Rockwell Automation Allen-Bradley PowerFlex 750-21G Bedienungsanleitung

Installation Instructions

Original Instructions

PowerFlex 750-Series Service Cart Frames 8…10 Conversion Kit

Bulletin Numbers

20G and 21G

This publication provides basic information to disassemble the 20-750-MCART1 service cart and attach the 20-750-MPLT755T frame 8…10

conversion kit for use with PowerFlex 750-Series frame size 8…10 modules, bulletin numbers 20G and 21G.

The PowerFlex® 750-Series service cart was initially designed to handle and transport PowerFlex 755T modules that are used with PowerFlex 750-

Series products with TotalFORCE™ control. The frames 8…10 conversion kit allows the PowerFlex 750-Series service cart to be converted to a

service cart capable of removing the power modules in the PowerFlex 750-Series frame 8…10 product size.

To use the PowerFlex 750-Series frames 8…10 module conversion kit catalog number 20-750-MPLT755T, you must first follow the instructions to

unpack and stage the PowerFlex 750-Series service cart 20-750-MCART1. Some disassembly of the PowerFlex 750-Series service cart will be

required.

Personal Safety

Topic Page Topic Page

Before You Being 3 Install the Frames 8…10 Conversion Kit 8

Setup the Service Cart 5 Adjust the Service Cart 9

Service Cart Components 2 Service Cart Requirements and Safety for Power Module Removal 10

Disassemble the Service Cart and Stage for Conversion 6 Move the Power Module 11

Service Cart Frames 8…10 Conversion Kit Components 7 Store the Service Cart 12

ATTENTION: The PowerFlex 750-Series service cart (20-750-MCART1) weighs approximately 60 kg (133 lb) and requires two persons to lift.

The PowerFlex 750-Series service cart frames 8…10 conversion kit (20-750-MPLT755T) weighs approximately 32 kg (70 lb) and requires two persons to lift.

ATTENTION: Personal protective equipment is required to perform this installation. At minimum, goggles, steel toe shoes, and gloves should be used.

2Rockwell Automation Publication 750-IN017B-EN-P - June 2018

PowerFlex 750-Series Service Cart Frames 8…10 Conversion Kit

Product Overview

Service Cart Components

Item Description

1Handle

2Jackscrew

(1)

(1) The jackscrew lock (13) must be removed before operating the jackscrew.

3 Anchor pin (one left and one right)

4 Vertical support (one left and one right)(2)

(2) This item must be removed to use the PowerFlex 750-Series frames 8…10 module

conversion kit. See Setup the Service Cart on page 5 for additional instructions.

5 Bridge span (2)

6Tie-inplate(2)

7 Undercarriage wheel mount (one left and one right)

8 Carriage assembly

9 Wheel mount clevis pins (one left and one right)

10 Lockable wheel caster (one left and one right)

11 Carriage assembly clevis pins (2) (one left and one right)

12 Bridge floor (2)

13 Jackscrew lock (1)

PowerFlex 750-Series Service Cart staged (sold separately)

Catalog Number 20-750-MCART1

Max Lifting Weight Capacity: 340 kg (750 lb)

Dimensions (HxWxD): 1100 mm x 542 mm x 803 mm

(43.3 in. x 21.3 in. x 31.6 in.)

PowerFlex 750-Series Service Cart shown with Frames 8…10 Conversion Kit

installed

Catalog Number

20-750-MPLT755T

Max Weight Capacity: 363 kg (800 lb)

Max Reach: 130 mm (5.1 in.)

ATTENTION: The PowerFlex 750-Series service cart (20-750-MCART1) weighs

approximately 60 kg (133 lb) and requires two persons to lift.

Rockwell Automation Publication 750-IN017B-EN-P - June 2018 3

PowerFlex 750-Series Service Cart Frames 8…10 Conversion Kit

Before You Being

The installation and removal of modules that are part of the PowerFlex 750-Series Products, must be performed by personnel familiar with the

hardware topology of the product. Review product details that are in these manuals before servicing the product. A list of tasks and their related

publications are provided.

