Rockwell Automation PF700 User Manual

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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

Basic Component Removal Procedures Chapter 2

9. Remove the six nuts for mounting the Stacking Panel.

Shown with Main Control Panel and Blower Control Panel Removed

Mounting Nuts (6)

10. Remove Stacking 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 5.6 N•m (50 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 27

Chapter 2 Basic Component Removal Procedures

Transitional Busbar

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 Main Control Panel

3. Remove Blower Control Panel

4. Remove Stacking Panel

5. Locate the Transitional Busbar.

on page 22.

on page 24.

on page 25.

DC Choke Output Cables

Transitional Busbar

Balancing Resistor

6. If present, remove all customer wiring to Transitional Busbar.

7. For AC input drives, remove the DC Choke output cables.

For DC input drives, there is no choke.

8. If present, disconnect the +DC IN and +DC OUT cables from the Transitional Busbar.

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

Basic Component Removal Procedures Chapter 2

9. Remove all IGBT Snubber components:

a. Remove the six nuts that secure each set of Snubber Capacitors.

Remove the capacitors, and save nuts and capacitors.

Tie Down Capacitor

Mount

Screw

Snubber

Capacitor

Mount Nuts (6)

Tie Down Capacitor

Mount

Screw

Snubber Capacitors

b. Remove the two screws that secure each Tie Down Capacitor Mount.

Remove the Tie Down Capacitor Mounts and save screws and Capacitor Mounts.

c. Remove the six setscrews from each IGBT and save.

Setscrews (6)

Nuts for

DC- Flexible

Capacitor

Busbars

d. If replacing an IGBT module, remove the nuts and DC- Flexible

Capacitor Busbars, and save nuts and busbars.

IMPORTANT

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 29

The positive (DC+) Flexible Capacitor Busbars are connected to the back side of the Transitional Busbar. The Transitional Busbar must be removed before they can be accessed and removed.

Chapter 2 Basic Component Removal Procedures

10. Cut tie wraps for the Balancing Resistor wiring.

11. Disconnect the yellow wire for the Balancing Resistor.

You do not need to disconnect the blue and black wires.

Balancing Resistor

Resistor wiring tie wraps

Balancing Resistor yellow wire

Disconnect here

12. Remove the four side standoffs and brackets for the Transitional Busbar

assembly.

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.

DC Choke Output Cables

Transitional Busbar Nuts (18) attached to Setscrews

Photo shows Setscrews in

Transitional Busbar

Capacitors; these Setscrews may come out with the Transitional Busbar nuts when they are removed.

Side Standoffs and Brackets (4)

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

Balancing Resistor

Basic Component Removal Procedures Chapter 2

14. Remove the Transitional Busbar unit.

Transitional Busbar Unit Removed

Negative (DC-) Flexible

Capacitor Busbar (attached to

top side of Transitional Busbar)

Positive (DC+) Flexible Capacitor Busbar (attached to bottom side of Transitional Busbar)

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 31

Chapter 2 Basic Component Removal Procedures

Install Components

See the photographs in the preceding Transitional Busbar section to identify any components discussed in this section.

Positive (DC+)

Flexible Capacitor

Busbar (short)

Negative (DC-) Flexible Capacitor Busbar (tall)

IMPORTANT

Each IGBT replacement kit includes three positive (DC+) and three negative (DC-) Flexible Capacitor Busbars. The positive ones are shorter (see above) because they attach to the back side of the Transitional Busbar. For ease of installation, replace positive Flexible Capacitor Busbars while the Transitional Busbar is removed.

1. Replace the three positive (DC+) Flexible Capacitor Busbars supplied in an IGBT replacement kit on the back side of the Transitional Busbar for each IGBT module being replaced.

2. Mount Transitional Busbar to Bus Capacitors. If needed, use a rubber mallet to gently tap the Transitional Busbar onto the longer setscrews of the Bus Capacitors.

3. Add a washer (rounded side down) and nut to each Bus Capacitor setscrew. Finger tighten only.

4. Install the nine negative Flexible Capacitor Busbars to the Transitional Busbar with two washers (rounded side down) and two nuts for each Flexible Capacitor Busbar. Finger tighten only.

5. Install the six setscrews to secure the Flexible Capacitor Busbars to each IGBT board. Finger tighten only.

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

Basic Component Removal Procedures Chapter 2

6. Reinstall the screws for the four side standoffs and brackets to secure the

Transitional Busbar assembly to the chassis. a. Torque the screws to 5.6 N•m (50 lb•in) to secure the brackets to the

four red glastic spacers.

b. Torque screws to 2.9 N•m (26 lb•in) to secure the two brackets to the

drive chassis.

7. Torque the six setscrews for each IGBT board to 5.6 N•m (50 lb•in).

IMPORTANT

When torquing down each setscrew, place a flathead screwdriver against the side of the Flexible Capacitor Busbar to minimize twisting. Do not rest the screwdriver against any IGBT board while performing this task to avoid cracking or breaking the board.

8. Reinstall the Tie Down Capacitor Mount on each IGBT board.

Reinstall two screws simultaneously to secure each Mount. Torque screws to 5.6 N•m (50 lb•in).

9. Install three Snubber Resistors onto the six setscrews for each IGBT board.

Reinstall two screws to secure each Snubber Resistor against the Tie Down Capacitor Mount. Torque screws to 5.6 N•m (50 lb•in).

10. Torque the nuts that secure the nine negative Flexible Capacitor 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 Balancing Resistor.

13. Install a new tie wrap for the Balancing Resistor wiring.

14. If present, reconnect the +DC IN and +DC OUT cables from the

Transitional Busbar.

