Rockwell Automation PF700 User Manual

Installation Instructions

PowerFlex 700 Drive - Frame 9 Components Replacement

Catalog Numbers

XXX XXX XXXX XXX XXX XXX

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.

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.

available from

) describes some

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

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.

Identifies information that is critical for successful application and understanding of the product.

Summary of Changes

Preface

New and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Component Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Important Initial Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Chapter 1 Component Diagrams and Torque Specs

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Fastener Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Chapter 2 Basic Component Removal Procedures

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Main Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Blower Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Stacking Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Transitional Busbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Chapter 3 Component Replacement Procedures

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Main Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

T-Comm Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Power Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Switch Mode Power Supply Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

24V Power Supply Board (for Current Transducers) . . . . . . . . . . . . . . . . 45

Precharge Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

DC Bus Filter Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Bus Capacitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Capacitor Bank Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Balancing Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Inverter Power Module (IGBT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Gate Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Current Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Converter Power Module (SCR) - AC Input Only. . . . . . . . . . . . . . . . . . 62

Converter Snubber Resistors - AC Input Only. . . . . . . . . . . . . . . . . . . . . . 64

Converter Snubber Board - AC Input Only . . . . . . . . . . . . . . . . . . . . . . . . 66

Fan Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Heatsink Fan - Removal from Back of Drive . . . . . . . . . . . . . . . . . . . . . . . . 68

Heatsink Fan - Removal from Front of Drive . . . . . . . . . . . . . . . . . . . . . . . 70

Thermal Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

DC Link Choke - AC Input Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

MOV Surge Suppressor - AC Input Only . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Precharge SCR Module and Diode - DC Input Only . . . . . . . . . . . . . . . . 80

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 3

Table of Contents

Notes:

4 Rockwell Automation Publication 20B-IN025B-EN-P - January 2011

Summary of Changes

This manual contains new and updated information. Changes throughout this revision are marked by change bars, as shown to the right of this paragraph.

New and Updated Information

This table contains the changes made to this revision.

Topic Page Preface

Balancing resistor part number corrected in Component Kits table 8

Chapter 1

Overview heading and text added 11

Chapter 2

Overview heading added 16 Circuit board cross-reference text added to Overview section 16

Chapter 3

Overview heading and text added 35 Step 6 figure orientation changed in T-Comm removal section 39 J6 connector location changed from Main Control Board to Power Interface Board 75 Figure 7 removed from the Thermal Sensors section 75

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 5

Summary of Changes

Notes:

6 Rockwell Automation Publication 20B-IN025B-EN-P - January 2011

Preface

Introduction

Component Kits

This publication provides guidelines for replacing the major components in the PowerFlex 700 Frame 9 drive.

All kits include necessary components, ESD wrist strap and hardware (if required), and thermal grease (if required).

Description Kit Catalog No. Notes Printed Circuit Boards

Gate Interface Board SK-G1-GDB1-F8910 Drive requires three kits Precharge Board SK-G9-PRE1-V480 AC input

1336-PB-SP22C DC input Power Interface Board SK-G9-GDB1-D700 730 A 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 24V Power Supply Board (CTS) SK-G9-PSR24 DC Bus Filter Board 2364-SPP02A

Fans and Main Fan Circuit Components

Heatsink Fan SK-G1-FAN1-F9 Includes Fan and Fan 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 Flexible Capacitor Busbars

• Three Snubber Capacitors

• One Tie Down Capacitor Mount

Drive requires three kits.

Converter Power Module (SCR) SK-G1-SCR1-F89 For AC input drives only.

Kit includes three SCR Modules.

SCR Snubber Kit SK-G1-SCRSNUBRB AC input drive requires three kits.

DC input drive requires one kit.

DC Precharge SCR Module SK-G1-SCR2-F89 For DC input drives only.

Includes:

• One SCR Module

• One Diode

DC Link Choke SK-G1-DCCHOKE1-F9 For AC input drives only

Miscellaneous

Current Transducer SK-G1-CT1-F910 Includes one Transducer.

Drive requires three kits.

Thermal Sensor Kit SK-G1-THM1-F89 For AC input drives only.

Includes:

• Main Control Panel Thermal

Sensor

• Heatsink Thermal Sensor

SK-G1-THM2-F89 For DC input drives only.

Includes:

• Main Control Panel Thermal

Sensor

• Heatsink Thermal Sensor

Bus Capacitor Kit SK-G1-BUSCAP1-F9 Includes one Capacitor.

Drive requires 18 kits.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 7

Preface

Description Kit Catalog No. Notes Miscellaneous (continued)

Capacitor Bus Finger Kit SK-G1-FLXBUS1 Included with the kit for Inverter

Power Module (IGBT). Can be ordered separately. Includes:

• Three positive Flexible Capacitor

Busbars

• Three negative Flexible Capacitor

Busbars MOV Surge Suppressor SK-G1-MOV1-F89 For AC input drives only. Power Supply, 24V SK-G9-PWRS24 Transformer, 500 VA SK-G9-XFMR1-F89 For AC input drives only.

