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PowerFlex 700 Drive - Frame 7 Components Replacement

Installation Instructions

Summary of Contents for Allen-Bradley PowerFlex 700

Page 1: ...PowerFlex 700 Drive Frame 7 Components Replacement Installation Instructions ...

Page 2: ...bility is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Allen Bradley Rockwell Software Rockwe...

Page 3: ...l Panel Assembly 21 Remove Stacking Panel 22 Remove Precharge Board Assembly 23 Remove Transitional Bus Bar 23 Chapter3 ComponentReplacementProcedures Precharge Board 25 Main Control Board 26 T Comm Board 27 Switch Mode Power Supply Board 30 Power Interface Board 31 Fan 32 Fan Transformer 35 Current Transducer 35 Inverter Snubber Board 38 Inverter Snubber Resistor 40 Inverter Power Module IGBT 42 ...

Page 4: ...4 Rockwell Automation Publication 20B IN017B EN P September 2011 Table of Contents Notes ...

Page 5: ...ormation This table contains the changes made to this revision Topic Page Added Heatsink Fan Transformer kit 1336 T SP5A to table of component kits Instructions were already in this manual but the kit was not listed in the table 7 Added T Comm Board kit SK G9 TCOMM to table of component kits 7 Added T Comm Board removal and installation instructions 27 ...

Page 6: ...6 Rockwell Automation Publication 20B IN017B EN P September 2011 Summary of Changes Notes ...

Page 7: ...9 GDB1 D292 292A Drives SK G9 GDB1 D325 325A Drives Heatsink Fan SK G1 FAN1 F7 Heatsink Fan Transformer 1336 T SP5A 480 to 120 Auto transformer fan only Current Transducer SK G1 CT1 F7 Includes one Transducer Inverter Power Module IGBT SK G1 QOUT1 F7 Includes Two IGBTs Two Gate Interface Boards Inverter Snubber Kit SK G1 INVSNB1 F7 Includes One Snubber Board One Resistor SCR Snubber Kit SK G1 SCRS...

Page 8: ... sections for details Description Notes Torque wrench metered in lb in or N m T30 and T40 bits Torque seal or colored marker Screwdrivers standard Phillips star various sizes Magnetic screwdriver long Socket set metric Cylindrical pick up magnet Pliers regular and needle nose Wire cutters Volt ohm meter Used to test Inverter Snubber Resistors Isopropyl alcohol Nylon tie wraps Pencil 14 or 16 gauge...

Page 9: ...ock by measuring between the DC DC terminals between the DC terminal and the chassis and between the DC terminalandthechassis Thevoltage mustbe zerofor all three measurements ATTENTION Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by s...

Page 10: ...e exists if codes are ignored ATTENTION Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION HOT surfaces can cause severe burns Do not touch the heatsink surface during operation of t...

Page 11: ... Component Diagrams and Torque Specs on page 13 Remove protective shields only as necessary Before disconnecting any wire or cable verify that it is labeled Also when removing components note hardware type and location When torquing any fasteners use a colored marker or torque seal to mark each screw after torquing so you know when all are done and to indicate signs of any subsequent tampering Ref...

Page 12: ...12 Rockwell Automation Publication 20B IN017B EN P September 2011 Preface Notes ...

Page 13: ... Current Transducer Gate Interface Board U V and W not shown Heatsink Thermal Sensor location Main Control Panel Assembly Motor Bus Bars AC Bus Bars R S T W Inverter Power Module IGBTs U V W under Inverter Snubber Board U V W Phase U Phase V Phase T Phase R Phase S Phase Precharge Board Assembly TB2 J3 J1 J2 Power Interface Board under Main Control Panel TB11 Transitional Bus Bar HIM Communication...

Page 14: ...ase Precharge Board Assembly Power Interface Board location under Main Control Panel Transitional Bus Bar Communications Panel Main Control Panel Bus Fuse DC Link Choke MainControl PanelThermalSensor Wire DC Capacitor Bank under Transitional Bus Bar HIM Blank shown on this Drive TB11 Switch Mode Power Supply Board under Main Control Panel Ribbon Cable Main Control Board to Comm Board Main Control ...

