Allen-Bradley PowerFlex 700 Installation Instructions Manual
  1. Manuals
  2. Brands
  3. Allen-Bradley Manuals
  4. Controller
  5. powerflex 700
  6. Installation instructions manual

Allen-Bradley PowerFlex 700 Installation Instructions Manual

Adjustable frequency ac drive
Hide thumbs Also See for PowerFlex 700:
Table of Contents

Advertisement

Quick Links

See also: Reference Manual , User Manual
Installation Instructions
PowerFlex 700 Drives - Frame 10 Components Replacement

Advertisement

Table of Contents
loading

Related Manuals for Allen-Bradley PowerFlex 700

Summary of Contents for Allen-Bradley PowerFlex 700

  • Page 1 Installation Instructions PowerFlex 700 Drives - Frame 10 Components Replacement...
  • Page 2 Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE). Allen-Bradley, PowerFlex, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.
  • Page 3 Summary of Changes This manual contains new and updated information. New and Updated This table contains the changes made to this revision. Information Topic Page Updated the Component Kits table with the new balancing resistor kit catalog numbers. Updated Figure 2 - Frame 10 Assembly Busbar Locations to include the new balancing resistor bus bar assembly.
  • Page 4 Summary of Changes Notes: Rockwell Automation Publication 20B-IN026C-EN-P - October 2015...

  • Page 5: Table Of Contents

    Table of Contents Preface Introduction............9 Component Kits .
  • Page 6 Table of Contents 24V Power Supply Board......... . 49 Remove Components .
  • Page 7 Table of Contents Remove Components......... 83 Install Components .
  • Page 8 Table of Contents Rockwell Automation Publication 20B-IN026C-EN-P - October 2015...

  • Page 9: Introduction

    This publication provides guidelines for replacing the major components in the PowerFlex 700 Frame 10 drive. The PowerFlex 700 Frame 10 drive is available in AC input and DC input. AC input drives ship as two separate units (inverter and converter) that must be connected when installed on site, and DC input drives ship as one unit (inverter).

  • Page 10: Component Kits

    Preface Component Kits All kits include the necessary components, ESD wrist strap and hardware (if required), and thermal grease (if required). Do not reuse any hardware unless directed to do so. Description Kit Catalog No. Notes Printed Circuit Boards Gate Interface Board SK-G1-GDB1-F8910 Drive requires three kits.

  • Page 11: Recommended Tools

    SK-G1-GASKET1-F10 For DC input only (1) This kits was issued to correct a potential anomaly for frame 10 PowerFlex 700 AC drives. See Product Safety Advisory #2014-06-002 for more information. (2) AC input applies to PowerFlex 700 catalog numbers beginning with 20BC875 or 20BD875.

  • Page 12: Safety Precautions

    Follow all the precautions and general installation requirements provided in the PowerFlex 700 Frame 7-10 Installation Instructions (publication 20B-IN014) and the PowerFlex 700 User Manual (publication 20B-UM002) along with those included here. ATTENTION: To avoid an electric shock hazard, ensure that all power has been removed before proceeding.

  • Page 13: Important Initial Steps

    Component damage may result if you ignore electrostatic discharge control procedures. If you are not familiar with static control procedures, reference Allen-Bradley Guarding Against Electrostatic Damage (publication 8000-4.5.2) or any other applicable ESD protection handbook.
  • Page 14 Preface Notes: Rockwell Automation Publication 20B-IN026C-EN-P - October 2015...

  • Page 15: Overview

    Chapter Component Diagrams and Torque Specifications Overview This chapter details the various assembly components and fastener torque specifications when replacing or reinstalling components in Chapters 2 through Chapter 4. The inverter and converter assemblies are separate assemblies. Both assemblies are included when you order AC input, but only the inverter assembly is included when you order DC input.
  • Page 16 Chapter 1 Component Diagrams and Torque Specifications Figure 1 - Frame 10 Assembly Components Inverter Assembly Converter Assembly (DC input and AC input with converter assembly) (AC input only) Gate Interface Boards (3) IGBT Interface Boards (3) Current Transducers (3) DC+ Busbar IGBT Snubber Capacitors (9) SCR Modules (6)
  • Page 17 Component Diagrams and Torque Specifications Chapter 1 Figure 2 - Frame 10 Assembly Busbar Locations Inverter Assembly Converter Assembly Inverter Assembly Shown With Stacking Panel Removed DC+ Busbar Upper DC Bus Capacitors (18) AC Busbars (3) Upper Capbus Support Transitional Busbar Assembly (4 pcs: DC+ Busbar, DC- Busbar, Upper Capbus Support, and Lower Capbus Support)
  • Page 18 Chapter 1 Component Diagrams and Torque Specifications Figure 3 - Circuit Boards on Inverter Assembly Encoder Board (optional) Main Control Panel Communications Panel Stacking Panel Description Description HIM Cradle/Communication Board Power Interface Board Communication Board Slots (for optional devices) Switch Mode Power Supply Board T-Comm Board 24V Power Supply Board for Current Transducers (CTs)
  • Page 19 Component Diagrams and Torque Specifications Chapter 1 Figure 4 - Circuit Boards on Converter Assembly (AC only) Precharge Board Snubber Boards (3) Rockwell Automation Publication 20B-IN026C-EN-P - October 2015...

  • Page 20: Fastener Torque Specifications

    Chapter 1 Component Diagrams and Torque Specifications Fastener Torque Torque Sequence Specifications 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.

  • Page 21: Torque Specifications

    Component Diagrams and Torque Specifications Chapter 1 Torque Specifications The following table lists fastener locations by component, how the fasteners are used, and torque specifications. See Torque Sequenceon page for fastening two-point, four-point, and six-point components to the heat sink. Table 1 - Inverter Torque Specifications Torque Component...
  • Page 22 Chapter 1 Component Diagrams and Torque Specifications Torque Component Fastener Application lb•in N•m Side Standoffs and Brackets Fasten Transitional Busbar Assembly to standoffs Fasten brackets to the drive chassis Snubber Capacitor Mount Nuts Fasten Snubber Capacitor to the Tie Down Capacitor Mount Switch Mode Power Supply Board Fasten to the Main Control Panel...
  • Page 23 Chapter Basic Component Removal Procedures Component removal procedures detailed in this chapter are located on the Inverter and Converter assemblies highlighted below. Components removed in this chapter are to access the Bus Capacitors in the Inverter assembly and the SCR Modules in the Converter assembly. IMPORTANT Photos are for illustration purposes only.

  • Page 24: Main Control Panel

    Chapter 2 Basic Component Removal Procedures See Chapter 1 - Component Diagrams and Torque Specifications on page Main Control Panel (Inverter Assembly) locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13.

  • Page 25: Install Components

    Basic Component Removal Procedures Chapter 2 6. Remove the two mounting screws below TB11. 7. Remove Main Control Panel; support. 8. Disconnect wire harnesses from TB11 to: a. J4 on the Switch Mode Power Supply Board. b. TB1 and TB2 on the Power Interface Board. 9.

  • Page 26: Stacking Panel

    Chapter 2 Basic Component Removal Procedures Stacking Panel See Chapter 1 - Component Diagrams and Torque Specifications on page (Inverter Assembly) locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13.
  • Page 27 Basic Component Removal Procedures Chapter 2 5. Carefully label and disconnect the red and black wires from TB2 on the DC Bus Filter Board. Do not disconnect the wires from TB1. 6. Disconnect the black Thermal Sensor Wire from J6. Do not remove the sensor from the bracket.

  • Page 28: Install Components

    Chapter 2 Basic Component Removal Procedures 8. Remove the six nuts for mounting the Stacking Panel. Mounting Nuts (6) 9. Remove Stacking Panel and carefully set aside. Install Components 1. Reinstall the Stacking Panel components in the reverse order of removal. 2.

