Installation Instructions

3

SCR, Brake IGBT, Power Module, Thermistor, Power Supply Board, Power Interface Board, & Current Transducer Replacement - Frame 5

1 L1 L2 L3

O

I

=

WIRE RANGE: 14-1/0 AWG (2.5-35 MM2)TORQUE: 32 IN-LB (3.6 N-M)STRIP LENGTH: 0.67 IN (17 MM)USE 75 C CU WIRE ONLY

POWER TERMINAL RATINGS

WIRE RANGE: 6-1/0 AWG (16-35 MM2)TORQUE: 44 IN-LB (5 N-M)STRIP LENGTH: 0.83 IN (21 MM)

GROUND TERMINAL RATINGS (PE)

300 VDC EXT PWR SPLY TERM (PS+, PS-)

WIRE RANGE: 22-10 AWG (0.5-4 MM2)TORQUE: 5.3 IN-LB (0.6 N-M)STRIP LENGTH: 0.35 IN (9 MM)

17

21

INPUT ACOUTPUT

OptionalCommunications

Module

9

2

DC–DC+

0V

0V

A. Remove front covers.

B. Disconnect cables from cassette. Remove cassette.

C. Remove the Plastic Shield by taking out the screws.

D. Remove the screws securing the HIM Support Plate. Disconnect cables. Remove HIM Support Plate and set aside.

E. Locate component(s) to be replaced.

HIM Support Plate

Remove Screws(6 Places)

Plastic Shield

Power Interface BoardSee Steps H-M

Current TransducersSee Steps H-R

ThermistorSee Steps F-G

Power ModulesSee Steps H-M & S-Z

Power Supply BoardSee Steps H-I

SCRs & Brake IGBTSee Steps a-m on page 4

2

Thermistor Replacement

F. Remove the thermistor lead (see photo below) from the Power Interface Board. Remove the screw securing the thermistor. Discard thermistor. Thoroughly clean mounting surface. Apply a thin film of thermal grease (supplied) to the new thermistor and replace in reverse order. Torque thermistor screw to 1.7 N-m (15 lbf.-in.).

G. Re-assemble drive in reverse order. Tighten screws to 3.2 N-m (28 lbf.-in.).

Power Supply Board Removal/Replacement

H. Remove the ground lead and screw at the bottom of the cassette frame. Remove the cassette frame by taking out the remaining screw.

I. Loosen the Power Supply Board Support Plate. Leave wires connected and position board/plate off to the side.

If board replacement is required, transfer wires/cables to new board. Remove old board, install new board and tighten screw to 1.7 N-m (15 lbf.-in.).

Power Interface Board, Current Transducer and Power Module Removal/Replacement

J. Remove upper sheet metal enclosure by taking out the appropriate screws.

K. Label and remove the wires/cables from the Power Interface Board.

L. Remove the five screws that secure the board. Remove the board.

M.If further component replacement is required, proceed to step N for Current Transducer and/or step S for Power Module replacement.

If further replacement is not required, replace Power Interface Board and re-assemble drive in reverse order.

Important: When replacing the Power Interface Board, the six gate leads must also be replaced with the leads supplied. Replace the leads one-at-a-time to assure correct orientation.

Tighten board screws to 1.7 N-m (15 lbf.-in.) and sheet metal screws to 3.2 N-m (28 lbf.-in.).

Transducer

Gate LeadsPower Interface BoardThermistor Lead

TransducerLeads

Shown w/Enclosure Removed

Cassette Frame

Remove Screws

Ground Lead

Power Supply Board Support Plate

Power Supply BoardSupport Plate

3

Current Transducer Replacement

N. With the Power Interface Board still removed, locate the transducer to be replaced.

O. Remove the screw securing the U, V or W lead that extends through the transducer. Remove the lead from the center of the transducer.

P. Remove the transducer and insulator (located under transducer) by taking the 2 screws out. Orient new transducer and insulator as shown, install screws and tighten to 1.7 N-m (15 lbf.-in.).

Q. Replace the U, V or W lead and tighten screw to 4.5 ±0.5 N-m (40 ±4.0 lbf.-in.).

R. If further component replacement is required, proceed to step S for Power Module replacement.

If further replacement is not required, replace Power Interface Board.

Important: If a new Power Interface board is being installed, the six gate leads must also be replaced with the new leads supplied. It is recommended that the leads be replaced one-at-a-time to assure correct orientation.