Page 15: ...nt Transducers behind Mounting Clamps IGBT Bus Bars Motor Bus Bars Inverter Power Module IGBTs Inverter Snubber Boards Current Transducers Gate Interface Boards Motor Bus Bars Inverter Power Module IGBTs Note Components are shown as seen from right side without drive covers Current Transducer Mounting Clamps Gate Interface Boards Bottom of Drive Top of Drive ...

Page 16: ...Drive components do not carry these labels Figure 1 Two Point Mounting TB11 and Main Control Board HIM Stacking Panel Switch Mode Power Supply Board and Power Interface Board Note Components are shown as seen from right side without drive covers Components are listed left to right for each level Communications Panel Main Control Panel Bottom of Drive Top of Drive Front Back ATTENTION When mounting...

Page 17: ...s and Torque Specs Chapter 1 Figure 2 Four Point Mounting Figure 3 Six Point Mounting 1 2 3 4 3 4 Initial Sequence 1 2 1 2 3 4 Final Sequence 6 4 2 3 5 1 3 4 Initial Sequence 1 2 6 5 Final Sequence 3 4 1 2 6 5 Do not exceed 0 7 Newton meters 6 lb in on initial torque of all six screws ...

Page 18: ... Snubber Board Board to Input Rectifier 50 6 Balancing Resistor Resistor to heat sink Initial sequence 6 0 7 Final sequence 26 3 Balancing Resistor Wires to Capacitor Bus Bar Assembly 50 6 Heatsink Thermal Sensor Thermistor to heatsink 14 2 Bus Capacitor Holder Holder to Bus Capacitors 26 3 Capacitor Bus Bar Assembly Assembly to Bus Capacitors 50 6 Gate Interface Board Board to Power Modules 14 2 ...

Page 19: ...ires to TB3 8 10 0 9 1 1 CT Mounting Plate Mounting Plate to CT Clamping Plate 14 2 CT Clamping Plate Clamping Plate to Bus Bar 26 3 Power Cables Cables to terminals 80 9 Main Control Gate Driver Precharge Board Mounting Plates Plates to chassis 26 3 High Voltage Guard Guard to chassis 26 3 Component Fastener Application Torque lb in Torque N m ...

Page 20: ...20 Rockwell Automation Publication 20B IN017B EN P September 2011 Chapter 1 Component Diagrams and Torque Specs Notes ...

Page 21: ...onent you are replacing Remove Main Control Panel Assembly Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions RemoveComponents 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Remove safety shields as needed 3 Remove the ribbon cable going from the Main Control Board J2 to the Power Interface Board J1 4 Remove th...

Page 22: ...Diagrams and Torque Specs on page 13 for these instructions RemoveComponents 1 Perform Remove Main Control Panel Assembly on page 21 2 Remove remaining wiring harnesses from the Power Interface Board Do not disconnect the wiring between the Power Interface Board and the Switch Mode Power Supply Board 3 Disconnect the Main Control Panel Assembly Thermal Sensor wire from the Monitor Wire See diagram...

Page 23: ...he board Note Some connectors may not be labeled Be sure to label them 3 For DC input only Verify that customer wiring to TB2 is properly labeled and then disconnect wiring from TB2 4 Unscrew the two mounting screws at the top of the mounting panel 5 Slide the board and mounting plate out by pulling down and out InstallComponents When instructed for the component you are replacing reinstall the Pr...

Page 24: ...t This allows access to the wire connections below it if needed InstallComponents When instructed for the component you are replacing reinstall the Transitional Bus Bar components in the reverse order of removal Only torque screws after all components are in place Remove these screws TIP When you remove the screws in the next step you will remove the Bus Fuse as well There is a plate over the top ...

Page 25: ...move the three 3 wiring harnesses J1 J2 J3 at the top of the board Note Some connectors may not be properly labeled Be sure to label them appropriately 5 Remove the Precharge Board mounting star screw located at the lower left corner of the Precharge Board 6 For AC input Using your fingers or needle nose pliers squeeze the wings of each of the three spacers and separate the Precharge Board from th...

Page 26: ...o nuts and two screws and washers for the Communications Panel 5 Disconnect both ribbon cables from the left side of the Main Control Board 6 Holding the Communications Panel release the cable at the bottom of the panel from its clamp and set the Communications Panel aside 7 If needed unscrew and disconnect the wire set going to TB11 from the Main Control Board 8 Unscrew the six 6 screws holding t...

