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Rockwell Automation Allen-Bradley PowerFlex 700 Drive Frame 9, Руководство по установке

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PowerFlex 700 Drive - Frame 9 Components Replacement

Catalog Numbers  20B

Installation Instructions

Содержание Allen-Bradley PowerFlex 700 Drive Frame 9

Страница 1: ...PowerFlex 700 Drive Frame 9 Components Replacement Catalog Numbers 20B Installation Instructions...

Страница 2: ...hole 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 Labels may also be on...

Страница 3: ...n Topic Page Updated the Component Kits table with the new balancing resistor kit catalog numbers 9 Updated Figure 3 Frame 9 Busbars AC Drive shown to include the new balancing resistor bus bar assemb...

Страница 4: ...4 Rockwell Automation Publication 20B IN025C EN P October 2015 Summary of Changes Notes...

Страница 5: ...Panel 24 Remove Components 24 Install Components 25 Blower Control Panel 26 Remove Components 26 Install Components 26 Stacking Panel 27 Remove Components 27 Install Components 29 Transitional Busbar...

Страница 6: ...ents 63 Install Components 65 Gate Interface Board 67 Remove Components 67 Install Components 68 Current Transducer 69 Remove Components 69 Install Components 70 Converter Power Module SCR AC Input On...

Страница 7: ...C Link Choke AC Input Only 87 Remove Components 87 Install Components 87 MOV Surge Suppressor AC Input Only 88 Remove Components 88 Install Components 88 Precharge SCR Module and Diode DC Input Only 8...

Страница 8: ...8 Rockwell Automation Publication 20B IN025C EN P October 2015 Table of Contents...

Страница 9: ...n enclosure Capacitor Fan SK G1 FAN2 F8910 Power Module Sub assemblies Inverter Power Module IGBT SK G1 QOUT1 F910 Includes One IGBT module One Gate Interface Board Gate Interconnect Harness Six Flexi...

Страница 10: ...Fuses SK G9 FUSE1 F8 For AC input drives only Includes three fuses Balancing Resistor Kit SK G1 RB1 F910 Replaces 1336 RLOAD SP3A 1 AC Input includes DC bus bar and resistor assembly SK G1 CBRB1 F910...

Страница 11: ...To avoid an electric shock hazard ensure that all power has been removed before proceeding In addition before servicing verify that the voltage on the bus capacitors has discharged Check the DC bus vo...

Страница 12: ...ge 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 8...

Страница 13: ...October 2015 13 Chapter 1 Component Diagrams and Torque Specifications Overview Drive components and their locations are identified in this chapter as well as torque specifications for fasteners that...

Страница 14: ...oard 3 Output Busbar 3 Converter Busbar 2 DC DC Busbars AC Busbars R S T Balancing Resistor Old Resistor Style Shown Snubber Capacitors 9 for IGBTs Capacitor Bank Fan IGBT Interface Board and IGBT 3 e...

Страница 15: ...cing Resistor Old Resistor Style Shown Snubber Capacitors 9 for IGBTs Capacitor Bank Fan IGBT Interface Board and IGBT 3 each Flexible Capacitor Busbars 18 Heatsink Fan Behind Busbar Mounting Plate DC...

Страница 16: ...6 Rockwell Automation Publication 20B IN025C EN P October 2015 Chapter 1 Component Diagrams and Torque Specifications Figure 3 Frame 9 Busbars AC Drive shown Transitional Bus Bar Assembly DC Bar DC Ba...

Страница 17: ...nel Transitional Busbar Main Control Board below Communication Panel Inverter Snubber Capacitors 3 per IGBT DC Link Choke DC Bus Filter Board IGBT Gate and CT Wire Harness Main Control Panel Fan Termi...

Страница 18: ...Panel Main Control Panel T Comm Interface No Description 0 TB11 1 HIM Cradle Communication Board 2 Communication Board Slots for optional devices 3 Main Control Board shown with optional encoder boar...

Страница 19: ...s do not carry these labels Figure 6 Various Point Mounting ATTENTION When mounting components to a drive s heat sink component fastener torque sequences and tolerances are crucial to component to hea...

Страница 20: ...s to Capacitor Busbar Assembly 50 6 Converter Heatsink Thermal Sensor Thermistor to heatsink 14 2 Main Control Panel Thermal Sensor Thermistor to mounting bracket 14 2 Bus Capacitor Holder Holder to B...

Страница 21: ...o TB3 8 10 0 9 1 1 CT Mounting Plate Mounting Plate to CT Clamping Plate 14 2 CT Clamping Plate Clamping Plate to Busbar 26 3 Power Cables Cables to terminals 80 9 Main Control Gate Driver Precharge B...

Страница 22: ...22 Rockwell Automation Publication 20B IN025C EN P October 2015 Chapter 1 Component Diagrams and Torque Specifications Notes...

Страница 23: ...s Overview Component removal procedures detailed in this chapter are located on the Stacking Panel and Transitional Busbar assemblies highlighted below See Circuit Boards on page 18 to identify the va...

Страница 24: ...n Control Board J2 to the Power Interface Board J1 4 Disconnect the incoming ground wire to TB11 5 Remove the two mounting screws below TB11 6 Remove the two screws that adjoin the Blower Control Pane...

Страница 25: ...ower Interface Board 10 Label and remove all customer wiring from TB11 11 Carefully set aside the Main Control Panel Install Components 1 When instructed for the component you are replacing reinstall...

Страница 26: ...o screws that connect the Blower Control Panel to the Main Control Panel NOTE These screws are already removed if the Main Control Panel has been removed 5 Remove the two screws that connect the Blowe...

Страница 27: ...onnecting IMPORTANT The figure below is shown with the Blower Control Panel removed for visual clarity However you don t need to remove the Blower Control Panel to remove the Stacking Panel TIP This s...

Страница 28: ...Main Control Panel Thermal Sensor Wire above the Main Control Board at the connector junction See Figure 4 on page 17 for the location Do not remove the sensor from the bracket 8 Carefully label and d...

Страница 29: ...Panel carefully set aside Install Components 1 When instructed for the component you are replacing reinstall the Stacking Panel components in the reverse order of removal 2 Torque mounting screws to...

Страница 30: ...ge 11 and Important Initial Steps on page 12 2 Remove Main Control Panel on page 24 3 Remove Blower Control Panel on page 26 4 Remove Stacking Panel on page 27 5 Locate the Transitional Busbar 6 If pr...

Страница 31: ...r Mounts and save screws and Capacitor Mounts c Remove the six setscrews from each IGBT and save d If replacing an IGBT module remove the nuts and DC Flexible Capacitor Busbars and save nuts and busba...

Страница 32: ...13 Remove the 18 nuts fastening the Transitional Busbar assembly to the Bus Capacitors Setscrews may come out with the nuts Save all nuts and setscrews Balancing Resistor yellow wire Disconnect here R...

Страница 33: ...onent Removal Procedures Chapter 2 14 Remove the Transitional Busbar unit Negative DC Flexible Capacitor Busbar attached to top side of Transitional Busbar Transitional Busbar Unit Removed Positive DC...

Страница 34: ...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 dow...

Страница 35: ...Busbars to the Transitional Busbar to 5 6 N m 50 lb in 11 Torque the nuts that secure the Transitional Bus Bar to the Bus Capacitor setscrews to 5 6 N m 50 lb in 12 Reconnect the yellow wire for the B...

Страница 36: ...36 Rockwell Automation Publication 20B IN025C EN P October 2015 Chapter 2 Basic Component Removal Procedures Notes...

Страница 37: ...tions Remove Components 1 Read and follow the Safety Precautions on page 11 and Important Initial Steps on page 12 2 Remove safety shields as needed 3 Unscrew the green yellow ground wire from the Com...

Страница 38: ...hex standoffs if Encoder Board is present holding the Main Control Board 12 If present disconnect the J7 connectors for the Encoder Board 13 Remove the Encoder Board and put aside to reinstall later...

Страница 39: ...ects to J1on 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 t...

Страница 40: ...rees from the screw mount 6 If needed use the same flathead screwdriver tip to pry the seven locking tabs away from the T Comm Board 7 Remove the T Comm Board from the Main Control Board return or dis...

Страница 41: ...t 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 Power Interface Bo...

Страница 42: ...wer 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 Tr...

Страница 43: ...e 6 Remove the Power Interface Board return or dispose of it properly Install Components 1 Install the new Power Interface Board Tighten board screws to 1 7 N m 15 lb in 2 Reconnect all wiring as deta...

Страница 44: ...w the Safety Precautions on page 11 and Important Initial Steps on page 12 2 Remove the Main Control Panel See page 24 for details 3 Disconnect all wiring from the Switch Mode Power Supply Board 4 Rem...

Страница 45: ...roperly Install Components 1 Install the new Switch Mode Power Supply Board Tighten board screws to 1 7 N m 15 lb in 2 Reconnect all wiring as detailed in the Table on the previous page 3 Reassemble a...

Страница 46: ...wiring from the 24V Power Supply Board 5 Remove the mounting torx screw located at the lower right corner of the board 6 Using your fingers or needle nose pliers squeeze the tabs of each of the three...

Страница 47: ...age 26 for details 3 For DC input Label customer wiring to TB2 and then disconnect TB2 4 Disconnect the all wiring from the Precharge Board Note Label unidentified connectors to simplify reinstallatio...

Страница 48: ...pliers 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 Install...

Страница 49: ...Disconnect all wiring from TB1 and TB2 terminals 4 Remove the four board mounting bolts 5 Remove the DC Bus Filter Board return or dispose of it properly Install Components 1 Install the new DC Bus F...

Страница 50: ...in Control Panel See page 24 for details 3 Remove the Stacking Panel See page 27 4 Remove the Transitional Busbar See page 30 for details 5 Label and remove all wires and connectors from the Bus Capac...

Страница 51: ...ition but do not install yet Verify the Bus Capacitor setscrews Flexible Capacitor Busbars and all washers and nuts fit Adjust as needed 6 Remove the Transitional Busbar and tighten all washers and nu...

Страница 52: ...e 24 for details 3 Remove the Stacking Panel See page 27 4 Locate the Capacitor Bank Fan 5 Label and disconnect all wires for the fan 6 Remove the top and bottom mounting screws 7 Remove the fan assem...

Страница 53: ...ications on page 13 to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 11 and Important Initial Steps on page 12 2 Remove the Mai...

Страница 54: ...ures 5 Because the existing resistor wires will be reused cut the wires off of the resistor at the solder joint to keep the wires as long as possible 6 Strip the tip of each wire to approximately 6 mm...

Страница 55: ...Rockwell Automation Publication 20B IN025C EN P October 2015 55 Component Replacement Procedures Chapter 3 7 Cut and remove the tie wraps that secure the resistor wire bundle 7...

Страница 56: ...n 20B IN025C EN P October 2015 Chapter 3 Component Replacement Procedures 8 Remove the bolts between the right angled bus bar and the large bus bar IMPORTANT Do not remove the bolts that attach the ca...

Страница 57: ...Rockwell Automation Publication 20B IN025C EN P October 2015 57 Component Replacement Procedures Chapter 3 9 Remove the two bolts from the bottom of the bus bar as shown in the following image...

Страница 58: ...is and remove the bus bar Install Components 1 Install the set screws and nuts removed in step 10 on page 58 Tighten the nuts to 5 65 N m 50 lb in 2 Install the bolts removed in step 9 on page 57 Tigh...

Страница 59: ...R2 on the top of the resistor assembly To do so route the wire through the bottom and out of the top of the holes in the insulator material on the resistor assembly as shown in the following images No...

Страница 60: ...r for a non insulated connector crimp the wires to the lugs 6 Secure the lug with the black resistor wire to the left terminal R1 on the bottom of the resistor assembly 7 Secure the lug with the blue...

Страница 61: ...Replacement Procedures Chapter 3 9 Secure the resistor wire bundle below the assembly using tie wraps as shown in the following image 10 Install the stacking panel as detailed on page 27 11 Replace a...

Страница 62: ...ue Specifications on page 13 to locate the component detailed in these instructions Qty Component 1 IGBT module with circuit board 1 Gate Interface Board 1 Gate Interconnect Harness 3 Flexible Capacit...

Страница 63: ...edures Chapter 3 Remove Components 1 Read and follow the Safety Precautions on page 11 and Important Initial Steps on page 12 2 Locate the Inverter Power Module to be replaced Gate Interface Board Ass...

Страница 64: ...standoff nuts that secure the AC Output Busbar to the IGBT b Remove and save the two nuts that secure the AC Output Busbar to the standoffs c Remove and save the AC Output Busbar 5 Remove all IGBT Snu...

Страница 65: ...ating 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 d Place the IGBT on the chassis w...

Страница 66: ...or 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 N m 50 lb in b Install the Tie Down Capacit...

Страница 67: ...the drive Gate Interface Board See Chapter 1 Component Diagrams and Torque Specifications on page 13 to locate the component detailed in these instructions Remove Components 1 Read and follow the Saf...

Страница 68: ...ts 6 Remove the board return or dispose of it properly Install Components 1 Install the new board 2 Torque mounting nuts to 1 6 N m 14 lb in 3 Reconnect wiring as detailed in the Table on previous pag...

Страница 69: ...Transducer See page 64 for details 4 Remove the two torx screws that secure the Current Transducer assembly transducer and brackets to the chassis 5 Rotate the Current Transducer assembly counterclock...

Страница 70: ...a Place the AC Output Busbar onto the two existing standoff set screws b Reinstall the six torx screws that secure the busbar to the IGBT heatsink Torque to 5 6 N m 50 lb in c Reinstall the two stand...

Страница 71: ...rd and set aside 6 Note the orientation of the Converter Busbars and remove the eight bolts that secure the busbars to the SCR modules and to the DC and DC Busbars Set the Converter Busbars aside 7 Re...

Страница 72: ...front 6 Install the Converter Busbars per the illustration and step 6 on the previous page Torque all bolts to 9 0 N m 80 lb in 7 Install the Snubber Boards oriented with the serial number at the top...

Страница 73: ...l See page 24 for details 3 Remove the Stacking Panel See page 27 4 Locate the Snubber Resistor s to be replaced 5 Verify the Snubber Resistor s with a volt ohm meter The reading should be 8 ohms 10 I...

Страница 74: ...nting surface of the new Snubber Resistor is clean If not clean with isopropyl alcohol 3 Using a 3 inch paint roller or putty knife apply a thin even coating of the supplied thermal grease to the moun...

Страница 75: ...anel See page 27 4 Locate the Converter Snubber Board to be replaced 5 Label and disconnect wires from the Converter Snubber Resistor and the Converter Snubber Board to be replaced 6 Remove the two sc...

Страница 76: ...nitial Steps on page 12 2 Label and unplug or disconnect the five wires for the Fan Transformer 3 Unscrew the four transformer mounting bracket screws 4 Remove the transformer and properly discard Ins...

Страница 77: ...nd Important Initial Steps on page 12 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...

Страница 78: ...Place Fan assembly in final position in the chassis 4 On the back of the drive install the 11 screws for the Fan cover Torque to 9 0 N m 80 lb in TIP The connectors one set shown below are designed so...

Страница 79: ...e Chapter 1 Component Diagrams and Torque Specifications on page 13 to locate the component detailed in these instructions Remove Components 1 Read and follow the Safety Precautions on page 11 and Imp...

Страница 80: ...erter Busbars at the top of each bar Do not disconnect the U V or W Busbars at the bottom 6 AC input only Disconnect all busbars where they connect to the Converter SCR modules with 16 mm bolts Discon...

Страница 81: ...s for the Current Transducers with two 17 mm bolts and one 11 mm nut Do not remove the busbars from the setscrew on the Output Busbars at this time Do not disconnect the U V or W Busbars at the bottom...

Страница 82: ...ponent Replacement Procedures 9 Remove the entire busbar and mounting plate assembly Set aside 10 Unplug the fan cables 11 For AC input only Remove the MOV Surge Suppressor as instructed on page 88 12...

Страница 83: ...the mounting plate away from the gasket The fan housing remains mounted on the chassis Install Components 1 Remove the new fan housing from the new fan and mounting plate Discard the new fan housing 2...

Страница 84: ...mal Sensor system consists of A connector to J8 on each of the three Gate Interface Boards A sensor secured to the Heatsink above the SCR modules A sensor secured to the upper mounting bracket for the...

Страница 85: ...al Sensor TO INV CNV 3 CNV 2 TO INV TO CNV Main Control Panel Thermal Sensor J6 J8 U J8 V J8 W A B Power Interface Board TO INV TB9 9 10 TO INV TB9 9 10 CNV 1 TB9 DC Choke Plate TB15 OUT TB15 OUT jump...

Страница 86: ...r locations 7 Unplug the other end of this wiring harness at the J6 connector on the Power Interface Board See page 39 for connector locations Install Components 1 For the Main Control Panel thermal s...

Страница 87: ...s on page 12 2 Locate the DC Link Choke 3 Label and disconnect DC Choke connectors L1 L4 4 Label and disconnect wiring to TB15 5 Remove the four screws that mount the DC Link Choke to the DC Choke Pla...

Страница 88: ...the Stacking Panel See page 27 4 Locate the MOV Surge Suppressor assembly 5 Note wire placement and connections Disconnect the MOV ground wire to transformer and the R S and T wires to the AC Busbars...

Страница 89: ...for details 3 Remove the Stacking Panel See page 27 4 Locate the Precharge SCR module and Diode to be replaced 5 Label and remove all DC power cables and all connected wires from the two busbars 6 Re...

Страница 90: ...iagram below 5 Install the busbars all wires and the DC cables 6 Torque DC cable screws to 12 2 N m 108 lb in 7 Reassemble remaining components in reverse order 8 Replace all safety shields and enclos...

Страница 91: ...ware based on information added with previous revisions of this manual 20B IN025B EN P January 2011 Topic Preface Balancing resistor part number corrected in Component Kits table Chapter 1 Overview he...

Страница 92: ...92 Rockwell Automation Publication 20B IN025C EN P October 2015 Appendix A History of Changes Notes...

Страница 93: ......

Страница 94: ...Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not fun...

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