Allen-Bradley powerflex 700 Installation Instructions Manual

PowerFlex 700 Drives - Frame 10 Components Replacement

Installation Instructions

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and

operation of this equipment before you install, configure, operate, or maintain this product. Users are required to

familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,

and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required

to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be

impaired.

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.

Labels may also be on or inside the equipment to provide specific precautions.

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.

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.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

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.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to

potential 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).

Rockwell Automation Publication 20B-IN026C-EN-P - October 2015 3

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

Updated the Component Kits table with the new balancing resistor

kit catalog numbers.

10

Updated Figure 2 - Frame 10 Assembly Busbar Locations to include

the new balancing resistor bus bar assembly.

17

Updated the Balancing Resistor and DC+ Bus Bar instructions for

removing and installing the new kit.

53

Moved the summary of changes information for the previous

revision to Appendix A - History of Changes.

93

4 Rockwell Automation Publication 20B-IN026C-EN-P - October 2015

Summary of Changes

Notes:

Rockwell Automation Publication 20B-IN026C-EN-P - October 2015 5

Table of Contents

Preface

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Component Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Important Initial Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 1

Component Diagrams and Torque

Specifications

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Fastener Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chapter 2

Basic Component Removal

Procedures

Main Control Panel

(Inverter Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Stacking Panel

(Inverter Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Transitional Busbar Assembly

(Inverter Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Busbar Assembly

(Converter Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Chapter 3

Inverter Assembly

Component Replacement Procedures

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Main Control Board (version 2.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

T-Comm Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Power Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Switch Mode Power Supply Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6 Rockwell Automation Publication 20B-IN026C-EN-P - October 2015

Table of Contents

24V Power Supply Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

DC Bus Filter Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Capacitor Bank Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Inverter Power Module (IGBT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Gate Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Current Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Heatsink Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Thermal Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Balancing Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Fan Transformer

(IP20 version only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Chapter 4

Converter Assembly

Component Replacement Procedures

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

DC Link Choke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

MOV Surge Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Converter Power Modules (SCR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Precharge Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Rockwell Automation Publication 20B-IN026C-EN-P - October 2015 7

Table of Contents

Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Snubber Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Snubber Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Thermal Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Heatsink Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Appendix A

History of Changes

20B-IN026B-EN-P, July 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

8 Rockwell Automation Publication 20B-IN026C-EN-P - October 2015

Table of Contents

Rockwell Automation Publication 20B-IN026C-EN-P - October 2015 9

Preface

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).

Overview on page 15

for more details.

The PowerFlex 700 Frame 10 drive is available in two enclosure types:

• IP00, NEMA/UL Type Open

• IP20, NEMA/UL Type 1

The IP00 enclosure type is shown in most visual aids throughout the manual.

Any component replacement information specific to the IP20 enclosure type is

noted as IP20 version only.

889.0

(35.00)

Inverter Assy. Converter Assy.

1267.7

(49.91)

757.7

(29.83)

503.7

(19.83)

2373.9

(93.46)

120

IN1

120

IN2

3

4

5

6

DC+

DANGER

TB9

8 AMPERES RMS

MAXIMUM

120

IN1

120

IN2

3

4

5

6

VWU

TB11

PE

25 AMPERES RMS

MAXIMUM

GND

RISK OF SHOCK

REPLACE AFTER

SERVICING

!

DANGER

RISK OF SHOCK

REPLACE AFTER

SERVICING

!

DANGER

RISK OF SHOCK

REPLACE AFTER

SERVICING

!

DANGER

TB10

8 AMPERES RMS

MAXIMUM

120

IN1

120

IN2

3

4

5

6

TB10

8 AMPERES RMS

MAXIMUM

GND

RISK OF SHOCK

REPLACE AFTER

SERVICING

!

DANGER

543.1

(21.38)

Inverter Assy.

IP00, NEMA/UL Type Open IP20, NEMA/UL Type 1

Converter Assy.

1267.7

(49.91)

757.7

(29.83)

503.7

(19.83)

2275.8

(89.60)

475

(18.7)

252.7

(9.95)

445.8

(17.55)

353.8

(13.93)

591.3

(23.28)

All dimensions are in millimeters and (inches).

10 Rockwell Automation Publication 20B-IN026C-EN-P - October 2015

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.

Precharge Board SK-G9-PRE1-V480 For AC input only

(2)

1336-PB-SP22C For DC input only

(3)

Power Interface Board SK-G9-GDB1-D875 875 A

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

DC Bus Filter Board 2364-SPP02A

Fans and Main Fan Circuit Components

Converter Heatsink Fan SK-G1-FAN1-F810 Includes fan and fan enclosure

Inverter Heatsink Fan SK-G1-FAN1-F10 Includes fan and fan enclosure

Capacitor Fan SK-G1-FAN2-F8910

Power Module Sub-assemblies

Inverter Power Module (IGBT) SK-G1-QOUT1-F910 Includes:

• One IGBT module

• One Gate Interface Board

• Gate Interconnect Harness

• Six Flexible Capacitor Busbars

• Three Snubber Capacitors

• One Tie Down Capacitor Mount

Drive requires three kits.

Converter Power Module (SCR) SK-G1-SCR1-F10 For AC input only.

(2)

Kit includes two SCR Modules.

Drive requires three kits.

We recommend replacing all three phases

(three kits) at the same time.

SCR Snubber Kit SK-G1-SCRSNUBRB AC input requires three kits.

DC input requires one kit.

DC Link Choke SK-G1-DCCHOKE1-F10 For AC input only

(2)

Miscellaneous

Balancing Resistor Kit SK-G1-RB1-F910 (Replaces

1336-RLOAD-SP3A)

(1)

AC and DC Input (includes DC+ bus bar and

resistor assembly).

Bus Capacitor Kit SK-G1-BUSCAP1-F10 Includes one Capacitor.

Drive requires 26 kits.

Capacitor Bus Finger Kit SK-G1-FLXBUS1 Included with the kit for Inverter Power

Module (IGBT).

Can be ordered separately without Inverter

Power Module (IGBT) if needed.

Includes busbars for one phase:

• Three positive Flexible Capacitor Busbars

• Three negative Flexible Capacitor Busbars

Drive requires three kits.

Current Transducer SK-G1-CT1-F910 Includes one Transducer.

Drive requires three kits.

MOV Surge Suppressor SK-G1-MOV1-F10 For AC input only

(2)

Power Supply, 24V SK-G9-PWRS24 For Current Transducers (CTs)

Thermal Sensor Kit SK-G1-THM1-F10 Includes:

• Main Control Panel Thermal Sensor

• Heatsink Thermal Sensor

Transformer, 1000 VA SK-G9-XFMR1-F10 For AC input only.

(4)

Includes:

• One Transformer

• Three fuses

(5)

Transformer Fuses

(5)

SK-G9-FUSE1-F10 For AC input only

(4)

Rockwell Automation Publication 20B-IN026C-EN-P - October 2015 11

Preface

See the master parts list for the most up-to-date information:

http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf

Recommended Tools

The following list of tools is provided for your reference to disassemble and

reassemble the drive and components. This list may not include all tools for your

situation. Not all tools are needed for some components. See specific sections for

details.

Enclosure Options

Converter Gasket Kit SK-G1-GASKET2-F10 For AC input only

(2)

Inverter Gasket Kit SK-G1-GASKET1-F10 For DC input only

(3)

(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.

(3) DC input applies to PowerFlex 700 catalog numbers beginning with 20BH875 or 20BJ875.

(4) Transformer and transformer fuses apply to AC input PowerFlex 700 catalog numbers beginning with 20BC875A or 20BD875A (IP20,

NEMA/UL Type 1 only).

(5) Fuses included with order are two 6 A fuses and one 9 A fuse.

IMPORTANT

See the instruction sheet included with each component kit for discarding

or returning replaced components.

If discarding, be sure to discard according to local, state, and federal

regulations.

Description Kit Catalog No. Notes

Description

Torque wrench (metered in N•m or lb•in)

Volt ohm meter

Torque seal or colored marker

Screwdrivers (standard, Phillips, torx

– various sizes)

Magnetic screwdriver, long

Socket set, metric

Cylindrical pick-up magnet

Pliers, regular and needle-nose

Wire cutters

Isopropyl alcohol and applicator cloth

Nylon tie wraps

3- or 4-inch paint roller with short nap or 3- or 4-inch putty knife (for applying thermal grease)

Pencil

12 Rockwell Automation Publication 20B-IN026C-EN-P - October 2015

Preface

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.

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 Terminals 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, ensure that 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 Terminals 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.

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.

Electrical arcing causes excessive wear to contacts on the module and its

mating connector. Worn contacts may create electrical resistance.

L1 L2 L3

O

I

Rockwell Automation Publication 20B-IN026C-EN-P - October 2015 13

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 12

.