Includes:

• One Transformer

• Three fuses

Transformer Fuses SK-G9-FUSE1-F8 For AC input drives only.

Includes three fuses.

Balancing Resistor 1336-RLOAD-SP3A

See the master parts list for the most up-to-date information:

http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf

Recommended Tools

IMPORTANT

See the instruction sheet included with each component kit for discarding or returning replaced components.

If discarding, be sure to discard according to local, state, and federal regulations.

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. See pertinent sections for details.

Description

Torque wrench (metered in N•m or lb•in) Volt ohm meter Torque seal or colored marker Screwdrivers (standard, Phillips, torx 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

– various sizes)

8 Rockwell Automation Publication 20B-IN025B-EN-P - January 2011

Preface

Safety Precautions

The precautions and general installation requirements provided in the PowerFlex 700 Frame 7-10 Installation Instructions (publication 20B-IN014 PowerFlex 700 User Manual (publication 20B-UM002

) must be followed with

) and the

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 Terminals 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.

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.

Electrical arcing causes excessive wear to contacts on 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 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-IN025B-EN-P - January 2011 9

Preface

ATT ENTI ON: 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 handbook.

The information in this publication is merely a guide for proper installation. Rockwell Automation, Inc. cannot assume responsibility for the compliance or the noncompliance to any code (national, local, or otherwise) for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored.

Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.

HOT surfaces can cause severe burns. Do not touch the heatsink surface during operation of the drive. After disconnecting power, allow time for cooling.

Replace all protective shields before applying power to the drive. Failure to replace protective shields may result in death or serious injury.

, or any other applicable ESD protection

Important Initial Steps

Read and follow these statements before performing any service on the drive.

· Read and follow the precautions in Safety Precautions

· Identify components to be replaced using Drive Components on page 13

on page 9.

· 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.

· See the product installation documentation for startup and other instructions after servicing.

10 Rockwell Automation Publication 20B-IN025B-EN-P - January 2011

Chapter

Component Diagrams and Torque Specs

Overview

Drive components and their locations are identified in this chapter, as well as torque specifications for fasteners that are part of component removal and replacement.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 11

Chapter 1 Component Diagrams and Torque Specs

Figure 1 - Frame 9 - AC Drive Components

Drive Shown With Stacking Panel Removed

Transitional Busbar

Flexible Capacitor Busbars (18)

DC Bus Capacitor (18)

Tie Down Capacitor Mount (3)

Gate Interface Board (3)

Current Transducer (3)

Output Busbar (3)

IGBT Interface Board and IGBT (3 each)

Snubber Capacitors (9) for IGBTs

Balancing Resistor

Capacitor Bank Fan

MOV Surge Suppressor

Fan Transformer (AC)

Converter Snubber Resistors (3)

Heatsink Thermal Sensor location

Converter Power Module (SCR) (3)

Converter Snubber Board (3)

Converter Busbar (2) Heatsink Fan

(Behind Busbar Mounting Plate) Busbar Mounting Plate

+DC, -DC Busbars

AC Busbars (R, S, T)

12 Rockwell Automation Publication 20B-IN025B-EN-P - January 2011

Motor Busbars (U, V, W)

PE Ground (and MOV Wire)

Drive Shown With Stacking Panel Removed

Transitional Busbar

Flexible Capacitor

Busbars (18)

DC Bus Capacitor (18)

Component Diagrams and Torque Specs Chapter 1

Figure 2 - Frame 9 - DC Drive Components

Gate Interface Board (3)

Current Transducer (3)

Output Busbar (3)

IGBT Interface Board and IGBT (3 each)

Tie Down Capacitor Mount (3)

Balancing Resistor

Precharge SCR Module

Capacitor Bank Fan

Precharge Resistors (2)

Precharge Fuse

Snubber Capacitors (9) for IGBTs

Precharge Busbar (Top)

Diode

Precharge Busbar (Bottom)

Heatsink Fan (Behind Busbar Mounting Plate)

Busbar Mounting Plate

Motor Busbars (U, V, W)

PE Ground

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 13

Chapter 1 Component Diagrams and Torque Specs

Figure 3 - Frame 9 Busbars (AC Drive shown)

DC- Bar

DC+ Bar

Transitional Bus Bar Assembly

14 Rockwell Automation Publication 20B-IN025B-EN-P - January 2011

Figure 4 - Frame 9 (AC input drive shown)

Component Diagrams and Torque Specs Chapter 1

DC Link Choke Output

Connection (Top)

