Installation Instructions

PowerFlex 700 Drive - Frame 8 Components Replacement

Catalog Numbers 20B
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.

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.

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

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).

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.
 Summary of Changes

New and Updated This table contains the changes made to this revision.
Information Topic Page
Updated the Component Kits table with the new balancing resistor kit catalog numbers. 9
Updated Figure 3 - Frame 8 Busbars (AC Drive shown) to include the new balancing resistor 17
bus bar assembly.
Updated the Balancing Resistor and DC+ Bus Bar instructions for removing and installing 48
the new kit.
Moved the summary of changes information for the previous revision to Appendix A - 83
History of Changes.

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 3

Summary of Changes

Notes:

4 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Table of Contents

Preface Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Component Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Important Initial Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 1
Component Diagrams and Torque Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Specifications Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fastener Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chapter 2
Basic Component Removal Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Procedures Main Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Stacking Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Transitional Busbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Chapter 3
Component Replacement Procedures Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
T-Comm Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Power Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Switch Mode Power Supply Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Precharge Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DC Bus Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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Table of Contents

Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Bus Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Capacitor Bank Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Balancing Resistor and DC+ Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Inverter Power Module (IGBT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Gate Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Current Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Converter Power Module - (SCR) AC Input Only . . . . . . . . . . . . . . . . . . 65
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Converter Snubber Resistors - AC Input Only . . . . . . . . . . . . . . . . . . . . . . 67
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Converter Snubber Board - AC Input Only. . . . . . . . . . . . . . . . . . . . . . . . . 68
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fan Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Heatsink Fan - Removal from Back of Drive . . . . . . . . . . . . . . . . . . . . . . . . 70
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Heatsink Fan - Removal from Front of Drive . . . . . . . . . . . . . . . . . . . . . . . 72
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Thermal Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
DC Link Choke - AC Input Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
MOV Surge Suppressor - AC Input Only. . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

6 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Table of Contents

Precharge SCR Module and Diode - DC Input Only . . . . . . . . . . . . . . . . 81

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

Appendix A
History of Changes 20B-IN024C-EN-P, June 2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 7

Table of Contents

8 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Preface

Introduction This publication provides guidelines for replacing the major components in the
PowerFlex® 700 Frame 8 drive.

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 AC input
1336-PB-SP22C DC input
Power Interface Board SK-G9-GDB1-D365 365A drives
SK-G9-GDB1-D415 415A drives
SK-G9-GDB1-D481 481A drives
SK-G9-GDB1-D535 535A drives
SK-G9-GDB1-D600 600A drives
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
Heatsink Fan SK-G1-FAN1-F810 Includes fan and fan enclosure.
Capacitor Fan SK-G1-FAN2-F8910
Power Module Sub-assemblies
Inverter Power Module (IGBT) SK-G1-QOUT1-F8 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-F89 AC input.
Kit includes three SCR modules.
SCR Snubber Kit SK-G1-SCRSNUBRB AC input drive requires three kits.
DC Precharge SCR Module SK-G1-SCR2-F89 DC input.
Includes:
• One SCR module
• One diode
Miscellaneous
Current Transducer SK-G1-CT1-F8 Includes one transducer.
Drive requires three kits.

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 9

Preface

Description Kit Catalog No. Notes

Thermal Sensor Kit SK-G1-THM1-F89 AC input.
Includes:
• Main control panel thermal sensor
• Heatsink thermal sensor
SK-G1-THM2-F89 DC input.
Includes:
• Main control panel thermal sensor
• Heatsink thermal sensor
Miscellaneous (continued)
Bus Capacitor Kit SK-G1-BUSCAP1-F8 365A, 415A and 481A only.
Includes one capacitor.
Drive requires 18 kits.
SK-G1-BUSCAP2-F8 535A and 600A only.
Includes one capacitor.
Drive requires 18 kits.
Capacitor Bus Finger Kit SK-G1-FLXBUS1 Included with the kit for inverter
power module (IGBT).
Can be ordered separately.
Includes:
• Three positive flexible capacitor
busbars
• Three negative flexible capacitor
busbars
MOV Surge Suppressor SK-G1-MOV1-F89 AC input.
Power Supply, 24V SK-G9-PWRS24
DC Link Choke SK-G1-DCCHOKE1-F8 AC input.
Transformer, 500 VA SK-G9-XFMR1-F89 AC input.
Includes
• One transformer
• Three fuses
Transformer Fuses SK-G9-FUSE1-F8 AC input.
Includes three fuses.
Balancing Resistor Kit SK-G1-RB1-F8 (Replaces AC Input (includes DC+ bus bar and
1336-RLOAD-SP3A) (1) resistor assembly).
SK-G1-CBRB1-F8 DC Input (includes DC+ bus bar and
(Replaces 1336-RLOAD- resistor assembly).
SP3A) (1)
(1) This kits was issued to correct a potential anomaly for frame 8 PowerFlex 700 AC drives. See Product Safety
Advisory #2014-06-002 for more information.

Refer to the master parts list for the most recent information:
http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf

IMPORTANT Refer to the instruction sheet included with each component kit for
instructions regarding discarding or returning replaced components.
If discarding, be sure to discard according to local, state, and federal
regulations.

10 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Preface

Recommended Tools The following list includes the most common tools used to disassemble and
assemble the drive and components. This list may not include all the tools for
your situation. Not all tools are needed for some components. Refer to the
specific sections for details.

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 installing SCR modules)
Pencil

Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
PowerFlex 700 Adjustable Frequency AC Drive Frames Provides basic information needed to mount, wire, and
7…10 Installation Instructions, publication 20B-IN014 start-up a PowerFlex 700 drive.
PowerFlex 700 AC Drives User Manual, publication Provides basic information needed to install, start-up
20B-UM002 and troubleshoot the PowerFlex 700 drive.
Industrial Automation Wiring and Grounding Guidelines, Provides general guidelines for installing a Rockwell
publication 1770-4.1 Automation industrial system.
Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and
other certification details.

You can view or download publications at

http:/www.rockwellautomation.com/literature/. To order paper copies of
technical documentation, contact your local Allen-Bradley® distributor or
Rockwell Automation sales representative.

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 11

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.
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 & 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 both the
module and its mating connector. Worn contacts may create electrical
resistance.

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.

12 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Preface

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, refer to Guarding Against Electrostatic
Damage, Allen-Bradley 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.

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 figures in Chapter 1.
• 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.

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 13

Preface

Notes:

14 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Chapter 1
Component Diagrams and Torque
Specifications

Drive Components Figure 1 - Frame 8 AC Drive Components

Gate Interface Board (3)

Drive Shown With

Stacking Panel Removed
Current Transducer (3)

Transitional Busbar

Flexible Capacitor
Busbars (18) Output Busbar (3)

AC Output Busbar (3)

DC Bus Capacitor (18) IGBT Interface Board and IGBT (3)

Balancing Resistor (Old

Resistor Style Shown) Tie Down Capacitor Mount

Snubber Capacitors for IGBTs (9) Converter Snubber Resistors (3)

SCR Converter
Power Module

Converter Snubber Board (3)

Capacitor Bank Fan

Converter Busbar (2)

MOV Surge Suppressor

Fan Transformer Busbar Mounting Plate

(Heatsink Fan is behind this plate)

Motor Busbars (U, V, W)

DC+ Busbar

PE Ground (and MOV Wire) DC- Busbar

AC Busbars (R, S, T)

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 15

Chapter 1 Component Diagrams and Torque Specifications

Figure 2 - Frame 8 DC Drive Components

Gate Interface Board (3)

Drive Shown With Stacking

Panel Removed
Current Transducer (3)

Transitional Busbar

Flexible Capacitor
Busbars (18) Output Busbar (3)

AC Output Busbar (3)

DC Bus Capacitor (18)
IGBT Interface Board and
IGBT (3 each)

Tie Down Capacitor Mount

Snubber Capacitors for IGBTs (9)

Balancing Resistor (Old

Resistor Style Shown)

Precharge Busbar (top)

Precharge SCR Module Diode

Precharge Busbar (bottom)

Capacitor Bank Fan

Precharge Resistors (2)

Busbar Mounting Plate

(Heatsink Fan is behind this plate)

