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Installation Instructions

1. Plug with O No Prongs Plug with Prongs 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 below ah o O Oo Lis O OI e First Torque Final Torque Sequence Sequence 0 7 Nem 6 0 beim 5 6 Nem 50 Ibein O b o e 0 Q O Q Install the precharge busbars Torque to 5 6 Nem 50 bein Install the precharge wires Torque to 2 9 Nem 26 bein Install the precharge cables Torque the screws to 12 2 Nem 108 bein Install the stacking panel as detailed on page 27 D N nn 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 th
2. Chapter 1 Component Diagrams and Torque Specifications Figure 1 Frame 8 AC Drive Components O wii d INE e d E Se It VP SR l 0 W H HIS BI gt o o H o DC R SI DC o o o Ip vi AC Busbars R S T Rockwell Automation Publication 20B INO24C EN P June 2012 Gate Interface Board 3 Current Transducer 3 Output Busbar 3 AC Output Busbar 3 IGBT Interface Board and IGBT 3 Tie Down Capacitor Mount Converter Snubber Resistors 3 SCR Converter Power Module Converter Snubber Board 3 Converter Busbar 2 Busbar Mounting Plate Heatsink Fan is behind this plate Motor Busbars U V W DC Busbar 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 el SG eiei 00 weie e Flexible Capacitor Busbars 18 Output Busbar 3 AC Output Busbar 3 DC Bus Capacitor 18 G IGBT Interface Board and IG
3. 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 INO24C EN P June 2012 61 Chapter 3 Component Replacement Procedures 6 Remove the fan Fan Cover Screw Locations on Back of Drive Four on top and bottom E 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 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 INO24C EN P June 2012 Component Replacement Procedures Chanter 3 Heatsink Fan Removal The heatsink fan is located on the back of the drive These instructions explain
4. e A sensor secured to the upper mounting bracket for the main control panel 2 wires s A sensor secured to the heatsink above the SCR modules s A connector to J8 on each of the three gate interface boards 4 wires See Chapter 1 Component Diagrams and Torque Specifications to locate the component detailed in these instructions 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 4 For the 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 1
5. 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 A Disconnect the DC and DC busbars that connect to the converter busbars at the top of each bar Rockwell Automation Publication 20B INO24C EN P June 2012 63 Chapter 3 Component Replacement Procedures 64 Do not disconnect the U V or W busbars at the bottom AC Drive Shown 17 mm bolt on oe 1191 d SE Hez DC Busbar Do not disconnect Busbars at the bottom 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 Rockwell Automation Publication 20B INO24C 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
6. J8 wires as shown above NOTE J4 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 Label and 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 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 Compone
7. Use a3 mm angle hex wrench to replace the setscrews for each new capacitor Torque to 0 7 Nem 6 bein 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 Longer Setscrew for Transitional Busbar 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 S Place the transitional busbar in position Make sure that all setscrews washers 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 bein 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 46 Rockwell Automation Publication 20B INO24C EN P June 2012 Component Replacement Procedures Chapter 3 Capacitor 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 S
8. 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 wg 1 SC d a Output Busbar E SZ 17 mm bolts tan mm nut E s Current Transducer k F gt 9 Setscrew after 11 mm nut is removed Busbar Mounting Plate 10 mm nuts 4 Rockwell Automation Publication 20B INO24C EN P June 2012 65 Chanter 3 Component Replacement Procedures 8 Remove the entire busbar and mounting plate assembly Set aside DC Input Drive O AC Input Drive 0 ie H 8 D o D D d o o o DC np S T 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 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 INO24C EN P June 2012 Component Replacement Procedures Chapter 3 Install Components 1 Remove the new fan housing from the new fan
9. 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 EPP 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 Pro
10. 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 INO24C EN P June 2012 33 Chanter 2 Notes 34 Basic Component Removal Procedures Rockwell Automation Publication 20B INO24C EN P June 2012 Chapter 3 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 yellow 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 INO24C EN P June 2012 35 Chapter 3 Component Replacement Procedures 5 Disconnect both ribbon cables from the left side of the main control board Main Control Board Screws 4 Ribbon Cable 9