Page 27: ... the component detailed in these instructions RemoveComponents 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Remove the Main Control Board a Remove the HIM board from its slot if used b Disconnect the ribbon cable from the Main Control Board connects to J1on Power Interface Board c Disconnect the wiring connector from the Main Control Board connects to...

Page 28: ...omm x Board is not used remove the screw securing the T Comm grounding tab 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 HIM Board slot Mounting Screw Optional 20 Comm x Board Detail Ribbon Cable Connector Grounding Wire Screw Wiring Connector Ribbon...

Page 29: ...ll seven locking tabs 3 Carefully bend the T Comm grounding tab until it is flush with the screw mount on the Main Control Board 4 Reassemble all components in the reverse order of removal 5 Reconnect all cables safety shields and enclosure covers before applying power to the drive T Comm Board Locking Tab Locations Five locking tabs are on the back side of the Main Control Board above two are on ...

Page 30: ...r right corner of the board 4 Using your fingers or needle nose pliers squeeze the wings of each of the three spacers and separate the Switch Mode Power Supply Board from the mounting plate 5 Remove the Switch Mode Power Supply Board InstallComponents 1 Install the new Switch Mode Power Supply Board Tighten board screws to 1 7 N m 15 lb in 2 Reconnect all cables 3 Reassemble all components in the ...

Page 31: ...ly Board 4 Remove the two Power Interface Board mounting star screws located at the upper right and lower left corners of the board 5 Using your fingers or needle nose pliers squeeze the wings of each of the nine 9 spacers and removethePowerInterfaceBoard from the mounting plate Connector Connected Components J1 Main Control Board J10 Precharge Board only on DC input systems J16 W Phase CT J15 V P...

Page 32: ...ain Control Board J2 3 Reinstall the Main Control Panel Assembly Tighten sheet metal screws to 3 2 N m 28 lb in 4 Reconnect the ribbon cable going from the Power Interface Board J1 to the Main Control Board J2 5 Replace all safety shields and enclosure covers before applying power to the drive Fan The Fan is located behind the Main Control Panel assembly and Precharge Board Refer to the figure bel...

Page 33: ...anying wires from the Power Terminal Block including the DC and DC Bus cables the PE jumper cable to chassis ground and the PE Bus Bar located over the third and fourth Terminal Blocks 6 Remove the single screws on the right end of U V and W Current Transducer bus bars The Current Transducer assemblies do not need to be removed 7 Remove the U V and W Bus Bars To do so move the top end of the bar t...

Page 34: ...rews at the exterior of fan cover Do not remove screws near Fan cable at this time 15 Remove the Fan cover and the Fan You may need to pry the cover from the drive enclosure 16 Remove the four screws near Fan cable that hold the Fan and cover together InstallComponents 1 If needed remove the old gasket from Fan cover and replace gasket 2 Mate cover and new Fan positioning Fan cable in notch of ope...

Page 35: ... 9 and Important Initial Steps on page 11 2 Perform Remove Precharge Board Assembly on page 23 3 Label and unscrew or disconnect wires for the Transformer 4 Unscrew Transformer mounting brackets InstallComponents 1 Install new Transformer by screwing mounting brackets to drive 2 Reconnect all wires and connectors for the Transformer 3 Reassemble remaining components in reverse order 4 Replace all ...

Page 36: ...ith it 6 Using your fingers or needle nose pliers squeeze the wings of each of the four spacers and separate the transducer and board from the mounting clamp 7 Loosen the two screws that hold the two sections of the CT mounting clamp but do not take the screws completely out Only loosen them so that the end is flush with the bottom of the CT mounting clamp 8 Remove mounting clamp from the bus bar ...

Page 37: ...hrough the assembly taking care not to damage the insulation on the bus bar and not to loosen the wiring 3 Orient the transducer mounting clamp with the smaller section on the bottom and the notch toward you 4 Slide the mounting clamp onto the bus bar by sliding the gentle bend of the bus bar the end with only one screw hole through the assembly taking care not to damage the insulation on the bus ...