15. For AC input drives, reinstall the DC Choke output cables.

16. Reinstall any customer wiring to the Transitional Busbar.

17. Reinstall the Stacking Panel as instructed on page 27

18. Reinstall the Blower Control Panel as instructed on page 24

19. Reinstall the Main Control Panel as instructed on page 23

20. Verify all wiring to the three panels and the Transitional Busbar has been

reconnected.

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

drive.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 33

Chapter 2 Basic Component Removal Procedures

Notes:

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

Chapter

Component Replacement Procedures

Overview

Main Control Board

Component procedures detailed in this chapter apply to PowerFlex 700 Frame 9 drives for AC or DC input. Removal and replacement instructions for the Stacking Panel and Transitional Bar assemblies are detailed in Chapter 2.

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.

Communication Panel Mounting Nuts (2)

Ribbon Cable from HIM Cradle/Board to Main Control Board

HIM Cradle/Board

(Located over Main Control Panel)

Cable at DPI Port 2 Clamp

Screw for green/yellow Ground Wire

Communication Panel Mounting Screws and Washers (2 each)

3. Unscrew the green/yellow ground wire from the Communications Panel.

4. Remove the nuts, screws and washers (two each) that secure the

Communications Panel to the Main Control Panel.

5. Disconnect the ribbon cable that connects the HIM Cradle/Board to the

Main Control Board.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 35

Chapter 3 Component Replacement Procedures

6. Holding the Communications Panel, release the cable from the DPI Port 2 clamp and set the Communications Panel aside.

Ribbon Cable

from Main Control

Panel to Power

Interface Board

Connector

Screw

Main Control Board Screws (6)

TB11 Harness

Connector

Screw

Main Control Board

7. Disconnect the ribbon cable that connects the Main Control Board to the Power Interface Board.

8. Loosen the two connector screws for the TB11 Harness Connector on the Main Control Board.

9. Gently pull to disconnect the TB11 Harness Connector from the Main Control Board.

Do not disconnect any Harness Connector wires from TB11.

10. If present, unscrew the two screws for the Encoder Board. Gently pull off

the Encoder Board.

11. Unscrew the six screws and two 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.

14. Remove the Main Control Board; return or dispose of it properly.

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

Component Replacement Procedures Chapter 3

Install Components

1. Install the new Main Control Board with six screws and two hex standoffs

(if Encoder Board is present).

2. If present, reinstall the Encoder Board with two screws, taking care to

match the J7 connectors.

3. Torque screws on Main Control Board and Encoder Board to 0.6 N•m

(5 lb•in).

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.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 37

Chapter 3 Component Replacement Procedures

T-Comm Board

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 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 8-pin serial port in the lower-right corner of Main Control

Board panel). d. Remove and save the grounding-wire screw (connects to PE on TB11). e. Remove and save the two mounting screws for the Main Control Board. f. Remove the Main Control Board.

HIM Board slot

Ribbon Cable Connector

Mounting Screw

Ribbon Cable Connection to T-Comm Board

Wiring Connector

Grounding-Wire Screw

Optional 20-Comm-C Board Detail

Mounting Screws (4)

Mounting Screw

3. Remove the 20-Comm-C Board (if used):

a. Disconnect the ribbon cable between the 20-Comm-C Board and T-

Comm board; disconnect only from the T-Comm board.

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

Component Replacement Procedures Chapter 3

b. Remove and save the four mounting screws.

4. If the 20-Comm-C Board is not used, remove the screw securing the T-

Comm grounding tab.

T-Comm grounding tab screw T-Comm grounding tab flat T-Comm grounding tab upright

5. Place the tip of a flathead screwdriver between the T-Comm grounding tab

and screw mount. Gently pry up until the grounding tab is in an upright position or about 90 degrees from the screw mount.

6. If needed, use the same flathead screwdriver tip to pry the seven locking

tabs away from the T-Comm Board.

T-Comm Board Locking Tab Locations

Five locking tabs are on the back side of the Main Control Board (above); two are on the front side in the area between the optional HIM and 20-Comm-C board slots (upper right).

NOTE: Use a flathead screwdriver tip to pry the locking tabs away from the T-Comm Board (lower right).

7. Remove the T-Comm Board from the Main Control Board; return or

dispose of it properly.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 39

Chapter 3 Component Replacement Procedures

Install Components

1. Install the new T-Comm Board.

2. Verify the board is locked into all seven locking tabs.

Power Interface Board

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.

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. Perform Remove Main Control Panel on page 22

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

Component Replacement Procedures Chapter 3

3. Remove wiring to this Board, and wiring from this board to the Switch

Mode Power Supply Board.

DC input shown

J10

J9 J16 J15

J14

J24

J13

Connector Wire Color(s) Connects To:

J1 Ribbon J2 on Main Control Board (ribbon cable) J2 Black J1 on Switch Mode Power Supply Board J6 Black Monitor wire to thermal sensors J8 Red/White/Black J7-U on U Phase Gate Interface Board

J9 Red/White/Black J1 on 24V Power Supply Board J10 Red/Black/White/Blue J3 on Precharge Board J12 Red/White J3 on Switch Mode Power Supply Board J13 Black J2 on Switch Mode Power Supply Board J14 Red/White/Black U Phase Current Transducer J15 Red/White/Black V Phase Current Transducer J16 Red/White/Black W Phase Current Transducer J18 Blue/White U, V, W negative (–) gates (lower phase) J23 Orange/Black U, V, W positive (+) gates (upper phase) J24 Red/Black J1 on Precharge Board,

TB1 on DC Bus Filter Board (AC input only) TB1 on DC Bus Filter Board (DC input only)

TB1 Green/Yellow PE on TB11 TB2 Red #33, #34, and #35 on TB11

TB1

TB2

Spacers (9)

J18

J23

J12

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 41

Chapter 3 Component Replacement Procedures

4. Remove the two mounting torx screws located

at the upper right and lower left corners of the board as shown at right.

5. Using your fingers or needle-nose pliers,

squeeze the tabs of each of the nine spacers (see previous page for their locations), and separate the Power Interface Board from the mounting plate.

6. Remove the Power Interface Board; 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 detailed in the Table on the previous page.

3. Reconnect the Main Control Board wires to TB1 and TB2 on the Power

Interface Board. 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. Reinstall the Main Control Board as instructed on page 22

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

drive.

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

Component Replacement Procedures Chapter 3

Switch Mode Power Supply Board

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. Perform Remove Main Control Panel on page 22

3. Disconnect all wiring from the Switch Mode Power Supply Board.

Connector Wire Color(s) Connects To:

J1 Black J2 on Power Interface Board J2 Black J13 on Power Interface Board J3 Red/White J12 on Power Interface Board J4 Open

4. Remove the Switch Mode Power Supply Board mounting torx screw

located at the lower right corner of the board.

J2 J4 J3

Spacers (3)

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 43

Screw

Chapter 3 Component Replacement Procedures

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

three spacers and separate the Switch Mode Power Supply Board from the mounting plate.

6. Remove the Switch Mode Power Supply Board; return or dispose of it

properly.

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 all components in the reverse order of removal.

4. Tighten sheet metal screws to 3.2 N•m (28 lb•in).

5. Reconnect the ribbon cable going from the Power Interface Board (J1) to

the Main Control Board ( J2).

6. Reinstall the Main Control Board as instructed on page 22

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

drive.

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

Component Replacement Procedures Chapter 3

24V Power Supply Board (for Current Transducers)

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. Perform Remove Blower Control Panel on page 24

3. Remove the safety shield over the 24V Power Supply Board.

4. Disconnect all wiring from the 24V Power Supply Board.

Connector Wire Color(s) Connects To:

J1 Red/White/Black J9 on Power Interface Board J3 Red/Black TB1 on DC Bus Filter 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 spacers and separate the board from the mounting plate.

J3 J1

7. Remove the 24V Power

Supply Board; return or dispose of it properly.

Install Components

1. Install the new 24V Power Supply Board.

Tighten the torx screw to 1.7 N•m (15 lb•in).

2. Reconnect all wiring as detailed in the Table on previous page.

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

drive.

ScrewSpacers (3)

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 45

Chapter 3 Component Replacement Procedures

Precharge Board

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. Perform Remove Blower Control Panel on page 24

3. For DC input: Label customer wiring to TB2 and then disconnect TB2.

4. Disconnect the all wiring from the Precharge Board.

Connector Wire Color(s) Connects To:

AC Input J1 Red/Black J24 (+BUS IN) on Power Interface Board J2 Red/White Converter SCR Modules (R, S, T) J3 Red/White Converter SCR Modules (R, S, T) DC Input J1 Red/White Precharge SCR Module J2 Blue Precharge +DC In Busbar

Red Precharge +DC Out Busbar

Black DC- Bus Capacitor

J3 Red/White J10 on Power Interface Board TB1 Open TB2 Blue +DC In Busbar

Red +DC Out Busbar

Note: Label unidentified connectors to simplify reinstallation.

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

Component Replacement Procedures Chapter 3

AC Input

Screw

Spacers (3)

DC Input

Lock Screws (6)

5. For AC input: Remove the Precharge Board mounting torx screw located

at the upper left corner of the Precharge Board.

6. Remove the Precharge Board; return or dispose of it properly.

• For AC input: Using your fingers or needle-nose 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.

TB2

TB1

Install Components

1. Install the new Precharge Board.

2. Reconnect all wiring as detailed in the Table on the previous page.

3. Reinstall the Blower Control Board as instructed on page 24

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

drive.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 47

Chapter 3 Component Replacement Procedures

DC Bus Filter Board

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 the safety shield over the DC Bus Filter Board.

3. Disconnect all wiring from TB1 and TB2 terminals.

Board Mounting Bolts (4)

TB2 TB1

TB2-3 TB2-1

Connector Wire Color(s) Connects To:

TB1-1 Black J24 on Power Interface Board TB1-3 Red J24 on Power Interface Board TB2-1 Black DC- Bus Capacitor TB2-3 Red DC+ Bus Capacitor

TB1-3 TB1-1

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 Filter Board. Torque mounting bolts to 1.7 N•m

(15 lb•in).

2. Reconnect all wiring as detailed in the above Table.

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

drive.

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

Component Replacement Procedures Chapter 3

Bus Capacitor

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. Perform Remove Main Control Panel on page 22

3. Perform Remove Stacking Panel on page 25

4. Perform Remove Transitional Busbar on page 28

Transitional Busbar Unit Removed

Bus Capacitor Busbar

Bus Capacitor Busbar Nuts and Washers (18 each)

5. Label and remove all wires and connectors from the Bus Capacitor Busbar.

6. Remove nuts and washers (18 each) fastening the Bus Capacitor Busbar to

the Bus Capacitors. The setcrews may come out with the nuts. Save all nuts and setscrews.

7. Remove the Bus Capacitor Busbar.

8. Remove Capacitors by pulling them out; dispose of them properly.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 49

Chapter 3 Component Replacement Procedures

Install Components

ATT ENTI ON: Install each capacitor so its vent plug is at the top

or 12 o’clock. Component and system damage may result if you position any Bus Capacitor incorrectly.

1. Replace setscrews for each new Capacitor using a 3 mm angle hex wrench.

Each Capacitor needs a short and long setscrew; see the illustration below for where to install each one.

Vent Plug (must be at

top or 12 o’clock)

Longer Setscrew for

Transitional Busbar

Shorter Setscrew for

Bus Capacitor Busbar

– + – +

Capacitors shown

with Bus Capacitor

Busbar installed

2. Place Capacitors into correct position in drive (vent plug at top or

12 o’clock).

3. Place Bus Capacitor Busbar onto Capacitors.

4. Install washers and nuts onto the shorter setscrews to secure the Bus

Capacitor Busbar to the Bus Capacitors.

Note: Install all setscrews, washers, and nuts but do not tighten yet.

5. Place the Transitional Busbar in position, 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 nuts for the

Bus Capacitor Busbar. Torque to 5.6 N•m (50 lb•in).

7. Install the Transitional Busbar according to the instructions on page 32

8. Reconnect all wires and connectors.

9. Reassemble remaining components in reverse order.

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

drive.

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

Component Replacement Procedures Chapter 3

Capacitor Bank Fan

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. Perform Remove Main Control Panel on page 22

3. Perform Remove Stacking Panel on page 25

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 assembly and dispose of it

properly.

Top Fan Mounting Screw

Install Components

1. Install the new fan assembly. Hand tighten the

two mounting screws.

Bottom Mounting Screw is

directly behind this screw

2. Reconnect wires.

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

4. Reassemble remaining components in reverse order.

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

drive.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 51

Chapter 3 Component Replacement Procedures

Balancing Resistor

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. Perform Remove Main Control Panel on page 22

3. Perform Remove Stacking Panel on page 25

4. Locate the Balancing Resistor as shown below.

Balancing Resistor and Mounting Screws

Screw for Resistor black wire

Screw for Resistor blue wire Screw for Resistor yellow wire

5. Label and disconnect all wires for the Balancing Resistor.

Black: Negative (–) Busbar Yellow: Bus Capacitor Busbar Blue: Converter (+) Busbar

6. Remove the Balancing Resistor mounting screws.

7. Remove the Balancing Resistor and dispose of it properly.

Install Components

1. Install the new Balancing Resistor. Hand tighten the two mounting screws.

2. Reconnect all wires for the Balancing Resistor.

Black: Negative (–) Busbar Yellow: Bus Capacitor Busbar Blue: Converter (+) Busbar

3. Torque the two Balancing Resistor mounting screws to 2.9 N•m

(26 lb•in).

4. Reassemble remaining components in reverse order.

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

drive.

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

Component Replacement Procedures Chapter 3

Inverter Power Module (IGBT)

Kit includes:

Qty Component

1 IGBT module with circuit board 1 Gate Interface Board 1 Gate Interconnect Harness 3 Flexible Capacitor Busbar, Positive 3 Flexible Capacitor Busbar, Negative 1 Tie Down Capacitor Mount 3 Snubber Capacitor

The photograph below is an example of an IGBT module failure. IGBT damage may impact other components near or associated with IG BT operation, including components that are not part of the aforementioned kit.

Example of IGBT Module Failure

Bus Capacitor,

under Transitional

Busbar

Flexible Capacitor

Busbar, Negative

Transitional

Busbar

IMPORTANT

If any IGBT module is damaged, all IGBT modules and associated components should be replaced. Perform the following procedure for all IGBT modules.

See Chapter 1 - Drive Components instructions.

to locate the component detailed in these

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 53

Chapter 3 Component Replacement Procedures

Remove Components

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

Steps on page 10.

2. Locate the Inverter Power Module to be replaced.

Tie Down Capacitor Mount

AC Output Busbar

Snubber Capacitors

IGBT

Gate Interface Board Assembly

Current Transducer

3. Remove the Output Busbar at the Current Transducer:

a. Remove and save the torx head bolt that secures the Output Busbar to

the AC Output Busbar.

b. Remove and save the two hex head bolts that secure the Output Busbar

to the U, V or W Busbar. c. Remove and save the nut and setscrew for the Output Busbar standoff. d. Slide the Output Busbar to the right as far as it goes.

4. Remove the AC Output Busbar:

a. Remove and save the six torx screws and two 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.

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

Component Replacement Procedures Chapter 3

AC Output Busbar Torx

Screws (6)

Output Busbar

Torx Head Bolt

AC Output Busbar Standoff Nuts (2)

Output Busbar Standoff Nut

Output Busbar

Hex Head Bolts(2)

and Setscrew

5. Perform Remove all IGBT Snubber components: on page 29.

6. Perform component removal for Gate Interface Board

7. Perform Remove Transitional Busbar on page 28

on page 58.

if Bus Capacitors or the positive (DC+) Flexible Capacitor Busbars supplied with the kit must be installed.

8. Remove the eight screws that secure the IGBT to the chassis. Remove the

IGBT by tipping the right edge out first; return or dispose of it properly.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 55

Chapter 3 Component Replacement Procedures

Install Components

1. Carefully examine the Transitional Busbar and Bus Capacitors for damage.

When replacing any IGBT, it is recommended that you replace all Bus Capacitors. If needed, see Bus Capacitor Bus Capacitors.

2. Install the IGBT module.

a. Using isopropyl alcohol, thoroughly clean the surface of the Heatsink. b. Verify that the mounting surface of the new IGBT module is clean. If

not, clean with isopropyl alcohol.

c. Using a 3- or 4-inch paint roller or putty knife, apply a thin even coating

of the supplied thermal grease to the mounting surface of the IGBT module.

In the next step, take care to not disturb any of the thermal grease on the IGBT module.

on page 49 to replace damaged

IMPORTANT

If the Transitional Busbar was not removed, take care to not damage the Flexible Capacitor Busbars fitting over and under the Transitional Busbar.

d. Place the IGBT on the chassis with the serial number label at the top.

Install with supplied screws using this torque sequence:

IGBT Torque Sequence

First Sequence: 0.7 N-m (6.0 lb.-in.) Second Sequence: 2.3 N-m (20 lb.-in.) Final Sequence: 5.6 N-m (50 lb.-in.)

IMPORTANT

The three positive (+) Flexible Capacitor Busbars supplied with the kit must be installed on the back side of the Transitional Busbar before they can be installed on the IGBT. See page 32 busbars on the Transitional Busbar.

for how to install these

3. If needed, install the three supplied positive (DC+) Flexible Capacitor

Busbars on the back side of the Transitional Busbar. The positive (DC+) Flexible Capacitor Busbars have a shorter angle.

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

Component Replacement Procedures Chapter 3

Shown with Transitional Busbar and all Flexible Capacitor Busbars installed

Negative (DC-) Flexible Capacitor Busbars

Positive (DC+) Flexible Capacitor Busbars

4. Reinstall the Transitional Busbar as instructed on page 32.

5. Install the three supplied negative (DC-) Flexible Capacitor Busbars in

positions 1, 3, and 5 on the IGBT. The negative (DC-) Flexible Capacitor Busbars have a higher angle.

6. Install the Tie Down Capacitor Mount:

a. Insert the short ends of the six threaded studs with nuts through the

Flexible Capacitor Busbars and into the left side of the IGBT. Torque to

5.6 N•m (50 lb•in).

WARNING: Correct torque is critical to ensure correct operation of the drive. Improper torquing could cause premature failure when attempting to operate the drive.

b. Install the Tie Down Capacitor Mount with the two screws previously

removed from the top and bottom of the Capacitor Mount. Torque to

2.9 N•m (26 lb•in).

7. Install the Current Transducer, AC Output Busbar, and Output Busbar

according to Install Components

on page 61.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 57

Chapter 3 Component Replacement Procedures

8. Install the Gate Interface Board:

a. Install the Gate Interface Board using the four nuts removed previously.

Torque screws to 2.9 N•m (26 lb•in). b. Install the supplied Gate Interconnect Harness. c. Connect wiring between the IGBT and Gate Interface Board as shown

in Gate Interface Board

on page 58.

d. Connect wires to the Current Transducer.

9. Install the three Snubber Capacitors in the reverse order of Remove all

IGBT Snubber components: on page 29.

Torque nuts to 5.6 N•m (50 lb•in).

10. Reassemble remaining components in reverse order.

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

drive.

Gate Interface Board

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. Locate the Gate Interface Board to be replaced.

3. Remove the safety cover over the Gate Interface Board.

4. Label and disconnect all wires.

Connector Wire Color(s) Connects To:

J1 Red/White/Black J1 on IGBT J2 Red/White/Black J2 on IGBT J3 Red/White/Black J3 on IGBT J4 Orange/Black J23 on Power Interface Board J5 Blue/White J18 on Power Interface Board J6 Red/White J4 on IGBT J7 Red/White/Black J7-W to J7-V (Gate Interface Boards W and V)

J7-V to J7-U (Gate Interface Boards V and U) J7-U to J8 on Power Interface Board

J8 Black J8-W to J8-V (Gate Interface Boards W and V)

J8-V to J8-U (Gate Interface Boards V and U) J8-U to J6 on Power Interface Board

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

Component Replacement Procedures Chapter 3

5. Remove the four 7 mm board-mounting nuts.

6. Remove the board; return or dispose of it properly.

Gate Interface Board Mounting Nuts (4)

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 page.

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

drive.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 59

Chapter 3 Component Replacement Procedures

Current Transducer

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. Locate the Current Transducer to be replaced.

3. Perform Remove the Output Busbar at the Current Transducer:

page 54.

Wire to Transducer

Transducer Assembly

Torx Screws (2)

4. Remove the two torx screws that secure the Current Transducer assembly

(transducer and brackets) to the chassis.

5. Rotate the Current Transducer assembly counterclockwise and tip until

the Output Busbar clears the U, V, or W Busbar and spacer. NOTE: Avoid any contact with the circuit board to the left of the

transducer being removed.

6. Move the busbar and transducer to an ESD-safe flat surface for working

with it.

7. Separate the Output Busbar from the Current Transducer.

8. Separate the Current Transducer from the brackets.

9. Properly discard the Current Transducer.

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Component Replacement Procedures Chapter 3

Install Components

1. Mount brackets to the new Current Transducer. Torque screw to 2.9 N•m

(26 lb•in).

2. Slide Output Busbar through the Current Transducer assembly with the

angled end to the left.

3. Replace the Current Transducer assembly in mounting position by

reversing the process used in Step 5.

4. Secure the Current Transducer assembly to the drive chassis with two torx

screws. Torque to 2.9 N•m (26 lb•in).

5. Reinstall the AC Output Busbar:

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 standoff nuts. Torque to 5.7 N•m (50 lb•in).

6. Reinstall the Output Busbar:

a. Reinstall the set screw. Hand tighten. b. Reinstall the torx bolt that secures the busbar to the AC Output Busbar.

Torque to 9.0 N•m (80 lb•in).

c. Reinstall the two hex head bolts that secure the busbar to the U, V, or W

Busbar. Torque to 5.7 N•m (50 lb•in).

d. Reinstall the standoff nut to the set screw. Torque the nut to 5.6 N•m

(50 lb•in), which will torque the set screw correctly.

of the removal process.

7. Reconnect the wire to the Current Transducer.

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

drive.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 61

Chapter 3 Component Replacement Procedures

Converter Power Module (SCR) - AC Input Only

IMPORTANT

If any Converter SCR module fails, all three SCR modules should be replaced (kit includes all three modules).

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. Perform Remove Main Control Panel on page 22

3. Perform Remove Stacking Panel on page 25

4. Locate the Converter SCR modules (R, S, T) to be replaced.

Converter SCR Modules (3)

Converter Snubber Boards (3)

Converter Busbar, Lower (+DC)

Converter Busbar, Upper (-DC)

R S T

AC Busbar

(R) Bolt

AC Busbar

(S) Bolt

AC Busbar

(T) Bolt

5. Remove all three Converter Snubber Boards:

a. Disconnect the wires between each Converter Snubber Resistor and

Converter Snubber Board. b. Remove the two screws that secure each board. c. Remove each board 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 DCBusbars. Set the Converter Busbars aside.