Transitional Busbar

DC Capacitor Bank

(Under Transitional Busbar)

Inverter Power Module IGBT

(under Capacitors)

IGBT Gate and CT Wire Harness

Balancing Resistor

Stacking Panel

Blower Control Panel

Inverter Snubber

Capacitors (3 per IGBT)

Gate Interface Board

Current Transducer (3)

Motor Busbars (U, V, W)

Main Control Board (below Communication Panel)

Communication Panel

Fan Terminal Block – TB9

Phase Monitor Relay

DC Bus Filter Board

24V Power Supply Board

Fan Transformer

+DC Busbar

HIM Cradle/ Communication Board

Main Control Panel

TB 11

-DC Busbar

AC Busbars (R, S, T)

DC Link Choke

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 15

Chapter 1 Component Diagrams and Torque Specs

Circuit Boards

Blower Control Panel

Fuse Holders

Overload Protector

Communications Panel

Main Control Panel

Safety Shield

T- Co mm Interface

Figure 5 - Circuit Boards on Frame 9

Encoder Board (optional)

[

]

No. Description

· TB11

· HIM Cradle/Communication Board

· Communication Board Slots

(for optional devices)

· Main Control Board

(shown with optional encoder board)

· DC Bus Filter Board

· TB9

· 24V Power Supply Board (CTS)

· Phase Monitor Relay

· Power Interface Board

· Switch Mode Power Supply Board

· Precharge Board (DC input shown)

Stacking Panel

]

[

16 Rockwell Automation Publication 20B-IN025B-EN-P - January 2011

Component Diagrams and Torque Specs Chapter 1

Fastener Torque Specifications

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.

Figure 6 illustrates initial and final tightening sequences for components fastened to a heat sink using two, four, and six screws. Initial torque is one-third (33.3%) 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 6 - Various-Point Mounting

Two-Point Mounting

Four-Point Mounting

Start

End

1212

Start

Torque Sequence

End

Initial

End Start

Final

Torque Sequence

1243 3 42 1

End

Initial

Torque Sequence

Start

Final

Six-Point Mounting

End

3 1

Start

Initial Torque Sequence

Note: Do not exceed 0.7 N•m (6 lb•in) on initial torque.

End

3 1

Start

Final Torque Sequence

Rockwell Automation Publication 20B-IN025B-EN-P - January 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. See To r qu e S e q ue nc e two-point, four-point, and six-point components to the heat sink.

in this chapter for fastening

Torque

Component Fastener Application lb•in N•m

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 Converter Snubber Board Board to Input Rectifier 50 6

Balancing Resistor

Balancing Resistor Wires to Capacitor Busbar Assembly 50 6 Converter Heatsink Thermal

Sensor Main Control Panel Thermal

Sensor Bus Capacitor Holder Holder to Bus Capacitors 26 3 Capacitor Busbar Assembly Assembly to Bus Capacitors 50 6 Gate Interface Board Board to Power Modules 14 2 Inverter Power Module (IGBT)

Busbar

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 Busbar Assembly Assembly to Power Module Busbar

DC Bus Inductor L1 Inductor to chassis 50 6 Busbar Cable Adaptor Adaptor to Transitional Busbar and DC Bus

Converter Bus and Motor Busbars

Wires (PE) Wires to Ground Stud 80 9 Wires Wires to TB1 80 9 Wire (TE) Wire to TB1 50 6 Wires Wires to TB2 7 0.8

Resistor to heat sink Initial sequence: 6 0.7

Final sequence: 26 3

Thermistor to heatsink 14 2

Thermistor to mounting bracket 14 2

Busbar 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

80 9

Assembly

80 9

Inductor Busbars to all connections 80 9

18 Rockwell Automation Publication 20B-IN025B-EN-P - January 2011

Component Diagrams and Torque Specs Chapter 1

Torque

Component Fastener Application lb•in N•m

Wires Wires 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 Busbar 26 3 Power Cables Cables to terminals 80 9 Main Control, Gate Driver,

Precharge Board Mounting Plates

High Voltage Guard Guard to chassis 26 3

Plates to chassis 26 3

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 19

Chapter 1 Component Diagrams and Torque Specs

Notes:

20 Rockwell Automation Publication 20B-IN025B-EN-P - January 2011

Chapter

Basic Component Removal Procedures

Overview

Component removal procedures detailed in this chapter are located on the Stacking Panel and Transitional Busbar assemblies highlighted below.

See Circuit Boards Stacking Panel assembly.

on page 16 to identify the various panels that comprise the

Transitional Busbar Assembly

Stacking Panel Assembly

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 21

Chapter 2 Basic Component Removal Procedures

Main Control Panel

See Chapter 1 - Drive Components to locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 8 and Important Initial

Steps on page 10.

