Installation Instructions
PowerFlex 700 Drive - Frame 7 Components Replacement
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
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/
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, 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.
available from
) describes some
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.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Summary of Changes
Preface
Component Diagrams and Torque
Specs
Basic Component Removal
Procedures
New and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Component Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Important Initial Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 1
Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inverter Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Main Control Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fastener Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chapter 2
Remove Main Control Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Remove Stacking Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Remove Precharge Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Remove Transitional Bus Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Component Replacement Procedures
Chapter 3
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
Main Control Panel Thermal Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Heatsink Thermal Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Bus Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Bus Capacitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Converter Snubber Board - AC Input Only . . . . . . . . . . . . . . . . . . . . . . . . 50
Converter Power Module (SCR) - AC Input Only . . . . . . . . . . . . . . . . . . 51
MOV - AC Input Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DC Link Choke - AC Input Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Precharge SCR Module Snubber Board - DC Input Only. . . . . . . . . . . . 56
Precharge SCR Module - DC Input Only . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 3
Table of Contents
Notes:
4 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
This manual contains new and updated information.
Summary of Changes
New and Updated Information
This table contains the changes made to this revision.
Top ic Pag e
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.)
Added T-Comm Board kit, SK-G9-TCOMM, to table of component kits. 7
Added T-Comm Board removal and installation instructions. 27
7
Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 5
Summary of Changes
Notes:
6 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
Preface
Introduction
Component Kits
This publication provides guidelines for replacing the major components in the
PowerFlex 700 Frame 7 drive.
All kits include necessary components, ESD wrist strap and hardware (if
required), and thermal grease (if required).
Description Kit Catalog No. Notes
Precharge Board SK-G9-PRE1-V480 AC input
1336-PB-SP22C DC input
Main Control Board SK-G9-VMCB1-D0 115V I/O
SK-G9-VMCB1-C0 24V I/O
T-Comm Board SK-G9 -TCOMM
Switch Mode Power Supply Board SK-G9-PWRS1-D0
Power Interface Board SK-G9-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 IGB Ts.
·Two Gate Interface Boards.
Inverter Snubber Kit SK-G1-INVSNB1-F7 Includes:
·One Snubber Board.
·One Resistor.
SCR Snubber Kit SK-G1-SCRSNUBRB AC input requires three kits.
DC input requires one kit.
Converter Power Module (SCR) SK-G1-SCR1-F7 AC input.
Kit includes three SCR Modules.
DC Precharge SCR Module SK-G1-SCR2-F7 DC input.
Kit includes one SCR Module
Thermal Sensors SK-G1-THM1-F7 Includes:
·Main Control Panel Thermal Sensor
·Heatsink Thermal Sensor.
Bus Fuse 1336-F1-SP6A
Bus Capacitor SK-G1-BUSCAP1-F7 Includes one Capacitor.
MOV SK-G1-MOV1-F7 AC input.
DC Link Choke SK-G1-DCCHOKE1-F7 AC input.
Balancing Resistor 1336-RLOAD-SP4A Includes one Resistor.
Refer to the master parts list for the most up-to-date information:
http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf
Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 7
Preface
Recommended Tools
The following list of tools is provided for your reference to disassemble and
assemble the drive and components. This list may not be all-encompassing for
your situation. Not all tools are needed for some components. Refer to pertinent
sections for details.
Description Notes
Torque wrench (metered in lb•in or N-m), T30 and T40 bits
Torque seal o r colored marke r
Screwdrivers (standard, Phillips, star – various sizes)
Magnetic screwdriver, long
Socket set, metric
Cylindrical pick-up magnet
Pliers, regular and needle-nose
Wire c utters
Volt ohm meter Used to test Inver ter Snubber Resistors
Isopropyl alcohol
Nylon tie wraps
Penci l
14 or 16 gauge wire, about 10 cm (4 in.) Needed whenever IGBT gates are exposed. Used to
Two (2) #10 wire lugs, either fork or ring
short the gates.
8 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
Preface
Safety Precautions
The precautions and general installation requirements provided in the PowerFlex
700 Frame 7-10 Installation Instructions (publication 20B-IN014) and the
PowerFlex 700 User Manual (publication 20B-UM002) must be followed in
addition to those included here.