  • Page 29: Transitional Busbar Assembly

    Basic Component Removal Procedures Chapter 2 Transitional Busbar See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Assembly (Inverter Assembly) The instructions detailed in this section describe how to remove the IMPORTANT Transitional Busbar assembly as a single unit. Remove Components 1.
  • Page 30 Chapter 2 Basic Component Removal Procedures 6. If present, remove all customer wiring to Transitional Busbar assembly. 7. Remove the DC Choke output cables. 8. Disconnect the DC+ and DC– cables from the Transitional Busbar assembly. 9. Remove all IGBT Snubber components (3 sets): a.
  • Page 31 Basic Component Removal Procedures Chapter 2 The positive (DC+) Flexible Capacitor Busbars are connected to the back IMPORTANT side of the Transitional Busbar assembly. The Transitional Busbar assembly must be removed before the DC+ Flexible Capacitor Busbars can be accessed and removed. 10.
  • Page 32 Chapter 2 Basic Component Removal Procedures IMPORTANT Set screws may come out with the nuts. Save all nuts and set screws. DC Choke Output Cables Upper Capbus Support Nuts (18) attached to Set Screws Note: Photo shows set screws in Capacitors;...

  • Page 33: Install Components

    Basic Component Removal Procedures Chapter 2 Install Components See the figures in the preceding Transitional Busbar Assembly (Inverter Assembly) on page section to identify any components discussed in this section. Negative (DC–) Flexible Capacitor Busbar attached to top side of Transitional Busbar Assembly (3).
  • Page 34 Chapter 2 Basic Component Removal Procedures 1. Replace the three positive (DC+) Flexible Capacitor Busbars supplied in an IGBT replacement kit on the back side of the Transitional Busbar assembly for each IGBT module being replaced. 2. Mount Transitional Busbar assembly to Bus Capacitors. If needed, use a rubber mallet to gently tap the Transitional Busbar assembly onto the longer set screws of the Bus Capacitors.

  • Page 35: Busbar Assembly

    Basic Component Removal Procedures Chapter 2 16. Reinstall the DC Choke output cables. 17. Reinstall any customer wiring to the Transitional Busbar assembly. 18. Reinstall the Stacking Panel as instructed on page 28. 19. Reinstall the Main Control Panel as instructed on page 25. 20.
  • Page 36 Chapter 2 Basic Component Removal Procedures 5. Remove the three bolts, washers, and nuts that secure the Busbar to each SCR Module, and save. 6. Remove the two set screw nuts that secure the busbar to the glastic standoffs and save. 7.
  • Page 37 Basic Component Removal Procedures Chapter 2 11. Remove the two bolts, washers, and nuts that secure each AC Busbar to the SCR Modules, and save. 12. Remove the two set screw nuts that secure each AC Busbar to the glastic standoffs and save.

  • Page 38: Install Components

    Chapter 2 Basic Component Removal Procedures Install Components 1. Reinstall the Busbars in reverse order of removal. 2. Reinstall the two set screw nuts that secure the DC– Busbar to the glastic standoffs. Torque each set screw to 1.8 N•m (16 lb•in). 3.

  • Page 39: Overview

    Chapter Inverter Assembly Component Replacement Procedures Overview This section details components that are replaceable on the Inverter assembly. See Chapter 4 - Converter Assembly Component Replacement Procedures on page components replaceable on the Converter assembly. The components addressed in this section are as follows.
  • Page 40 Chapter 3 Inverter Assembly Component Replacement Procedures Main Control Board (version See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. 2.0) Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13.

  • Page 41: Main Control Board (Version 2.0)

    Inverter Assembly Component Replacement Procedures Chapter 3 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. Ribbon Cable (J2) to Power Interface Board (J1) Ribbon Cable (J3)

  • Page 42: Remove Components

    Chapter 3 Inverter Assembly Component Replacement Procedures T-Comm Board See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13. 2.
  • Page 43 Inverter Assembly Component Replacement Procedures Chapter 3 4. 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. b. Remove and save the four mounting screws. 5.
  • Page 44 Chapter 3 Inverter Assembly Component Replacement Procedures Install Components 1. Install the new T-Comm Board. 2. Verify the board is locked into all seven locking tabs. 3. Carefully bend the T-Comm grounding tab until it is flush with the screw mount on the Main Control Board.

  • Page 45: Remove Components

    Inverter Assembly Component Replacement Procedures Chapter 3 Power Interface Board See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13.
  • Page 46 Chapter 3 Inverter Assembly Component Replacement Procedures Connector Wire Color(s) Connects To: Red/Black TB1 on DC Bus Filter Board Green/Yellow PE on TB11 #33, #34, and #35 on TB11 6. Remove the two mounting torx screws located on the board as shown at right. 7.

  • Page 47: Remove Components

    Inverter Assembly Component Replacement Procedures Chapter 3 Switch Mode Power Supply See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Board Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13.
  • Page 48 Chapter 3 Inverter Assembly Component Replacement Procedures 6. Use your fingers or needle-nose pliers to squeeze the tabs of each of the three spacers and separate the Switch Mode Power Supply Board from the mounting plate. 7. Remove the Switch Mode Power Supply Board; return or dispose of it properly.

  • Page 49: Remove Components

    Inverter Assembly Component Replacement Procedures Chapter 3 24V Power Supply Board See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13.

  • Page 50: Remove Components

    Chapter 3 Inverter Assembly Component Replacement Procedures DC Bus Filter Board See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13.

  • Page 51: Remove Components

    Inverter Assembly Component Replacement Procedures Chapter 3 Bus Capacitors See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13. 2.
  • Page 52 Chapter 3 Inverter Assembly Component Replacement Procedures 8. The set screws may come out with the nuts. Save all nuts and set screws. 9. Remove the Bus Capacitor Busbar. 10. Remove the Capacitors by pulling them out. ATTENTION: Dispose of the Capacitors properly, in accordance with local regulations and laws.

  • Page 53: Remove Components

    Inverter Assembly Component Replacement Procedures Chapter 3 Capacitor Bank Fan See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13.

  • Page 54: Inverter Power Module (Igbt)

    Chapter 3 Inverter Assembly Component Replacement Procedures Inverter Power Module This kit includes: (IGBT) Component IGBT module with circuit board Gate Interface Board Gate Interconnect Harness Flexible Capacitor Busbar, Positive Flexible Capacitor Busbar, Negative Tie Down Capacitor Mount Snubber Capacitor The photograph below is an example of an IGBT module failure.

  • Page 55: Remove Components

    Inverter Assembly Component Replacement Procedures Chapter 3 Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13. 2. Remove safety shields and enclosure covers as needed. 3. Locate the Inverter Power Module (IGBT Module) to be replaced. 4.
  • Page 56 Chapter 3 Inverter Assembly Component Replacement Procedures 5. 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.

  • Page 57: Install Components

    Inverter Assembly Component Replacement Procedures Chapter 3 Install Components 1. Carefully examine the Transitional Busbar Assembly and Bus Capacitors for damage. When replacing any IGBT module, we recommend that you replace all Bus Capacitors. If needed, see Bus Capacitors on page to replace damaged Bus Capacitors.
  • Page 58 Chapter 3 Inverter Assembly Component Replacement Procedures 3. If needed, install the three supplied positive (DC+) Flexible Capacitor Busbars on the back side of the Transitional Busbar Assembly. The positive (DC+) Flexible Capacitor Busbars have a shorter angle. Shown with Transitional Busbar and all Flexible Capacitor Busbars installed for illustration purposes only 4.
  • Page 59 Inverter Assembly Component Replacement Procedures Chapter 3 7. Install the Gate Interface Board: a. Install the Gate Interface Board using the four nuts removed previously. Torque screws to 1.6 N•m (14 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 60.

  • Page 60: Remove Components

    Chapter 3 Inverter Assembly Component Replacement Procedures Gate Interface Board See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13.
  • Page 61 Inverter Assembly Component Replacement Procedures Chapter 3 7. Remove the four mounting nuts. 8. Remove the Gate Interface Board; return or dispose of it properly. Gate Interface Board Mounting Nuts (4; 7 mm) Install Components 1. Install the new board. 2.

  • Page 62: Remove Components

    Chapter 3 Inverter Assembly Component Replacement Procedures Current Transducer See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13. 2.
  • Page 63 Inverter Assembly Component Replacement Procedures Chapter 3 Install Components 1. Mount brackets to the new Current Transducer. Torque screw to 5.6 N•m (50 lb•in). 2. Slide Output Busbar through the Current Transducer assembly with the angled end to the left. 3.

  • Page 64: Remove Components

    Chapter 3 Inverter Assembly Component Replacement Procedures Heatsink Fan See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Disconnect TB10 green/ yellow grounding wire. Heatsink Fan Mounting Plate Bolts (16) Heatsink Fan Mounting Bolts (4) Remove Components 1.

  • Page 65: Remove Components

    Inverter Assembly Component Replacement Procedures Chapter 3 The Thermal Sensor system for the Inverter Assembly consists of: Thermal Sensor • A connector to J8 on each of the three Gate Interface Boards. The J8 connectors are wired in series: – J8 (V phase) has four wires: two wires that sense an over-temperature condition, and two wires for temperature feedback.
  • Page 66 Chapter 3 Inverter Assembly Component Replacement Procedures Install Components 1. For the Main Control Panel 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 (15 lb•in).

  • Page 67: Remove Components

    Inverter Assembly Component Replacement Procedures Chapter 3 Balancing Resistor See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13. 2.
  • Page 68 Chapter 3 Inverter Assembly Component Replacement Procedures Do not install the resistor if the measurement is not within the recommended IMPORTANT range. 5. Because the existing resistor wires will be reused, cut the wires off of the resistor at the solder joint, to keep the wires as long as possible. 6.
  • Page 69 Inverter Assembly Component Replacement Procedures Chapter 3 7. Cut and remove the tie wraps that secure the resistor wire bundle. Rockwell Automation Publication 20B-IN026C-EN-P - October 2015...
  • Page 70 Chapter 3 Inverter Assembly Component Replacement Procedures 8. Remove the bolts between the right-angled bus bar and the large bus bar. Do not remove the bolts that attach the cables to the right-angled IMPORTANT bus bar. Rockwell Automation Publication 20B-IN026C-EN-P - October 2015...
  • Page 71 Inverter Assembly Component Replacement Procedures Chapter 3 9. Remove the two bolts from the bottom of the bus bar (as shown in the following image). Rockwell Automation Publication 20B-IN026C-EN-P - October 2015...
  • Page 72 Chapter 3 Inverter Assembly Component Replacement Procedures 10. While holding the bus bar, remove the nuts that secure the bus bar to the chassis and remove the bus bar. IMPORTANT The set screws can come out when a nut is removed. Install Components 1.
  • Page 73 Inverter Assembly Component Replacement Procedures Chapter 3 4. Verify that the yellow resistor wire is long enough to connect to the left terminal (R2) on the top of the resistor assembly. To do so, route the wire through the bottom and out of the top of the holes in the insulator material on the resistor assembly (as shown in the following images).
  • Page 74 Chapter 3 Inverter Assembly Component Replacement Procedures 5. Remove the lugs from the resistor terminals and, using an 18 AWG wire crimper for a non-insulated connector, crimp the wires to the lugs. 6. Secure the lug with the black resistor wire to the left terminal (R1) on the bottom of the resistor assembly.
  • Page 75 Inverter Assembly Component Replacement Procedures Chapter 3 9. Secure the resistor wire bundle below the assembly using tie-wraps (as shown in the following image). 10. Install the stacking panel as detailed on page 26. 11. Replace all safety shields and enclosure covers before applying power to the drive.

  • Page 76: Remove Components

    Chapter 3 Inverter Assembly Component Replacement Procedures Fan Transformer See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. (IP20 version only) Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13.

  • Page 77: Converter Assembly Component Replacement Procedures

    Chapter Converter Assembly Component Replacement Procedures Overview This section details components that are replaceable on the converter assembly. See Chapter 3 - Inverter Assembly Component Replacement Procedures on page for components replaceable on the inverter assembly. The components addressed in this section are as follows.

  • Page 78: Dc Link Choke

    Chapter 4 Converter Assembly Component Replacement Procedures DC Link Choke See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Note: For the IP20 model, the DC Link Choke is mounted at the bottom front of the enclosure.

  • Page 79: Remove Components

    Converter Assembly Component Replacement Procedures Chapter 4 See Chapter 1 - Component Diagrams and Torque Specifications on page MOV Surge Suppressor locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13.

  • Page 80: Remove Components

    Chapter 4 Converter Assembly Component Replacement Procedures Converter Power Modules If any Converter SCR module fails, all three phases should be replaced (one IMPORTANT (SCR) kit includes two Converter SCR modules for one phase). See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions.
  • Page 81 Converter Assembly Component Replacement Procedures Chapter 4 Install Components 1. Use isopropyl alcohol to thoroughly clean the Heatsink mounting surface where the SCR modules will be installed. 2. Verify the mounting surface of the new SCR module is clean. If not, clean with isopropyl alcohol.
  • Page 82 Chapter 4 Converter Assembly Component Replacement Procedures 6. Reinstall the Precharge Board wires to the MOV modules. SCR Modules (6) Installed with Wiring Plug Facing the top of the chassis. Red and White Wires from Upper SCR Modules to J2 on the Precharge Board Red and White Wires from Lower SCR Modules to J3 on the Precharge...

  • Page 83: Remove Components

    Converter Assembly Component Replacement Procedures Chapter 4 Precharge Board See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13. 2.

  • Page 84: Remove Components

    Chapter 4 Converter Assembly Component Replacement Procedures Snubber Resistors See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13. 2.
  • Page 85 Converter Assembly Component Replacement Procedures Chapter 4 Install Components 1. Use isopropyl alcohol to clean the surface where the new Snubber Resistor(s) will be installed. 2. Verify that the mounting surface of the new Snubber Resistor(s) is clean. If not, clean with isopropyl alcohol. 3.

  • Page 86: Remove Components

    Chapter 4 Converter Assembly Component Replacement Procedures Snubber Boards See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Remove Components 1. Read and follow the Safety Precautions on page and Important Initial Steps on page 13. 2.
  • Page 87 Converter Assembly Component Replacement Procedures Chapter 4 Install Components 1. Torque the DC1 terminal screw and mounting screw to 2.9 N•m (26 lb•in). 2. Reinstall the terminal wires or connectors to each Snubber Board. Terminal From Wire Color Snubber Board (R) Snubber Resistor (R) Black Snubber Resistor (R)

  • Page 88: Remove Components

    Chapter 4 Converter Assembly Component Replacement Procedures The Thermal Sensor system for the Converter Assembly consists of two Thermal Sensor sensors. Both sensors have a tripping point of 105 °C (221 °F). • Sensor TSW1 is located on the upper heatsink •...
  • Page 89 Converter Assembly Component Replacement Procedures Chapter 4 6. Unplug the wiring harness at the J6 connector on the Power Interface Board on the Inverter. See page for connector locations. Install Components 1. Use isopropyl alcohol to clean the surface where the new Thermal Sensor will be installed.

  • Page 90: Remove Components

    Chapter 4 Converter Assembly Component Replacement Procedures Heatsink Fan Assembly See Chapter 1 - Component Diagrams and Torque Specifications on page locate components in these instructions. Heatsink Fan Mounting Plate Bolts (12) Heatsink Fan Mounting Bolts (4) TB12 and Fan Capacitor Wiring Plugs Remove Components...

  • Page 91: Install Components

    Converter Assembly Component Replacement Procedures Chapter 4 Install Components 1. Install the new heatsink fan to the mounting plate. Torque the mounting screws to 5.6 N•m (50 lb•in). 2. Install the new gasket (if needed) and mounting plate to the chassis. Torque the mounting screws to 2.9 N•m (26 lb•in).
  • Page 92 Chapter 4 Converter Assembly Component Replacement Procedures Notes: Rockwell Automation Publication 20B-IN026C-EN-P - October 2015...

  • Page 93: History Of Changes

    Appendix History of Changes This appendix summarizes the revisions to this manual. Reference this appendix if you need information to determine what changes have been made across multiple revisions. This may be especially useful if you are deciding to upgrade your hardware or software based on information added with previous revisions of this manual.
  • Page 94 Appendix A History of Changes Notes: Rockwell Automation Publication 20B-IN026C-EN-P - October 2015...
  • Page 96 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. http://www.rockwellautomation.com/support you can find technical and application notes, sample code, and links to software service packs. You can also visit our Support Center at https://rockwellautomation.custhelp.com/ for software updates, support chats and forums, technical information, FAQs, and to sign up for product notification updates.

Table of Contents