Rockwell Automation Allen-Bradley PowerFlex 700 User manual

PowerFlex 700 Drive - Frame 7 Components Replacement
Installation Instructions

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 available from
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some
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.
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.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.

Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 3
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Summary of Changes New and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preface Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Component Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Important Initial Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 1
Component Diagrams and Torque
Specs
Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inverter Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Main Control Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fastener Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chapter 2
Basic Component Removal
Procedures
Remove Main Control Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Remove Stacking Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Remove Precharge Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Remove Transitional Bus Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 3
Component Replacement Procedures
Precharge Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Main Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
T-Comm Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Switch Mode Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Power Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fan Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Current Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Inverter Snubber Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Inverter Snubber Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Inverter Power Module (IGBT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Main Control Panel Thermal Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Heatsink Thermal Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Bus Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Bus Capacitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Converter Snubber Board - AC Input Only . . . . . . . . . . . . . . . . . . . . . . . . 50
Converter Power Module (SCR) - AC Input Only . . . . . . . . . . . . . . . . . . 51
MOV - AC Input Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DC Link Choke - AC Input Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Precharge SCR Module Snubber Board - DC Input Only. . . . . . . . . . . . 56
Precharge SCR Module - DC Input Only . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
Table of Contents
Notes:

Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 5
Summary of Changes
This manual contains new and updated information.
New and Updated
Information
This table contains the changes made to this revision.
Topic Page
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.)
7
Added T-Comm Board kit, SK-G9-TCOMM, to table of component kits. 7
Added T-Comm Board removal and installation instructions. 27

6Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
Summary of Changes
Notes:

Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 7
Preface
Introduction This publication provides guidelines for replacing the major components in the
PowerFlex 700 Frame 7 drive.
Component Kits All kits include necessary components, ESD wrist strap and hardware (if
required), and thermal grease (if required).
Refer to the master parts list for the most up-to-date information:
http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf
Description Kit Catalog No. Notes
Precharge Board SK-G9-PRE1-V480 AC input
1336-PB-SP22C DC input
Main Control Board SK-G9-VMCB1-D0 115V I/O
SK-G9-VMCB1-C0 24V I/O
T-Comm Board SK-G9-TCOMM
Switch Mode Power Supply Board SK-G9-PWRS1-D0
Power Interface Board SK-G9-GDB1-D292 292A Drives
SK-G9-GDB1-D325 325A Drives
Heatsink Fan SK-G1-FAN1-F7
Heatsink Fan Transformer 1336-T-SP5A 480 to 120 Auto transformer (fan only)
Current Transducer SK-G1-CT1-F7 Includes one Transducer.
Inverter Power Module (IGBT) SK-G1-QOUT1-F7 Includes
·Two IGBTs.
·Two Gate Interface Boards.
Inverter Snubber Kit SK-G1-INVSNB1-F7 Includes:
·One Snubber Board.
·One Resistor.
SCR Snubber Kit SK-G1-SCRSNUBRB AC input requires three kits.
DC input requires one kit.
Converter Power Module (SCR) SK-G1-SCR1-F7 AC input.
Kit includes three SCR Modules.
DC Precharge SCR Module SK-G1-SCR2-F7 DC input.
Kit includes one SCR Module
Thermal Sensors SK-G1-THM1-F7 Includes:
·Main Control Panel Thermal Sensor
·Heatsink Thermal Sensor.
Bus Fuse 1336-F1-SP6A
Bus Capacitor SK-G1-BUSCAP1-F7 Includes one Capacitor.
MOV SK-G1-MOV1-F7 AC input.
DC Link Choke SK-G1-DCCHOKE1-F7 AC input.
Balancing Resistor 1336-RLOAD-SP4A Includes one Resistor.

8Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
Preface
Recommended Tools The following list of tools is provided for your reference to disassemble and
assemble the drive and components. This list may not be all-encompassing for
your situation. Not all tools are needed for some components. Refer to pertinent
sections for details.
Description Notes
Torque wrench (metered in lb•in or N-m), T30 and T40 bits
Torque seal or colored marker
Screwdrivers (standard, Phillips, star – various sizes)
Magnetic screwdriver, long
Socket set, metric
Cylindrical pick-up magnet
Pliers, regular and needle-nose
Wire cutters
Volt ohm meter Used to test Inverter Snubber Resistors
Isopropyl alcohol
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 9
Preface
Safety Precautions The precautions and general installation requirements provided in the PowerFlex
700 Frame 7-10 Installation Instructions (publication 20B-IN014) and the
PowerFlex 700 User Manual (publication 20B-UM002) must be followed in
addition to those included here.
1. Turn off and lock out input power. Wait five minutes.
2. Verify that there is no voltage at the drive’s input power terminals.
3. Check the DC bus voltage at the Power Terminal Block by measuring
between the DC+ and DC– terminals, between the DC+ terminal and
the chassis, and between the DC– terminal and the chassis. The voltage
must be zero for all three measurements.
ATTENTION: To avoid an electric shock hazard, ensurethat all power has
been removed before proceeding. In addition, before servicing, verify
that the voltage on the bus capacitors has discharged. Check the DC bus
voltage at the Power Terminal Block by measuring between the DC+ &
DC– terminals, between the DC+ terminal and the chassis, and
between the DC– terminal and the chassis. The voltage must be zero for
all three measurements.
ATTENTION: Remove power before making or breaking cable
connections. When you remove or insert a cable connector with power
applied, an electrical arc may occur. An electrical arc can cause personal
injury or property damage by:
·sending an erroneous signal to your system’s field
devices, causing unintended machine motion.
·causing an explosion in a hazardous environment.
ATTENTION: Electrical arcing causes excessive wear to contacts on both
the module and its mating connector. Worn contacts may create
electrical resistance.
ATTENTION: This assembly contains parts and sub-assemblies that are
sensitive to electrostatic discharge. Static control precautions are
required when servicing this assembly. Component damage may result
if you ignore electrostatic discharge control procedures. If you are not
familiar with static control procedures, reference Allen-Bradley
Publication 8000-4.5.2 Guarding Against Electrostatic Damage, or any
other applicable ESD protection handbook.
L1 L2 L3
O
I

