Home

Spec Sheet - The Reynolds Company

1. E ae JN n 8 Fy i E i M gm NN CY IE TE a EP adoc gi s cp oci JU V WY 9 Unplug the fan cables 10 For AC drives remove the MOV surge suppressor as detailed on page 71 11 Remove the left busbar mounting plate bracket 12 Remove the 12 exterior screws on the fan mounting plate Fan Mounting Plate Screws 12 3 Plate Bracket Removed d 13 Carefully remove the mounting plate and fan through the front of the drive chassis you may need to pry the mounting plate away from the gasket The fan housing remains mounted on the chassis 66 Rockwell Automation Publication 20B IN024C EN P June 2012 Component Replacement Procedures Chapter 3 Install Components 1 Remove the new fan housing from the new fan and mounting plate Discard the new fan housing Install the new gasket if the old gasket was damaged and mounting plate to the chassis Torque the mounting screws to 2 9 Nem 26 lbein Install the left busbar mounting plate bracket Torque the mounting screws to 5 6 Nem 50 Ibein a For AC drives install the MOV surge suppressor as detailed on page
2. Positive DC Flexible Capacitor Busbar attached to bottom side of Transitional Busbar 31 Chapter2 Basic Component Removal Procedures Install Components See the photographs in the preceding Transitional Busbar Assembly section to identify any components discussed in this section Positive DC B8 Flexible Capacitor z Busbar short 48 Negative DC Flexible Capacitor Busbar tall IMPORTANT Each IGBT replacement kit includes three positive DC and three negative DC flexible capacitor busbars The positive ones are shorter see above because they attach to the back side of the transitional busbar For ease of installation replace positive flexible capacitor busbars while the transitional busbar is removed 1 Replace the three positive DC flexible capacitor busbars supplied in an IGBT replacement kit on the back side of the transitional busbar for each IGBT module being replaced 2 Mount transitional busbar to bus capacitors If needed use a rubber mallet to gently tap the transitional busbar onto the longer setscrews of the bus capacitors 3 Add a washer rounded side down and nut to each bus capacitor setscrew Finger tighten only Install the nine negative flexible capacitor busbars to the transitional busbar with two washers rounded side down and two nuts for each flexible capacitor busbar Finger tighten only 5 Install the s
3. Torque Component Fastener Application Nem Ibein 20 Comm x board fasten to HIM cradle board 2 9 26 AC busbars R S and T fasten to converter SCR module 9 80 AC output busbar fasten to standoffs on heatsink 5 6 50 fasten to IGBT 5 6 50 Balancing resistor fasten to the transitional busbar 2 9 26 Balancing resistor wires black negative busbar 2 9 26 yellow bus capacitor busbar 2 9 26 blue converter busbar 2 9 26 Busbars DC and DC fasten upper busbar mounts to the converter busbars 23 5 208 Busbar mounting plate fasten the busbars to the bottom of the chassis 6 50 Busbar mounting plate bracket left fasten to the left side of the converter busbar 6 50 Bus capacitor busbar fasten to the capacitor setscrews short 5 6 50 Cables fasten DC IN and DC OUT cables to the transitional busbar 23 5 208 Capacitor bank fan fasten to chassis below the capacitor bank 1 8 16 Capacitor setscrews short setscrew fastens capacitor to the bus capacitor busbar 0 7 6 long setscrew fastens capacitor to the transitional busbar 0 7 6 Communications panel fasten to the main control panel top of the communications panel 5 6 50 bottom of the communications panel 2 9 26 Converter busbars fasten to converter SCR modules 9 80 Converter power modules SCR AC input only fasten to heatsink first sequence 0 7 6 final sequence 5 6 50 Converter SCR modules wiring fasten to the busbar connection at the SCR module 2 8 26 Converter snu
4. 2 wires Main Control Panel Thermal Sensor Power Interface Board 68 Rockwell Automation Publication 20B IN024C EN P June 2012 Component Replacement Procedures Chapter 3 Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Cut the wire ties for the wiring harness along the gate interface boards 3 Note wire routing and location of sensors Forthe main control panel thermal sensor remove the screw and nut on the main control panel and disconnect the other end from the wiring harness IMPORTAN This screw and nut on the main control panel are small Do not drop them 5 For the Heatsink thermal sensor remove the screw on the Heatsink above the SCR modules and unplug the other end from the wiring harness IMPORTAN This screw and nut on the heatsink are small Do not drop them 6 Label the wires and unplug the J8 connectors on each of the three gate interface boards and unplug the other end of this wiring harness at the J6 connector on the power interface board Install Components Use isopropyl alcohol to thoroughly clean the mounting surface of the control panel and heatsink and the mounting surface of the thermal sensors 2 Apply a thin layer of supplied thermal grease to the metal side of the new thermal sensors 3 Install the thermal sensors with the screw and star washer Hand tighten For the three
5. IMPORTANT Refer to the instruction sheet included with each component kit for instructions regarding discarding or returning replaced components If discarding be sure to discard according to local state and federal regulations Rockwell Automation Publication 20B INO24C EN P June 2012 Preface Recommended Tools The following list includes the most common tools used to disassemble and assemble the drive and components This list may not include all the tools for your situation Not all tools are needed for some components Refer to the specific sections for details Description Torque wrench metered in Nem or Ibein Volt ohm meter Torque seal or colored marker Screwdrivers standard Phillips torx various sizes Magnetic screwdriver long Socket set metric Cylindrical pick up magnet Pliers regular and needle nose Wire cutters Isopropyl alcohol and applicator cloth Nylon tie wraps 3 or 4 inch paint roller with short nap or 3 or 4 inch putty knife for installing SCR modules Pencil Additional Resources from Rockwell Automation Resource PowerFlex 700 Adjustable Frequency AC Drive Frames 7 10 Installation Instructions publication 20B IN014 These documents contain additional information concerning related products Description Provides basic information needed to mount wire and start up a PowerFlex 700 drive P
6. 12 Connect the yellow wire for the balancing resistor 13 Install a new tie wrap for the balancing resistor wiring 14 If present connect the DC IN and DC OUT cables from the transitional busbar Torque to 23 5 Nem 208 Ibein 15 For AC input drives reinstall the DC choke output cables Torque to 9 Nem 80 Ibein 16 Reinstall any customer wiring to the transitional busbar 17 Reinstall the stacking panel as instructed on page 27 18 Verify all wiring to the two panels and the transitional busbar has been reconnected 19 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B IN024C EN P June 2012 33 Chapter 2 Notes 34 Basic Component Removal Procedures Rockwell Automation Publication 20B INO24C EN P June 2012 Chapter J Component Replacement Procedures Overview Component procedures detailed in this chapter apply to PowerFlex 700 Frame 8 drives for AC or DC input Removal and replacement instructions for the stacking panel and transitional busbar assemblies are detailed in Chapter 2 Main Control Board See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove safety shields as needed Located over main control panel Screw for green ye
7. Leave space for accessing fan cables from the front of the drive Take care to not pinch wires Fan Assembly Front View Removed from Drive 3 From the front of the drive connect the fan cables TIP The connectors one set shown below are designed so they go together only one way The two end sections are flat on one side and each section has a ridge at the matching edge Connectors shown slightly separated Flat Sections Ridges 4 Place fan assembly in final position in the chassis 5 On the back of the drive install the eleven screws for the heatsink fan cover Torque to 2 9 Nem 26 lbein 62 Rockwell Automation Publication 20B IN024C EN P June 2012 Component Replacement Procedures Chapter 3 Heatsi nk Fan Removal The heatsink fan is located on the back of the drive These instructions explain how to remove the fan from the front of the drive from Front of Drive Heatsink Fan behind mounting plate See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Disconnect all appropriate wiring to AC and DC busbars so you can remove entire set of busbars with the busbar mounting plate in a later step 3 Remove the stacking panel as detailed on page 26 4 Disconnect the DC and DC busbars that connect to the c
8. Procedures Component Replacement Procedures Table of Contents New and Updated Information 1e42easd duae teu eaa ded Rege dex Erb tua 7 Introduction sssess eniinn eni EEA EREE EEE E EE EAEEREN 9 Component Kits ssa s p rr ER ti nin e Er EREE EE EEEE A 9 Recommended Tools ipe eddaxe wk oa UA VERSER E Vb ERR ORAS 11 Additional BesolECER o eod bao ETUR TRO AUREAS EPA dies Eod 11 Safety Preca ions siae sto a duud seia hiid aaen i ne a 12 Important Initial Steps secssressisisisrendireiieriiisriessvveandis 13 Chapter 1 Driye Components ies pest devbepi tese Et ERR roiret ry RATES 15 Circuit Boatds 1 iioeaciasecic in Rache ERE ERR bbdnrbe aequare 19 Fastener Torque Specifications ii caavesbEL AR bd EE edd baa e 20 Torque Seguen M 20 Torque Spee isha iaa dene arua inici ti skett o Eo ninne 21 Chapter 2 OVERVIEWS ewes 23 M n Control Dinelioioedaseddpedd eas Vea rend derbi daa equus 24 Remove Coimponents sssese ero rersvetuE e yeenoVe Eua aes 24 Install Components icdssscecdes scat eU PRUEREDR CU PUR FERRE Cea 25 Stacking Panelaioeccensdesr Etre RO RREREL PERRA TNOCA UR Edd e GE 26 Remove Copolelll sisaesduAxes uoa os anERARTAR AERE REPE 26 Install Components ca es deoa aua ee Sacve plex E acde dede Serin dea 27 Transitional Busbar Assembly iia serves erede ERR dado eb RU d 28 Remove Components soe ae ver Peta we ier pe d rEE ERE RA 28 nstall Cosupobelits s2ebidu eria bidrba b equebvb bito aa e deba dr
9. and nuts fit Adjust as needed 6 Remove the transitional busbar and tighten all washers and nuts for the bus capacitor busbar Torque to 5 6 Nem 50 lbein 7 Install the transitional busbar assembly as detailed on page 32 8 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B INO24C EN P June 2012 Component Replacement Procedures Chapter 3 Cap acitor Bank Fan See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove the stacking panel as detailed on Four Mounting Screw page 26 3 Labeland disconnect all wires for the fan Remove the four mounting screws 5 Remove the fan assembly Install Components 1 Install the new fan assembly Torque the four mounting screws to 1 8 Nem 16 Ibein 2 Connect the wires 3 Install the stacking panel as detailed on page 27 4 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B IN024C EN P June 2012 47 Chapter 3 Component Replacement Procedures Balancing Resistor See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Prec
10. 71 Connect the fan cables Install the busbar and mounting plate assembly Torque the four 10 mm nuts for the busbar mounting plate to 5 6 Nem 50 Ibein Torque the 11 mm mounting nut on the setscrew for each U V and W busbar at the current transducer output busbar to 5 6 Nem 50 Ibein Torque the two 17 mm mounting bolts for each U V and W busbar at the current transducer output busbar to 9 Nem 80 Ibein Torque the three 16 mm mounting bolts for the busbar connection to the converter SCR modules to 9 Nem 80 Ibein Torque the six wiring screws for the busbar connection to the converter SCR modules to 2 9 Nem 26 lbein Torque the 17 mm mounting bolts for the DC and the DC busbars one each that connect to the converter busbars to 23 5 Nem 208 Ibein Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B IN024C EN P June 2012 67 Chapter 3 Component Replacement Procedures Thermal Sensors The thermal sensor system consists of Thermal Sensor wiring for both drives e A sensor secured to the upper mounting bracket for the main control 2 wires panel A sensor secured to the heatsink above the SCR modules Aconnector to J8 on each of the three 4 wires gate interface boards See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions
11. ER CU 47 Remove Components 500 ctecaavsdnseseiedoonenesesanbetenes s 47 Install CCODipobefibit song dorbassu end d inicea aie addo dpa d apad ida 47 Balancing ReslstOE e zeseoos ch ts kabet eex eer ro e PE PE rentia 48 R move ComponelliSssesceetertt REF ERE EV Pre PEE NERA ARAS 48 Install Compolletit isses cir Rd HR Ker EE ada E bbadrbd Kidd debes 48 Inverter Power Module IGBT 0c cece cence renner ronnen 49 Remove C GimpOnenis cocus ded cassava a S Deuda diua pidas 49 Install Components e eousageee QA Pitra aae Rule FR dS Ud de 51 Gate Interface Doatd iios spesso cadet oder HX Ue rp ORA EE PRAE TEE 53 Remove Componehts isis ae e Re Re riii E EN RRERERA EE 29 Install Components iiec Dub eER Pad ERE berba dap b a ut 53 Current Transducer MC 54 Remove CODO sss corta t sentni ide EE Dad Eu PR dard a 54 Install CoitipobleEBr es v2 daa ex RE Rt er Ee Ura d dae E Eyed ad 55 Converter Power Module SCR AC Input Only 56 Remove Components ossis cna det Qr don e EP ee pF CL KRE P bad bis 56 Install Components cu asado qa pipa AY Ga ndi dq rid 57 Converter Snubber Resistors AC Input Only s00000ss000e00 58 Remove Compobelite eowassaoed Pet squas sa eobis kom REX KE 58 Install Compotent e s sicco rh ER pA RO e RE AL pipa rn 59 Converter Snubber Board AC Input Only ssueeuueees 59 Remove Compobsehtsces sie ce so sake te CRRRRER E CKEVERERERPE E 24 Install Components ee db maion Fl abl O
12. IN024C EN P June 2012 15 Chapter 1 Component Diagrams and Torque Specifications Figure 2 Frame 8 DC Drive Components O Gate Interface Board 3 Drive Shown With Stacking e Panel Removed Current Transducer 3 Transitional Busbar Flexible Capacitor Busbars 18 COO OO OW Output Busbar 3 AC Output Busbar 3 DC Bus Capacitor 18 o IGBT Interface Board and IGBT 3 each o lollo l le o o Tie Down Capacitor Mount Snubber Capacitors for IGBTs 9 Balancing Resistor Precharge Busbar top Precharge SCR Module Diode Precharge Busbar bottom Capacitor Bank Fan Precharge Resistors 2 Busbar Mounting Plate Heatsink Fan is behind this plate Precharge Fuse Motor Busbars U V W 16 Rockwell Automation Publication 20B IN024C EN P June 2012 DC Busbar e 9 Mo Figure 3 Frame 8 Busbars AC Drive shown DC Busbar Transitional 9 Busbar Assembly p H Rockwell Automation Publication 20B IN024C EN P June 2012 Component Diagrams and Torque Specifications Chapter 1 17 Chapter 1 Component Diagrams and Torque Specifications Figure 4 Frame 8 AC input drive shown DC Capacitor Bank Gate Interface Heatsink Thermal Sensor Connector Under Transitional Busbar Board J8 on each Gate Interface Board DC Link Choke Output Connection LL 0 Top b Transitional Busbar Inverter Snub
13. One diode Miscellaneous Current Transducer SK G1 CT1 F8 Includes one transducer Drive requires three kits Thermal Sensor Kit SK G1 THM1 F89 AC input Includes Main control panel thermal sensor Heatsink thermal sensor SK G1 THM2 F89 DC input Includes Main control panel thermal sensor Heatsink thermal sensor Rockwell Automation Publication 20B IN024C EN P June 2012 9 Preface 10 Description Miscellaneous continued Kit Catalog No Notes Bus Capacitor Kit SK G1 BUSCAP1 F8 365A 415A and 481A only ncludes one capacitor Drive requires 18 kits SK G1 BUSCAP2 F8 535A and 600A only ncludes one capacitor Drive requires 18 kits Capacitor Bus Finger Kit SK G1 FLXBUS1 ncluded with the kit for inverter power module IGBT Can be ordered separately ncludes e Three positive flexible capacitor busbars e Three negative flexible capacitor busbars MOV Surge Suppressor SK G1 MOV1 F89 AC input Power Supply 24V SK G9 PWRS24 DC Link Choke SK G1 DCCHOKE1 F8 AC input Transformer 500 VA SK G9 XFMR1 F89 AC input Includes One transformer Three fuses Transformer Fuses SK G9 FUSE1 F8 AC input Includes three fuses Balancing Resistor 1336 RLOAD SP3A Includes one resistor Refer to the master parts list for the most recent information http www ab com support abdrives powerflex70 PF7ReleasedParts pdf
14. Output Busbar 6 Carefully examine the transitional busbar and bus capacitors for damage When replacing any IGBT Rockwell Automation recommends that you replace all bus capacitors If needed refer to Bus Capacitor on page 45 to replace damaged bus capacitors Example of IGBT Module Failure Bus Capacitor under Transitional Busbar Transitional Busbar Flexible Capacitor gt Busbars V 7 Remove the eight screws that secure the IGBT to the chassis 8 Remove the IGBT by tipping the right edge out first 50 Rockwell Automation Publication 20B INO24C EN P June 2012 Install Components 1 Install the IGBT module Component Replacement Procedures Chapter 3 a Use isopropyl alcohol to thoroughly clean the mounting surface of the heatsink and the mounting surface of the new IGBT module b Use a 3 or 4 inch paint roller or putty knife to apply a thin even coating of the supplied thermal grease to the mounting surface of the IGBT module In the next step take care to not disturb any of the thermal grease on the IGBT module c Place the IGBT on the chassis with the serial number label at the top Install with supplied screws using this torque sequence e e o for ca eue elfe P JO E tefte Toff Lo oe Tel e 27 o e IGBT Torque Sequenc
15. Precharge Power Cables 3 Label and remove all precharge power cables and precharge wires from both precharge busbars DC IN and DC OUT Remove both precharge busbars and carefully set aside 5 For the Precharge SCR module remove its connector wire 6 Remove the SCR module and diode Install Components 1 Use isopropyl alcohol to thoroughly clean the mounting surface of the heatsink and the mounting surface of the new SCR module and diode 2 Usea3 or 4 inch paint roller or putty knife to apply a thin even coating of the supplied thermal grease to the mounting surface of each SCR module and diode 72 Rockwell Automation Publication 20B IN024C EN P June 2012 Component Replacement Procedures Chapter 3 WARNING In the next step be sure to properly install the A modules as shown If you install the SCR incorrectly it will not work If you install the diode incorrectly then the drive and the bus capacitors may not operate properly and may prematurely fail e The SCR on the left has a plug with prongs located at the bottom The diode on the right has a plug without prongs located at the top Plug with O No Prongs Plug with Prongs ih IMPORTANT In the next step take care to not disturb any of the thermal grease on the SCR module 3 Install the SCR module or diode with supplied screws and torque using the sequences and specifications shown in the diagram be
16. 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 systems 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 drives input power terminals 3 Check the DC bus voltage at the power terminals 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 Rockwell Automation Publication 20B IN024C EN P June 2012 Preface Important Initial Steps ATTENTION 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 refer to Guarding Against Electrostatic Damage Allen Bradley publication 8000 4 5 2 or any other appli
17. the AC busbars 6 Labeland note the position ofthe converter SCR module leads Remove the leads Typically the leads are marked as R S or T and each is notched with the notch to the front of the converter SCR module 7 Remove the four Phillips screws that hold each converter SCR to the heatsink and remove the converter SCR modules Install Components 1 Use isopropyl alcohol to thoroughly clean the mounting surface of the heatsink and the mounting surface of each new converter SCR module 2 Usea3 or 4 inch paint roller or putty knife to apply a thin even coating of the supplied thermal grease to the mounting surface of each new converter SCR module IMPORTANT In the next step take care to not disturb any of the thermal grease on the converter SCR module 3 Install each new converter SCR module with supplied screws and tighten using this torque sequence Q o o9 O o o SCR Torque O SCR Torque 9 First Sequence Final Sequence 0 7 N m 6 0 Ib in O 5 6 N m 50 Ib in O O o oj e o o O O 4 Replace the SCR module leads Each set of leads is marked R S or T The notch and red wire on each lead are positioned to the front 5 Install the converter busbars per diagram in step 2 and torque to 9 0 Nem 80 Ibein 6 Install the snubber boards oriented with the serial nu
18. the output busbar Current Transducer Output Busbar 4 Remove the bolt on the left end of the output busbar 5 Use a hex wrench to remove the setscrew Setscrew 6 Remove the two screws that secure the transducer assembly to the backplane transducer and brackets 54 Rockwell Automation Publication 20B INO24C EN P June 2012 Component Replacement Procedures Chapter 3 7 Remove assembly by lifting the assembly up and turning it slightly counterclockwise while rotating the top of the output busbar toward you and around the U V or W busbar 8 Move the busbar and transducer to an ESD safe flat surface for working with it 9 Separate the transducer from the brackets Install Components 1 Mount brackets to the transducer Torque screws to 1 6 Nem 14 lbein 2 Slide output busbar through the current transducer assembly with the angled end to the left 3 Replace the current transducer assembly in mounting position by reversing the process used in Step 7 of the removal process Secure the transducer assembly to the drive chassis with two screws Torque to 2 9 Nem 26 lbein 5 Replace the output busbar setscrew and nut Torque the nut to 5 6 Nem 50 Ibein 6 Install the three output busbar bolts Torque to 9 0 Nem 80 Ibein 7 Connect the wires 8 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation P
19. 59 Chapter 3 Component Replacement Procedures Install Components 1 Install the new snubber board Torque screws to 2 9 Nem 26 lbein 2 Connect the wires Black wire goes to J1 Blue wire goes to J2 3 Install stacking panel as detailed on page 27 4 Replace all safety shields and enclosure covers before applying power to the drive Fan Transformer See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 f f Fan Transformer pl D ire T Label and unplug these two red wires Label and disconnect these three wires Mounting bracket screws 4 2 Label and unplug or disconnect the five wires for the fan transformer 3 Unscrew the four fan transformer mounting bracket screws Install Components 1 Install new fan transformer Torque four screws to 5 6 Nem 50 Ibein 2 Connect the wires for the fan transformer 3 Replace all safety shields and enclosure covers before applying power to the drive 60 Rockwell Automation Publication 20B INO24C EN P June 2012 Component Replacement Procedures Chapter 3 Heatsink Fan Removal The heatsink fan is located on the back of the drive from Back of Drive l ESE For equipment clearance considerations the fan can also be removed from the front of the drive See Heatsink Fan Removal fr
20. Installation Instructions Allen Bradley PowerFlex 700 Drive Frame 8 Components Replacement a E T T1 d ES 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 equi
21. Rockwell Automation Publication 20B INO24C EN P June 2012 27 Chapter2 Basic Component Removal Procedures Transitional Busbar See Chapter 1 Component Diagrams and Torque Specifications to locate the Assembly component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove the stacking panel as detailed on page 26 DC Choke Output Cables Balancing Resistor 3 If present remove all customer wiring to transitional busbar 4 For AC input drives remove the DC choke output cables For DC input drives there is no choke 5 If present disconnect the DC IN and DC OUT cables from the transitional busbar 28 Rockwell Automation Publication 20B INO24C EN P June 2012 Basic Component Removal Procedures Chapter 2 6 Remove all IGBT Snubber components a Remove the six nuts that secure each set of snubber capacitors Remove the capacitors and save nuts and capacitors Tie Down Capacitor Mount Screw Snubber Capacitor Mount Nuts Tie Down Capacitor Mount b Remove the two screws that secure each tie down capacitor mount Remove the tie down capacitor mounts and save screws and capacitor mounts c Remove the six setscrews from each IGBT and save Setscrews Nuts for DC Flexible Capacitor Busbars If replacing an IGBT module remove the nuts and DC flexible capacitor busbars and save
22. 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 Fast 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 IN024C EN P June 2012 Supersedes Publication 20B IN024B EN P January 2011 Copyright 2012 Rockwell Automation Inc All rights reserved Printed in the U S A
23. U cao PRA aa Ra d 60 Fan Transforme io ossev ena ads brise uode a bia deq E aa 60 Remove COomboleltg escas zetaue perdices o sebo Rage Eid acra 60 Tristall Components oo p cxx re e Feb vate ia ipee Y de n bl aC 60 Heatsink Fan Removal from Back of Drive seuuuuue 61 Remove CCOmpOBEhlbs Lo scs ora Ohne ER eR Ea E UE Rd Eae FERE 61 Install Components uet ad Pet RorbR da FA AINE P PRA rd 62 Heatsink Fan Removal from Front of Drive suueue 63 Remove Components cis eee cbe reds ev s rier ERE Tra ES 63 Install Components espet eiieeii NER rin Rea aerea ad 67 Thermal Sensors vocc do iret EE PXC IAE YR Erbe XH ba E ERba EN 68 Remove Components coa paoaa perdo Ebo AREETOR RE AERA RTPE 69 Install Componente cctendxayaceereadiaucersartasasdeonbieds 69 DC Link Choke AC Input Oblyi us diosa peso haasbe e tdor berbirbds 70 Remove Componclibssoexesasbechb e eden ERE ES E REPRE EM 70 Install Conpofleli oniia debs kid viae ead d adadbl Vid debate 70 Rockwell Automation Publication 20B INO24C EN P June 2012 Table of Contents MOV Surge Suppressor AC Input Only 0 0 ee eee eee 71 Remove Components ssie srice es Boeter a Ena RE 71 Install Cobupab etg disse aie ded Dua ti teiseni Eri Sass 71 Precharge SCR Module and Diode DC Input Only 72 Remove Components esscsiseverevexsete kr ra vay EE PR E EE 72 Install Components sccs ccscsa HERE e CEPR NEE EE EAE PR UO E uE 72 Rockwell A
24. ation 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 Use the Worldwide Locator at http www rockwellautomation com support americas phone en html or contact Canada 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 complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information
25. autions on page 12 and Important Initial Steps on page 13 2 Remove the stacking panel as detailed on page 26 Balancing Resistor and Mounting Screws t C NO YN O Screw for Resistor black wire d Screw for Resistor blue wire Af N Screw for Resistor yellow wire 3 Label and disconnect all wires for the balancing resistor Black negative busbar e Yellow bus capacitor busbar Blue converter busbar 4 Remove the two mounting screws 5 Remove the balancing resistor Install Components 1 Use isopropyl alcohol to thoroughly clean the mounting surface of the transitional busbar and the mounting surface of the new balancing resistor 2 Apply thermal grease to the mounting surface of the new balancing resistor Torque the two mounting screws to 2 9 Nem 26 lbein 3 Connect the wires for the balancing resistor Torque the three screws to 2 9 Nem 26 lbein Black negative busbar Yellow bus capacitor busbar e Blue converter busbar 4 Install the stacking panel as detailed on page 27 5 Replace all safety shields and enclosure covers before applying power to the drive 48 Rockwell Automation Publication 20B IN024C EN P June 2012 Component Replacement Procedures Chapter 3 Inverter Power Module Kit includes IG BT Qty Component 1 IGBT module with circuit board 1 gate interface board 1 Gate interconnect harness 3 Flexible capaci
26. bber board AC input only fasten to the standoffs on the converter busbars 2 9 26 Converter snubber resistors AC input only fasten to the frame around the heatsink 2 9 26 Current transducer brackets fasten the mounting brackets to the current transducer 1 6 14 Current transducer assembly fasten to the backplane 2 9 26 DC bus filter board fasten to glastic standoffs on stacking panel 17 15 DC link choke AC input only fasten mounting brackets to the bottom of the chassis 9 80 fasten cables to the choke connectors 9 80 Encoder board optional fasten to standoffs on main control board 2 14 Heatsink fan cover fasten to the back of the drive 2 9 26 Heatsink fan mounting plate fasten the heatsink fan to the fan mounting plate 2 9 26 Fan transformer fasten to the mounting plate below the capacitor bank fan 5 6 50 Rockwell Automation Publication 20B IN024C EN P June 2012 21 Chapter 1 Component Diagrams and Torque Specifications Torque Component Fastener Application Nem Ibein Flexible capacitor busbars fasten to the transitional busbar 5 6 50 fasten to the IGBT module 5 6 50 Gate interface board fasten to upright bracket on heatsink 1 8 16 Ground wire green and yellow from TB11 to the HIM cradle board 1 6 14 HIM cradle board fasten to the main control panel 2 9 26 IGBT module fasten to the heatsink first sequence 0 7 6 0 second sequence 2 3 20 fi
27. ber Capacitors 3 per IGBT Inverter Power Module IGBT W under Capacitors V and U below W IGBT Gate Harness and CT Harness Balancing Resistor Power Interface Board under Main Control Panel E 2 Main Control Panel Thermal Ribbon Cable Main Control Sensor and Wire Board to Power Interface Board shown disconnected Main Control Board Ribbon Cable Main Control Nuria HIM Cradle Board to Comm Board i HIM Blank shown on this Drive Fan Terminal Block TB9 HIM Cradle Precharge Board Stacking Panel Main Control Panel TB11 DC Bus Filter Board Fan Transformer 3 DC Link Choke Input Connection Top DC Link Choke T DC Link Choke Input Output Connection Connection Bottom Bottom DC Link Choke 18 Rockwell Automation Publication 20B INO24C EN P June 2012 Component Diagrams and Torque Specifications Chapter 1 Circuit Boards Figure 5 Circuit Boards on Frame 8 Description DC bus filter board Precharge board HIM cradle board Main control board Power interface board Switch mode power supply board Communication board slots optional Main Control Panel Stacking Panel Mme Encoder board optional Rockwell Automation Publication 20B IN024C EN P June 2012 19 Chapter 1 Component Diagrams and Torque Specifications Fastener Torque Specifications Torque Sequence ATTENTION When mounting components to a driv
28. board 5 6 26 Transitional busbar mounting brackets to the glastic spacers 5 6 50 mounting brackets to the drive 2 9 26 fasten to the bus capacitor setscrews 5 6 50 22 Rockwell Automation Publication 20B IN024C EN P June 2012 Chapter 2 Basic Component Removal Procedures Overview Component removal and replacement in this chapter are located on the stacking paneland transitional busbar assemblies highlighted below See Circuit Boards on page 19 to identify the various panels that comprise the stacking panel assembly Transitional Busbar Assembly a E Stacking Panel Assembly p2 Et l EY Main Control Panel Assembly A x y i Rockwell Automation Publication 20B IN024C EN P June 2012 23 Chapter2 Basic Component Removal Procedures Main Control Panel See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove the ribbon cable going from the main control board J2 to the power interface board J1 Ribbon 3 Disconnect the incoming ground wire to TB11 Remove the two screws on the main control panel below TB11 5 Remove the two mounting nuts at the top of the main control panel Mounting Nuts 2 at top of Main Control Panel Ground Wire Main Control Panel Mounting Scre
29. cable 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 Read and follow these statements before performing any service on the drive Read and follow the precautions in Safety Precautions on page 12 Identify components to be replaced using the figures in Chapter 1 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 k
30. cement Procedures Chapter 3 MOV Su rge Suppressor See Chapter 1 Component Diagrams and Torque Specifications to locate the AC Input Only component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove the stacking panel as detailed on page 26 3 Note wire placement and connections Disconnect the MOV ground wire and the R S and T wires to the AC busbars Remove the MOV mounting nut 5 Remove the MOV assembly Install Components 1 Install the new MOV assembly Torque the MOV mounting nut to 2 9 Nem 26 lbein 2 Connect all wires and connectors for the MOV 3 Torque the R S and T Phase power terminal block screws to 2 9 Nem 26 Ibein 4 Torque the ground wire nut to 9 0 Nem 80 lbein 5 Install the stacking panel as detailed on page 27 6 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B IN024C EN P June 2012 71 Chapter 3 Component Replacement Procedures Precharge SCR Module and See Chapter 1 Component Diagrams and Torque Specifications to locate the Diode DC Input Only component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove the stacking panel as detailed on page 26 Precharge Wires two places
31. e First Sequence 0 7 Nem 6 0 Ibein Second Sequence 2 3 Nem 20 Ibein Final Sequence 5 6 Nem 50 Ibein 2 Install the three supplied positive flexible capacitor busbars in positions 2 4 and 6 on the IGBT The positive flexible capacitor busbars have a shorter angle Shown with Transitional Busbar and all Flexible Capacitor Busbars installed for illustration purposes only Negative Flexible Capacitor Busbars Positive Flexible Capacitor Busbars Rockwell Automation Publication 20B IN024C EN P June 2012 51 Chapter 3 52 Component Replacement Procedures 3 Install the transitional busbar assembly See page 32 Only torque nuts and screws after all components are in place Install the three supplied negative flexible capacitor busbars in positions 1 3 and 5 on the IGBT The negative flexible capacitor busbars have a higher angle Install the tie down capacitor mount a Insert the short ends of the six threaded studs with nuts through the flexible capacitor busbars and into the left side of the IGBT Torque to 5 6 Nem 50 lbein WARNING Correct torque is critical to ensure correct operation of the drive Improper torquing could cause premature failure when attempting to operate the drive b Install the tie down capacitor mount with the two screws previously removed from the top and bottom of the capacitor mount Torque to 2 9 Nem 26 lbein 6 Install the AC output busbar ou
32. e s heatsink component fastener torque sequences and tolerances are crucial to component to heatsink 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 heatsink using two four and six screws Initial torque is 1 3 3396 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 6 Various point Mounting D DAD Initial Final End Initial Torque Sequence Two Point Mounting Four Point Mounting Start End End Start 1 2 o 3 Torque Sequence Torque Sequence 3 LT OA 4 D End Start Final Torque Sequence Six Point Mounting End End OY OY 906 9 D 9 Start Start Initial Torque Sequence Final Torque Sequence Note Do not exceed 0 7 Nem 6 Ibein on initial torque Rockwell Automation Publication 20B INO24C EN P June 2012 Component Diagrams and Torque Specifications Chapter 1 Torque Specifications The following table lists fastener locations by component how the fasteners are used and torque specifications Refer to Torque Sequence in this chapter for fastening two point four point and six point components to the heatsink
33. ea 32 Chapter 3 cio PPP 35 Main Control Board voseuasa dadas ead ME AEN pra dede eu Ed 35 Remove Components iiivsh2saeceiasaossagesses aE e enine 35 Install Components oo brdaeiked dUepauwt kao dd ou NEUE p ERE RE 36 T Gomm Dosis es ouuo Sau aU pe t POSEEEFRERY XC aeiaai 37 Remove Components sssr sue kareves eine bx wa va ele E nisk 37 Install Components e5sbaedetiatekebetesdi pola bede ba ep aba ua 39 Power Interface Boat au ceci edo d qua rd ddl Vale qas a SUA T dele bu edi 40 Remove Components ssis ne rueda Ee 40 Install Components oa cvaau accede Rd acrabiht eu rb DUI Ui rire 4l Switch Mode Power Supply Board 0 cee ce eee ee eee eee ee es 42 Remove OMPONChBcucsinhlacsivetbdasiceeesaltidstesmatee 42 Install Components cnt dice iece soo tiaietdteiicaanaebennds 42 Precharge Board as sssa seseque bte FA deen dnauadiaverasuiadaeesy 43 Remove Components eserine bte druide edMIpEe da beau EE 43 Install Components s 125405 eden Ubique pietinio ia todas 43 Rockwell Automation Publication 20B IN024C EN P June 2012 3 Table of Contents DC Bus Filter Boat ici eve baia vibe eddie bx Tiddd s bti 44 Remove Components eode dapi inoata p Ped dude d vgt 44 Install Components Pausa bae Cada vidc adu uaa adio d Mad dupa d 44 Bas Capa ro RIT c 45 Remove Componhehlts ssoos seek xis verre ee ois eae cee Pea weds 45 Install Conpobetibiu ei cep ERO pes Rp RARE S ERA ERE are as 46 Capacitor Bank Pattenden a seven dade EU DIR PER e CU RE
34. gate interface boards carefully route wires and connect to J8 on each gate interface board Be sure that the J8 connectors go to the correct IGBT 5 Connect the other end of this wiring harness at the J6 connector on the power interface board 6 Secure the wire harnesses with plastic ties 7 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B IN024C EN P June 2012 69 Chapter 3 Component Replacement Procedures i See Chapter 1 Component Diagrams and Torque Specifications to locate the In oke npu p p g que Sp Only component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 fs DC Back L2 Connector DC Back L1 Connector DC Front L3 Connector DC Front L4 Connector DC Choke Connectors 2 Labeland disconnect DC choke connectors 3 Remove the four screws for the DC link choke mounting brackets Remove the DC link choke Install Components 1 Install the new DC link choke mounting brackets to the drive Torque the four mounting screws to 9 0 Nem 80 Ibein 2 Install the choke connectors Torque the four choke connector screws to 9 0 Nem 80 Ibein 3 Replace all safety shields and enclosure covers before applying power to the drive 70 Rockwell Automation Publication 20B INO24C EN P June 2012 Component Repla
35. interface board Torque the two mounting screws to 1 7 Nem 15 Ibein 2 Connect all wiring For the ribbon cable going from the power interface board J1 to the main control board J2 connect the cable at J1 on the power interface board 3 Reinstall the main control panel See page 25 4 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B INO24C EN P June 2012 y Chapter 3 Component Replacement Procedures Switch Mode Power See Chapter 1 Component Diagrams and Torque Specifications to locate the Supply Board component detailed in these instructions Remove Components l Use your fingers or needle Remove the switch mode Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 Remove the main control panel as detailed on page 24 Disconnect all cables J2 J4 J3 J1 from the switch mode power supply board Remove the switch mode Spacers power supply board mounting torx screw located at the lower right corner of the board nose pliers to squeeze the tabs of each of the three spacers and separate the switch mode power supply board from the mounting plate Screw power supply board Install Components 1 Install the new switch mode power supply board Torque the mounting screw to 1 7 Nem 15 Ibein Connect J2 J4 J3 and J1 cables 3 Reinstall the main cont
36. ire Screw 7 g Optional 20 Comm x Board Detail Mounting Screws 4 Mounting Screw Rockwell Automation Publication 20B IN024C EN P June 2012 37 Chapter 3 Component Replacement Procedures 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 6 Ifneeded use the same flathead screwdriver tip to pry the seven locking tabs away from the T Comm board Q anen Bradwy 1X T Comm Board Locking Tab Locations Five locking tabs are on the back side 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 38 Rockwell Automation Publication 20B INO24C EN P June 2012 Component Replacement Procedures Chapter 3 Install Components 1 In
37. ix setscrews to secure the flexible capacitor busbars to each IGBT board Finger tighten only 32 Rockwell Automation Publication 20B IN024C EN P June 2012 Basic Component Removal Procedures Chapter 2 6 Reinstall the screws for the four side standoffs and brackets to secure the transitional busbar assembly to the chassis a Torque the screws to 5 6 Nem 50 bein to secure the brackets to the four red glastic spacers b Torque screws to 2 9 Nem 26 lbein to secure the two brackets to the drive chassis 7 Torque the six setscrews for each IGBT board to 5 6 Nem 50 Ibein IMPORTANT When torquing down each setscrew place a flathead screwdriver against the side of the flexible capacitor busbar to minimize twisting Do not rest the screwdriver against any IGBT board while performing this task to avoid cracking or breaking the board 8 Reinstall the tie down capacitor mount on each IGBT board Reinstall two screws simultaneously to secure each Mount Torque screws to 2 9 Nem 26 Ibein 9 Install three snubber resistors onto the six setscrews for each IGBT board Reinstall two screws to secure each snubber resistor against the tie down capacitor mount Torque screws to 5 6 Nem 50 lbein 10 Torque the nuts that secure the nine negative flexible capacitor busbars to the transitional busbar to 5 6 Nem 50 Ibein 11 Torque the nuts that secure the transitional bus bar to the bus capacitor setscrews to 5 6 Nem 50 Ibein
38. llow Ground Wire Screws and Washers 2 each 3 Unscrew the green yellow ground wire from the communications panel 4 Remove the two nuts and two screws and washers for the communications panel Rockwell Automation Publication 20B IN024C EN P June 2012 35 Chapter3 Component Replacement Procedures 5 Disconnect both ribbon cables from the left side of the main control board Main Control Board Screws 4 Ribbon Cable 1 of 2 h TB11 Cable B Ze I Connector Encoder Board Optional Encoder Board Screws 2 Hex standoffs 2 are between both boards Oc M 6 Hold the communications panel and release the cable at the bottom of the panel from its clamp see previous page for its location and set the communications panel aside 7 Ifneeded unscrew and disconnect the connector from the main control board for the wire set going to TB11 Do not disconnect any wires from TB11 8 If present unscrew the two screws for the encoder board Gently pull off the encoder board 9 Unscrew the four screws and two hex standoffs holding the main control board 10 Remove the main control board Install Components 1 Install the new main control board with four screws and two hex standoffs Torque the screws and standoffs to 2 Nem 14 lbein 2 Install the encoder board if the optional encoder board was installed with two screws Be sure to match up the J7 connectors T
39. low 1 O oe e oe First Torque Final Torque Sequence Sequence 0 7 Nem 6 0 Ibein 5 6 Nem 50 Ibein O c ol O o O QO Install the precharge busbars Torque to 5 6 Nem 50 bein Install the precharge wires Torque to 2 9 Nem 26 lbein Install the precharge cables Torque the screws to 12 2 Nem 108 Ibein Install the stacking panel as detailed on page 27 ont ON Ww A Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B INO24C EN P June 2012 73 Chapter 3 Component Replacement Procedures Notes 74 Rockwell Automation Publication 20B INO24C EN P June 2012 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http 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 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 www rockwellautomation com support Install
40. mber at the top and torque to 2 9 Nem 26 lbein 7 Replace the wires from the converter snubber resistors to the snubber boards The black wire goes to J1 The blue wire goes to J2 8 Reinstall AC busbars R S T Torque to 9 0 Nem 80 Ibein Rockwell Automation Publication 20B IN024C EN P June 2012 57 Chapter3 Component Replacement Procedures 9 Reinstall the DC and DC busbars and torque to 9 0 Nem 80 Ibein 10 Install stacking panel as detailed on page 27 11 Replace all safety shields and enclosure covers before applying power to the drive Converter Snubber See Chapter 1 Component Diagrams and Torque Specifications to locate the Resistors AC Input Only component detailed in these instructions Remove Components Kit includes snubber board and resistor 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove the stacking panel as detailed on page 26 Snubber Resistor for R SCR Snubber Resistor for S SCR Resistor for T SCR 3 Verify the snubber resistor s with a volt ohm meter The reading should be 8 ohms 1096 e Ifthe reading is not within tolerance perform the remainder of this procedure e Ifthe reading is within tolerance do not perform the remainder of this procedure 4 For the R snubber resistor only Remove the transitional busbar assembly as detailed on page 28 5 Label and disconnect the wires from snubbe
41. n control panel NOTE Mounting position of boards on stacking panel may vary J8 J6 J2 F B J18 J16 J14 J23 Tp TB2 f e TIP Remove the main control panel first to provide better access to wiring and fasteners See Main Control Panel on page 24 Connected Label on Wire Label on Notes Component or Connector Board Precharge board J2 J3 J2 J3 DC bus filter board TB1 TB1 Power interface board J8 J8 J16 U U phase CT J15 V V phase CT J14 W W phase CT J23 UP VP WP U V W positive gates J18 UN VN WN U V W negative gates J6 J6 TB11 Customer wiring Remove if not already done 3 Disconnect the main control panel thermal sensor and wire located above the main control board from the wiring harness see Figure 4 on page 18 26 Rockwell Automation Publication 20B INO24C EN P June 2012 Basic Component Removal Procedures Chapter 2 Remove the six nuts for mounting the stacking panel Shown without main control panel NOTE Mounting position of boards on stacking panel may vary ME m al 5 Remove the stacking panel carefully set aside Install Components 1 Torque the six mounting nuts to 5 6 Nem 50 lbein 2 Connect the main control panel thermal sensor and wire located above the main control board 3 Connect all wiring that was removed 4 Replace all safety shields and enclosure covers before applying power to the drive
42. nal Busbar Assembly Removed 3 Bus Capacitor Busbar oo P E Bus Capacitor Busbar Oma ee Nuts and Washers 18 each mi 3 Labeland remove all wires and connectors from the bus capacitor busbar Remove nuts and washers 18 each fastening the bus capacitor busbar to the capacitors 5 Remove the bus capacitor busbar 6 Remove the capacitors Rockwell Automation Publication 20B INO24C EN P June 2012 45 Chapter 3 Component Replacement Procedures 46 Install Components ATTENTION Install each capacitor so its vent plug is at the IN top or 12 o clock Component and system damage may result if you position any bus capacitor incorrectly 1 Usea 3 mm angle hex wrench to replace the setscrews for each new capacitor Torque to 0 7 Nem 6 lbein IMPORTANT Each capacitor needs a short and long setscrew See the illustration below for where to install each setscrew Capacitors shown with Bus Capacitor Busbar installed Vent Plug must be at top or 12 o clock F A F Longer Setscrew EM Y for Transitional pi Busbar Mud Shorter Setscrew for Bus Capacitor Busbar 2 Place capacitors into correct position in drive vent plug at top or 12 o clock 3 Place bus capacitor busbar onto capacitors 4 Install the 18 washers and nuts onto setscrews but do not tighten yet 5 Place the transitional busbar in position Make sure that all setscrews washers
43. nal sequence 5 6 50 Main control board fasten to the main control panel 2 14 Main control panel fasten to the stacking panel top of the main contro panel 5 6 50 bottom of the main control panel 2 9 26 MOV surge suppressor AC input only fasten to the chassis 2 9 26 MOV surge suppressor AC input only wiring fasten black wires to R S and T busbar connection at the SCR modules 2 9 26 fasten green and yellow ground wire to ground stud at the bottom of the 9 0 80 chassis Output busbar fasten to the AC output busbar 9 0 80 fasten to the U V or W busbar 9 0 80 setscrew and nut to the U V or W busbar 5 6 50 Power interface board fasten to stacking panel 1 7 15 Precharge board fasten to stacking panel for AC input 1 7 15 for DC input 1 4 turn clockwise Precharge SCR module and diode DC input only fasten to the heatsink first sequence 0 7 6 0 final sequence 5 6 50 Precharge busbars DC input only fasten to the SCR module and diode 5 6 50 Precharge wires DC input only fasten to the precharge busbars 2 9 26 Precharge power cables DC input only fasten to the precharge busbars 12 2 108 Snubber resistors fasten to the IGBT setscrews at the tie down capacitor mount 5 6 50 Stacking panel fasten to the chassis 5 6 50 Switch mode power supply board fasten to stacking panel 17 15 Thermal sensors fasten to heatsink hand tighten fasten to main control panel hand tighten Tie down capacitor mount fasten to the bracket at left of IGBT
44. now 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 IN024C EN P June 2012 13 Preface Notes 14 Rockwell Automation Publication 20B IN024C EN P June 2012 Chapter 1 Component Diagrams and Torque Specifications Drive Components Figure 1 Frame 8 AC Drive Components lo Gate Interface Board 3 Drive Shown With r7 S Stacking Panel Removed m rs o o Current Transducer 3 Transitional Busbar Flexible Capacitor Busbars 18 Output Busbar 3 AC Output Busbar 3 DC Bus Capacitor 18 IGBT Interface Board and IGBT 3 Balancing Resistor 3 Tie Down Capacitor Mount Snubber Capacitors for IGBTs 9 Converter Snubber Resistors 3 SCR Converter Power Module Capacitor Bank Fan Converter Snubber Board 3 MOV Surge Suppressor Converter Busbar 2 Fan Transformer Busbar Mounting Plate Heatsink Fan is behind this plate DC Busbar Motor Busbars U V W PE Ground and MOV Wire DC Busbar AC Busbars R S T Rockwell Automation Publication 20B
45. nuts and busbars 7 Cuttie wraps for the balancing resistor wiring Rockwell Automation Publication 20B IN024C EN P June 2012 29 Chapter2 Basic Component Removal Procedures 8 Disconnect the yellow wire for the balancing resistor You do not need to disconnect the blue and black wires Balancing Resistor Balancing Resistor yellow wire Disconnect here 9 Remove the four side standoffs and brackets for the transitional busbar assembly 10 Remove the 18 nuts fastening the transitional busbar assembly to the bus capacitors The setscrews may come out with the nuts Save all nuts and Setcrews DC Choke Output Cables Transitional Busbar Nuts 18 attached to Setscrews Photo shows setscrews in Capacitors these setscrews may come out with the Transitional Busbar nuts when they are removed 30 Rockwell Automation Publication 20B IN024C EN P June 2012 Basic Component Removal Procedures Chapter 2 11 Remove the transitional busbar assembly OHO 4 9 Rockwell Automation Publication 20B IN024C EN P June 2012 Negative DC Flexible Capacitor Busbar attached to top side of
46. om Front of Drive on page 63 See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Verify that there is at least a 91 cm 3 ft clearance in back of the drive for access to the heatsink fan 3 From the front of the drive disconnect the cables for both the fan and the fan capacitor Access the cables by gently pulling the wiring from behind the busbar mounting panel Front of drive IJ Connectors Press tabs in for removal 1 Disconnect here s 4 On the back of the drive remove the eleven screws for the fan cover see the figure on the next page for the screw locations Do not remove the screws for the screen 5 Use the handle to separate the fan assembly from the drive enclosure Some force may be needed to separate the fan from the enclosure as the gasket may be tight or sticky Rockwell Automation Publication 20B IN024C EN P June 2012 61 Chapter 3 Component Replacement Procedures 6 Remove the fan Fan Cover Screw Locations on Back of Drive SO Four on top and bottom for a total of eight Three on right side NOTE No screws on left side Install Components 1 Install the new gasket if the old gasket was damaged 2 Place the fan assembly into the chassis but not installed in final position
47. onnector Wire Color s Connects To J1 ribbon J2 on main control board ribbon cable J2 black J1 on switch mode power supply board J6 black Monitor wire to thermal sensors J8 red white black J7 U on U phase gate interface board J9 red white black J1 on 24V power supply board J10 red black white blue J3 on precharge board J12 red white J3 on switch mode power supply board J13 black J2 on switch mode power supply board J14 red white black U phase current transducer J15 red white black V phase current transducer J16 red white black W phase current transducer J18 blue white U V W negative gates lower phase J23 orange black U V W positive gates upper phase 40 Rockwell Automation Publication 20B INO24C EN P June 2012 Component Replacement Procedures Chapter 3 Connector Wire Color s Connects To J24 red black J1 on precharge board TB1 on DC bus filter board AC input only TB1 on DC bus filter board DC input only TB1 green yellow PE on TB11 TB2 red 33 34 and 35 on TB11 Remove the two power interface board mounting torx screws located at the upper right and lower left corners of the board as shown at right 5 Use your fingers or needle nose pliers to squeeze the tabs of each of the nine spacers see previous page for their locations and separate the power interface board from the mounting plate 6 Remove the power interface board Install Components 1 Install the new power
48. onverter busbars at the top of each bar Rockwell Automation Publication 20B INO24C EN P June 2012 63 Chapter3 Component Replacement Procedures Do not disconnect the U V or W busbars at the bottom AC Drive Shown DC Busbar Do not disconnect Busbars at the bottom 5 Disconnect all busbars where they connect to the converter SCR modules with 16 mm bolts Disconnect wiring Do not disconnect the U V or W busbars at the bottom AC Drive Shown 16 mm bolts Do not disconnect Busbars at the bottom 64 Rockwell Automation Publication 20B IN024C EN P June 2012 Component Replacement Procedures Chapter 3 6 Disconnect the U V and W busbars at the top of each bar where they connect to the output busbars for the current transducers with two 17 mm bolts and one 11 mm nut Do not remove the busbars from the setscrew on the output busbars at this time Do not disconnect the U V or W busbars at the bottom Output Busbar T mm bolts v mm nut E Current Transducer Setscrew after 11 mm nut is removed 7 Remove the four 10 mm nuts for the busbars mounting plate T amp Busbar Mounting Plate Rockwell Automation Publication 20B INO24C EN P June 2012 65 Chapter3 Component Replacement Procedures 8 Remove the entire busbar and mounting plate assembly Set aside AC Input Drive O DC Input Drive E
49. orque the screws to 2 Nem 14 lbein 3 Connect the ribbon cable and TB11 cable connector to the main control board Torque the two mounting nuts at the top of the communications panel to 5 6 Nem 50 Ibein 5 Torque the two screws on the communications panel near TB11 to 3 Nem 26 lbein 6 Torque the screw for the green yellow ground wire from TB11 to the HIM cradle board to 1 6 Nem 14 Ibein 7 Replace all safety shields and enclosure covers before applying power to the drive 36 Rockwell Automation Publication 20B INO24C EN P June 2012 Component Replacement Procedures Chapter 3 T Comm Board See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 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 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 HIM cradle board Remove the HIM cradle board HIM Board slot Ribbon Cable Connector Wiring Connector Pcrouncing w
50. owerFlex 700 AC Drives User Manual publication 20B UM002 Provides basic information needed to install start up and troubleshoot the PowerFlex 700 drive Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 Provides general guidelines for installing a Rockwell Automation industrial system Product Certifications website http www ab com You can view or download publications at Provides declarations of conformity certificates and other certification details http www rockwellautomation com literature To order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative Rockwell Automation Publication 20B IN024C EN P June 2012 11 Preface Safety Precautions The precautions and general installation requirements provided in the PowerFlex 700 Frame 7 10 Installation Instructions publication 20B INO14 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 A 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 Terminals 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
51. pment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss 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 Pe eD IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley Rockwell Software Rockwell Automation PowerFlex 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 Specifications Basic Component Removal
52. publication provides guidelines for replacing the major components in the PowerFlex 700 Frame 8 drive All kits include necessary components ESD wrist strap and hardware if required and thermal grease if required Description Kit Catalog No Notes Printed Circuit Boards Gate Interface Board SK G1 GDB1 F8910 Drive requires three kits Precharge Board SK G9 PRE1 V480 AC input 1336 PB SP22C DC input Power Interface Board SK G9 GDB1 D365 365A drives SK G9 GDB1 D415 415A drives SK G9 GDB1 D481 481A drives SK G9 GDB1 D535 535A drives SK G9 GDB1 D600 600A drives Main Control Board SK G9 VMCB1 DO 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 DC Bus Filter Board 2364 SPP02A Fans and Main Fan Circuit Components Heatsink Fan SK G1 FAN1 F810 Includes fan and fan enclosure Capacitor Fan SK G1 FAN2 F8910 Power Module Sub assemblies Inverter Power Module IGBT SK G1 QOUT1 F8 ncludes One IGBT module One gate interface board Gate interconnect harness Six flexible capacitor busbars Three snubber capacitors One tie down capacitor mount Drive requires three kits Converter Power Module SCR SK G1 SCR1 F89 AC input Kit includes three SCR modules SCR Snubber Kit SK G1 SCRSNUBRB AC input drive requires three kits DC Precharge SCR Module SK G1 SCR2 F89 DC input Includes One SCR module
53. r resistors that will be replaced 6 Remove the resistor 58 Rockwell Automation Publication 20B INO24C EN P June 2012 Component Replacement Procedures Chapter 3 Install Components 1 Use isopropyl alcohol to thoroughly clean the mounting surface of the heatsink and the mounting surface of the new snubber resistor 2 Use a 3 inch paint roller or putty knife to apply a thin even coating of the supplied thermal grease to the mounting surface of the new snubber resistor and install Torque screws to 2 9 Nem 26 lbein 3 Connect the wires 4 For the R snubber resistor only Install the transitional busbar assembly as detailed on page 32 5 Install stacking panel as detailed on page 27 6 Replace all safety shields and enclosure covers before applying power to the drive Converter Snubber Board See Chapter 1 Component Diagrams and Torque Specifications to locate the AC Input Only component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove the stacking panel as detailed on page 26 Snubber Board for R SCR Snubber Board for S SCR Snubber Board for T SCR pem 3 Labeland disconnect wires from the converter snubber board to be ZA RE uU replaced Remove the two screws that secure the board 5 Remove the board Rockwell Automation Publication 20B IN024C EN P June 2012
54. re covers before applying power to the drive Rockwell Automation Publication 20B IN024C EN P June 2012 Component Replacement Procedures Chapter 3 Gate Interface Boa rd See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove the safety cover over the gate interface board 3 Label and disconnect all wires J1 J8 Remove the four mounting nuts and remove the board Gate Interface Board Mounting Nuts 4 Install Components 1 Install the new board Torque the four mounting nuts to 1 8 Nem 16 Ibein 2 Connect J1 J8 wires as shown above NOTE J from the corresponding IGBT connects to J6 on the gate interface board 3 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B INO24C EN P June 2012 53 Chapter 3 Component Replacement Procedures Current Transducer See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Labeland disconnect the wire from the transducer 3 Remove the two 17 mm bolts and one 11 mm nut that connect the U V or W busbar to
55. rol panel See page 25 Replace all safety shields and enclosure covers before applying power to the drive 42 Rockwell Automation Publication 20B IN024C EN P June 2012 Component Replacement Procedures Chapter 3 Precharge Board See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove the safety cover over the precharge board 3 For DC input only Verify that customer wiring to TB2 is properly labeled and then disconnect wiring from TB2 4 Using pliers if needed remove the three wiring harnesses J1 J2 J3 Note Some connectors may not be labeled Label them if needed DC 5 For AC input Remove the precharge board mounting torx screw located at the upper left corner of the precharge board 6 For AC input Use your fingers or needle nose pliers to squeeze the tabs of each of the three spacers and separate the precharge board from the mounting plate 7 For DC input Turn each of the six lock screws 1 4 turn counterclockwise to unlock 8 Remove the precharge board Install Components 1 Install the new precharge board e For AC input Torque the mounting screw to 1 7 Nem 15 Ibein e For DC input Turn each of the six lock screws 1 4 turn clockwise to lock 2 Connect the wiring 3 Replace all safety shield