7. Remove the bolt at the top of each AC Busbar (R, S, T) where they

connect to the SCR modules. You do not need to remove the wires from the AC Busbars.

8. Label and note the position of the SCR module leads. Remove the leads.

Typically, the leads are marked as R, S, or T, and each is notched with the notch to the front of the SCR module.

9. Remove the four Phillips screws that hold each SCR to the Heatsink.

10. Remove the SCR modules; return or dispose of them properly.

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Component Replacement Procedures Chapter 3

Install Components

1. Using isopropyl alcohol, thoroughly clean the Heatsink mounting surface

where each new SCR module will be installed.

2. Verify that the mounting surface of each new SCR module is clean. If not,

clean with isopropyl alcohol.

3. Using a 3- or 4-inch paint roller or putty knife, apply a thin, even coating of

the supplied thermal grease to the mounting surface of each new SCR module.

IMPORTANT

In the next step, take care to not disturb any of the thermal grease on the SCR module.

4. Install each new SCR module with supplied screws and tighten using this

torque sequence:

➍➋

➊

SCR Torque

First Sequence:

0.7 N-m (6.0 lb.-in.)

➊➌

SCR Torque

Final Sequence:

5.6 N-m (50 lb.-in.)

➍➋

5. Replace the SCR module leads.

Each set of leads is marked R, S, or T. The notch and red wire on each lead are positioned to the front.

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, and

torque to 2.9 N•m (26 lb•in).

➌

8. Replace the wires from the Converter Snubber Resistors to the Snubber

Boards. See Converter Snubber Resistors - AC Input Only

on page 64 to

identify each resistor. The black wire goes to J1.

The blue wire goes to J2.

9. Reinstall the bolts at the top of the AC Busbars (R, S, T). Torque to 9.0

N•m (80 lb•in).

10. Reinstall the DC+ and DC- Busbars and torque to 9.0 N•m (80 lb•in).

11. Reassemble remaining components in reverse order.

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

drive.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 63

Chapter 3 Component Replacement Procedures

Converter Snubber Resistors - AC Input Only

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

Remove Components

Kit includes Snubber Board and Resistor.

1. Read and follow the Safety Precautions on page 8

Steps on page 10.

2. Perform Remove Main Control Panel on page 22

3. Perform Remove Stacking Panel on page 25

4. Locate the Snubber Resistor(s) to be replaced.

Snubber Resistor for “R” SCR

Snubber Resistor for “S” SCR

and Important Initial

Snubber Resistor for “T” SCR

5. Verify the Snubber Resistor(s) with a volt ohm meter. The reading should

be 8 ohms ± 10%.

• If the reading is not

within tolerance, perform the remainder of this

procedure.

• If the reading is within tolerance, do not perform the remainder of this

procedure.

6. For the R Snubber Resistor only: Perform Remove Transitional Busbar on

page 28.

7. Label and disconnect the wires from Snubber Resistor(s) that will be

replaced.

8. Remove the resistor(s) and properly discard.

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Component Replacement Procedures Chapter 3

Install Components

1. Using isopropyl alcohol, clean the surface where the new Snubber Resistor

will be installed.

2. Verify that the mounting 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 mounting surface of the new Snubber Resistor and install. Torque screws to 2.9 N•m (26 lb•in).

4. Reconnect wires.

5. Reassemble remaining components in reverse order.

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

drive.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 65

Chapter 3 Component Replacement Procedures

Converter Snubber Board AC Input Only

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. Perform Remove Main Control Panel on page 22

3. Perform Remove Stacking Panel on page 25

4. Locate the Converter Snubber Board to be replaced.

Snubber Board

for “R” SCR

Snubber Board for “S” SCR

Snubber Board for “T” SCR

5. Label and disconnect wires from the Converter Snubber Resistor and the

Converter Snubber Board to be replaced.

6. Remove the two screws that secure the board.

7. Remove the board and properly discard.

Install Components

1. Install the new Snubber Board. Torque screws to 2.9 N•m (26 lb•in).

2. Reconnect wires from the Converter Snubber Resistor.

3. Black wire goes to J1. Blue wire goes to J2.

4. Reassemble remaining components in reverse order.

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

drive.

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Component Replacement Procedures Chapter 3

Fan Transformer

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.

Fan Transformer

Label and unplug these two red wires

Label and disconnect these three wires

Mounting bracket screws (4)

2. Label and unplug or disconnect the five wires for the Fan Transformer.

3. Unscrew the four transformer mounting bracket screws.

4. Remove the transformer and properly discard.

Install Components

1. Install the new Fan Transformer by screwing mounting brackets to drive.

2. Reconnect all wires for the transformer.

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

drive.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 67

Chapter 3 Component Replacement Procedures

Heatsink Fan - Removal from Back of Drive

The Heatsink Fan is located on the back of the drive.

(For equipment clearance considerations, the Fan can also be removed from the front of the drive. See

Heatsink Fan - Removal from Front of Drive

page 70.)

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. 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 the Fan and the Fan

Capacitor. Access the cables by gently pulling the wiring from behind the busbar

mounting panel.

Front of drive

Connectors

Press tabs in for removal

Disconnect

here

4. On the back of the drive, remove the 11 screws for the Fan cover; see the

figure on the next page for the screw locations. Do not remove the screws for the screen.

5. Using the handle, separate the Fan assembly from the drive enclosure.

Some force may be needed to separate the Fan from the enclosure as the gasket may be tight or sticky.

6. Remove Fan and properly discard.

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Component Replacement Procedures Chapter 3

Fan Cover Screw Locations on Back of Drive

4 on top and bottom for a total of 8

3 on right side NOTE: No screws on left side

Install Components

1. Place Fan assembly into the chassis but not installed in final position. Leave

space for accessing Fan cables from the front of the drive. Take care to not pinch wires.

Fan Assembly (Front View), Removed from Drive

2. From the front of the drive, reconnect Fan cables.

TIP

The connectors, one set shown below, are designed so they go together only one way. The two end sections are flat on one side and each section has a ridge at the matching edge.

Connectors shown slightly separated

Flat Sections

Ridges

3. 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).

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 69

Chapter 3 Component Replacement Procedures

Heatsink Fan - Removal from Front of Drive

The Heatsink Fan is located on the back of the drive. These instructions explain how to remove the fan from the front of the drive.

Heatsink Fan (DC input drive shown)

See Chapter 1 - Drive Components instructions.

to locate the component detailed in these

Remove Components

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

Steps on page 10.

2. Disconnect all wiring to AC and DC Busbars so you can remove all

busbars with the busbar mounting plate in a later step.

3. Perform Remove Main Control Panel on page 22

4. Perform Remove Stacking Panel on page 25

5. AC input only: Disconnect the DC+ and DC- Busbars that connect to

the Converter Busbars at the top of each bar.

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Component Replacement Procedures Chapter 3

Do not disconnect the U, V, or W Busbars at the bottom.

AC Drive Shown

17 mm bolt on DC+ Busbar

Do not disconnect Busbars at the bottom.

17 mm bolt on DC– Busbar

16 mm bolts

6. AC input only: Disconnect all busbars where they connect to the

Converter SCR modules with 16 mm bolts. Disconnect wiring. Do not disconnect the U, V, or W Busbars at the bottom.

7. Disconnect the U, V, and W Busbars at the top of each bar where they

connect to the Output Busbars for the Current Transducers with two 17 mm bolts and one 11 mm nut.

Do not remove the busbars from the setscrew on the Output Busbars at this time.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 71

Chapter 3 Component Replacement Procedures

Do not disconnect the U, V, or W Busbars at the bottom.

11 mm Nut

and Setscrew

Current

Transducer

U, V, and W Busbars

Output Busbar

8. Remove the four 10 mm nuts for the busbars mounting plate.

AC Input Drive Shown

Busbar Mounting Plate

17 mm Bolts (2)

10 mm nuts (4)

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

Component Replacement Procedures Chapter 3

9. Remove the entire busbar and mounting plate assembly. Set aside.

AC Input Drive DC Input Drive

10. Unplug the fan cables.

11. For AC input only: Remove the MOV Surge Suppressor as instructed on

page 79

12. Remove the left busbar mounting plate bracket.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 73

Chapter 3 Component Replacement Procedures

13. Remove the 12 exterior screws on the fan mounting plate.

Fan Mounting Plate Screws (12)

Busbar Mounting Plate Bracket

14. Carefully remove the mounting plate and fan through the front of the

drive chassis; you may need to pry the mounting plate away from the gasket.

The fan housing remains mounted on the chassis.

Install Components

1. Remove the new fan housing from the new fan and mounting plate.

Discard the new fan housing.

2. Install new fan and screw mounting plate to chassis.

3. Reassemble remaining components in reverse order of removal

instructions.

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

drive.

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

Component Replacement Procedures Chapter 3

Thermal Sensors

In the AC input drive, the Thermal 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 Main Control

Panel.

• A connector to J6 on the Power Interface Board.

• Wiring to TB9 (terminals 9 and 10) on the Stacking Panel.

• Wiring to the DC Choke Plate at TB15 OUT and TB OUT, jumpered

together internally.

ATTENTION: Thermal sensors wired to the DC Choke Plate and to the three-phase motor cannot be replaced. The DC link choke and three-phase motor must be replaced if these thermal sensors or their wiring are destroyed.

In the DC input drive, the Thermal 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 Main Control

Panel.

• A connector to J6 on the Power Interface Board.

• Wiring to TB9 (terminals 9 and 10) on the Stacking Panel.

The connectors to J8 on each of the three Gate Interface Boards are wired in series. There is one J8 connector with four wires that senses the temperature of its IGBT. The other two connectors have two wires and only sense an overtemperature condition.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 75

Chapter 3 Component Replacement Procedures

Thermal Sensor wiring for AC input drive Thermal Sensor wiring for DC input drive

J8-U J8-V J8-W

TO INVTO CNV

Heatsink

Thermal

Sensor

TO INV

CNV-3

CNV-2

TO INVTB9 - 9 & 10

Main Control

TO INVTB9 - 9 & 10 CNV-1

TO INVTB9 - 9 & 10

Panel Thermal Sensor

TO INV

CNV TOPCNV BOT

Main Control

Panel Thermal Sensor

J8-U J8-V J8-W

Heatsink

Thermal

Sensor

Power

Interface

Board

TB15 OUT

(jumpered)

DC Choke Plate

TB9

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

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

Power

Interface

Board

Component Replacement Procedures Chapter 3

Remove Components

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

Steps on page 10.

2. Cut the wire ties for the

wiring harness along the Gate Interface Boards.

Heatsink Thermal Sensor & Screw

3. Note wire routing and

location of sensors.

MCP

4. For the Main Control Panel

thermal sensor, remove its screw and nut on the Main Control Panel and disconnect the other end

Thermal Sensor Wiring Harness End

from the wiring harness. Note: This screw and nut are

Main Control Panel (MCP) Thermal Sensor & Bracket

Wire Ties along Gate Interface Boards

small. Take care to not drop or misplace.

5. For the Heatsink thermal sensor, remove its screw on the Heatsink above

the SCR modules and unplug the other end from the wiring harness.

Note: This screw and nut are small. Take care to not drop or misplace.

6. Unplug the J8 connectors on each of the three Gate Interface Boards. See

page 58

for connector locations.

7. Unplug the other end of this wiring harness at the J6 connector on the

Power Interface Board. See page 38

for connector locations.

Install Components

1. For the Main Control Panel thermal sensor or the Heatsink thermal sensor,

apply a thin layer of supplied thermal grease to the metal side of the new Thermal Sensor and install it with supplied screw with star washer toward the panel. Torque screw to 1.7 N•m

2. For the three Gate Interface Boards, carefully route wires and connect to J8

on each Gate Interface Board. Be sure that the J8 connectors go to the correct IGBT. See page 58

for connector locations.

3. Reconnect the other end of this wiring harness at the J6 connector on the

Power Interface Board. See page 38

4. Reassemble remaining components in reverse order.

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

drive.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 77

(15 lb•in).

for connector locations.

Chapter 3 Component Replacement Procedures

DC Link Choke AC Input Only

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. Locate the DC Link Choke.

L1 L4

L2 L3

TB15

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

Plate.

6. Remove the DC Link Choke and properly discard.

DC Choke Plate

Mounting Screws (4)

Install Components

1. Install new DC Link Choke to DC Choke Plate.

2. Torque the four mounting 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.

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

Component Replacement Procedures Chapter 3

MOV Surge Suppressor AC Input Only

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. Perform Remove Main Control Panel on page 22

3. Perform Remove Stacking Panel on page 25

4. Locate the MOV Surge Suppressor assembly.

MOV

5. Note wire placement and connections. Disconnect the MOV ground wire

to transformer and the R, S, and T wires to the AC Busbars.

6. Remove the MOV mounting nut.

7. Remove the MOV assembly and properly discard.

Install Components

1. Install the new MOV assembly. Torque the MOV mounting nut to

2.9 N•m (26 lb•in).

2. Reconnect all wires and connectors for the MOV.

3. Torque the R, S, and T Phase power terminal block screws to 9.8 N•m (80

lb•in).

4. Reassemble remaining components in reverse order.

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

drive.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 79

Chapter 3 Component Replacement Procedures

Precharge SCR Module and Diode - DC Input Only

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. Perform Remove Main Control Panel on page 22

3. Perform Remove Stacking Panel on page 25

4. Locate the Precharge SCR module and Diode to be replaced.

SCR Diode

Busbars

5. Label and remove all DC+ power cables and all connected wires from the

two busbars.

6. Remove the two busbars and carefully set aside.

7. For the Precharge SCR module, remove its connector wire.

8. Remove the SCR module and Diode, and properly discard them.

Install Components

1. Using isopropyl alcohol, thoroughly clean the Heatsink mounting surface

where the SCR module and Diode will be installed.

2. Verify the mounting surfaces of the new SCR module and Diode are clean.

If not, clean with isopropyl alcohol.

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

Component Replacement Procedures Chapter 3

3. Using a 3- or 4-inch paint roller or putty knife, apply a thin, even coating of

the supplied thermal grease to the mounting surface of each SCR module and Diode.

WARNING: In the next step, be sure to properly install the modules as shown. If you install the SCR incorrectly, it will not work. If you install the Diode incorrectly, then the Drive and the Bus Capacitors may not operate properly and may prematurely fail.

The SCR (on the left) has a plug with prongs located at the bottom. The Diode (on the right) has a plug without prongs located at the top.

Plug with No Prongs

Diode

IMPORTANT

SCR

Plug with Prongs

In the next step, take care to not disturb any of the thermal grease on the SCR module.

4. Install the SCR module or Diode with supplied screws and torque using

the sequences and specifications shown in the diagram below.

First Torque

Sequence:

0.7 N•m (6.0 lb•in)

➊➌

Final Torque

Sequence:

5.6 N•m (50 lb•in)

➍➋

➊

➌

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 enclosure covers before applying power to the

drive.

Rockwell Automation Publication 20B-IN025B-EN-P - January 2011 81

Chapter 3 Component Replacement Procedures

Notes:

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

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products. At http://www.rockwellautomation.com/support/ application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools.

For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer TechConnect support programs. For more information, contact your local distributor or Rockwell Automation representative, or visit http://www.rockwellautomation.com/support/

Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running.

United States or Canada 1.440.646.3434 Outside United States or

Canada

Use the Worldwide Locator your local Rockwell Automation representative.

, you can find technical manuals, a knowledge base of FAQs, technical and

at http://www.rockwellautomation.com/support/americas/phone_en.html, or contact

New Product Satisfaction Return

Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.

United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain

Outside United States Please contact your local Rockwell Automation representative for the return procedure.

one) to your distributor to complete the return process.

Documentation Feedback

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, available at http://www.rockwellautomation.com/literature/.

Publication 20B-IN025B-EN-P - January 2011 84 PN-XXXXX

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

Install Components

Transitional Busbar

Remove Components

Install Components

Overview

Main Control Board

Remove Components

Install Components

T-Comm Board

Remove Components

Install Components

Power Interface Board

Remove Components

Install Components

Switch Mode Power Supply Board

Remove Components

Install Components

24V Power Supply Board (for Current Transducers)

Remove Components

Install Components

Precharge Board

Remove Components

Install Components

DC Bus Filter Board

Remove Components

Install Components

Bus Capacitor

Remove Components

Install Components

Capacitor Bank Fan

Remove Components

Install Components

Balancing Resistor

Remove Components

Install Components

Inverter Power Module (IGBT)

Remove Components

Install Components

Gate Interface Board

Remove Components

Install Components

Current Transducer

Remove Components

Install Components

Converter Power Module (SCR) - AC Input Only

Remove Components

Install Components

Converter Snubber Resistors - AC Input Only

Remove Components

Install Components

Remove Components

Install Components