• Identify components to be replaced using the illustrations in Frame 10

Assembly Components on page 16

.

• 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 fastener after torquing so you know when all are done and to indicate

signs of any subsequent tampering.

• See the product installation documentation for startup and other

instructions after servicing.

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

Guarding Against Electrostatic Damage (publication 8000-4.5.2

) or any

other applicable ESD protection handbook.

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.

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.

HOT surfaces can cause severe burns. Do not touch the heatsink surface

during operation of the drive. After disconnecting power, allow time for

cooling.

Replace all protective shields before applying power to the drive. Failure to

replace protective shields may result in death or serious injury.

14 Rockwell Automation Publication 20B-IN026C-EN-P - October 2015

Preface

Notes:

Rockwell Automation Publication 20B-IN026C-EN-P - October 2015 15

Chapter 1

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. See the table below to determine which voltage input

you ordered.

Ordered Item

Cat. Nos. Beginning With: Input Assembly

20BC875 or 20BD875 AC Inverter and Converter

20BH875 or 20BJ875 DC Inverter

AC Input

(inverter and converter assemblies)

DC Input

(inverter assembly only)

(IP00, NEMA/UL Type Open Assemblies Shown)

16 Rockwell Automation Publication 20B-IN026C-EN-P - October 2015

Chapter 1 Component Diagrams and Torque Specifications

Figure 1 - Frame 10 Assembly Components

Inverter Assembly

(DC input and AC input with converter assembly)

Converter Assembly

(AC input only)

Heatsink Fan Assembly

Stacking Panel

SCR Modules (6)

Motor Busbars (3)

MOV Suppressor

AC Busbars (3)

Snubber Boards (3)

Capacitor Bank Fan

Balancing Resistor (Old

Resistor Style Shown)

Precharge Board

Snubber

Resistors (3)

DC- Busbar

DC+ Busbar

IGBT Snubber Capacitors (9)

Transitional Busbar Assembly

(4 pcs: DC+ Busbar, DC- Busbar,

Upper Capbus Support, and

Lower Capbus Support)

Gate Interface Boards (3)

Current Transducers (3)

DC Bus Capacitors (26)

IGBT Interface Boards (3)

Heatsink Fan Assembly

(IP00, NEMA/UL Type Open Assemblies Shown)

Rockwell Automation Publication 20B-IN026C-EN-P - October 2015 17

Component Diagrams and Torque Specifications Chapter 1

Figure 2 - Frame 10 Assembly Busbar Locations

R

L1

S

L2

T

L3

Inverter Assembly Converter Assembly

Motor Busbars

Lower DC Bus Capacitors (8)

Inverter Assembly Shown With

Stacking Panel Removed

Upper DC Bus Capacitors (18)

Lower Capbus Support

Transitional Busbar Assembly

(4 pcs: DC+ Busbar, DC- Busbar,

Upper Capbus Support, and

Lower Capbus Support)

Upper Capbus Support

AC Busbars (3)

DC- Busbar

DC+ Busbar

U

W

V

18 Rockwell Automation Publication 20B-IN026C-EN-P - October 2015

Chapter 1 Component Diagrams and Torque Specifications

Figure 3 - Circuit Boards on Inverter Assembly

No. Description No. Description

1 HIM Cradle/Communication Board 6 Power Interface Board

2 Communication Board Slots (for optional devices) 7 Switch Mode Power Supply Board

3 T-Comm Board 8 24V Power Supply Board for Current Transducers

(CTs)

4 Main Control Board 9 DC Bus Filter Board

5 TB11 10 TB9

































Communications

Panel

Main Control Panel

Stacking

Panel



Encoder Board

(optional)

Rockwell Automation Publication 20B-IN026C-EN-P - October 2015 19

Component Diagrams and Torque Specifications Chapter 1

Figure 4 - Circuit Boards on Converter Assembly (AC only)

Precharge Board

Snubber Boards (3)

20 Rockwell Automation Publication 20B-IN026C-EN-P - October 2015

Chapter 1 Component Diagrams and Torque Specifications

Fastener Torque

Specifications

Torque Sequence

Figure 5 illustrates initial and final tightening sequences for components fastened

to a heat sink using two, four, and six screws. Initial torque is one-third (33.3%)

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 5 - Various-Point Mounting

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.

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Allen-Bradley powerflex 700 Installation Instructions Manual

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