix the two sets For Frame 7 only Verify that all wiring to lower side of TB11 is properly labeled and then disconnect wiring from TB11 Remove the two nuts at the top of the Main Control Panel i o alfo
13. ion citcuits 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 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 E Identifies information about practices or circumstances that can cause an explosion in a hazardous environment ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or A 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 IN 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 Allen Bradley PowerFlex TechConnect and Rockwell Automation are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Component Diagrams Component Replacement Procedures Publication 20B IN22B EN P December 2009
14. nts are listed left to right for each level Communication Comm Module Mounting Board and HIM 4 Communication Panel TB11 and Main Control Board Main Control Panel Switch Mode Power Supply Board and Power Interface Board x Stacking Panel Note Components are shown as seen from right side without drive covers Circuit Boards Figure 3 Circuit Boards Frame 7 AC input drive shown T Comm Interface HIM Cradle Board HIM Support Plate Encoder Board Control Board Switch Mode Power Interface Board Power Supply Main Control Panel Precharge Board 10 Publication 20B IN22B EN P December 2009 Component Diagrams Chapter 1 Figure 4 Circuit Boards Frames 8 10 This diagram indicates the location of all boards on Frames 8 10 except for the Precharge Board on Frame 10 Frame 8 shown Switch Mode Power Supply Options may be Power Interface Board Board installed here HIM Cradle Board T Comm Interface HIM Support Plate Encoder Board Control Board Main Control Panel Precharge Board See Figure 5 for Frame 10 Precharge Board 24V Power Supply Board Frames 9 10 DC Bus Filter Board Publication 20B IN22B EN P December 2009 11 Chapter 1 Component Diagrams Figure 5 Frame 10 AC Input Circuit Boards This diagram indicates the location of the Precharge Board on Frame 10 as dif
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