10 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
Preface
ATTENTION: The information in this publication is merely a guide for
proper installation. Rockwell Automation, Inc. cannot assume
responsibility for the compliance or the noncompliance to any code
(national, local, or otherwise) for the proper installation of this drive or
associated equipment. A hazard of personal injury and/or equipment
damage exists if codes are ignored.
ATTENTION: Only qualified personnel familiar with adjustable
frequency AC drives and associated machinery should plan or
implement the installation, start-up, and subsequent maintenance of
the system. Failure to comply may result in personal injury and/or
equipment damage.
ATTENTION: HOT surfaces can cause severe burns. Do not touch the
heatsink surface during operation of the drive. After disconnecting
power, allow time for cooling.
ATTENTION: Replace all protective shields before applying power to
the drive. Failure to replace protective shields may result in death or
serious injury.

Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 11
Preface
Important Initial Steps Read and follow these statements before performing any service on the drive.
·Read and follow the precautions in Safety Precautions on page 9.
·Identify components to be replaced using the figures in Component
Diagrams and Torque Specs on page 13.
·Remove protective shields only as necessary.
·Before disconnecting any wire or cable, verify that it is labeled. Also, when
removing components, note hardware type and location.
·When torquing any fasteners, use a colored marker or torque seal to mark
each screw after torquing so you know when all are done and to indicate
signs of any subsequent tampering.
·Refer to the product installation documentation for startup and other
instructions after servicing.

12 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
Preface
Notes:

Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 13
Chapter 1
Component Diagrams and Torque Specs
Drive Components AC input drive is shown.
+DC
USE 75°COPPER WIRE ONLY TORQUE LARGE TERMINALSTO 10 N-m (87LB-IN)
-DC PE PE R-L1 T-L3 U-M1 V-M2 W-M3S-L2
RISK OF SHOCK
REPLACE AFTER
SERVICING
!
DANGER
TB11
25 AMPERES RMS
MAXIMUM
CAUTION
HOT SURFACES
ALLEN-BRADLEY
MADE IN U.S.A.
PE
!
Converter Snubber Boards (3)
with Converter Power SCR
Modules underneath
MOV Location
Inverter Snubber Boards (U,
V, W)
Inverter Snubber Resistors
Current Transducer
Gate Interface Board (U)
(V and W not shown)
Heatsink Thermal
Sensor location
Main Control Panel Assembly
Motor Bus Bars
AC Bus Bars (R, S, T)
W
Inverter Power Module IGBTs
(U, V, W) (under Inverter
Snubber Board)
U
V
W Phase U Phase V Phase T Phase R Phase S Phase
Precharge Board
Assembly
TB2
J3 J1 J2
Power Interface Board (under Main Control Panel)
TB11
Transitional Bus Bar
HIM
Communications Module
Main Control Panel (Stacking Panel (underneath)
Bus Fuse
Balancing Resistors
DC Link Choke
Main Control
Panel Thermal
Sensor
DC Capacitor Bank
(under Transitional Bus Bar)
Switch Mode Power Supply Board (under Main Control Panel)
Power Terminal Block
Transformer
Capacitor
for Fan
Motor
Connections
AC Power Input
Connections

14 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
Chapter 1 Component Diagrams and Torque Specs
AC input drive is shown.
MOV Location
Inverter Snubber Board (U)
(V and W not visible in this image)
Current Transducer
(quantity: 3) Gate Interface Board
Heatsink Thermal
Sensor location
Motor Bus Bars (U, V, W)
W
Inverter Power Module IGBT (U)
(V and W below U)
U
V
W Phase U Phase V Phase T Phase R Phase S Phase
Precharge Board Assembly
Power Interface Board
location (under Main
Control Panel)
Transitional Bus Bar
Communications Panel
Main Control Panel
Bus Fuse
DC Link Choke
Main Control Panel Thermal Sensor
Wire
DC Capacitor Bank
(under Transitional Bus Bar)
HIM
(Blank shown on this Drive)
TB11
Switch Mode Power
Supply Board (under
Main Control Panel)
Ribbon Cable -
Main Control Board
to Comm Board
Main Control Board
(under HIM mounting)
Ribbon Cable - Main
Control Board to Power
Interface Board
IGBT Gate Harness and
CT Harness
Power Terminal Block
Tr an sf or m e r
Capacitor for Fan
Motor ConnectionsAC Power Input Connections

Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 15
Component Diagrams and Torque Specs Chapter1
Inverter Section
Inverter Snubber Boards
Current Transducers
(behind Mounting Clamps)
IGBT Bus Bars
Motor Bus Bars
Inverter Power Module IGBTs
Inverter Snubber Boards
Current Transducers
Gate Interface Boards
Motor Bus Bars
Inverter Power Module IGBTs
Note: Components are shown as seen from right side without drive covers.
Current Transducer Mounting Clamps
Gate Interface Boards
Bottom of Drive Top of Drive

16 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
Chapter 1 Component Diagrams and Torque Specs
Main Control Panel Assembly
Fastener Torque
Specifications
Torque Sequence
The following illustrates initial and final tightening sequences for components
fastened to a heat sink using two, four, and six screws. Initial torque is 1/3 (33%)
of final torque, except six-point mountings, which require 0.7 N•m (6 lb•in) The
numeric illustration labels are for your assistance. Drive components do not carry
these labels.
Figure 1 - Two-Point Mounting
TB11 and Main Control Board
HIM
Stacking Panel
Switch Mode Power Supply Board and
Power Interface Board
Note: Components are shown as seen from right side without drive covers.
Components are listed left to right for
each level
Communications Panel
Main Control Panel
Bottom of Drive Top of Drive
Front
Back
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.
12
Initial Sequence
12
12
Final Sequence

Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 17
Component Diagrams and Torque Specs Chapter1
Figure 2 - Four-Point Mounting
Figure 3 - Six-Point Mounting
1
2
3
4
3 4
Initial Sequence
12
1234
Final Sequence
6 42
3 51
3 4
Initial Sequence
1 2 65
Final Sequence
3 41 2 65
Do not exceed 0.7 Newton-meters (6 lb•in) on initial torque of all six screws.

18 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
Chapter 1 Component Diagrams and Torque Specs
Torque Specifications
The following table lists fastener locations by component, how the fasteners are
used, and torque specifications. Refer to To r q u e S e q u e n c e in this chapter for
fastening two-point, four-point, and six-point components to the heat sink.
Component Fastener Application
Torque
lb•in
Torque
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
Inverter Snubber Resistor
Resistor to heat sink Initial sequence: 6 0.7
Final sequence: 26 3
Inverter Snubber Resistor Wires to Capacitor Bus Bar Assembly 50 6
Inverter Snubber Bracket Bracket to Power Module 80 9
Inverter Snubber Board Board to Brackets 50 6
Converter Snubber Board Board to Input Rectifier 50 6
Balancing Resistor
Resistor to heat sink Initial sequence: 6 0.7
Final sequence: 26 3
Balancing Resistor Wires to Capacitor Bus Bar Assembly 50 6
Heatsink Thermal Sensor Thermistor to heatsink 14 2
Bus Capacitor Holder Holder to Bus Capacitors 26 3
Capacitor Bus Bar Assembly Assembly to Bus Capacitors 50 6
Gate Interface Board Board to Power Modules 14 2
Inverter Power Module (IGBT) Bus
Bar
Bus Bar to Power Modules 80 9
Inverter Power Module (IGBT)
Module to heat sink Initial sequence: 6 0.7
Final sequence: 32 3.6
DIN Rail (TB1) Rail to chassis 50 6
PE Shortening Bar Bar to TB1 80 9
Converter Power Module (SCR)
SCR to heat sink Initial sequence: 6 0.7
Final sequence: 50 6
Transitional Bus Bar Assembly Assembly to Power Module Bus Bar Assembly 80 9
Bus Fuse F1 Fuse to Transitional Bus Bar 80 9
DC Bus Inductor L1 Inductor to chassis 50 6
Bus Bar Cable Adaptor Adaptor to Transitional Bus Bar and DC Bus
Inductor
80 9
Converter Bus and Motor Bus Bars Bus Bars to all connections 80 9
Wires (PE) Wires to Ground Stud 80 9
Wires Wires to TB1 80 9
Wire (TE) Wire to TB1 50 6

Rockwell Automation Publication 20B-IN017B-EN-P - September 2011 19
Component Diagrams and Torque Specs Chapter1
Wires Wires to TB2 7 0.8
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 Bus Bar 26 3
Power Cables Cables to terminals 80 9
Main Control, Gate Driver, Precharge
Board Mounting Plates
Plates to chassis 26 3
High Voltage Guard Guard to chassis 26 3
Component Fastener Application
Torque
lb•in
Torque
N•m

20 Rockwell Automation Publication 20B-IN017B-EN-P - September 2011
Chapter 1 Component Diagrams and Torque Specs
Notes: