Rockwell Automation Allen-Bradley PowerFlex 700 Installation Instructions Manual
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Rockwell Automation Allen-Bradley PowerFlex 700 Installation Instructions Manual

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Installation Instructions
PowerFlex 700 Drive - Frame 7 Components Replacement

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Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex 700

  • Page 1 Installation Instructions PowerFlex 700 Drive - Frame 7 Components Replacement...

  • Page 2: Important User Information

    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.

  • Page 3: Table Of Contents

    Precharge SCR Module - DC Input Only ......57 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 4 Table of Contents Notes: Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 5: New And Updated Information

    Added Heatsink Fan Transformer kit, 1336-T-SP5A, to table of component kits. (Instructions were already in this manual, but the kit was not listed in the table.) Added T-Comm Board kit, SK-G9-TCOMM, to table of component kits. Added T-Comm Board removal and installation instructions. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 6 Summary of Changes Notes: Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 7: Introduction

    Bus Capacitor SK-G1-BUSCAP1-F7 Includes one Capacitor. SK-G1-MOV1-F7 AC input. DC Link Choke SK-G1-DCCHOKE1-F7 AC input. Balancing Resistor 1336-RLOAD-SP4A Includes one Resistor. Refer to the master parts list for the most up-to-date information: http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 8: Recommended Tools

    Nylon tie wraps Pencil 14 or 16 gauge wire, about 10 cm (4 in.) Needed whenever IGBT gates are exposed. Used to short the gates. Two (2) #10 wire lugs, either fork or ring Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 9: Safety Precautions

    Component damage may result if you ignore electrostatic discharge control procedures. If you are not familiar with static control procedures, reference Allen-Bradley Publication 8000-4.5.2 Guarding Against Electrostatic Damage, or any other applicable ESD protection handbook. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 10 Preface ATTENTION: The information in this publication is merely a guide for proper installation. Rockwell Automation, Inc. cannot assume responsibility for the compliance or the noncompliance to any code (national, local, or otherwise) for the proper installation of this drive or associated equipment.

  • Page 11: Important Initial Steps

    · Refer to the product installation documentation for startup and other instructions after servicing. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 12 Preface Notes: Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 13: Drive Components

    Capacitor for Fan Transformer MOV Location Power Terminal Block R-L1 S-L2 T-L3 U-M1 V-M2 W-M3 USE 75° COPPER WIRE ONLY TORQUE LARGE TERMINALS TO 10 N-m (87LB-IN) AC Power Input Motor Connections Connections Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 14 Communications Panel Switch Mode Power Main Control Panel Supply Board (under Main Control Panel) TB11 Capacitor for Fan Transformer Precharge Board Assembly MOV Location Power Terminal Block AC Power Input Connections Motor Connections Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 15: Inverter Section

    Current Transducers (behind Mounting Clamps) Motor Bus Bars Inverter Snubber Boards IGBT Bus Bars Gate Interface Boards Inverter Power Module IGBTs Note: Components are shown as seen from right side without drive covers. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 16: Main Control Panel Assembly

    0.7 N•m (6 lb•in) The numeric illustration labels are for your assistance. Drive components do not carry these labels. Figure 1 - Two-Point Mounting Initial Sequence Final Sequence Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 17 Chapter 1 Figure 2 - Four-Point Mounting Initial Sequence Final Sequence Figure 3 - Six-Point Mounting Initial Sequence Do not exceed 0.7 Newton-meters (6 lb•in) on initial torque of all six screws. Final Sequence Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 18: Torque Specifications

    Adaptor to Transitional Bus Bar and DC Bus Inductor Converter Bus and Motor Bus Bars Bus Bars to all connections Wires (PE) Wires to Ground Stud Wires Wires to TB1 Wire (TE) Wire to TB1 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 19 Mounting Plate to CT Clamping Plate CT Clamping Plate Clamping Plate to Bus Bar Power Cables Cables to terminals Main Control, Gate Driver, Precharge Plates to chassis Board Mounting Plates High Voltage Guard Guard to chassis Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 20 Chapter 1 Component Diagrams and Torque Specs Notes: Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 21: Remove Main Control Panel Assembly

    4. Remove the two screws on the Main Control Panel below TB11 for the Main Control Board. 5. Verify that all wiring to lower side of TB11 is properly labeled and then disconnect wiring from TB11. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 22: Remove Stacking Panel

    45.) 4. Remove the two screws at the bottom of the Stacking Panel for the Power Interface and the Switch Mode Power Supply Boards. Remove the panel by sliding it up and out. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 23: Remove Precharge Board Assembly

    Remove Components 1. Read and follow the Safety Precautions on page 9 Important Initial Steps on page 2. Remove the upper safety cover (four screws). 3. Locate the Transitional Bus Bar. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 24 This allows access to the wire connections below it if needed. Install Components When instructed for the component you are replacing, reinstall the Transitional Bus Bar components in the reverse order of removal. Only torque screws after all components are in place. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 25: Precharge Board

    8. Remove the Precharge Board. AC Input Shown Install Components 1. Install the new Precharge Board. 2. Reconnect wiring. 3. Replace all safety shields and enclosure covers before applying power to the drive. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 26: Main Control Board

    7. If needed, unscrew and disconnect the wire set going to TB11 from the Main Control Board. 8. Unscrew the six (6) screws holding the Main Control Board. 9. Remove the Main Control Board. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 27: T-Comm 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. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 28 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. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 29 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. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 30: Switch Mode Power Supply Board

    4. Reconnect the ribbon cable going from the Power Interface Board ( J1) to the Main Control Board ( J2). 5. Replace all safety shields and enclosure covers before applying power to the drive. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 31: Power Interface Board

    Screws 5. Using your fingers or needle-nose pliers, squeeze the wings of each of the nine (9) spacers and remove the Power Interface Board from the mounting plate. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 32: Fan

    The Fan is located behind the Main Control Panel assembly and Precharge Board. Fan Assembly Refer to the figure below and the figures in Component Diagrams and Torque Specs on page 13 for these instructions. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 33 To do so, move the top end of the bar to the right and the bottom end of the bar to the left, pull down on a angle, then rotate the bar 180° and fully remove the bar. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 34 Fan and cover together. Install Components 1. If needed, remove the old gasket from Fan cover and replace gasket. 2. Mate cover and new Fan, positioning Fan cable in notch of opening in cover. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 35: Fan Transformer

    Refer to the figures in Component Diagrams and Torque Specs on page 13 these instructions. Remove Components 1. Read and follow the Safety Precautions on page 9 Important Initial Steps on page 2. Remove the safety cover. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 36 (the end with only one screw hole) through the assembly, taking care not to damage the transducer or the insulation on the bus bar. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 37 1.6 N•m (14 Spacers lb•in.) 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 tampering. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 38: Inverter Snubber Board

    Disconnect the wiring harness from the transducer board. Clip the wire tie and remove the wiring harness. b. Remove the three button head screws that secure the bus bar. Move the bus bar and transducer to an ESD- safe flat surface. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 39 4. Torque screws for any Motor Bus Bars that were removed to 9.0 N•m (80 lb•in) 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-IN017B-EN-P - September 2011...

  • Page 40: Inverter Snubber Resistor

    If the reading is other than 8 ohms, continue with the instructions in Step 4.…Step 10. to replace any faulty Resistor. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 41 5. Connect the wire with push-on connector to J1 of its Inverter Snubber Board. 6. Replace all wire ties. 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-IN017B-EN-P - September 2011...

  • Page 42: Inverter Power Module (Igbt)

    Exact positioning is critical for alignment of other components, especially the Transitional Bus Bar unit. 8. Remove the IGBT Bus Bar from the modules. Set aside. 9. Disconnect connections for the Gate Interface Boards. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 43 Place the IGBT module on the Heatsink and install with supplied screws and tighten using this torque sequence: IGBT Torque Sequence First Sequence: 0.7 N-m (6.0 lb.-in.) Final Sequence: 3.6 N-m (32 lb.-in.) Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 44 Torque screws to 5.6 N•m (50 lb•in) 11. Position each Motor Bus Bar but do not torque mounting screws yet. 12. Position each Current Transducer and install screws but do not torque yet. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 45: Main Control Panel Thermal Sensor

    Torque screw to 1.7 N•m ( 15 lb•in) 2. Reconnect the Monitor Wire. 3. Reinstall the Main Control Panel Assembly. 4. Replace all safety shields and enclosure covers before applying power to the drive. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 46: Heatsink Thermal Sensor

    ATTENTION: The IGBT gate terminals must not be exposed longer than one minute. Do not let the gate connections remain disconnected longer than one minute. Locate jumper wire (from Step 2.) before proceeding to the next step. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 47 5. Remove the jumper wire to gate connections on the IGBT module and immediately reinstall the left Gate Interface Board onto the IGBT module. 6. Reassemble remaining components in reverse order. 7. Replace all safety shields and enclosure covers before applying power to the drive. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 48: Bus Fuse

    1. Install new Bus Fuse. 2. Torque 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. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 49: Bus Capacitor

    Note: Install all posts, washers, and nuts before tightening. 5. Reconnect all wires and connectors. 6. Reassemble remaining components in reverse order. 7. Replace all safety shields and enclosure covers before applying power to the drive. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 50: Converter Snubber Board - Ac Input Only

    3. If removed, reinstall the U Phase Motor Bus Bar and torque screws to 9.0 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-IN017B-EN-P - September 2011...

  • Page 51: Converter Power Module (Scr) - Ac Input Only

    9. Remove the three AC Bus Bars (R, S, T). 10. Remove the six Snubber Board Mounting Brackets (M6 T40 screws). 11. Remove the four (4) M6 screws from the DC Link Choke terminal (1) and (4). Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 52 SCR module. 4. Install each new SCR module with supplied screws and tighten using this torque sequence: SCR Torque SCR Torque First Sequence: Final Sequence: 0.7 N-m (6.0 lb.-in.) 5.6 N-m (50 lb.-in.) Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 53 11. Torque screws for Converter Bus Bars to 9.0 N•m (80 lb•in) 12. Reassemble remaining components in reverse order. 13. Replace all safety shields and enclosure covers before applying power to the drive. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 54: Mov - Ac Input Only

    3. Torque the R, S, and T Phase power terminal block nuts to 9.8 N•m (80 lb•in) 4. Reinstall the Precharge Board. 5. Replace all safety shields and enclosure covers before applying power to the drive. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 55: Dc Link Choke - Ac Input Only

    1. Install new DC Link Choke by screwing mounting brackets to drive. 2. Torque 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. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 56: Precharge Scr Module Snubber Board - Dc Input Only

    Remove Main Control Panel Assembly on page 5. Perform Remove Stacking Panel on page 6. Remove the push-on lead from the Snubber Board. 7. Unscrew and remove the Snubber Board from its bus bar. Set aside. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...

  • Page 57: Precharge Scr Module - Dc Input Only

    5. Label and remove power cables (DC+ and DC–) and all connected wires from the SCR module. 6. Remove the entire Snubber Board Bus Bar assembly, including its lead wires, and carefully set assembly aside. 7. Remove the SCR module and discard. Rockwell Automation Publication 20B-IN017B-EN-P - September 2011...
  • Page 58 N•m (108 lb•in) Shown with Phillips screws, but may be hex nuts. 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-IN017B-EN-P - September 2011...
  • Page 60 Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444 Europe/Middle East/Africa: Rockwell Automation NV, Pegasus Park, De Kleetlaan 12a, 1831 Diegem, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640...

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