11. Board SK G9 VMCB1 D0 115V 1 0 SK G9 VMCB1 CO 24V 1 0 T Comm Board SK G9 TCOMM Switch Mode Power Supply Board SK G9 PWRS1 D0 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 Power Module Sub assemblies SK G1 FAN2 F8910 Inverter Power Module IGBT SK G1 QOQUT1 F8 Includes e One IGBT module e 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 Miscellaneous SK G1 SCR2 F89 DC input Includes e One SCR module e One diode Current Transducer SK G1 CT1 F8 Includes one transducer Drive requires three kits Thermal Sensor Kit SK G1 THM1 F89 AC input Includes e Main control panel thermal sensor e Heatsink thermal sensor SK G1 THM2 F89 Rockwell Automation Publication 20B INO24C EN P June 2012 DC input Includes e Main control panel thermal sensor e Heatsink thermal sensor Preface 10 Description Miscellaneous continued Kit Catalog No Notes Bus Capacitor Kit SK G1 BUSCAP1 F8 365A 415A and 481A only Includes
12. 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 Adda washer rounded side down and nut to each bus capacitor setscrew Finger tighten only 4 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 six setscrews to secure the flexible capacitor busbars to each IGBT board Finger tighten only 32 Rockwell Automation Publication 20B INO24C 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 lbein to secure the brackets to the four red glastic spacers b Torque sc
13. 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 Allen Bradley Z 20 COMM C m smr rr a Ce Mot 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 Install the new T Comm board 2 Verify the board is locked into all seven locking tabs 3 Carefully bend the T Comm grounding tab until it is flush with the screw mount on the main control board 4 Install the 20 Comm x board if used Torque the four mounting screws to 2 9 Nem 26 lbein 5 Install the HIM cradle board Torque the two mounting screws to 3 Nem 26 lbein 6 Install the screw for the green yellow ground wire from TB11 to the HIM cradle board Torque the screw
14. new balancing resistor Torque the two mounting screws to 2 9 Nem 26 Ibein 3 Connect the wires for the balancing resistor Torque the three screws to 2 9 Nem 26 lbein e Black negative busbar e Yellow bus capacitor busbar s 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 INO24C EN P June 2012 Inverter Power Module IGBT Component Replacement Procedures Chapter 3 Kit includes Qty Component 1 IGBT module with circuit board gate interface board 1 Gate interconnect harness 3 Flexible capacitor busbar positive 3 Flexible capacitor busbar negative 1 Tie down capacitor mount 3 Snubber capacitor IMPORTANT fany 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 Remove the stacking panel as detailed on page 26 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 ee et Busbar B
15. one capacitor Drive requires 18 kits SK G1 BUSCAP2 F8 535A and 600A only Includes one capacitor Drive requires 18 kits Capacitor Bus Finger Kit SK G1 FLXBUS1 Included with the kit for inverter power module IGBT Can be ordered separately Includes 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 e One transformer e 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 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 fo
16. power to the drive 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 Ton 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 L Remove the HIM cradle board HIM Board slot TLL py Wm Wiring Connector Ces Screw KS Optional 20 Comm x Board Detail Mounting Screws 4 W s Mounting Screw Rockwell Automation Publication 20B INO24C 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
17. to 1 6 Nem 14 lbein 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 INO24C EN P June 2012 39 Chanter 3 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 Refer to the illustration above for connector locations 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
18. 10 1 of 2 Main Control Board Encoder Board Optional Encoder Board Screws 2 Hex standoffs 2 are between both boards 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 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 Ifpresent unscrew the two screws for the encoder board Gently pull off the encoder board Unscrew the four screws and two hex standoffs holding the main control board Remove the main control board Install Components 36 Install the new main control board with four screws and two hex standoffs Torque the screws and standoffs to 2 Nem 14 lbein Install the encoder board if the optional encoder board was installed with two screws Be sure to match up the J7 connectors Torque the screws to 2 Nem 14 lbein 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 lbein Torque the two screws on the communications panel near TB11 to 3 Nem 26 bein Torque the screw for the green yellow ground wire from TB11 to the HIM cradle board to 1 6 Nem 14 Ibein Replace all safety shields and enclosure covers before applying
19. BT 3 each oi lo Seel ee 66 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 INO24C EN P June 2012 DC Busbar oo SNS Component Diagrams and Torque Specifications Figure 3 Frame 8 Busbars AC Drive shown DC Busbar Transitional 9 Busbar Assembly e Rockwell Automation Publication 20B INO24C EN P June 2012 Chapter 1 17 Chapter 1 DC Link Choke Output Connection Top Transitional Busbar Inverter Snubber Capacitors 3 per IGBT Inverter Power Module IGBT W under Capacitors V and U below W IGBT Gate Harness and CT Harness Balancing Resistor Component Diagrams and Torque Specifications Figure 4 Frame 8 AC input drive shown DC Capacitor Bank Gate Interface Under Transitional Busbar Board Heatsink Thermal Sensor Connector J8 on each Gate Interface Board an Current Transducer 3 L M 1 Motor Busbars ES 3 Ki Power Interface Board fe e under Main Control Panel Ribbon Cable Main Control Board to Power Interface Board shown disconnected Ribbon Cable Main Contr
20. Installation Instructions Allen Bradley PowerFlex 700 Drive Frame 8 Components Replacement KI at ut K e ZZ E Allen Bradley Rockwell Software Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment
21. 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 UV 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 IN024C EN P June 2012 Basic Component Removal Procedures Chapter 2 4 Remove the six nuts for mounting the stacking panel Shown without main control panel NOTE Mounting position of boards on stacking panel may vary 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 Rockwell Automation Publication 20B INO24C EN P June 2012 27 Chanter 2 Basic Component Removal Procedures Transitional Busbar See Chapter 1 Component Diagrams and Torque Specifications to locate the Ass embly 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 d
22. Remove Components x Ses e e e Ee E e ie 61 Install Components dee ZE 62 Heatsink Fan Removal from Front of Drive 63 Remove Components xe tea neces cei we GARR Seated Wace 63 Install Components sse eee e e tes ne recers 67 DR EE 68 Remove EE 69 Install EEN 69 DG Link Choke AC Input On 70 Remove Components int e e id Shin tewd eesti heh 70 Install Components 2 G Gant coweclaaye cn ce Hre ss Sure sae eu 70 Rockwell Automation Publication 20B INO24C EN P June 2012 Table of Contents MOV Surge Suppressor AC Input On e 71 Remove Components x alee e e e gis ale are eae EE 71 Install Components ss sila nite da e e e oul elie dade Bac 71 Precharge SCR Module and Diode DC Input Only 72 Remove Components id e e e e e e SAS 72 Install Components 22s4 o es ee e 72 Rockwell Automation Publication 20B IN024C EN P June 2012 5 Table of Contents Notes 6 Rockwell Automation Publication 20B INO24C EN P June 2012 Summary of Changes New and Updated This table contains the changes made to this revision Information Fi Topic Page Added additional resources table AR Updated the torque specifications table vAR Updated torques and steps for these install components procedures Main control panel 25 Stacking panel 27 Transitional busbar assembly 32 Main control board 36 T comm board 39 Power int
23. TB2 Using pliers if needed remove the three wiring harnesses J1 J2 J3 Note Some connectors may not be labeled Label them if needed For AC input Remove the precharge board mounting torx screw located at the upper left corner of the precharge board 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 For DC input Turn each of the six lock screws 1 4 turn counterclockwise to unlock 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 bein s For DC input Turn each of the six lock screws 1 4 turn clockwise to lock Connect the wiring Replace all safety shields 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 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 I
24. Unscrew the four fan transformer mounting bracket screws Install Components 1 Install new fan transformer Torque four screws to 5 6 Nem 50 bein 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 Chanter 3 Heatsink Fan Removal The heatsink fan is located on the back of the drive from Back of Drive EEN For equipment clearance considerations the fan can also be removed from the front of the drive See Heatsink Fan Removal from 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 Z Connectors Press tabs in for removal Disconnect here L A 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
25. 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 4 For the three 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 INO24C EN P June 2012 69 Chapter 3 Component Replacement Procedures DC Link Choke AC Input See Chapter 1 Component Diagrams and Torque Specifications to locate the 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 DC Back L2 Connector DC Back L1 Connector DC Front L3 Connector DC Front L4 Connector DC Choke Connectors 2 Label and disconnect DC choke connectors 3 Remove the four screws for the DC link choke mounting brackets A Remove the DC link choke Install Components 1 Install the new DC link choke mounting brackets to the drive T
26. W positive gates upper phase 40 Rockwell Automation Publication 20B INO24C EN P June 2012 Component Replacement Procedures Chanter 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 4 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 interface board Torque the two mounting screws to 1 7 Nem 15 lbein 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 Ai 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 instruc
27. 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 10 s 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 snubber 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 Snubb
28. 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 lbein For AC drives install the MOV surge suppressor as detailed on page 71 Connect the fan cables Install the busbar and mounting plate assembly a 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 lbein Torque the two 17 mm mounting bolts for each U V and W busbar at the current transducer output busbar to 9 Nem 80 lbein Torque the three 16 mm mounting bolts for the busbar connection to the converter SCR modules to 9 Nem 80 lbein Torque the six wiring screws for the busbar connection to the converter SCR modules to 2 9 Nem 26 Ibein 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 INO24C EN P June 2012 67 Chapter 3 Component Replacement Procedures Thermal Sensors The thermal sensor system consists of Thermal Sensor wiring for both drives
29. ar with the setscrew and nut Torque the nut to 5 6 Nem 50 bein g Install the two screws that connect the output busbar to the U V or W busbar Torque to 9 0 Nem 80 ein Install the gate interface board a Install the gate interface board using the four nuts removed previously Torque screws to 2 9 Nem 26 lbein 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 Ibein 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 Chanter 3 Gate 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 safety cover over the gate interface board 3 Label and disconnect all wires J1 J8 4 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 lbein 2 Connect J1
30. 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 or AC input 1 7 15 or DC input 1 4 turn clockwise Precharge SCR module and diode DC input only fasten to the heatsink irst sequence 0 7 6 0 inal 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 1 7 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 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 Automatio n Publication 20B IN024C EN P June 2012 Chapter 2 Basic Component Removal Procedures Overview Component remova
31. cal Allen Bradley distributor or Rockwell Automation sales representative Rockwell Automation Publication 20B INO24C EN P June 2012 11 Preface Safety Precautions 12 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 La 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 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 Ver
32. cedures Component Replacement Procedures Table of Contents New and Updated Information 1 4 54 22 ehcks ee e ebusele cbse 7 Introductionis errie e Sa bea TTA need e ART EET NES 9 Component EE 9 Recommended Tale eet Reger 11 Additional Resources c c rr T SYR a EE EE dE 11 Safety Breed EUSE EE EEA TT d 12 Important Initial Steps ocx droves eee 13 Chapter 1 EE 15 Circuit T T 19 Fastener Torque Specifications se e Seve May eee Melos 20 Porque EE 20 RE 21 Chapter 2 OVERVIEW ais aa Z 9 EET e EE RS 23 M in Control amel EE 24 Remove Components eebe Eed Shinde ee 24 Install Components EE 25 Stacking Panel add EANA Ee 26 Remove Components x e e e e eeRAEEeEERN 26 Install Compon nts Xs a R Y RX alco e mane ns ea ere 27 Transitional EE 28 EE 28 Install Components e see e e aleve es ees sss 32 Chapter 3 Weve W ee 25555 te ete reek edie es ase tee 35 Main Control Reeder eg Zeta ee 35 Remove Components eet eh dete ties cae eee E Te 35 Install Components i222 tp feiss ede tee ee oe 36 Fs Comin EE 37 Remove COM PONENES sina kite S NR N cll tk celal RRR a Mid cle 37 TEE 39 Power Interface E 40 Remove Components RER 40 Install Components c SKST sr T aT Te ati ue KET S ice 41 Switch Mode Power Supply Board 42 Remove Components sis e e e e e K ov eekerasetonsumbes 42 Install Components Giedi eege Ee holes 42 Precharge Board aaae EN da 43 Remove Components casts md e e e K a tae aeten iad hoses 43 Install Component
33. cing resistor wires black negative busbar 2 9 26 yellow bus capacitor busbar 29 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 9 26 Converter snubber 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 fil
34. crew page 26 3 Label and disconnect all wires for the fan 4 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 lbein 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 INO24C EN P June 2012 41 Chapter 3 Component Replacement Procedures Bal ancing 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 Precautions 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 y K A X Wr E Screw for Resistor black wire Ch Screw for Resistor blue wire 5 el Screw for Resistor yellow wire 3 Label and disconnect all wires for the balancing resistor e Black negative busbar e Yellow bus capacitor busbar s 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
35. dule with supplied screws and tighten using this torque sequence ah o OI e O o o e SCR Torque O SCR Torque O First Sequence Final Sequence 0 7 N m 6 0 lb in O 5 6 N m 50 Ib in O O fo o0 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 number 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 lbein Rockwell Automation Publication 20B INO24C EN P June 2012 57 Chapter 3 Component Replacement Procedures 9 Reinstall the DC and DC busbars and torque to 9 0 Nem 80 lbein 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
36. er 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 3 Label and disconnect wires from the converter snubber board to be replaced A Remove the two screws that secure the board 5 Remove the board Rockwell Automation Publication 20B INO24C EN P June 2012 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 L ees Fan Transformer LI L E S 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
37. ere 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 E cl Photo shows setscrews in Capacitors these setscrews may come out with the Transitional Busbar nuts when they are removed 30 Rockwell Automation Publication 20B INO24C EN P June 2012 Basic Component Removal Procedures Chapter 2 11 Remove the transitional busbar assembly Negative DC Flexible Capacitor Busbar attached to top side of Transitional Busbar Bal ry Pa Positive DC Flexible Capacitor l Busbar attached to bottom side of Transitional Busbar Rockwell Automation Publication 20B IN024C EN P June 2012 31 Chanter 2 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 HC gt Z Flexible Capacitor Se Busbar short i Negative DC Flexible
38. erface board 41 Switch mode power supply board 42 Precharge board 43 Bus capacitor 46 Capacitor bank fan 41 Balancing resistor 48 Balancing resistor al Gate interface board 53 Current transducer 55 Converter power module SCR AC input only BI Converter snubber resistors AC input only 5g 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 H Precharge SCR module and diode DC input only Ee Rockwell Automation Publication 20B INO24C EN P June 2012 7 Summary of Changes Notes 8 Rockwell Automation Publication 20B INO24C EN P June 2012 Introduction Component Kits Preface This 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 Printed Circuit Boards Kit Catalog No Notes 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
39. ese 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 Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or 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
40. etailed on page 26 DC Choke Output Cables Transitional Busbar 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 Ifpresent 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 nuts and busbars 7 Cut tie wraps for the balancing resistor wiring Rockwell Automation Publication 20B INO24C EN P June 2012 29 Chanter 2 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 lt Balancing Resistor yellow wire Disconnect h
41. ic 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 4 Torque the two screws on the main control panel below TB11 to 2 9 Nem 26 lbein 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 INO24C EN P June 2012 25 Chanter 2 Basic Component Removal Procedures Stacking 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 Label and disconnect wiring as listed below Shown without main control panel NOTE Mounting position of boards on stacking panel may vary emm Filter Board 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 orConnector Board Precharge board
42. ify that there is no voltage at the drive s 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 INO24C 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 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 perso
43. l and replacement in this chapter are located on the stacking panel and 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 Stacking Panel Assembly Main Control Panel Assembly Rockwell Automation Publication 20B INO24C EN P June 2012 23 Chanter 2 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 Cable 3 Disconnect the incoming ground wire to TB11 4 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 Screws 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 Bas
44. l 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 output 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 bein c Ifremoved 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 Thein L Secure the other end of the output busbar to the U V or W busb
45. nal 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 know when all are done and to indicate signs of any subsequent tampering Refer to the product installation documentation for startup and other instructions after servicing Rockwell Automation Publication 20B INO24C EN P June 2012 13 Preface Notes 14 Rockwell Automation Publication 20B INO24C EN P June 2012 Drive Components Drive Shown With Stacking Panel Removed Transitional Busbar Flexible Capacitor Busbars 18 DC Bus Capacitor 18 Balancing Resistor Snubber Capacitors for IGBTs 9 Capacitor Bank Fan MOV Surge Suppressor Fan Transformer DC Busbar PE Ground and MOV Wire
46. nent 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 Precharge Power Cables 3 Label and remove all precharge power cables and precharge wires from both precharge busbars DC IN and DC OUT 4 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 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 each SCR module and diode 72 Rockwell Automation Publication 20B INO24C EN P June 2012 Component Replacement Procedures Chanter 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 e The diode on the right has a plug without prongs located at the top
47. ng two four and six screws Initial torque is 1 3 33 of final torque except six point mountings which require 0 7 Nem 6 Ibein The numeric illustration labels are for your assistance Drive components do not carry these labels Figure 6 Various point Mounting Start End End Start End Initial Torque Sequence Two Point Mounting Four Point Mounting End 00 OAD D72 DAL Initial Final Torque Sequence Torque Sequence DLD DLT Start Final Torque Sequence Six Point Mounting End End R O l 900 006 Start Start Initial Torque Sequence Final Torque Sequence Note Do not exceed 0 7 Nem 6 lbe in on initial torque Rockwell Automation Publication 20B IN024C 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 Torque Component Fastener Application Nem Ibein 20 Comm x board fasten to HIM cradle board 29 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 Balan
48. nstall Components 1 Install the new DC bus filter board Torque the four mounting bolts to 1 7 Nem 15 Ibein A 2 Connect the red and black wires to TB1 and TB2 inal h oh TB2 3 TB2 1 1B1 3 TB1 1 terminals as shown at right red black red black 3 Replace all safety shields and enclosure covers before applying power to the drive 44 Rockwell Automation Publication 20B IN024C EN P June 2012 Component Replacement Procedures Chanter 3 Bus Capacitor 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 Transitional Busbar Assembly Removed Bus Capacitor Busbar da Bus Capacitor Busbar CBee Nuts and Washers 18 each 3 Label and remove all wires and connectors from the bus capacitor busbar 4 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 Install Components ATTENTION Install each capacitor so its vent plug is at the A top or 12 o clock Component and system damage may result if you position any bus capacitor incorrectly 1
49. nts 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 4 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 bein 6 Install the three output busbar bolts Torque to 9 0 Nem 80 lbein 7 Connect the wires 8 Replace all safety shields and enclosure covers before applying power to the drive Rockwell Automation Publication 20B INO24C EN P June 2012 55 Chapter 3 Component Replacement Procedures Converter Power Module z IMPORTANT If any converter SCR module fails all three SCR modules should be SCR AC Input Only 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 R e T Converter SCR eee T Converter Snubber Boards Converter Snubber Boards Serial Number Label R S T a Snubber Board Standoff LY Does not need to be removed Converter Converter Busbar Upper B
50. ol Board to Comm Board Fan Terminal Block TB9 Precharge Board Stacking Panel DC Bus Filter Board Fan Transformer DC Link Choke Output Connection Bottom DC Link Choke 18 Main Control Panel Thermal Sensor and Wire Main Control Board under HIM Cradle HIM Blank shown on this Drive HIM Cradle Main Control Panel IEN DC Link Choke Input Connection Top DC Link Choke Input Connection Bottom 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 No 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 Encoder board optional Main Control Panel Stacking Panel Rockwell Automation Publication 20B INO24C EN P June 2012 19 Chapter 1 Component Diagrams and Torque Specifications Fastener Torque Specifications 20 Torque Sequence ATTENTION When mounting components to a drive 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 usi
51. ol 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 Vd oP Ja o o 9 o DE La 2 o G Oje xO o o D Je 6 G IGBT Torque Sequence First Sequence 0 7 Nem 6 0 bein Second Sequence 2 3 Nem 20 bein Final Sequence 5 6 Nem 50 Dein 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 INO24C 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 Instal
52. olts 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 4 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 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 j Flexible Capacitor Busbars T Di 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 Chanter 3 a Use isopropyl alcoh
53. orque the four mounting screws to 9 0 Nem 80 bein 2 Install the choke connectors Torque the four choke connector screws to 9 0 Nem 80 lbein 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 Replacement Procedures Chanter 3 MOV Surge 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 4 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 lbein 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 INO24C EN P June 2012 71 Chapter 3 Component Replacement Procedures Precharge SCR Module and See Chapter 1 Compo
54. r details Description Torque wrench metered in Nem or heim 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 These documents contain additional information concerning related products from Rockwell Automation Resource Description PowerFlex 700 Adjustable Frequency AC Drive Frames Provides basic information needed to mount wire and 7 10 Installation Instructions publication 20B IN014 start up a PowerFlex 700 drive PowerFlex 700 AC Drives User Manual publication Provides basic information needed to install start up 20B UM002 and troubleshoot the PowerFlex 700 drive Industrial Automation Wiring and Grounding Guidelines Provides general guidelines for installing a Rockwell publication 1770 4 1 Automation industrial system Product Certifications website http www ab com Provides declarations of conformity certificates and other certification details You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your lo
55. rews 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 bein 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 lbein 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 bein 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 lbein 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 lbein 15 For AC input drives reinstall the DC choke output cables Torque to 9 Nem 80 lbein 16 Reinstall any customer wiring to the transitional busbar 17 Reinstall the stacking panel as instructed on page
56. s d ease K vend esse assets 43 Rockwell Automation Publication 20B INO24C EN P June 2012 3 Table of Contents DC Bus Filter Board 44 Remove Components x e aa e e 44 erareechen dere Bechen 44 Bus Capacitor ee toluene et Ee 45 Remove Components x ee e e NEE e 15 Install Components vivre ct stented 46 Capacitor Bank Ean nd suc totais RER da AET me RN AR des 47 Remove Components x x e e e e e sans Vebe denice eis aos 47 Tista Components e Sexo dance ope Eaa AE omens 47 lee Eeer kale cud ees 48 Remove E 48 Install E 48 Inverter Power Module IGRT 49 Remove Components atc e e eur caiede lane e indicate 49 Install Components a See Ee ee EEN 51 EE 53 Remove Components eh delet See ua Een 53 Install Components Ate 53 Cu rrent Transducer enirere Eeer 54 Remove Components x e nese Eed 54 l stall Componenten Wie eater T Lease encase trae sae 55 Converter Power Module SCR AC Input Onb 56 Remove Components x e e e e e aporsthe vebeees ences 56 Install Components NEE Tra aeea T Se STAR Ro arda 57 Converter Snubber Resistors AC Input Onb 58 Remove Components eege seemed ea AER 58 Install Components yee see gek E erte 59 Converter Snubber Board AC Input On ENN 59 Remove Components sen 45555555 via vcabede EEN 59 Install Components dg denge d alte E 60 NR 60 Remove Components x e e e e e ta ii een eases 60 Install EE 60 Heatsink Fan Removal from Back of Die 61
57. ter board fasten to glastic standoffs on stacking panel 1 7 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 INO24C 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 29 26 IGBT module fasten to the heatsink first sequence 0 7 6 0 second sequence 2 3 20 final 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 control 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
58. tions Remove Components 1 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 control panel See page 25 Replace all safety shields and enclosure covers before applying power to the drive 42 Rockwell Automation Publication 20B INO24C EN P June 2012 Component Replacement Procedures Chanter 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 Remove the safety cover over the precharge board For DC input only Verify that customer wiring to TB2 is properly labeled and then disconnect wiring from
59. to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Otomasyon Ticaret A S Kar Plaza Ig Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 20B INO24C 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
60. usbar Lower 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 56 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 the AC busbars 6 Label and note the position of the 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 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 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 mo

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