Tighten board screws to 1.7 N-m (15 lbf.-in.).

Re-assemble remainder of drive. Tighten sheet metal screws to 3.2 N-m (28 lbf.-in.).

Power Module Replacement

S. For easier component access, position drive on its right side. With the Power Interface Board still removed, locate the Power Modules and Bus Bar.

T. Disconnect the U, V and W leads, but leave the Gate Leads in place.

U. Remove the Bus Bar by taking out the appropriate screws and spacers. Discard bar.

V. Remove the first Power Module and set aside. Place a new module next to the old, and transfer the leads.

W. Thoroughly clean the module mounting surface. Apply a thin coating of the supplied thermal grease to the new module. Install with the supplied screws and tighten using the sequence below

X. Repeat for remaining modules.

Y. Replace the U, V and W leads. Tighten screws to 4.5 N-m (40 ±4.0 lbf.-in.).

Z. Install new Bus Bar (supplied) and tighten screws/spacers to 4.5 ±0.5 N-m (40 ±4.0 lbf.-in.).

Replace the Power Interface Board and tighten board screws to 1.7 N-m (15 lbf.-in.).

Important: If a new Power Interface board is being installed, the six gate leads must also be replaced with the new leads supplied. It is recommended that the leads be replaced one-at-a-time to assure correct orientation.

Re-assemble remainder of drive. Tighten sheet metal screws to 3.2 N-m (28 lbf.-in.).

Transducer Arrow “ ” Must Point Away from Circuit Board

Bus Bar U, V, W LeadsPower Modules

1

3

4

2C2E1 E2 C1

Power Module Torque Sequence

First Sequence: 0.7 N-m (6.0 lbf.-in.)Second Sequence: 2.3 N-m (20 lbf.-in.)Final Sequence: 4.5 ±0.5 N-m (40 ±4.0 lbf.-in.)

4

SCR and Brake IGBT Removal/Replacement

a. Remove upper sheet metal enclosure by taking out the appropriate screws.

b. Locate the components to be replaced.

SCR Replacement

c. Disconnect the Gate Leads and the R, S or T cable of the SCR to be replaced.

d. Remove the Bus Bars and Snubber Board. Remove the SCR.

e. Thoroughly clean the SCR mounting surface. Apply a thin coating of the supplied thermal grease to the new SCR. Install with the supplied screws and tighten to 3.3 ±0.3 N-m (29 ±3.0 lbf.-in.).

f. Replace the Gate Leads and verify correct lead placement. Note: Placement is the same for all SCR’s.

g. Replace the R, S or T lead. Tighten screws to 3.3 ±0.3 N-m (29 ±3.0 lbf.-in.).

h. Replace Bus Bars and tighten screws to 3.3 ±0.3 N-m (29 ±3.0 lbf.-in.).Tighten Snubber Board screws to 1.7 ±0.1 N-m (15 ±1.0 lbf.-in.).

i. If Brake IGBT replacement is necessary, proceed to step j. Otherwise, re-assemble drive. Tighten sheet metal screws to 3.2 N-m (28 lbf.-in.).

Brake IGBT Replacement

j. Locate Brake IGBT (see photo). Note cable placement. Remove Bus Bars and disconnect cables.

k. Remove the IGBT by taking out the two screws.

l. Thoroughly clean the IGBT mounting surface. Apply a thin coating of the supplied thermal grease to the new IGBT. Secure with the supplied screws and tighten to 4.5 ±0.5 N-m (40 ±4.0 lbf.-in.).

m. Re-assemble in reverse order. Tighten Bus Bar screws to 3.3 ±0.3 N-m (29 ±3.0 lbf.-in.) and sheet metal screws to 3.2 N-m (28 lbf.-in.).

4

SCR Bus Bars

SnubberBoard

Brake IGBT(Not on All drives)

GateLeads

SCRs

R

S

T

Lead Assembly “X3”

“T” Lead from “X3” Lead Assembly

“T” Lead from “X2”Lead Assembly

Lead Assembly “X2”

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Publication RA-IN019B-EN-P – October, 2006 P/N 390247-P02Supersedes RA-IN019A-EN-P January, 2006 Copyright © 2006 Rockwell Automation, Inc. All rights reserved. Printed in USA.

U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives