Rockwell Automation PowerFlex 7000

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90 Rockwell Automation Publication 7000-UM202H-EN-P - November 2023

Chapter 2 Power Component Definition and Maintenance

Figure 81 - Thermal sensor replacement (Heatsink Model)

Figure 82 - Thermal Sensor Replacement (SPS Board Model)

Temperature

Feedback

Circuit Board

Mounting Pad

Insulating

Bushing

Mounting Screw

Thermal Sensor and

Cable Assembly

Mounting Screw

Insulating

Bushing

Mounting Pad

Thermal Sensor and

Cable Assembly

Temperature Feedback

Circuit Board

Main Page

Table of Contents3
Preface9
About this Publication9
Download Firmware, AOP, EDS, and Other Files9
Summary of Changes9
Who Should Use this Manual9
What Is Not in this Manual9
General Precautions10
Connect to Service and Support and Product Documentation11
Abbreviations11
Additional Resources12
Powerflex 7000 Drive Overview13
Topology13
Rectifier Designs14
Configurations14
Cooling Technology16
Motor Compatibility17
Simplified Electrical Diagrams18
2400V18
3300/4160V19
6600V20
Functional Safety21
Safe Torque off21
Arcshield Technology22
Operator Interface23
Basic Configurations23
Power Component Definition and Maintenance25
Control Power off Tests25
Interlocking25
Control / Cabling Cabinet Components27
Voltage-Sensing Assembly34
Replacing the Voltage-Sensing Circuit Board Assembly34
Input Transient Protection35
Transient Suppression Network (TSN)35
Surge Arresters39
Filter Capacitor Cabinet44
Filter Capacitors44
Filter Capacitor Mounting Plate45
Replacing Filter Capacitors46
Testing Filter Capacitors49
Converter Cabinet Components51
Powercage Module Overview56
Resistance Checks57
SGCT and Snubber Circuit58
SGCT Testing64
SGCT Anode-To-Cathode (Sharing) Resistance64
Snubber Resistance (SGCT Device)67
Snubber Capacitance (SGCT Device)68
Replacing the SGCT69
Replacing Snubber and Sharing Resistor72
Replacing Sharing Resistors76
Replacing Snubber Capacitor76
Silicon Controlled Rectifier Powercage Modules77
SCR Testing78
SCR Anode-To-Cathode Resistance79
SCR Sharing Resistance Test80
SCR Gate-To-Cathode Resistance81
Snubber Resistance (SCR Device)82
Snubber Capacitance (SCR Device)84
Replacing SCR and SCR Self-Powered Gate Driver Boards85
(Spgdb)85
Uniform Clamping Pressure87
Checking Clamping Pressure88
Clamping Pressure Adjustment88
Temperature Sensing89
Replacing the Thermal Sensor89
Replacing Heatsinks/Heatpipes91
Replacing Heatsinks92
Replacing Heatpipes93
Powercage Gasket95
Replacing Powercage Gaskets96
Removing the Powercage Module97
Self-Powered SGCT Power Supply - SPS99
Board Calibration99
Test Points99
Testing Equipment100
Self-Powered Gate Driver Board - SPGDB101
Board Calibration101
Test Points102
Terminal/Connections103
Testing Procedure for SCR Self-Powered Gate Driver Board103
Testing Equipment103
Procedure103
Fiber Optic Cabling106
Air Pressure Sensor107
Replacing the Air Pressure Sensor107
DC Link Cabinet Components108
DC Link Reactor112
Cooling Fans114
Replacing Ziehl-Abegg Fans114
Replacing Continental/Daltec Fans123
Impeller Maintenance125
Installing Impeller Assembly Onto Motor Shaft126
Fan Balance127
Replacing Air Filters128
Control Component Definition and Maintenance131
Control Power Components131
Ride-Through131
AC/DC Power Supply133
Terminal / Connections Descriptions (Pioneer Power Supply)135
Terminal / Connections Descriptions (Cosel Power Supply)136
Output Calibration137
Power Supply Replacement138
Power Supply Diode Replacement140
UPS Option141
Replacing the UPS143
Low Voltage Control Section144
DC/DC Power Supply145
Terminal/Connections Descriptions145
Replacing a DC/DC Power Supply147
Drive Processor Module148
Replacing the Drive Processor Module150
Analog Control Board (ACB)151
Status Indicators155
Interface Module (IFM)155
Analog Inputs and Outputs156
Current Loop Transmitter156
Isolated Process Receiver157
Non-Isolated Process Outputs158
Auxiliary +24V Power Supply158
Replacing the Analog Control Board159
Encoder Feedback Board159
Encoder Options159
20B-ENC-3 Encoder Interface159
Quadrature Encoder Operation162
Positional Encoder Operations163
External Input/Output Boards164
Replacing the External Input/Output Board165
Optical Interface Boards (OIB)166
Replacing the Optical Interface Board167
Replace the Optical Interface Base Board170
Optical Interface Base Board Test Points170
Preventative Maintenance Schedule173
Preventative Maintenance Checklist173
Operational Maintenance173
Annual Maintenance173
Initial Information Gathering173
Physical Checks (no Medium Voltage and no Control Power)174
Control Power Checks (no Medium Voltage)175
Final Power Checks before Restarting175
Additional Tasks During Preventive Maintenance176
Final Reporting176
Time Estimations177
Tool / Parts / Information Requirements177
Overview178
Overview181
Power Supplies181
Control Equipment and Boards182
Sgct/Scr/Sps183
Cooling Fans183
Signal Conditioners183
Spare Parts Maintenance Schedule184
Spare Parts Connection Matrix185
Power Supply Connection Guidelines186
Pioneer/Cosel Power Supply186
Igdps186
Intellivac Control Module187
Absopulse AC/DC Converter187
Absopulse DC/DC Converter188
1606 Power Supply189
Control Equipment and Boards Connection Guidelines189
Analog Control Board (ACB)189
Power Components Connection Guidelines190
Sgct - Igdps190
SGCT - SPS Board191
SPS Board191
Scr - Spgdb192
Connection Wires Size193
Torque Requirements for Threaded Fasteners195
Overview197
Insulation Resistance Test197
Insulation Resistance Test Procedure198
Required Equipment198
Procedure198
Air Quality Requirements203
Hazardous Materials204
Capacitor Dielectric Fluid204
Printed Circuit Boards204
Lithium Batteries204
Chromate Plating204
In Case of Fire205
Disposal205

Rockwell Automation PowerFlex 7000

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