2. Remove safety shields as needed.

Ribbon Cable from Main Control Board to Power Interface Board

Mounting Screws (2) that adjoin Blower Control Panel to Main Control Panel

Mounting Nuts (2) at top of Main Control Panel

Mounting Screws (2) below TB11

Ground Wire to TB11

3. Remove the ribbon cable going from the Main 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 Panel to the Main

Control Panel. These screws are larger than the two removed from below TB11 so do not mix the two sets.

7. Remove the two mounting nuts above the Main Control Board.

8. Remove Main Control Panel; support.

22 Rockwell Automation Publication 20B-IN025B-EN-P - January 2011

Basic Component Removal Procedures Chapter 2

9. Disconnect wire harnesses from TB11 to:

• J4 on the Switch Mode Power Supply Board

• TB1 and TB2 on the Power 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 the Main

Control Panel Assembly components in the reverse order of removal.

2. Torque panel mounting screws to 2.9 N•m (26 lb•in).

3. Replace all safety shields and enclosure covers before applying power to the

drive.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 23

Chapter 2 Basic Component Removal Procedures

Blower Control Panel

See Chapter 1 - Drive Components to locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 8 and Important Initial

Steps on page 10.

2. Disconnect the three wires (red, white, and blue) at the top of the blower

fuse block.

Screws (2) to connect to Stacking Panel

Red

White Blue

Screws (2) to connect to Main Control Panel

3. Label and remove all wiring to TB9.

4. Remove the two 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 Blower Control Panel to the

Stacking Panel.

6. Carefully set the Blower Control Panel aside.

Install Components

1. When instructed for the component you are replacing, reinstall the Blower

Control Panel in the reverse order of removal.

2. See page 26

3. Torque panel mounting screws to 2.9 N•m (26 lb•in).

4. Replace all safety shields and enclosure covers before applying power to the

drive.

for reinstalling wires to TB9.

24 Rockwell Automation Publication 20B-IN025B-EN-P - January 2011

Basic Component Removal Procedures Chapter 2

Stacking Panel

See Chapter 1 - Drive Components to locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 8 and Important Initial

Steps on page 10.

2. All wiring and terminals attached to the Stacking Panel are shown below.

Label any unidentified wiring and terminals before disconnecting.

IMPORTANT

Shown with Main Control Panel, Blower Control Panel and Safety Shield Removed

TB2

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.

J14…J16

Power Interface Board

Thermal Sensor

Wire

Precharge

Board

(DC input

shown)

DC Bus

Filter Board

TB2

TIP

This step may be performed more easily if you first remove the Communications Panel following the instructions on page 22

Connected Component Label on Wire

or Connector

Precharge Board J1, J2 J1, J2

TB2 TB2 For DC input only. DC Bus Filter Board TB2 Thermal Sensor Wire

Label on Board Notes

J18

J23

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 25

Chapter 2 Basic Component Removal Procedures

Connected Component Label on Wire

or Connector

Power Interface Board J6 J6

J8 J8 J16 U U Phase CT J15 V V Phase CT J14 W W Phase CT J23 UP, VP, WP U, V, W positive gates J18 UN, VN, WN U, V, W negative gates

Label on Board Notes

3. Remove the J1 and J2 connectors on the Precharge Board.

4. DC input only: Remove the TB2 connector at the top of the Precharge

Board.

5. Using your fingers or needle-nose pliers, squeeze the tabs of each of the

four spacers and remove the safety shield over the DC Bus Filter Board and 24V Power Supply Board.

6. Disconnect the red and black wires from TB2 on the DC Bus Filter Board. Do not disconnect the wires from TB1.

7. Disconnect the black Main Control Panel Thermal Sensor Wire above the

Main Control Board at the connector junction. See page 73

for its

location.

Do not remove the sensor from the bracket.

8. Carefully label and disconnect all wiring to TB9.

TB9 Shown with Factory Wiring only

Connected Component Wire Color TB9 Terminal Notes

Fan Harness Black 120V, RT side Lower 120V slot

Black N, RT side Upper N slot Red 120V, LT side Upper 120V slot White N, LT side Upper N slot

Blower Harness White TB-9, RT side

White TB-10, RT side

LT = Left and RT = Right

26 Rockwell Automation Publication 20B-IN025B-EN-P - January 2011

+ 58 hidden pages

Rockwell Automation PF700 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Table of Contents

Summary of Changes

New and Updated Information

Preface

Introduction

Component Kits

Recommended Tools

Safety Precautions

Important Initial Steps

Overview

Circuit Boards

Fastener Torque Specifications

Torque Sequence

Torque Specifications

Overview

Main Control Panel

Remove Components

Install Components

Blower Control Panel

Remove Components

Install Components

Stacking Panel

Remove Components