• How to use the service cart (PowerFlex 750-Series Service Cart and DCPC Module Lift, publication 750-IN105)

• See PowerFlex 750-Series AC Drives Installation Instructions, publication 750-IN001 for information on:

• How to remove power from a PowerFlex 750-Series frame 8 or larger

• PowerFlex 750-Series AC input and DC bus voltage test points

• PowerFlex 750-Series lockout provisions

• PowerFlex 750-Series power module removal guidance

• Safety-related practices for electrical systems (NFPA 70E, Standard for Electrical Safety in the Work Place)

• Basic information to install, protect, wire, and ground pulse-width modulated (PWM) AC drives, (Wiring and Grounding for Pulse Width

Modulated (PWM) Drives, publication DRIVES-IN001)

Required Tools

Aisle Clearance

The minimum aisle clearance that is required to maneuver and position the service cart is 914 mm (36 in.).

Ratcheting wrench 25 mm socket (used with electric drill) 13 mm socket

Torque wrench Ratcheting extension, 3 in. (76 mm) min T40 hexalobular bit

Electric drill with torque rating 11.3 N•m (100 lb•in), min Pliers T45 hexalobular bit

914 mm

(36 in.)

Top View

4Rockwell Automation Publication 750-IN017B-EN-P - June 2018

PowerFlex 750-Series Service Cart Frames 8…10 Conversion Kit

Illustration Conventions

The following visual conventions are used in the IP00 kit installation illustrations.

Convention Description Convention Description Convention Description

Step number. Force application direction Areas that have eye

hazards are identified in

these instructions by this

image. Take precautions

when you install or remove

assemblies that are

identified as sensitive.

Number of times the step is

performed.

Part/assembly placement

ATTENTION: To avoid personal injury or equipment damage, only qualified personnel familiar with

adjustable frequency AC drives, and their equipment, can plan or implement installation, startup, and

subsequent maintenance of the system.

ATTENTION: To avoid dismemberment or personal injury, review all product labels and the potential pinch

point hazards before you assemble or use the service accessories. Do not place yourself near pinch points

during assembly or use.

ATTENTION: To guard against death, serious personal injury, or equipment damage, do not subject the

power module to high rates of acceleration or deceleration while transporting. Power modules have a high

center of gravity. Do not push or pull above the points that are indicated on the power module.

This label, affixed to

the power module

chassis, identifies the

center of gravity.

Renewal Part Availability

Description Cat. No.

PowerFlex 750-Series frame

8…10 conversion plate safety

clips

SK-R1-CARTCLIP

Rockwell Automation Publication 750-IN017B-EN-P - June 2018 5

PowerFlex 750-Series Service Cart Frames 8…10 Conversion Kit

Setup the Service Cart

Extend the Handle

To extend the handle, complete these steps.

1. Position the service cart on the floor as shown for step 1.

2. Rotate the service cart to its upright position.

3. To release the handle, remove the pin.

4. Rotate the handle to its upright position.

5. To lock the handle in the extended position, reinsert the pin.

Extend the Undercarriage

Perform the following steps to extend the undercarriage. Complete the steps for one side and then repeat for the other side.

Complete these steps to extend the undercarriage.

1. Remove the cotter pins from each of the lower wheel mounts on the undercarriage.

2. Remove the wheel mount clevis pins.

3. Lower the undercarriage wheel mount to its horizontal position.

4. Insert the wheel mount clevis pin through the forward holes of the undercarriage wheel mount and secure with the cotter pins.

ATTENTION: Lock all four caster brakes before beginning. Failure to do so could result in personal injury or equipment damage.

IMPORTANT Only cotter pins with clevis pins are removed. If, a cotter pin does not have a clevis pin, do not remove.

2x 2x

To align the holes, pull the wheel mount up.

To remove, pull the cotter key toward you and then up.

6Rockwell Automation Publication 750-IN017B-EN-P - June 2018

PowerFlex 750-Series Service Cart Frames 8…10 Conversion Kit

Extend the Carriage Assembly

To extend the carriage assembly, complete these steps.

1. Remove the cotter pins from the upper clevis pins that secure the bridge span and carriage assembly to the carriage trolley.

2. Remove the clevis pins.

3. Lower the bridge span and carriage assembly to its horizontal position.

4. Insert the clevis pins through the lower holes of the carriage trolley and secure with the cotter pins.

5. Remove the jackscrew lock.

Disassemble the Service Cart and Stage for Conversion

To disassemble the service cart and stage it for conversion to a frames 8…10 service cart, complete these steps.

1. Verify jackscrew lock is removed. Use the jackscrew to raise the carriage assembly 153 mm (6 in.) off of the floor.

2. Use the T40 hex bit to remove the four M8 bolts that connect the left and right vertical supports to the carriage assembly.

3. Use the T40 hex bit to remove the four M8 bolts that connect the bridge floor to the carriage assembly.

TIP Package all loose bolts and removed parts and store them in a dry place.

ATTENTION: Before adjusting the height of the cart, remove the jackscrew locking pin. Failure to remove this locking pin will result in equipment damage.

To remove, pull the cotter key toward you and then push up.

IMPORTANT Insert cotter pins from the inside to avoid

interference with carriage operation.

Rockwell Automation Publication 750-IN017B-EN-P - June 2018 7

PowerFlex 750-Series Service Cart Frames 8…10 Conversion Kit

4. Use the pliers to remove the cotter keys from the left and right carriage assembly clevis pins. Then remove the clevis pins.

5. Remove the bridge floor from the carriage assembly.

6. Insert the left and right, carriage assembly clevis pins into their original location and attach the cotter keys See step 4for more information.

Service Cart Frames 8…10 Conversion

Kit Components

ATTENTION: Avoid personal injury. Wear goggles to protect your eyes when removing cotter keys.

Avoid personal injury and equipment damage. The bridge span is loosely attached to the bridge floor, take precautions when removing the bridge floor

to ensure that the bridge span does not break free or fall causing personal injury.

Item Description

1 Frames 8…10 bridge plate

2 M8 nuts (three left and three right)

3 Anchor pins (two left and two right) (1)

(1) This item comes pre-attached to the frames 8…10 bridge plate.

4 Base extender (one left and one right)

5 M10 bolts (three left and three right)

6 Position indicators (A,B,C locations; six left and six right)

7 Cart lock safety clips (one left one right) (1)

ATTENTION: The PowerFlex 750-Series

service cart frames 8…10 conversion kit

weighs approximately 32 kg (70 lb) and

requires two persons to lift.

To align the holes, pull the wheel mount up.

To remove, pull the cotter key toward you and then push up.

6 (x12)

7 (x2)

5 (x6) 4 (x2)

3 (x4)

2 (x6)

8Rockwell Automation Publication 750-IN017B-EN-P - June 2018

PowerFlex 750-Series Service Cart Frames 8…10 Conversion Kit

Install the Frames 8…10 Conversion Kit

To install the frames 8…10 conversion kit to the service cart, complete these steps.

1. Use the T45 hex bit to attach the six M10 bolts of the left and right side base extenders to the outside of the carriage assembly.

Torque the bolts to 19.8 N•m (175 lb•in).

2. Use the 13 mm socket to attach the six M8 nuts for the frames 8…10 bridge plate to the base extenders.

Torque the nuts to 10.2 N•m (90 lb•in).

3. Insert the four tethered anchor pins. The four pins are inserted in the alpha character, which corresponds to the plate position.

WARNING: If using position A, the two safety clips (one left and one right) need to be flipped up. This allows the bridge plate to

successfully mate with the base extenders.

TIP The bolts on the base extender are used to select positions A, B, or C for the frame 8…10 conversion plate.

For more information on which position is best suited for your application, see Adjust the Service Cart on page 9.

EXAMPLE The plate being in position A, results in the four anchor pins being inserted into the four position A locations.