Precharge Fuse

Motor Busbars (U, V, W)

16 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Component Diagrams and Torque Specifications Chapter 1

Figure 3 - Frame 8 Busbars (AC Drive shown)

DC+ Busbar DC- Busbar

Transitional
Busbar Assembly

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Chapter 1 Component Diagrams and Torque Specifications

Figure 4 - Frame 8 (AC input drive shown)

DC Capacitor Bank Gate Interface Heatsink Thermal Sensor Connector
(Under Transitional Busbar) Board (J8 on each Gate Interface Board)
DC Link Choke
Output Connection
(Top)

Transitional Busbar

Current Transducer (3)

Inverter Snubber Capacitors
(3 per IGBT)
W
Inverter Power Module IGBT (W)
under Capacitors (V and U below W)
V Motor Busbars
IGBT Gate Harness and
CT Harness
U
Balancing Resistor (Old
Resistor Style Shown)
Power Interface Board
(under Main Control Panel)

Main Control Panel Thermal

Ribbon Cable - Main Control
Sensor and Wire
Board to Power Interface Board
(shown disconnected)
Main Control Board
(under HIM Cradle)
Ribbon Cable - Main Control
Board to Comm Board HIM (Blank shown on this Drive)
Fan Terminal Block – TB9
HIM Cradle
Precharge Board

Stacking Panel Main Control Panel

TB11
DC Bus Filter Board

Fan Transformer DC Link Choke Input

Connection (Top)

DC Link Choke DC Link Choke Input

Output Connection Connection (Bottom)
(Bottom)

DC Link Choke

18 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Component Diagrams and Torque Specifications Chapter 1

Circuit Boards Figure 5 - Circuit Boards on Frame 8

 

 

 


No. Description

1 DC bus filter board

 2 Precharge board
3 HIM cradle/board
T-Comm Interface 4 Main control board
5 Power interface board
6 Switch mode power supply board
Communications Panel 7 Communication board slots (optional)
8 Encoder board (optional)


Main Control Panel

Stacking Panel

 




Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 19

Chapter 1 Component Diagrams and Torque Specifications

Fastener Torque Torque Sequence

Specifications
ATTENTION: When mounting components to a drive’s heatsink,
component fastener torque sequences and tolerances are crucial
to component-to-heatsink heat dissipation.
Components can be damaged if initial tightening procedure is not
performed to specification.

The following illustrates initial and final tightening sequences for components
fastened to a heatsink 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 6 - Various-point Mounting

Two-Point Mounting Four-Point Mounting

Start End
1 2 2 1
Start End End Start 1 2 4 3
Initial Final
Torque Sequence Torque Sequence 3 4 2 1
End Start
Initial Final
Torque Sequence Torque Sequence

Six-Point Mounting
End End

6 2 4 6 2 4

3 1 5 3 1 5
Start Start
Initial Torque Sequence Final Torque Sequence

Note: Do not exceed 0.7 N•m (6 lb•in) on initial torque.

20 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Component Diagrams and Torque Specifications Chapter 1

Torque Specifications

The following table lists fastener locations by component, how the fasteners are
used, and torque specifications. Refer to Torque Sequence in this chapter for
fastening two-point, four-point, and six-point components to the heatsink.

Torque
Component Fastener Application N•m lb•in
20-Comm-x board fasten to HIM cradle/board 2.9 26
AC busbars (R, S, and T) fasten to converter SCR module 9 80
AC output busbar fasten to standoffs on heatsink 5.6 50
fasten to IGBT 5.6 50
Balancing resistor fasten to the transitional busbar 2.9 26
Balancing resistor wires black: negative (–) busbar 2.9 26
yellow: bus capacitor busbar 2.9 26
blue: converter (+) busbar 2.9 26
Busbars (DC+ and DC-) fasten upper busbar mounts to the converter busbars 23.5 208
Busbar mounting plate fasten the busbars to the bottom of the chassis 6 50
Busbar mounting plate bracket (left) fasten to the left side of the converter busbar 6 50
Bus capacitor busbar fasten to the capacitor setscrews (short) 5.6 50
Cables fasten +DC IN and +DC OUT cables to the transitional busbar 23.5 208
Capacitor bank fan fasten to chassis below the capacitor bank 1.8 16
Capacitor setscrews short setscrew fastens capacitor to the bus capacitor busbar 0.7 6
long setscrew fastens capacitor to the transitional busbar 0.7 6
Communications panel fasten to the main control panel
top of the communications panel 5.6 50
bottom of the communications panel 2.9 26
Converter busbars fasten to converter SCR modules 9 80
Converter power modules (SCR) – AC input only fasten to heatsink:
first sequence 0.7 6
final sequence 5.6 50
Converter SCR modules wiring fasten to the busbar connection at the SCR module 2.9 26
Converter snubber board – AC input only fasten to the standoffs on the converter busbars 2.9 26
Converter snubber resistors – AC input only fasten to the frame around the heatsink 2.9 26
Current transducer brackets fasten the mounting brackets to the current transducer 1.6 14
Current transducer assembly fasten to the backplane 2.9 26
DC bus filter board fasten to glastic standoffs on stacking panel 1.7 15
DC link choke – AC input only fasten mounting brackets to the bottom of the chassis 9 80
fasten cables to the choke connectors 9 80
Encoder board (optional) fasten to standoffs on main control board 2 14
Heatsink fan cover fasten to the back of the drive 2.9 26
Heatsink fan mounting plate fasten the heatsink fan to the fan mounting plate 2.9 26
Fan transformer fasten to the mounting plate below the capacitor bank fan 5.6 50

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Chapter 1 Component Diagrams and Torque Specifications

Torque
Component Fastener Application N•m lb•in
Flexible capacitor busbars fasten to the transitional busbar 5.6 50
fasten to the IGBT module 5.6 50
Gate interface board fasten to upright bracket on heatsink 1.8 16
Ground wire (green and yellow) from TB11 to the HIM cradle/board 1.6 14
HIM cradle/board fasten to the main control panel 2.9 26
IGBT module fasten to the heatsink:
first sequence 0.7 6.0
second sequence 2.3 20
final sequence 5.6 50
Main control board fasten to the main control panel 2 14
Main control panel fasten to the stacking panel:
top of the main control panel 5.6 50
bottom of the main control panel 2.9 26
MOV surge suppressor – AC input only fasten to the chassis 2.9 26
MOV surge suppressor – AC input only (wiring) fasten black wires to R, S, and T busbar connection at the SCR modules 2.9 26
fasten green and yellow ground wire to ground stud at the bottom of the 9.0 80
chassis
Output busbar fasten to the AC output busbar 9.0 80
fasten to the U, V, or W busbar 9.0 80
setscrew and nut to the U, V, or W busbar 5.6 50
Power interface board fasten to stacking panel 1.7 15
Precharge board fasten to stacking panel
for AC input 1.7 15
for DC input (1/4 turn clockwise) – –
Precharge SCR module and diode – DC input only fasten to the heatsink:
first sequence 0.7 6.0
final sequence 5.6 50
Precharge busbars – DC input only fasten to the SCR module and diode 5.6 50
Precharge wires – DC input only fasten to the precharge busbars 2.9 26
Precharge power cables – DC input only fasten to the precharge busbars 12.2 108
Snubber resistors fasten to the IGBT setscrews at the tie down capacitor mount 5.6 50
Stacking panel fasten to the chassis 5.6 50
Switch mode power supply board fasten to stacking panel 1.7 15
Thermal sensors fasten to heatsink hand tighten
fasten to main control panel hand tighten
Tie down capacitor mount fasten to the bracket at left of IGBT board 5.6 26
Transitional busbar mounting brackets to the glastic spacers 5.6 50
mounting brackets to the drive 2.9 26
fasten to the bus capacitor setscrews 5.6 50

22 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Chapter 2

Basic Component Removal Procedures

Overview Component removal and replacement in this chapter are located on the stacking
panel and transitional busbar assemblies highlighted below.

See Circuit Boards on page 19 to identify the various panels that comprise the
stacking panel assembly.