Page 38: ...d at the same time Refer to the figures in Component Diagrams and Torque Specs on page 13 for these instructions RemoveComponents 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Perform Remove Main Control Panel Assembly on page 21 3 Perform Remove Stacking Panel on page 22 4 Perform Remove Precharge Board Assembly on page 23 5 Locate the Inverter Snubbe...

Page 39: ...ove the wire at J1 from Snubber Board to be replaced 10 Remove the ten 10 T30 hex screws that secure the Snubber Board Remove the board and discard InstallComponents 1 Install the new Snubber Board with the J1 terminal lug towards the right side of the drive Torque screws to 5 6 N m 50 lb in Reconnect wire at J1 2 Reposition any Motor Bus Bars that were removed but do Not tighten screws at this ti...

Page 40: ...move the push on J1 connector from the Inverter Snubber Board Place one probe of a volt ohm meter inside the connector b At the bottom right of the DC capacitor bank under the Transitional Bus Bar locate the screw with several connections typically three with one for each Snubber Resistor Place the other probe of the volt ohm meter on that screw The reading should be 8 ohms c If the reading is 8 o...

Page 41: ...emove the screw for the Resistor wire 9 Remove the Resistor to be replaced by unscrewing it from the heatsink 10 Using isopropyl alcohol clean any grease off of the location where the Resistor is to be mounted InstallComponents 1 Apply a thin bead of thermal grease to the full length of the metal bottom of the new Resistor Spread grease evenly 2 Align the wire with push on connector to the right a...

Page 42: ...ower Module to be replaced 3 Perform Remove Transitional Bus Bar on page 23 4 Perform Remove Components on page 38 for the Inverter Snubber Board over the IGBT modules to be replaced but do not discard the Inverter Snubber Board 5 Remove the two Inverter Snubber brackets two screws each for each board Set aside 6 Disconnect the positive and negative IGBT bus bars four T40 screws each 7 Using a pen...

Page 43: ...l instructed b Verify that the mounting surface of the new IGBT module is clean If not clean with isopropyl alcohol c Using a 3 putty knife or similar tool apply a thin even coating of the supplied thermal grease to the mounting surface of the IGBT module Use enough thermal grease to create a conductive coating but not so much that the two surfaces can rock Important In the next step take care to ...

Page 44: ...his time 7 Install remaining M6 screws for the IGBT module and Bus Bar 8 Torque all screws on the Inverter Snubber Brackets and on the IGBT module Bus Bar to 9 0 N m 80 lb in 9 Torque DC and DC M6 screws to 5 9 N m 52 lb in 10 Install the new Snubber Board with the terminal lug towards the outside of the drive Torque screws to 5 6 N m 50 lb in 11 Position each Motor Bus Bar but do not torque mount...

Page 45: ...d to the figures in Component Diagrams and Torque Specs on page 13 for these instructions RemoveComponents 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Perform Remove Main Control Panel Assembly on page 21 3 Perform Remove Stacking Panel on page 22 4 Unscrew one end of the sensor from the Stacking Panel Note This screw and nut are small Take care that...

Page 46: ...orm Remove Precharge Board Assembly on page 23 6 To gain access to the wire harness in a later step you must remove the Current Transducers over the U V and W Phase Bus Bars Unscrew the button head screws on each transducer bus bar Move the transducers to a safe location 7 On the input power terminal block remove the top nuts securing the U V and W Phase Motor Bus Bars 8 Slide the top of each bus ...

Page 47: ...ducer Bus Bar at the right side of the unit Disconnect the sensor connector 16 Using a 5 16 offset open end wrench remove the sensor InstallComponents 1 Install the new Heatsink Thermal Sensor 2 Torque sensor to 1 6 N m 14 lb in 3 Connect the other end of the sensor wire to the Monitor Wire 4 Replace all wire ties to secure the wiring harness 5 Remove the jumper wire to gate connections on the IGB...

Page 48: ...nitial Steps on page 11 2 Remove the four screws noted in diagram above for the Bus Fuse 3 Remove Fuse InstallComponents 1 Install new Bus Fuse 2 Torque screws to 9 0 N m 80 lb in 3 Reassemble remaining components in reverse order 4 Replace all safety shields and enclosure covers before applying power to the drive TIP When you remove the screws in the next step you will remove the Bus Fuse as well...