56. s and enclosure covers before applying power to the drive Rockwell Automation Publication 20B INO24C EN P June 2012 43 Chapter 3 Component Replacement Procedures DC Bus Filter Board 44 See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove the safety cover over the DC bus filter board 3 Disconnect red and black Mounting Bolts 4 wires from TB1 and TB2 terminals 4 Remove the four mounting bolts 5 Remove the DC bus filter board Install Components 1 Install the new DC bus filter board Torque the four mounting bolts to 1 7 Nem 15 lbein 2 Connect the red and black wires to TB1 and TB2 inal h ich TB2 3 TB2 1 TB1 3 TB1 1 terminals as shown at rig t red black red black 3 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B INO24C EN P June 2012 Component Replacement Procedures Chapter 3 Bus Ca p acitor See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove the transitional busbar assembly as detailed on page 28 Transitio
57. stall 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 Install the 20 Comm x board if used Torque the four mounting screws to 2 9 Nem 26 Ibein 5 Install the HIM cradle board Torque the two mounting screws to 3 Nem 26 Ibein 6 Install the screw for the green yellow ground wire from TB11 to the HIM cradle board Torque the screw to 1 6 Nem 14 Ibein 7 Connect the 8 pin wiring connector to the serial port 8 Connect the ribbon cable 9 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B IN024C EN P June 2012 39 Chapter3 Component Replacement Procedures Power Interface Board See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove the main control panel as detailed on page 24 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 7 ETT H mL sae Wa ann LALLA L M RN BAA e9 LIS LI Refer to the illustration above for connector locations C
58. tor busbar positive 3 Flexible capacitor busbar negative 1 Tie down capacitor mount 3 Snubber capacitor IMPORTANT If any IGBT module is damaged all IGBT modules and associated components should be replaced Perform the following procedure for all IGBT modules Refer to the figures in Chapter 1 Component Diagrams and Torque Specifications for these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove the stacking panel as detailed on page 26 3 Remove the AC output busbar at the current transducer a Remove and save the three bolts that secure the output busbar to the AC output busbar and to the U V or W busbar Busbar Bolts 3 Threaded Hex Stud and Nut b Remove and save the nut and threaded hex stud for the standoff c Slide the output busbar to the right as far as it goes d Remove and save the six screws that secure the AC output busbar to the IGBT and two nuts that secure the AC output busbar to its standoffs Remove and save the AC output busbar Remove transitional busbar assembly as detailed on page 28 Rockwell Automation Publication 20B INO24C EN P June 2012 49 Chapter 3 Component Replacement Procedures 5 Remove the Gate Interface board See page 53 Current Transducer Tie Down Assembly Capacitor Mount Snubber Gate Interface Capacitors Board Assembly not shown above AC
59. tput busbar and current transducer a Secure the AC output busbar to the two standoffs using the two nuts previously removed Torque nuts to 5 6 Nem 50 Ibein b Secure the AC output busbar to the IGBT by inserting six screws into the IGBT Torque screws to 5 6 Nem 50 Ibein c If removed insert the output busbar through the current transducer assembly with the large end to the right d Secure the current transducer assembly transducer and brackets using the two screws that were removed with the assembly Torque to 2 9 Nem 26 lbein e Secure the left end of the output busbar to the AC output busbar with one screw Torque to 9 0 Nem 80 lbein f Secure the other end of the output busbar to the U V or W busbar with the setscrew and nut Torque the nut to 5 6 Nem 50 lbein g Install the two screws that connect the output busbar to the U V or W busbar Torque to 9 0 Nem 80 Ibein Install the gate interface board a Install the gate interface board using the four nuts removed previously Torque screws to 2 9 Nem 26 Ibein b Install the supplied Gate Interconnect Harness c Connect wiring between the IGBT and gate interface board as shown in Gate Interface Board on page 53 d Connect wires to the current transducer Install the three snubber capacitors in the reverse order of the removal instructions detailed on page 29 Torque nuts to 5 6 Nem 50 lbein Replace all safety shields and enclosu
60. ublication 20B IN024C EN P June 2012 55 Chapter 3 Component Replacement Procedures Converter Power Module 7 IMPORTANT If any converter SCR module fails all three SCR modules should be SCR AC Input Only 56 replaced kit includes three SCR modules See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Remove the stacking panel as detailed on page 26 Converter SCR Modules Converter Snubber Boards Converter Snubber Boards Serial Number Label R S T Snubber Board Standoff Does not need to be removed Bons i il I Converter Busbar Upper Busbar Lower oJ S Converter SCR Modules 3 Remove all three converter snubber boards and set them aside a Label and disconnect wires from the converter snubber board b Remove the two screws that secure the board c Remove the board and set aside 4 Note the orientation of the converter busbars and remove the eight bolts that secure the busbars to the converter SCR modules and to the DC and DC busbars Set the converter busbars aside Rockwell Automation Publication 20B IN024C EN P June 2012 Component Replacement Procedures Chapter 3 5 Disconnect the three AC busbars R S T at the top only You do not need to remove the wires from
61. utomation Publication 20B INO24C EN P June 2012 5 Table of Contents Notes 6 Rockwell Automation Publication 20B INO24C EN P June 2012 Summary of Changes New and Upd ated This table contains the changes made to this revision Information E Topic Page Added additional resources table 11 Updated the torque specifications table zl Updated torques and steps for these install components procedures Main control panel 25 Stacking panel 21 Transitional busbar assembly ae Main contro board 36 T comm board 2d Power interface board 41 Switch mode power supply board 42 Precharge board 43 Bus capacitor 46 Capacitor bank fan 47 Balancing resistor 48 Balancing resistor 51 Gate interface board 53 Current transducer 55 Converter power module SCR AC input only 57 Converter snubber resistors AC input only 59 Converter snubber board AC input only 60 Fan transformer 60 Heatsink fan removal from back of drive 62 Heatsink fan removal from front of drive 67 Thermal sensor 69 DC link choke AC input only 70 MOV surge suppressor AC input only ral Precharge SCR module and diode DC input only 22 Rockwell Automation Publication 20B INO24C EN P June 2012 7 Summary of Changes Notes 8 Rockwell Automation Publication 20B INO024C EN P June 2012 Preface Introduction Component Kits This
62. ws 2 below TB11 to TB11 6 Disconnect the wire harnesses from TB11 to the switch mode power supply board J4 connector and at TB1 and TB2 on the power interface board 7 Label and remove all customer wiring from TB11 8 Remove the main control panel and carefully set aside 24 Rockwell Automation Publication 20B INO24C EN P June 2012 Basic Component Removal Procedures Chapter 2 Install Components 1 Replace any customer wiring to TB11 2 Connect the wire harnesses from TB11 to the switch mode power supply board J4 connector and at TB1 and TB2 on the power interface board 3 Torque the two mounting nuts at the top of the main control panel to 5 6 Nem 50 Ibein Torque the two screws on the main control panel below TB11 to 2 9 Nem 26 Ibein 5 Connect the incoming ground wire to TB11 6 Connect the ribbon cable going from the main control board J2 to the power interface board J1 7 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B IN024C EN P June 2012 25 Chapter2 Basic Component Removal Procedures Stacki ng Panel See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13 2 Labeland disconnect wiring as listed below Shown without mai

Spec Sheet - The Reynolds Company

Contents

Download Pdf Manuals

Related Search

Related Contents