C6x

M10 nut

T30 / 15 mm

19.8 N•m (175 lb•in)

T25 / 15 mm

10.2 N•m (90 lb•in)

Rockwell Automation Publication 750-IN017B-EN-P - June 2018 9

PowerFlex 750-Series Service Cart Frames 8…10 Conversion Kit

Adjust the Service Cart

The height and reach of the service cart carriage assembly is adjustable.

Height

The jackscrew adjusts the height of the carriage assembly. Clockwise

rotation raises the carriage assembly and counterclockwise rotation

lowers the carriage assembly.

To make height adjustments quickly, use an electric hand drill fitted

with a 25 mm socket. An electric drill with a torque rating of 11.3 N•m

(100 lb•in) or higher is recommended. Height is from 0 mm (0 in.) to

137 mm (10.2 in.), where 0 mm (0 in.) is the lowest possible cart

position.

Reach

The frames 8…10 bridge plate sits on the base extenders. To adjust the

reach of the carriage assembly, remove the M8 nuts and the four

tethered anchor pins. Reposition the frames 8…10 bridge plate into an

available slot (A, B, or C).

The M8 nuts must be reattached and torqued to 10.2 N•m (90 lb•in)

when a position change is performed. After the nuts are torqued, the

four tethered anchor pins must be reinserted into the corresponding

slot (A, B, or C).

ATTENTION: Before adjusting the height of the cart, remove the jackscrew locking

pin. Failure to remove this locking pin will result in equipment damage.

ATTENTION: Avoid equipment damage. The left and right safety clips must be flipped up before the service cart is lowered. Failure to due so will result in

equipment damage. See Service Cart Requirements and Safety for Power Module Removal on page 10 for more information.

0…137 mm

(0…5.4 in.)

Note: Height is from 0 mm (0 in.) to 137 mm (5.4 in.),

where 0 mm (0 in.) is the lowest possible cart position.

0…130 mm

(0…5.1 in.)

C = 130 mm

(5.1 in.)

A = 0 mm

Top Views

B = 57 mm

(2.2 in.)

10 Rockwell Automation Publication 750-IN017B-EN-P - June 2018

PowerFlex 750-Series Service Cart Frames 8…10 Conversion Kit

Service Cart Requirements and Safety for

Power Module Removal

The frames 8…10 service cart is fully adjustable to suit your

need. If adjustments are needed to the reach or height of the

bridge, see section Adjust the Service Cart on page 9 for more

information.

The converted frames 8…10 service cart is designed with two

additional safety features. First there are two safety clips used

during the removal of a power module that anchor the service

cart to the control cabinet. Second, it is equipped with four

anchor pins that secure the power module to the service cart

for transport. The image shows the location of these safety

features.

The addition of the frames 8…10 conversion kit to the

PowerFlex 750-Series Service Cart poses additional pinch

hazards. Be sure to familiarize yourself with the other pinch

hazards listed in the PowerFlex 750-Series Service Cart and

DCPC Module Lift, publication 750-IN105.

•Pinch Point A: When loading or unloading the

power module, keep this area clear for the power

module. The power module will make direct contact

with the service cart when full extracted.

•Pinch Point B: When lowering the service cart

bridge, keep this area clear. The bridge will make

direct contact with the carriage assembly when the

service cart is lowered.

IMPORTANT The two safety clips must be raised when docking

to the control cabinet. Lower and lock the safety

clips during power module removal. Before

changing the height and before transport begins,

release the safety clips from the control cabinet.

IMPORTANT The four anchor pins must be removed after the

service cart is docked. Insert the anchor pins after

the power module is loaded and before transport

of the power module begins.

ATTENTION: Avoid personal injury and equipment damage. Lock wheel casters before removing a power module.

ATTENTION: Avoid personal injury. Do not remove or

disable the touch guards. Pinch points exist between

the movable parts of the service cart. Review all

product labels and familiarize yourself with the

potential pinch-point hazards before you operate the

service cart.

4 anchor pins:

2 left / 2 right

2 safety clips

(locked):

1 left / 1 right

safety clip

(raised)

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