Page 49: ...s from the Bus Capacitor Bus Bar 4 Remove nuts and washers fastening the Bus Capacitor Bus Bar 5 Remove the Bus Capacitor Bus Bar 6 Remove Capacitors by pulling them out InstallComponents 1 Replace screw posts for each new Capacitor using a 3 mm angle hex wrench 2 Place Capacitors into position in drive 3 Place Capacitor bank bus onto Capacitors 4 Install washers and nuts onto posts Note Install a...

Page 50: ...ace allows remove the U Phase Current Transducer and then disconnect both ends of the U Phase Motor Bus Bar and remove it to gain access to the Converter Snubber Board Otherwise if space does not allow using the instructions in Step 2 Step 5 in Component Replacement Procedures on page 25 remove all three Current Transducer assemblies and move them to a safe location but do not disassemble them 7 L...

Page 51: ... the Converter SCR modules R S T to be replaced 3 Perform Remove Main Control Panel Assembly on page 21 4 Perform Remove Stacking Panel on page 22 5 Using the instructions in Converter Snubber Board AC Input Only on page 50 remove all three Converter Snubber Boards 6 Label and note the position of the SCR module leads Remove the leads 7 Remove the two 2 M6 screws that hold the AC Bus Bar to SCR on...

Page 52: ... If not clean with isopropyl alcohol 3 Using a 3 putty knife or similar tool apply a thin even coating of the supplied thermal grease to the mounting surface of each SCR module Use enough thermal grease to create a conductive coating but not so much that the two surfaces can rock Important In the next step take care to not disturb any of the thermal grease on the SCR module 4 Install each new SCR ...

Page 53: ...ram in Step 12 on page 52 but do not torque screws at this time 7 Install the Snubber Board Mounting Brackets oriented as in the diagram to the right Torque to 9 0 N m 80 lb in 8 Install Snubber Boards oriented with the serial number as shown in the diagram to the right Torque to 2 9 N m 26 lb in 9 Replace leads 10 Install AC Bus Bars R S T Torque both ends to 9 0 N m 80 lb in 11 Torque screws for...

Page 54: ...echarge Board Assembly on page 23 4 Note wire placement and connections Disconnect the MOV ground wire and its R S and T wires at the top nut on the input power terminal block 5 Unscrew MOV mounting brackets 6 Remove the MOV assembly InstallComponents 1 Install the new MOV assembly Tighten the MOV mounting screw to 2 9 N m 26 lb in 2 Reconnect all wires and connectors for the MOV 3 Torque the R S ...

Page 55: ...Only on page 50 remove all three Converter Snubber Boards 6 Remove the six Snubber Board mounting brackets M6 T40 screws 7 Remove the four 4 M6 screws from the DC Link Choke terminals labeled 1 and 4 8 Remove the Converter Bus Bars DC and DC 9 Perform Remove Transitional Bus Bar on page 23 10 Remove the four 4 screws for the DC Link Choke mounting brackets 11 Remove the DC Link Choke InstallCompon...

Page 56: ...ure 5 above for these instructions RemoveComponents 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Locate the Precharge SCR module Snubber Board to be replaced 3 Remove the upper and lower safety shields 4 Perform Remove Main Control Panel Assembly on page 21 5 Perform Remove Stacking Panel on page 22 6 Remove the push on lead from the Snubber Board 7 U...

Page 57: ...reverse order 9 Replace all safety shields and enclosure covers before applying power to the drive Precharge SCR Module DC Input Only Refer to the figures in Component Diagrams and Torque Specs on page 13 and Figure 5 on page 56 for these instructions RemoveComponents 1 Read and follow the Safety Precautions on page 9 and Important Initial Steps on page 11 2 Locate the Precharge SCR module to be r...

Page 58: ...que using the sequence and specifications shown in the diagram below 4 Install the Snubber Board Bus Bar and assembly with its lead wires and the DC cables both positive as shown below Hold the lead wires in place while you torque DC cable screws to 12 2 N m 108 lb in 5 Reassemble remaining components in reverse order 6 Replace all safety shields and enclosure covers before applying power to the d...

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Page 60: ... 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 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 D...

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