Rockwell Automation Allen-Bradley PowerFlex 700 Bedienungsanleitung

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.)

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

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.

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