ATTENTION: To avoid an electric shock hazard, ensure that all power has
been removed before proceeding. In addition, before servicing, verify
that the voltage on the bus capacitors has discharged. Check the DC bus
voltage at the Power Terminal Block by measuring between the DC+ &
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.
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:
· sending an erroneous signal to your system’s field
devices, causing unintended machine motion.
· causing an explosion in a hazardous environment.
ATTENTION: Electrical arcing causes excessive wear to contacts on both
the module and its mating connector. Worn contacts may create
electrical resistance.
1. Turn off and lock out input power. Wait five minutes.
2. Verify that there is no voltage at the drive’s input power terminals.
3. Check the DC bus voltage at the Power Terminal Block by measuring
between the DC+ and DC– terminals, between the DC+ terminal and
the chassis, and between the DC– terminal and the chassis. The voltage
must be zero for all three measurements.
L1 L2 L3
I
O
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, reference Allen-Bradley
Publication 8000-4.5.2 Guarding Against Electrostatic Damage, or any
other applicable ESD protection handbook.
Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 9
Preface
ATTENTION: 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.
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 the drive. After disconnecting
power, allow time for cooling.
ATTENTION: Replace all protective shields before applying power to
the drive. Failure to replace protective shields may result in death or
serious injury.
10 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
Preface
Important Initial Steps
Read and follow these statements before performing any service on the drive.
· Read and follow the precautions in Safety Precautions on page 9
· Identify components to be replaced using the figures in 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.
· Refer to the product installation documentation for startup and other
instructions after servicing.
.
Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 11
Preface
Notes:
12 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
Component Diagrams and Torque Specs
Chapter 1
Drive Components
Main Control Panel Assembly
Main Control
Panel Thermal
Sensor
CAUTION
!
HOT SURFACES
Power Interf ace Boa rd
(under Main Control Panel)
TB11
25 AMPERES RMS
MAXIMUM
ALLEN-BRADLEY
MADE IN U.S.A.
Main Control Panel)
J3 J1 J2
TB2
!
DANGER
RISK OF SHOCK
REPLACE AFTER
SERVICING
Switch Mode Power Supply Board (under
Transitional Bus Bar
HIM
PE
Precharge Board
Assembly
Capacitor
for Fan
AC input drive is shown.
DC Capacitor Bank
(under Transitional Bus Bar)
Main Control Panel
(Stacking Panel (underneath)
Bus Fuse
Communications
Module
TB11
DC Link Choke
Heatsink Thermal
Sensor location
Gate Interface Board (U)
(V and W not shown)
Current Transducer
Inverter Snubber Boards (U,
V, W )
Inverter Power Module IGBTs
(U, V, W) (under Inverter
Snubber Board)
U
Motor Bus Bars
V
W
Balancing Resistors
Inverter Snubber Resistors
Converter Snubber Boards (3)
with Converter Power SCR
Modules underneath
AC Bus Bars (R, S, T)
Transformer
MOV Location
Power Termin al Block
+DC
-DC PE PE R-L1 T-L3 U-M1 V-M2 W-M3S-L2
USE 75° COPPER WIRE ONLY
TORQUE LARGE TERMINALS TO 10 N-m (87LB-IN)
R Phase
S Phase
AC Power Inp ut
Connect ions
T Phase
U Phase
V Phase
Motor
Connections
W Phase
Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 13
Chapter 1 Component Diagrams and Torque Specs
AC input drive is shown.
Transitional Bus Bar
Bus Fuse
Power Interface Board
location (under Main
Control Panel)
Ribbon Cable - Main
Control Board to Power
Interface Board
Ribbon Cable -
Main Control Board
to Comm Board
DC Capacitor Bank
(under Transitional Bus Bar)
Current Transducer
(quantit y: 3)
Heatsink Thermal
Sensor location
U
V
Gate Interface Board
Inverter Snubber Board (U)
(V and W not visible in this image)
Inverter Power Module IGBT (U)
(V and W below U)
IGBT Gate Harness and
CT Harness
Motor Bus Bars (U, V, W)
W
Main Control Panel Thermal Sensor
Wire
HIM
(Blank shown on this Drive)
Main Control Board
(under HIM mounting)
DC Link Choke
Switch Mode Power
Supply Board (under
Main Control Panel)
Capacitor for Fan
Tr an s f or m e r
MOV Location
Power Terminal Block
R Phase
S Phase
T Phase
Motor ConnectionsAC Power Input Connections
Communications Panel
Main Control Panel
TB11
Precharge B oard Assembly
V Phase
W Phase
U Phase
14 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
Inverter Section
Bottom of Drive Top of Drive
Component Diagrams and Torque Specs Chapter 1
Current Transducers
Current Transducer Mounting Clamps
Inverter Snubber Boards
Motor Bus Bars
Gate Interface Boards
Inverter Power Module IGBTs
Current Transducers
(behind Mounting Clamps)
Note: Components are shown as seen from right side without drive covers.
Motor Bus Bars
Inverter Snubber Boards
IGBT Bus Bars
Gate Interface Boards
Inverter Power Module IGBTs
Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 15
Chapter 1 Component Diagrams and Torque Specs
Main Control Panel Assembly
Bottom of Drive Top of Drive
Front
Back
Note: Components are shown as seen from right side without drive covers.
Fastener Torque Specifications
Components are listed left to right for
each level
HIM
Communications Panel
TB11 and Main Control Board
Main Control Panel
Switch Mode Power Supply Board and
Power Interface Board
Stacking Panel
Torque Sequence
ATTENTION: When mounting components to a drive’s heat sink,
component fastener torque sequences and tolerances are crucial to
component-to-heat sink 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 heat sink using two, four, and six screws. Initial torque is 1/3 (33%)
of final torque, except six-point mountings, which require 0.7 N•m (6 lb•in) The
numeric illustration labels are for your assistance. Drive components do not carry
these labels.
Figure 1 - Two-Point Mounting
1
1
Initial Sequence
Final Sequence
16 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
2
2
12
Figure 2 - Four-Point Mounting
Component Diagrams and Torque Specs Chapter 1
1
Figure 3 - Six-Point Mounting
1
4
2
Initial Sequence
Final Sequence
6 42
3
2
3 4
1234
3 51
1 2 65
Do not exceed 0.7 Newton-meters (6 lb•in) on initial torque of all six screws.
3 4
Initial Sequence
3 41 2 65
Final Sequence
Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 17
Chapter 1 Component Diagrams and Torque Specs
Torque Specifications
The following table lists fastener locations by component, how the fasteners are
used, and torque specifications. Refer to To rq ue Sequ en c e
fastening two-point, four-point, and six-point components to the heat sink.
in this chapter for
Tor que
Component Fastener Application
Fan Motor Motor to Fan Cover Assembly 14 2
Fan Cover Assembly Assembly to chassis 26 3
Fan Transformer Transformer to chassis 26 3
Fan Capacitor Capacitor to chassis Hand tighten
MOV Surge Suppressor MOV to chassis 14 2
Inverter Snubber Resistor
Inverter Snubber Resistor Wires to Capacitor Bus Bar Assembly 50 6
Inverter Snubber Bracket Bracket to Power Module 80 9
Inverter Snubber Board Board to Brackets 50 6
Converter Snubber Board Board to Input Rectifier 50 6
Balancing Resistor
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
Inverter Power Module (IGBT) Bus
Bar
Inverter Power Module (IGBT)
DIN Rail (TB1) Rail to chassis 50 6
PE Shortening Bar Bar to TB1 80 9
Converter Power Module (SCR)
Transitional Bus Bar Assembly Assembly to Power Module Bus Bar Assembly 80 9
Bus Fuse F1 Fuse to Transitional Bus Bar 80 9
DC Bus Inductor L1 Inductor to chassis 50 6
Bus Bar Cable Adaptor Adaptor to Transitional Bus B ar and DC Bus
Converter Bus and Motor Bus Bars Bus Bars to all connections 80 9
Wires (PE) Wi res to Groun d Stud 80 9
Wires Wires to TB1 80 9
Wire (TE) Wire to TB1 50 6
Resistor to heat sink Initial sequence: 6 0.7
Final sequence: 26 3
Resistor to heat sink Initial sequence: 6 0.7
Final sequence: 26 3
Bus Bar to Power Modules 80 9
Module to heat sink Initial sequence: 6 0.7
Final sequence: 32 3.6
SCR to heat sink Initial sequence: 6 0.7
Final sequence: 50 6
Inductor
lb•in
80 9
Tor que
N•m
18 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
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