Transitional Busbar Assembly

Stacking Panel Assembly

Main Control Panel Assembly

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Chapter 2 Basic Component Removal Procedures

Main Control Panel See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the ribbon cable going from the main control board ( J2) to the
power interface board ( J1).

Ribbon
Cable

3. Disconnect the incoming ground wire to TB11.

4. Remove the two screws on the main control panel below TB11.
5. Remove the two mounting nuts at the top of the main control panel.

Mounting Nuts (2) at top

of Main Control Panel

GroundWire
Ground Wire
Main Control Panel
MCPMounting Screws
Mounting (2) (2)
Screws below TB11
below TB11 totoTB11
TB11

6. Disconnect the wire harnesses from TB11 to the switch mode power
supply board ( J4 connector) and at TB1 and TB2 on the power interface
board.
7. Label and remove all customer wiring from TB11.
8. Remove the main control panel and carefully set aside.

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 Basic Component Removal Procedures Chapter 2

Install Components

1. Replace any customer wiring to TB11.

2. Connect the wire harnesses from TB11 to the switch mode power supply
board ( J4 connector) and at TB1 and TB2 on the power interface board.
3. Torque the two mounting nuts at the top of the main control panel to
5.6 N•m (50 lb•in).
4. Torque the two screws on the main control panel below TB11 to 2.9 N•m
(26 lb•in).
5. Connect the incoming ground wire to TB11.
6. Connect the ribbon cable going from the main control board ( J2) to the
power interface board ( J1).
7. Replace all safety shields and enclosure covers before applying power to the
drive.

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Chapter 2 Basic Component Removal Procedures

Stacking Panel See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Label and disconnect wiring as listed below.
Shown without main control panel.
NOTE: Mounting position of boards on stacking panel may vary.

J8 J6
J2
Power
J3 Interface J18
Board
J16…J14
J23
Precharge Board

TB1 DC Bus
Filter
Board
TB2

TIP Remove the main control panel first to provide better access to wiring
and fasteners. See Main Control Panel on page 24.

Connected Label on Wire Label on Notes

Component or Connector Board
Precharge board J2, J3 J2, J3
DC bus filter board TB1 TB1
Power interface board J8 J8
J16 U U phase CT
J15 V V phase CT
J14 W W phase CT
J23 UP, VP, WP U, V, W positive gates
J18 UN, VN, WN U, V, W negative gates
J6 J6
TB11 Customer wiring Remove if not already done

3. Disconnect the main control panel thermal sensor and wire located above
the main control board, from the wiring harness (see Figure 4 on page 18).

26 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Basic Component Removal Procedures Chapter 2

4. Remove the six nuts for mounting the stacking panel.

Shown without main control panel.
NOTE: Mounting position of boards on stacking panel may vary.

Mounting
Nuts (6)

5. Remove the stacking panel; carefully set aside.

Install Components

1. Torque the six mounting nuts to 5.6 N•m (50 lb•in).

2. Connect the main control panel thermal sensor and wire located above the
main control board.
3. Connect all wiring that was removed.
4. Replace all safety shields and enclosure covers before applying power to the
drive.

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Chapter 2 Basic Component Removal Procedures

Transitional Busbar See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.
Assembly

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the stacking panel as detailed on page 26.

DC Choke Output Cables

Transitional Busbar

Balancing Resistor
(Old Style Resistor Shown)

3. If present, remove all customer wiring to transitional busbar.

4. For AC input drives, remove the DC choke output cables.
For DC input drives, there is no choke.
5. If present, disconnect the +DC IN and +DC OUT cables from the
transitional busbar.

28 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Basic Component Removal Procedures Chapter 2

6. Remove all IGBT Snubber components:

a. Remove the six nuts that secure each set of snubber capacitors. Remove
the capacitors, and save nuts and capacitors.

Tie Down
Capacitor
Mount
Screw

Snubber Snubber
Capacitor Capacitors
Mount Nuts

Tie Down
Capacitor
Mount
Screw

b. Remove the two screws that secure each tie down capacitor mount.
Remove the tie down capacitor mounts and save screws and capacitor
mounts.
c. Remove the six setscrews from each IGBT and save.

Setscrews
Nuts for
DC– Flexible
Capacitor
Busbars

If replacing an IGBT module, remove the nuts and DC– flexible capacitor
busbars, and save nuts and busbars.

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 29

Chapter 2 Basic Component Removal Procedures

7. Cut tie wraps for the balancing resistor wiring.

8. Disconnect the yellow wire for the balancing resistor.
You do not need to disconnect the blue and black wires.

Balancing Resistor
(Old Style Resistor Shown)

Resistor wiring tie wraps

Balancing Resistor yellow wire

Disconnect here

9. Remove the four side standoffs and brackets for the transitional busbar
assembly.
10. Remove the 18 nuts fastening the transitional busbar assembly to the bus
capacitors.
The setscrews may come out with the nuts. Save all nuts and setcrews.

DC Choke Output Cables

Transitional Busbar Nuts (18)

attached to Setscrews

Photo shows setscrews in

Transitional Busbar Capacitors; these setscrews may come
out with the Transitional Busbar nuts
when they are removed.

Side Standoffs and Brackets (4)

Balancing Resistor
(Old Style Resistor Shown)

30 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Basic Component Removal Procedures Chapter 2

11. Remove the transitional busbar assembly.

Negative (DC-) Flexible Capacitor

Busbar (attached to top side of
Transitional Busbar)

Positive (DC+) Flexible Capacitor

Busbar (attached to bottom side
of Transitional Busbar)

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Chapter 2 Basic Component Removal Procedures

Install Components

See the photographs in the preceding Transitional Busbar Assembly section to

identify any components discussed in this section.

Positive (DC+)
Flexible Capacitor
Busbar (short)

Negative (DC-)
Flexible Capacitor
Busbar (tall)

IMPORTANT Each IGBT replacement kit includes three positive (DC+) and three
negative (DC-) flexible capacitor busbars. The positive ones are
shorter (see above) because they attach to the back side of the
transitional busbar. For ease of installation, replace positive flexible
capacitor busbars while the transitional busbar is removed.

1. Replace the three positive (DC+) flexible capacitor busbars supplied in an

IGBT replacement kit on the back side of the transitional busbar for each
IGBT module being replaced.
2. Mount transitional busbar to bus capacitors. If needed, use a rubber mallet
to gently tap the transitional busbar onto the longer setscrews of the bus
capacitors.
3. Add a washer (rounded side down) and nut to each bus capacitor setscrew.
Finger tighten only.
4. Install the nine negative flexible capacitor busbars to the transitional
busbar with two washers (rounded side down) and two nuts for each
flexible capacitor busbar. Finger tighten only.
5. Install the six setscrews to secure the flexible capacitor busbars to each
IGBT board. Finger tighten only.

32 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Basic Component Removal Procedures Chapter 2

6. Reinstall the screws for the four side standoffs and brackets to secure the
transitional busbar assembly to the chassis.
a. Torque the screws to 5.6 N•m (50 lb•in) to secure the brackets to the
four red glastic spacers.
b. Torque screws to 2.9 N•m (26 lb•in) to secure the two brackets to the
drive chassis.
7. Torque the six setscrews for each IGBT board to 5.6 N•m (50 lb•in).

IMPORTANT When torquing down each setscrew, place a flathead screwdriver

against the side of the flexible capacitor busbar to minimize twisting.
Do not rest the screwdriver against any IGBT board while performing
this task to avoid cracking or breaking the board.

8. Reinstall the tie down capacitor mount on each IGBT board.

Reinstall two screws simultaneously to secure each Mount. Torque screws
to 2.9 N•m (26 lb•in).
9. Install three snubber resistors onto the six setscrews for each IGBT board.
Reinstall two screws to secure each snubber resistor against the tie down
capacitor mount. Torque screws to 5.6 N•m (50 lb•in).
10. Torque the nuts that secure the nine negative flexible capacitor busbars to
the transitional busbar to 5.6 N•m (50 lb•in).
11. Torque the nuts that secure the transitional bus bar to the bus capacitor
setscrews to 5.6 N•m (50 lb•in).
12. Connect the yellow wire for the balancing resistor.
13. Install a new tie wrap for the balancing resistor wiring.
14. If present, connect the +DC IN and +DC OUT cables from the
transitional busbar. Torque to 23.5 N•m (208 lb•in).
15. For AC input drives, reinstall the DC choke output cables. Torque to
9 N•m (80 lb•in).
16. Reinstall any customer wiring to the transitional busbar.
17. Reinstall the stacking panel as instructed on page 27.
18. Verify all wiring to the two panels and the transitional busbar has been
reconnected.
19. Replace all safety shields and enclosure covers before applying power to the
drive.

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 33

Chapter 2 Basic Component Removal Procedures

Notes:

34 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Chapter 3

Component Replacement Procedures

Overview Component procedures detailed in this chapter apply to PowerFlex 700 Frame 8
drives for AC or DC input. Removal and replacement instructions for the
stacking panel and transitional busbar assemblies are detailed in Chapter 2.

Main Control Board See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove safety shields as needed.

Nuts (2)

Communications Panel
(Located over
main control panel)

Release Cable from Clamp

Screw for green/yellow

Ground Wire

Screws and
Washers (2 each)

3. Unscrew the green/yellow ground wire from the communications panel.

4. Remove the two nuts and two screws and washers for the communications
panel.

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Chapter 3 Component Replacement Procedures

5. Disconnect both ribbon cables from the left side of the main control board.

Main Control
Board Screws (4)
Ribbon Cable
(1 of 2)

Main Control Board

TB11 Cable
Connector Encoder Board
(Optional)

Encoder Board Screws (2);

Hex standoffs (2) are
between both boards

6. Hold the communications panel and release the cable at the bottom of the
panel from its clamp (see previous page for its location) and set the
communications panel aside.
7. If needed, unscrew and disconnect the connector from the main control
board for the wire set going to TB11.
Do not disconnect any wires from TB11.
8. If present, unscrew the two screws for the encoder board. Gently pull off
the encoder board.
9. Unscrew the four screws and two hex standoffs holding the main control
board.
10. Remove the main control board.

Install Components

1. Install the new main control board with four screws and two hex standoffs.
Torque the screws and standoffs to 2 N•m (14 lb•in).
2. Install the encoder board (if the optional encoder board was installed)
with two screws. Be sure to match up the J7 connectors. Torque the screws
to 2 N•m (14 lb•in).
3. Connect the ribbon cable and TB11 cable connector to the main control
board.
4. Torque the two mounting nuts at the top of the communications panel to
5.6 N•m (50 lb•in).
5. Torque the two screws on the communications panel near TB11 to 3 N•m
(26 lb•in).
6. Torque the screw for the green/yellow ground wire from TB11 to the
HIM cradle/board to 1.6 N•m (14 lb•in).
7. Replace all safety shields and enclosure covers before applying power to the
drive.

36 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Component Replacement Procedures Chapter 3

T-Comm Board See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the main control board:
a. Remove the HIM board from its slot (if used).
b. Disconnect the ribbon cable from the main control board (connects to
J1on power interface board).
c. Disconnect the wiring connector from the main control 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 HIM cradle/board.
f. Remove the HIM cradle/board.

HIM Board slot

Ribbon Cable Connector

Mounting Screw
Ribbon Cable Connection to T-Comm Board

Wiring Connector

Grounding-Wire Screw Optional 20-Comm-x Board Detail

Mounting Screws (4)

Mounting Screw

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Chapter 3 Component Replacement Procedures

3. Remove the 20-Comm-x board (if used):

a. Disconnect the ribbon cable between the 20-Comm-x Board and
T-Comm board; disconnect only from the T-Comm board.
b. Remove and save the four mounting screws.
4. If the 20-Comm-x board is not used, remove the screw securing the
T-Comm grounding tab.

T-Comm grounding tab screw T-Comm grounding tab flat T-Comm grounding tab upright

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.
6. If needed, use the same flathead screwdriver tip to pry the seven locking
tabs away from the T-Comm board.

T-Comm Board Locking Tab Locations

Five locking tabs are on the back side of the main control board (above); two are on the front side in the area between
the optional HIM and 20-Comm-x board slots (upper right).
NOTE: Use a flathead screwdriver tip to pry the locking tabs away from the T-Comm Board (lower right).

7. Remove the T-Comm board from the main control board.

38 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Component Replacement Procedures Chapter 3

Install Components

1. Install the new T-Comm board.

2. Verify the board is locked into all seven locking tabs.

3. Carefully bend the T-Comm grounding tab until it is flush with the screw
mount on the main control board.
4. Install the 20-Comm-x board (if used). Torque the four mounting screws
to 2.9 N•m (26 lb•in).
5. Install the HIM cradle/board. Torque the two mounting screws to 3 N•m
(26 lb•in).
6. Install the screw for the green/yellow ground wire from TB11 to the HIM
cradle/board. Torque the screw to 1.6 N•m (14 lb•in).
7. Connect the 8-pin wiring connector to the serial port.
8. Connect the ribbon cable.
9. Replace all safety shields and enclosure covers before applying power to the
drive.

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 39

Chapter 3 Component Replacement Procedures

Power Interface Board See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the main control panel as detailed on page 24.
3. Remove remaining wiring harnesses from the power interface board,
including the wiring between the power interface board and the switch
mode power supply board.
DC input shown J2

TB1
J1
J6
J10 TB2

Spacers (9)
J8

J9 J18
J16
J15
J14
J24 J23

J13 J12

Refer to the illustration above for connector locations.

Connector Wire Color(s) Connects To:

J1 ribbon J2 on main control board (ribbon cable)
J2 black J1 on switch mode power supply board
J6 black Monitor wire to thermal sensors
J8 red/white/black J7-U on U phase gate interface board
J9 red/white/black J1 on 24V power supply board
J10 red/black/white/blue J3 on precharge board
J12 red/white J3 on switch mode power supply board
J13 black J2 on switch mode power supply board
J14 red/white/black U phase current transducer
J15 red/white/black V phase current transducer
J16 red/white/black W phase current transducer
J18 blue/white U, V, W negative (–) gates (lower phase)
J23 orange/black U, V, W positive (+) gates (upper phase)

40 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Component Replacement Procedures Chapter 3

Connector Wire Color(s) Connects To:

J24 red/black J1 on precharge board,
TB1 on DC bus filter board (AC input only)
TB1 on DC bus filter board (DC input only)
TB1 green/yellow PE on TB11
TB2 red #33, #34, and #35 on TB11

4. Remove the two power interface board

mounting torx screws located at the upper
right and lower left corners of the board as
shown at right.
5. Use your fingers or needle-nose pliers to
squeeze the tabs of each of the nine spacers (see
previous page for their locations), and separate
the power interface board from the mounting
plate.
6. Remove the power interface board.

Install Components

1. Install the new power interface board. Torque the two mounting screws to
1.7 N•m (15 lb•in).
2. Connect all wiring. For the ribbon cable going from the power interface
board ( J1) to the main control board ( J2), connect the cable at J1 on the
power interface board.
3. Reinstall the main control panel. See page 24.
4. Replace all safety shields and enclosure covers before applying power to the
drive.

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 41

Chapter 3 Component Replacement Procedures

Switch Mode Power See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.
Supply Board

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the main control panel as detailed on page 24.
3. Disconnect all cables ( J2, J4, J3, J1) from the switch mode power supply
board.
4. Remove the switch mode Spacers
power supply board
mounting torx screw
located at the lower right
corner of the board.
5. Use your fingers or needle-
nose pliers to squeeze the
tabs of each of the three
spacers and separate the
switch mode power supply
board from the mounting
plate.
6. Remove the switch mode
Screw
power supply board.

Install Components

1. Install the new switch mode power supply board. Torque the mounting
screw to 1.7 N•m (15 lb•in).
2. Connect J2, J4, J3, and J1 cables.
3. Reinstall the main control panel. See page 24.
4. Replace all safety shields and enclosure covers before applying power to the
drive.

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 Component Replacement Procedures Chapter 3

Precharge Board See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.

Remove Components
1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the safety cover over the precharge board.
3. For DC input only: Verify that customer wiring to TB2 is properly labeled
and then disconnect wiring from TB2.
4. Using pliers if needed, remove the three wiring/harnesses ( J1, J2, J3).
Note: Some connectors may not be labeled. Label them if needed.
AC DC
Input Input
Screw
Lock Screws (6)
Spacers

5. For AC input: Remove the precharge board mounting torx screw located
at the upper left corner of the precharge board.
6. For AC input: Use your fingers or needle-nose pliers to squeeze the tabs of
each of the three spacers and separate the precharge board from the
mounting plate.
7. For DC input: Turn each of the six lock screws 1/4 turn counterclockwise
to unlock.
8. Remove the precharge board.

Install Components
1. Install the new precharge board.
• For AC input: Torque the mounting screw to 1.7 N•m (15 lb•in).
• For DC input: Turn each of the six lock screws 1/4 turn clockwise to
lock.
2. Connect the wiring.
3. Replace all safety shields and enclosure covers before applying power to the
drive.

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Chapter 3 Component Replacement Procedures

DC Bus Filter Board See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the safety cover over the DC bus filter board.
3. Disconnect red and black Mounting Bolts (4)
wires from TB1 and TB2
terminals.
4. Remove the four mounting
bolts.
5. Remove the DC bus filter
board.

Install Components

1. Install the new DC bus filter

board. Torque the four
TB2 TB1
mounting bolts to 1.7 N•m
(15 lb•in).
2. Connect the red and black
wires to TB1 and TB2
TB2-3 TB2-1 TB1-3 TB1-1
terminals as shown at right. (red) (black) (red) (black)
3. Replace all safety shields and
enclosure covers before applying power to the drive.

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 Component Replacement Procedures Chapter 3

Bus Capacitor See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the transitional busbar assembly as detailed on page 28.
Transitional Busbar
Assembly Removed

Bus Capacitor Busbar

Bus Capacitor Busbar

Nuts and Washers (18 each)

3. Label and remove all wires and connectors from the bus capacitor busbar.
4. Remove nuts and washers (18 each) fastening the bus capacitor busbar to
the capacitors.
5. Remove the bus capacitor busbar.
6. Remove the capacitors.

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Chapter 3 Component Replacement Procedures

Install Components

ATTENTION: Install each capacitor so its vent plug is at the

top or 12 o’clock. Component and system damage may result if
you position any bus capacitor incorrectly.

1. Use a 3 mm angle hex wrench to replace the setscrews for each new
capacitor. Torque to 0.7 N•m (6 lb•in).

IMPORTANT Each capacitor needs a short and long setscrew. See the illustration
below for where to install each setscrew.

Vent Plug (must be at Capacitors shown

top or 12 o’clock) with Bus Capacitor
Busbar installed
Longer Setscrew
for Transitional
Busbar

Shorter Setscrew
for Bus Capacitor
Busbar

2. Place capacitors into correct position in drive (vent plug at top or 12

o’clock).
3. Place bus capacitor busbar onto capacitors.
4. Install the 18 washers and nuts onto setscrews, but do not tighten yet.
5. Place the transitional busbar in position. Make sure that all setscrews,
washers, and nuts fit. Adjust as needed.
6. Remove the transitional busbar, and tighten all washers and nuts for the
bus capacitor busbar. Torque to 5.6 N•m (50 lb•in).
7. Install the transitional busbar assembly as detailed on page 28.
8. Replace all safety shields and enclosure covers before applying power to the
drive.

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 Component Replacement Procedures Chapter 3

Capacitor Bank Fan See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the stacking panel as detailed on page Four Mounting Screw
26.
3. Label and disconnect all wires for the fan.
4. Remove the four mounting screws.
5. Remove the fan assembly.

Install Components

1. Install the new fan assembly. Torque the four mounting screws to 1.8 N•m
(16 lb•in).
2. Connect the wires.
3. Install the stacking panel as detailed on page 26.
4. Replace all safety shields and enclosure covers before applying power to the
drive.

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Chapter 3 Component Replacement Procedures

Balancing Resistor and See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.
DC+ Bus Bar
Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the stacking panel as detailed on page 26.
3. Verify the rating of the resistors to be sure there was no damaged during
shipment (R1 to R2 = R2 to R3 = 6.8 kΩ ±5%).

IMPORTANT Do not install the resistor if the measurement is not within the recommended
range.

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 Component Replacement Procedures Chapter 3

4. Because the existing resistor wires will be reused, cut the wires off of the
resistor at the solder joint, to keep the wires as long as possible.

5. Strip the tip of each wire to approximately 6 mm (0.24 in.).

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Chapter 3 Component Replacement Procedures

6. Cut and remove the tie wraps that secure the resistor wire bundle.

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 Component Replacement Procedures Chapter 3

7. Remove the bolts between the right-angled bus bar and the large bus bar.

IMPORTANT Do not remove the bolts that attach the cables to the right-angled
bus bar.

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Chapter 3 Component Replacement Procedures

8. Remove the two bolts from the bottom of the bus bar (as shown in the
following image).

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 Component Replacement Procedures Chapter 3

9. While holding the bus bar, remove the nuts that secure the bus bar to the
chassis and remove the bus bar.

IMPORTANT The set screws can come out when a nut is removed.

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Chapter 3 Component Replacement Procedures

Install Components

1. Install the set screws and nuts removed in step 9 on page 53. Tighten the
nuts to 5.65 N•m (50 lb•in).
Frame 8 Drive Shown

2. Install the bolts removed in step 8 on page 52. Tighten the bolts to 23.5
N•m (208 lb•in).
3. Install the bolts removed in step 7 on page 51. Tighten the bolts to 23.5
N•m (208 lb•in).

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 Component Replacement Procedures Chapter 3

4. Verify that the yellow resistor wire is long enough to connect to the left
terminal (R2) on the top of the resistor assembly. To do so, route the wire
through the bottom and out of the top of the holes in the insulator
material on the resistor assembly (as shown in the following images).

Note: If the yellow resistor wire is not long enough to reach the top
terminal (R2) when routed through the assembly, it is acceptable to leave
the wire outside of the assembly to make the connection.

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Chapter 3 Component Replacement Procedures

5. Remove the lugs from the resistor terminals and, using an 18 AWG wire
crimper for a non-insulated connector, crimp the wires to the lugs.
6. Secure the lug with the black resistor wire to the left terminal (R1) on the
bottom of the resistor assembly.
7. Secure the lug with the blue resistor wire to the right terminal (R3) on the
bottom of the resistor assembly.
8. Secure the lug with the yellow resistor wire to the left terminal (R2) on the
top of the resistor assembly.

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 Component Replacement Procedures Chapter 3

9. Secure the resistor wire bundle below the assembly using tie-wraps (as
shown in the following image).

10. Install the stacking panel as detailed on page 26.

11. Replace all safety shields and enclosure covers before applying power to the
drive.

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Chapter 3 Component Replacement Procedures

Inverter Power Module The kit includes:

(IGBT) Qty. Component
1 IGBT module with circuit board
1 gate interface board
1 Gate interconnect harness
3 Flexible capacitor busbar, positive (+)
3 Flexible capacitor busbar, negative (-)
1 Tie down capacitor mount
3 Snubber capacitor

IMPORTANT If any IGBT module is damaged, all IGBT modules and associated
components should be replaced. Perform the following procedure for
all IGBT modules.

Refer to the figures in Chapter 1 - Component Diagrams and Torque

Specifications on page 15 for these instructions.

Remove Components
1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the stacking panel as detailed on page 26.
3. Remove the AC output busbar at the current transducer:
a. Remove and save the three bolts that secure the output busbar to the
AC output busbar and to the U, V or W busbar.
Busbar Bolts (3)

Threaded Hex Stud and Nut

b. Remove and save the nut and threaded hex stud for the standoff.
c. Slide the output busbar to the right as far as it goes.
d. Remove and save the six screws that secure the AC output busbar to the
IGBT, and two nuts that secure the AC output busbar to its standoffs.
Remove and save the AC output busbar.
4. Remove transitional busbar assembly as detailed on page 28.

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 Component Replacement Procedures Chapter 3

5. Remove the gate interface board. See page 62.

Current Transducer
Tie Down Assembly
Capacitor Mount

Output
Busbar

Snubber Gate Interface AC Output

Capacitors IGBT Board Assembly Busbar
(not shown above)

6. Carefully examine the transitional busbar and bus capacitors for damage.
When replacing any IGBT, Rockwell Automation recommends that you
replace all bus capacitors. If needed, refer to Bus Capacitor on page 45 to
replace damaged bus capacitors.

Example of IGBT
Module Failure

Bus Capacitor,
under Transitional
Busbar

Transitional Busbar

Flexible Capacitor
Busbars

7. Remove the eight screws that secure the IGBT to the chassis.
8. Remove the IGBT by tipping the right edge out first.

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Chapter 3 Component Replacement Procedures

Install Components

1. Install the IGBT module.

a. Use isopropyl alcohol to thoroughly clean the mounting surface of the
heatsink and the mounting surface of the new IGBT module.
b. Use a 3- or 4-inch paint roller or putty knife to apply a thin, even
coating of the supplied thermal grease to the mounting surface of the
IGBT module.
In the next step, take care to not disturb any of the thermal grease on the
IGBT module.
c. Place the IGBT on the chassis with the serial number label at the top.
Install with supplied screws using this torque sequence:
➎ ➑
IGBT Torque Sequence
➌ ➋
First Sequence: 0.7 N•m (6.0 lb•in)
Second Sequence: 2.3 N•m (20 lb•in)
➊ ➍ Final Sequence: 5.6 N•m (50 lb•in)

➐ ➏
2. Install the three supplied positive flexible capacitor busbars in positions 2,
4, and 6 on the IGBT.
The positive flexible capacitor busbars have a shorter angle.

Shown with Transitional Busbar and all Flexible

Capacitor Busbars installed for illustration
purposes only.

1
Negative (-) Flexible Capacitor Busbars

Positive (+) Flexible Capacitor Busbars

2

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 Component Replacement Procedures Chapter 3

3. Install the transitional busbar assembly. See page 28.

Only torque nuts and screws after all components are in place.
4. Install the three supplied negative flexible capacitor busbars in positions 1,
3, and 5 on the IGBT.
The negative flexible capacitor busbars have a higher angle.
5. Install the tie down capacitor mount:
a. Insert the short ends of the six threaded studs with nuts through the
flexible capacitor busbars and into the left side of the IGBT. Torque to
5.6 N•m (50 lb•in).

WARNING: Correct torque is critical to ensure correct operation

of the drive. Improper torquing could cause premature failure when
attempting to operate the drive.

b. Install the tie down capacitor mount with the two screws previously
removed from the top and bottom of the capacitor mount. Torque to
2.9 N•m (26 lb•in).
6. Install the AC output busbar, output busbar, and current transducer:
a. Secure the AC output busbar to the two standoffs using the two nuts
previously removed. Torque nuts to 5.6 N•m (50 lb•in).
b. Secure the AC output busbar to the IGBT by inserting six screws into
the IGBT. Torque screws to 5.6 N•m (50 lb•in).
c. If removed, insert the output busbar through the current transducer
assembly with the large end to the right.
d. Secure the current transducer assembly (transducer and brackets) using
the two screws that were removed with the assembly. Torque to 2.9
N•m (26 lb•in).
e. Secure the left end of the output busbar to the AC output busbar with
one screw. Torque to 9.0 N•m (80 lb•in).
f. Secure the other end of the output busbar to the U, V, or W busbar with
the setscrew and nut. Torque the nut to 5.6 N•m (50 lb•in).
g. Install the two screws that connect the output busbar to the U, V, or W
busbar. Torque to 9.0 N•m (80 lb•in).
7. Install the gate interface board:
a. Install the gate interface board using the four nuts removed previously.
Torque screws to 2.9 N•m (26 lb•in).
b. Install the supplied gate interconnect harness.
c. Connect wiring between the IGBT and gate interface board as shown
in Gate Interface Board on page 62.
d. Connect wires to the current transducer.
8. Install the three snubber capacitors in the reverse order of the removal
instructions detailed on page 29. Torque nuts to 5.6 N•m (50 lb•in).
9. Replace all safety shields and enclosure covers before applying power to the
drive.

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Chapter 3 Component Replacement Procedures

Gate Interface Board See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.

Remove Components
1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the safety cover over the gate interface board.
3. Label and disconnect all wires ( J1…J8).
4. Remove the four mounting nuts and remove the board.

Gate Interface Board

Mounting Nuts (4)

J5 J7

J3 J8

J2

J1

J4
J6

Install Components

1. Install the new board. Torque the four mounting nuts to 1.8 N•m
(16 lb•in).
2. Connect J1…J8 wires as shown above.
NOTE: J4 from the corresponding IGBT connects to J6 on the gate
interface board.
3. Replace all safety shields and enclosure covers before applying power to the
drive.

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 Component Replacement Procedures Chapter 3

Current Transducer See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Label and disconnect the wire from the transducer.

3. Remove the two 17 mm bolts and one 11 mm nut that connect the U, V, or
W busbar to the output busbar.

Current Transducer

Transducer Output
Brackets Busbar

4. Remove the bolt on the left end of the output busbar.

5. Use a hex wrench to remove the setscrew.

Setscrew

6. Remove the two screws that secure the transducer assembly to the
backplane (transducer and brackets).

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Chapter 3 Component Replacement Procedures

7. Remove assembly by lifting the

assembly up and turning it slightly
counterclockwise while rotating the
top of the output busbar toward you
and around the U, V, or W busbar.
8. Move the busbar and transducer to
an ESD-safe flat surface for working
with it.
9. Separate the transducer from the
brackets.

Install Components

1. Mount brackets to the transducer. Torque screws to 1.6 N•m (14 lb•in).
2. Slide output busbar through the current transducer assembly with the
angled end to the left.
3. Replace the current transducer assembly in mounting position by reversing
the process used in Step 7. of the removal process.
4. Secure the transducer assembly to the drive chassis with two screws.
Torque to 2.9 N•m (26 lb•in).
5. Replace the output busbar setscrew and nut. Torque the nut to 5.6 N•m
(50 lb•in).
6. Install the three output busbar bolts. Torque to 9.0 N•m (80 lb•in).
7. Connect the wires.
8. Replace all safety shields and enclosure covers before applying power to the
drive.

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 Component Replacement Procedures Chapter 3

Converter Power Module - IMPORTANT If any converter SCR module fails, all three SCR modules should be
(SCR) AC Input Only replaced (kit includes three SCR modules).

See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to

locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the stacking panel as detailed on page 28.
R S T Converter SCR
Modules

Converter
Snubber Boards

Converter Snubber Boards

Serial Number Label R S T
Snubber Board Standoff
(Does not need to be removed.)

Converter Busbar, Upper

Converter
Busbar, Lower
D
DC-
Converter SCR Modules

3. Remove all three converter snubber boards and set them aside.
a. Label and disconnect wires from the converter snubber board.
b. Remove the two screws that secure the board.
c. Remove the board and set aside.
4. Note the orientation of the converter busbars and remove the eight bolts
that secure the busbars to the converter SCR modules and to the DC+ and
DC- busbars. Set the converter busbars aside.

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Chapter 3 Component Replacement Procedures

5. Disconnect the three AC busbars (R, S, T) at the top only.

You do not need to remove the wires from the AC busbars.
6. Label and note the position of the converter SCR module leads. Remove
the leads.
Typically, the leads are marked as R, S, or T, and each is notched with the
notch to the front of the converter SCR module.
7. Remove the four Phillips screws that hold each converter SCR to the
heatsink and remove the converter SCR modules.

Install Components
1. Use isopropyl alcohol to thoroughly clean the mounting surface of the
heatsink and the mounting surface of each new converter SCR module.
2. Use a 3- or 4-inch paint roller or putty knife to apply a thin, even coating of
the supplied thermal grease to the mounting surface of each new converter
SCR module.

IMPORTANT In the next step, take care to not disturb any of the thermal grease on
the converter SCR module.

3. Install each new converter SCR module with supplied screws and tighten
using this torque sequence:
➊ ➌ ➍ ➋
SCR Torque SCR Torque

First Sequence: Final Sequence:

0.7 N-m (6.0 lb.-in.) 5.6 N-m (50 lb.-in.)

➍ ➋ ➊ ➌

4. Replace the SCR module leads.

Each set of leads is marked R, S, or T. The notch and red wire on each lead
are positioned to the front.
5. Install the converter busbars per diagram in step 2 and torque to 9.0 N•m
(80 lb•in).
6. Install the snubber boards, oriented with the serial number at the top, and
torque to 2.9 N•m (26 lb•in).
7. Replace the wires from the converter snubber resistors to the snubber
boards.
The black wire goes to J1. The blue wire goes to J2.
8. Reinstall AC busbars (R, S, T). Torque to 9.0 N•m (80 lb•in).

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 Component Replacement Procedures Chapter 3

9. Reinstall the DC+ and DC- busbars and torque to 9.0 N•m (80 lb•in).
10. Install stacking panel as detailed on page 26.
11. Replace all safety shields and enclosure covers before applying power to the
drive.

Converter Snubber See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.
Resistors - AC Input Only

Remove Components

Kit includes snubber board and resistor.

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the stacking panel as detailed on page 26.
Snubber Resistor for “R” SCR Snubber Resistor for “S” SCR

Snubber
Resistor for
“T” SCR

3. Verify the snubber resistor(s) with a volt ohm meter. The reading should
be 8 ohms ± 10%.
• If the reading is not within tolerance, perform the remainder of this
procedure.
• If the reading is within tolerance, do not perform the remainder of this
procedure.
4. For the R snubber resistor only: Remove the transitional busbar assembly
as detailed on page 28.
5. Label and disconnect the wires from snubber resistors that will be replaced.
6. Remove the resistor.

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Chapter 3 Component Replacement Procedures

Install Components

1. Use isopropyl alcohol to thoroughly clean the mounting surface of the

heatsink and the mounting surface of the new snubber resistor.
2. Use a 3-inch paint roller or putty knife to apply a thin even coating of the
supplied thermal grease to the mounting surface of the new snubber
resistor and install. Torque screws to 2.9 N•m (26 lb•in).
3. Connect the wires.
4. For the R snubber resistor only: Install the transitional busbar assembly
as detailed on page 28.
5. Install stacking panel as detailed on page 26.
6. Replace all safety shields and enclosure covers before applying power to the
drive.

Converter Snubber Board - See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.
AC Input Only

Remove Components
1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the stacking panel as detailed on page 26.
Snubber Board for “R” SCR Snubber Board for “S” SCR

Snubber Board
for “T” SCR

3. Label and disconnect wires from the converter snubber board to be

replaced.
4. Remove the two screws that secure the board.
5. Remove the board.

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 Component Replacement Procedures Chapter 3

Install Components

1. Install the new snubber board. Torque screws to 2.9 N•m (26 lb•in).
2. Connect the wires.
Black wire goes to J1. Blue wire goes to J2.
3. Install stacking panel as detailed on page 26.
4. Replace all safety shields and enclosure covers before applying power to the
drive.

Fan Transformer See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Label and unplug or disconnect the five wires for the fan transformer.
3. Unscrew the four fan transformer mounting bracket screws.

Fan Transformer

Label and unplug these two red wires

Label and disconnect these

three wires

Mounting bracket screws

Install Components

1. Install new fan transformer. Torque four screws to 5.6 N•m (50 lb•in).
2. Connect the wires for the fan transformer.
3. Replace all safety shields and enclosure covers before applying power to the
drive.

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Chapter 3 Component Replacement Procedures

Heatsink Fan - Removal The heatsink fan is located on the back of the drive.
from Back of Drive (For equipment clearance considerations, the fan can
also be removed from the front of the drive. See
Heatsink Fan - Removal from Front of Drive on
page 72.)

See Chapter 1 - Component Diagrams and Torque

Specifications on page 15 to locate the component
detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Verify that there is at least a 91 cm (3 ft) clearance in back of the drive for
access to the heatsink fan.
3. From the front of the drive, disconnect the cables for both the fan and the
fan capacitor.
Access the cables by gently pulling the wiring from behind the busbar
mounting panel.
Front of drive
Connectors

Press tabs in for removal

Disconnect
here

4. On the back of the drive, remove the eleven screws for the fan cover; see
the figure on the next page for the screw locations.
Do not remove the screws for the screen.
5. Use the handle to separate the fan assembly from the drive enclosure.
Some force may be needed to separate the fan from the enclosure as the
gasket may be tight or sticky.

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6. Remove the fan.

Fan Cover Screw Locations on Back of Drive

Four on top and bottom

for a total of eight

Three on right side

NOTE: No screws on left side

Install Components

1. Install the new gasket (if the old gasket was damaged).
2. Place the fan assembly into the chassis but not installed in final position.
Leave space for accessing fan cables from the front of the drive.
Take care to not pinch wires.

Fan Assembly
(Front View),
Removed from Drive

3. From the front of the drive, connect the fan cables.

TIP The connectors, one set shown below, are designed so they go
together only one way. The two end sections are flat on one side and
each section has a ridge at the matching edge.

Connectors shown
slightly separated

Flat Sections

Ridges

4. Place fan assembly in final position in the chassis.

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Chapter 3 Component Replacement Procedures

5. On the back of the drive, install the eleven screws for the heatsink fan
cover. Torque to 2.9 N•m (26 lb•in).

Heatsink Fan - Removal The heatsink fan is located on the back of the drive. These instructions explain
how to remove the fan from the front of the drive.
from Front of Drive

Heatsink Fan
behind
mounting
plate

See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to

locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Disconnect all appropriate wiring to AC and DC busbars so you can
remove entire set of busbars with the busbar mounting plate in a later step.
3. Remove the stacking panel as detailed on page 26.
4. Disconnect the DC+ and DC- busbars that connect to the converter
busbars at the top of each bar.

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 Component Replacement Procedures Chapter 3

Do not disconnect the U, V, or W busbars at the bottom.

AC Drive Shown

17 mm bolt on 17 mm bolt on
DC+ Busbar DC– Busbar

Do not
disconnect
Busbars at
the bottom.

5. Disconnect all busbars where they connect to the converter SCR modules
with 16 mm bolts. Disconnect wiring.
Do not disconnect the U, V, or W busbars at the bottom.
AC Drive Shown

16 mm bolts

Do not
disconnect
Busbars at
the bottom.

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 73

Chapter 3 Component Replacement Procedures

6. Disconnect the U, V, and W busbars at the top of each bar where they
connect to the output busbars for the current transducers with two 17 mm
bolts and one 11 mm nut.
Do not remove the busbars from the setscrew on the output busbars at this
time.
Do not disconnect the U, V, or W busbars at the bottom.

Output Busbar

17 mm bolts

11 mm nut

Current Transducer

Setscrew after 11 mm
nut is removed

7. Remove the four 10 mm nuts for the busbars mounting plate.

Busbar Mounting
Plate

10 mm nuts (4)

74 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Component Replacement Procedures Chapter 3

8. Remove the entire busbar and mounting plate assembly. Set aside.

9. Unplug the fan cables.

10. For AC drives, remove the MOV surge suppressor as detailed on page 80.
11. Remove the left busbar mounting plate bracket.
12. Remove the 12 exterior screws on the fan mounting plate.
Fan Mounting
Plate Screws (12)

Busbar Mounting
Plate Bracket,
Removed

13. Carefully remove the mounting plate and fan through the front of the
drive chassis; you may need to pry the mounting plate away from the
gasket.
The fan housing remains mounted on the chassis.

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 75

Chapter 3 Component Replacement Procedures

Install Components

1. Remove the new fan housing from the new fan and mounting plate.
Discard the new fan housing.
2. Install the new gasket (if the old gasket was damaged) and mounting plate
to the chassis. Torque the mounting screws to 2.9 N•m (26 lb•in).
3. Install the left busbar mounting plate bracket. Torque the mounting screws
to 5.6 N•m (50 lb•in).
4. For AC drives, install the MOV surge suppressor as detailed on page 80.
5. Connect the fan cables.
6. Install the busbar and mounting plate assembly:
a. Torque the four 10 mm nuts for the busbar mounting plate to 5.6 N•m
(50 lb•in).
b. Torque the 11 mm mounting nut on the setscrew for each U, V, and W
busbar at the current transducer output busbar to 5.6 N•m (50 lb•in).
c. Torque the two 17 mm mounting bolts for each U, V, and W busbar at
the current transducer output busbar to 9 N•m (80 lb•in).
d. Torque the three 16 mm mounting bolts for the busbar connection to
the converter SCR modules to 9 N•m (80 lb•in).
e. Torque the six wiring screws for the busbar connection to the converter
SCR modules to 2.9 N•m (26 lb•in).
f. Torque the 17 mm mounting bolts for the DC+ and the DC- busbars
(one each) that connect to the converter busbars to 23.5 N•m
(208 lb•in).
7. Replace all safety shields and enclosure covers before applying power to the
drive.

76 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Component Replacement Procedures Chapter 3

Thermal Sensors The thermal sensor system consists of: Thermal Sensor wiring for both drives
• A sensor secured to the upper

2 wires
J8-W
mounting bracket for the main control
panel.
• A sensor secured to the heatsink above
the SCR modules.

4 wires
J8-V
• A connector to J8 on each of the three
gate interface boards.

See Chapter 1 - Component Diagrams and

Torque Specifications on page 15 to locate the

2 wires
J8-U
component detailed in these instructions.

A
Main Control
Panel Thermal

B
Sensor

Heatsink
Thermal
Sensor

J6

Power
Interface
Board

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 77

Chapter 3 Component Replacement Procedures

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Cut the wire ties for the wiring harness along the gate interface boards.
3. Note wire routing and location of sensors.
4. For the main control panel thermal sensor, remove the screw and nut on
the main control panel and disconnect the other end from the wiring
harness.

IMPORTANT This screw and nut on the main control panel are small. Do not
drop them.

5. For the Heatsink thermal sensor, remove the screw on the Heatsink above
the SCR modules and unplug the other end from the wiring harness.

IMPORTANT This screw and nut on the heatsink are small. Do not drop them.

6. Label the wires and unplug the J8 connectors on each of the three gate
interface boards, and unplug the other end of this wiring harness at the J6
connector on the power interface board.

Install Components
1. Use isopropyl alcohol to thoroughly clean the mounting surface of the
control panel and heatsink, and the mounting surface of the thermal
sensors.
2. Apply a thin layer of supplied thermal grease to the metal side of the new
thermal sensors.
3. Install the thermal sensors with the screw and star washer. Hand tighten.
4. For the three gate interface boards, carefully route wires and connect to J8
on each gate interface board.
Be sure that the J8 connectors go to the correct IGBT.
5. Connect the other end of this wiring harness at the J6 connector on the
power interface board.
6. Secure the wire harnesses with plastic ties.
7. Replace all safety shields and enclosure covers before applying power to the
drive.

78 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Component Replacement Procedures Chapter 3

DC Link Choke - AC Input See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.
Only

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Label and disconnect DC choke connectors.
3. Remove the four screws for the DC link choke mounting brackets.
4. Remove the DC link choke.

+DC (Back/L2 Connector) +DC (Back/L1 Connector)

–DC (Front/L3 Connector) –DC (Front/L4 Connector)
DC Choke Connectors

Install Components

1. Install the new DC link choke mounting brackets to the drive. Torque the
four mounting screws to 9.0 N•m (80 lb•in).
2. Install the choke connectors. Torque the four choke connector screws to
9.0 N•m (80 lb•in).
3. Replace all safety shields and enclosure covers before applying power to the
drive.

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 79

Chapter 3 Component Replacement Procedures

MOV Surge Suppressor - See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.
AC Input Only

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the stacking panel as detailed on page 26.

MOV

3. Note wire placement and connections. Disconnect the MOV ground wire
and the R, S, and T wires to the AC busbars.
4. Remove the MOV mounting nut.
5. Remove the MOV assembly.

Install Components

1. Install the new MOV assembly. Torque the MOV mounting nut to
2.9 N•m (26 lb•in).
2. Connect all wires and connectors for the MOV.
3. Torque the R, S, and T Phase power terminal block screws to 2.9 N•m
(26 lb•in).
4. Torque the ground wire nut to 9.0 N•m (80 lb•in).
5. Install the stacking panel as detailed on page 26.
6. Replace all safety shields and enclosure covers before applying power to the
drive.

80 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Component Replacement Procedures Chapter 3

Precharge SCR Module and See Chapter 1 - Component Diagrams and Torque Specifications on page 15 to
locate the component detailed in these instructions.
Diode - DC Input Only

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial
Steps on page 13.
2. Remove the stacking panel as detailed on page 26.

Diode
SCR

Precharge Wires (two places) Precharge Power Cables

3. Label and remove all precharge power cables and precharge wires from
both precharge busbars (DC+ IN and DC+ OUT.)
4. Remove both precharge busbars and carefully set aside.
5. For the precharge SCR module, remove its connector wire.
6. Remove the SCR module and diode.

Install Components

1. Use isopropyl alcohol to thoroughly clean the mounting surface of the

heatsink and the mounting surface of the new SCR module and diode.
2. Use a 3- or 4-inch paint roller or putty knife to apply a thin, even coating of
the supplied thermal grease to the mounting surface of each SCR module
and diode.

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 81

Chapter 3 Component Replacement Procedures

WARNING: In the next step, be sure to properly install the

modules as shown. If you install the SCR incorrectly, it will not
work. If you install the diode incorrectly, then the drive and the bus
capacitors may not operate properly and may prematurely fail.

• The SCR (on the left) has a plug with prongs located at the bottom.
• The diode (on the right) has a plug without prongs located at the top.
Plug with
No Prongs

SCR Diode

Plug
with Prongs

IMPORTANT In the next step, take care to not disturb any of the thermal grease on
the SCR module.

3. Install the SCR module or diode with supplied screws and torque using the
sequences and specifications shown in the diagram below.

➊ ➌ ➍ ➋
First Torque Final Torque
Sequence: Sequence:
0.7 N•m (6.0 lb•in) 5.6 N•m (50 lb•in)

➍ ➋ ➊ ➌

4. Install the precharge busbars. Torque to 5.6 N•m (50 lb•in).

5. Install the precharge wires. Torque to 2.9 N•m (26 lb•in).
6. Install the precharge cables. Torque the screws to 12.2 N•m (108 lb•in).
7. Install the stacking panel as detailed on page 26.
8. Replace all safety shields and enclosure covers before applying power to the
drive.

82 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

 Appendix A

History of Changes

This appendix summarizes the revisions to this manual. Reference this appendix
if you need information to determine what changes have been made across
multiple revisions. This can be useful if you are deciding to upgrade your
hardware based on information added with previous revisions of this manual.

20B-IN024C-EN-P, June 2012

Topic
Added additional resources table.
Updated the torque specifications table.
Updated torques and steps for these install components procedures:
Main control panel
Stacking panel
Transitional busbar assembly
Main control board
T-comm board
Power interface board
Switch mode power supply board
Precharge board
Bus capacitor
Capacitor bank fan
Balancing resistor
Balancing resistor
Gate interface board
Current transducer
Converter power module (SCR) – AC input only
Converter snubber resistors – AC input only
Converter snubber board – AC input only
Fan transformer
Heatsink fan - removal from back of drive
Heatsink fan - removal from front of drive
Thermal sensor

Rockwell Automation Publication 20B-IN024D-EN-P - October 2015 83

Appendix A History of Changes

Topic
DC link choke – AC input only
MOV surge suppressor – AC input only
Precharge SCR module and diode – DC input only

84 Rockwell Automation Publication 20B-IN024D-EN-P - October 2015

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Publication 20B-IN024D-EN-P - October 2015

Supersedes Publication 20B-IN024C-EN-P - June 2012 Copyright © 2015 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.