Filter Capacitor Replacement Kit SK-L1-CAP2-D1250 for ......Filter Capacitor Replacement Kit SK-L1-CAP2-D1250 for PowerFlex 700L Frame 3B 480V AC Drives Catalog Number SK-L1-CAP2-D1250

Installation Instructions

Filter Capacitor Replacement Kit SK-L1-CAP2-D1250 for PowerFlex 700L Frame 3B 480V AC DrivesCatalog Number SK-L1-CAP2-D1250

Additional Resources These documents contain additional information concerning related products from Rockwell Automation.

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.

Topic Page

Additional Resources 1

What the Kit Contains 2

Tools That You Need 3

Precheck 3

What You Need To Do 4

Step 1: Disconnect and Lock Out Input Power at the Branch Circuit 4

Step 2: Turn Off the Drive Enclosure Circuit Breaker 4

Step 3: Verify that DC Bus Capacitors are Discharged 5

Step 4: Prepare for the Replacement 5

Step 5: Remove the Existing Filter Capacitor Assembly 6

Step 6: Remove Existing Mounting Brackets and Install New Kit Brackets 8

Step 7: Install the New Filter Capacitor Assembly 10

Step 8: Power Up the Drive and Filter Capacitor Assembly Replacement 11

Resource Description

PowerFlex 700L Frame 3A and 3B Hardware Service Manual, publication 20L-TG001

Provides detailed hardware service information.

PowerFlex 700L Liquid-Cooled AC Drive User Manual, publication 20L-UM001

Provides drive installation and operating information.

Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and other certification details.

Publication 20L-IN016A-EN-P - February 2012

http://www.ab.comhttp://www.rockwellautomation.com/literature/http://www.rockwellautomation.com/literature/

Filter Capacitor Replacement Kit SK-L1-CAP2-D1250 for PowerFlex 700L Frame 3B 480V AC Drives

What the Kit Contains • One Capacitor Bank Assembly

• Two Input Filter Mounting Brackets• One Upper Capacitor Bank Mounting Bracket• One Lower Capacitor Bank Mounting Bracket• Three Power Wires• One Bag of Hardware

Kit Weight

22.7 kg (50 lb)

ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this procedure in its entirety before proceeding.

ATTENTION: Do not remove the existing filter capacitor assembly or install the replacement kit with power applied to the drive. Disconnect, lock out, and tag all incoming power to the drive enclosure before attempting such removal or installation. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure that the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: The drive contains ESD- (Electrostatic-Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing the drive. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, refer to Allen Bradley publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook.

2 Rockwell Automation Publication 20L-IN016A-EN-P - February 2012


Tools That You Need • Properly-rated, isolated multi-meter (DMM) to measure the AC input and DC filter capacitor voltages (working voltage specifications should be 1000V)

• 3/8-inch drive ratchet• 3/8-inch drive 10 mm deep well socket• 3/8-inch drive 3/4-inch deep well socket• 3/8-inch drive 3/8-inch socket or 3/8-inch box wrench• Torque wrench capable of 50 lb•in (5.6 N•m)• Torque wrench capable of 35 lb•ft (47.5 N•m)• 10 mm box wrench• T25 Torx bit• #1 Phillips screwdriver• Small wire cutter• Lockout/Tagout kit• Work gloves• Nylon wire ties• Arc Flash Gear

You may also need a box or container to hold loose hardware.

Precheck

Drives built prior to May 2008 had older style SPDs mounted on the filter capacitor bank assemblies. If a surge trap style SPD is not installed in the drive, it is necessary to order and install a surge trap upgrade kit, Catalog Number 21T-385253-A01 to insure there is proper transient protection for the equipment.

IMPORTANT Inspect the surge trap (SPD) in the drive and note whether the visual inspection tab has been activated. This indicates internal damage and the need for replacement. For the location of the surge trap, see Figure 7 on page 11.

Visual Inspection Tab DetailSurge Trap (SPD) in Drive

Rockwell Automation Publication 20L-IN016A-EN-P - February 2012 3


What You Need To Do To install the filter capacitor assembly replacement kit you need to:

Step 1: Disconnect and lock out input power at the branch circuit.

Step 2: Turn off the drive enclosure circuit breaker.

Step 3: Verify that DC bus capacitors are discharged.

Step 4: Prepare for the replacement.

Step 5: Remove the existing filter capacitor assembly.

Step 6: Remove existing mounting brakets and install new kit brackets.

Step 7: Install the new filter capacitor assembly.

Step 8: Power up the drive and filter capacitor assembly replacement.

Step 1: Disconnect and Lock Out Input Power at the Branch Circuit

Disconnect input power upstream of the drive assembly enclosure. Follow required safety procedures to turn off and lock out input power during the repair.

Step 2: Turn Off the Drive Enclosure Circuit Breaker

Turn off the drive enclosure circuit breaker and open the drive enclosure door.

L1 L2 L3

O

I



Step 3: Verify that DC Bus Capacitors are Discharged

a. Using a confidence-tested AC voltmeter, verify that AC power is no longer present on the line side of the drive enclosure's main incoming circuit breaker.

b. Visually inspect the drive to insure no lamps or indicators are illuminated.

Step 4: Prepare for the Replacement

a. Read and follow the lock out, tag out, and safety verifications previously described.

b. Open the door of the drive. Refer to Figure 1 and Figure 2, and note the locations of the hardware in the existing Filter Capacitor Assembly.

Figure 1 - Tab Connectors

ATTENTION: DC Bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure that the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

IMPORTANT Prior to the removal and installation process, it is highly recommended that the left side panel of the enclosure be removed to gain proper access to the capacitor bank assembly. If the left side panel cannot be removed, please call Technical Support for assistance at 1-440-646-3434.

Tab Connectors (7x) Neutral Bus Plate



Figure 2 - Existing Filter Capacitor Assembly in Drive

Step 5: Remove the Existing Filter Capacitor Assembly

a. After power has been removed from the drive, the filter capacitor bank should discharge via the bleeder resistor discharge network. Wait five (5) minutes to fully discharge.

b. Carefully check for zero (0) volts between each of the three (3) Capacitor Bus Bars (input power) and the Neutral Bus Plate at the stake-on connectors (see Figure 1) using a confidence-tested DC voltmeter.

c. Gain access to the left side of the enclosure. Remove and retain the hardware that secures the left side panel to the enclosure, and remove the panel and set it aside.

d. Cover any components under the capacitor bank to protect them from any dropped hardware.

e. Place a piece of rigid cardboard or something similar on top of the three (3) Bus Bars connected to the contactors to prevent any damage to the Bus Bars (see Figure 3) or their protective coating.

1 μF Capacitor

Power Wires (3x) (not shown)

Mounting Hardware (4x)

Harness for Bleeder Resisitor network

Fiberglass Insulator Panel

Capacitor Bank Mounting Hardware (6x)

Panel Mounting Hardware (6x)

Capacitor Bus Bars (3x) Input Power

ATTENTION: Upon removing the assembly and hardware, sharp edges may be encountered. Use work gloves to protect your hands.



f. Using access from the left side of the enclosure, locate the three (3) power wires coming from the back of the capacitor bank assembly that are attached to the inductors. Remove the hex nuts securing the power wires to the inductors. Retain the hardware.

g. Disconnect the ground wire from the 1 μF Capacitor.h. If the existing capacitor bank assembly has a surge trap (SPD) device

mounted on the assembly, disconnect the ground wire.i. Remove the hardware that is securing the capacitor bank assembly to

the mounting panel and carefully remove the capacitor bank assembly from the enclosure. Once removed, remove the hardware that is securing the three (3) power wires (see Figure 2) to the back of the capacitor bank assembly. Retain the hardware.

j. Remove the front four (4) bolts that are securing the top of the capacitor bank mounting panel to the fiberglass insulator panel (see Figure 2). Retain the hardware.

k. Remove the remaining hardware that is securing the capacitor bank mounting panel in the enclosure (see Figure 2). Retain the hardware (6x).

Figure 3 - Removing Existing Mounting Brackets

Contactor Assembly Mounting Hardware

Existing Mounting Brackets (2x)

Bus Bars (3x)

Mounting Bracket Hardware

Contactors (3x)



Step 6: Remove Existing Mounting Brackets and Install New Kit Brackets

a. Starting on the left side of the drive, remove the hardware that is securing the contactor assembly to the mounting bracket (see Figure 3). Retain the hardware (2x).

b. Remove the hardware that is securing the mounting bracket to the frame of the enclosure (see Figure 3). Discard the hardware.

c. Remove and discard the mounting bracket.d. Install the new mounting bracket and re-use the hardware removed in

Step 6-b. Tighten only to finger-tight until both new brackets are installed (see Figure 4).

e. Use three (3) M5 x13 pan head screws (supplied with kit) to attach the new mounting bracket to the enclosure frame (see Figure 4).

f. On the right side of the drive, remove the hardware that is securing the contactor assembly to the mounting bracket (see Figure 3). Retain the hardware.

g. Remove the hardware that is securing the mounting bracket to the frame of the enclosure (see Figure 3). Discard the hardware.

h. Lift the right side bracket vertically then pull the bottom forward to remove the mounting bracket and discard.

i. Install the new mounting bracket to the contactor assembly by re-using the hardware removed in Step 6-b. Tighten only to finger-tight until both new brackets are installed (see Figure 4).

j. Use three (3) M5 x13 pan head screws (supplied with kit) to attach the new mounting bracket to the enclosure frame (see Figure 4).

k. Fully tighten all hardware.l. Locate the upper capacitor bank mounting bracket (see Figure 5).

Attach the 1 μF Capacitor to the top of the upper cap bank mounting bracket using two (2) M5 x 10 hex head screws (supplied with kit). Insure that the ground lead with the ring lug is on the right hand side.

m. Re-use the hardware removed in Step 5-j to attach the upper capacitor bank mounting bracket to the fiberglass insulator panel.

n. Using four (4) M6 x 16 hex head bolts and four (4) channel nuts (supplied with kit), attach the upper capacitor bank mounting bracket to the vertical channels of the enclosure. Use the upper left bolt to attach the ground lead from the 1 μF Capacitor (see Figure 5).

o. Attach the lower capacitor bank mounting bracket using the four (4) M6 x 16 hex head bolts and four (4) channel nuts (supplied with kit) to the vertical channels of the enclosure (see Figure 5).

p. Attach the Bleeder Resistor to the lower capacitor bank mounting bracket using the twelve (12) M3 x 8 pan head screws (supplied with kit). Use wire ties to properly secure the Bleeder Resistor wires.

ATTENTION: Upon removing and installing the mounting brackets and hardware, sharp edges may be encountered. Use work gloves to protect your hands.



Figure 4 - New Contactor Assembly Mounting Brackets

Figure 5 - New Capacitor Bank Assembly Mounting Brackets

New Mounting Bracket (2x)

Bracket andContactor AssemblyMounting Hardware


Upper Capacitor Bank Mounting Bracket

1 μF Capacitor

1 μF Capacitor Ground Lead Connection


Lower Capacitor Bank Mounting Bracket



Step 7: Install the New Filter Capacitor Assembly

a. Before installing the new capacitor bank assembly, attach the power wires to the back of the capacitor bank assembly using the hardware removed in Step 5-i (see Figure 6). Connect Rockwell Automation power wire PN-109106 to the Bus Bar labeled FU-4, Rockwell Automation power wire PN-109107 to the Bus Bar labeled FU-5, and the remaining Rockwell Automation power wire PN-109107 to the Bus Bar labeled FU-6. Tighten to 45…50 lb•in (5.1…5.6 N•m).

b. Place the new capacitor bank assembly in the enclosure and hang it from the three (3) studs on the upper capacitor bank mounting bracket (see Figure 7).

c. Using three (3) M6 hex nuts (supplied with kit), secure the top of the capacitor bank assembly in place. Tighten only to finger-tight until the remaining hardware is in place (see Figure 7).

d. Secure the bottom of the capacitor bank assembly with three (3) bolts removed from Step 5-i (see Figure 7).

e. Tighten all hardware installed in Step 7-c and Step 7-d.f. Using access from the left side and the hardware removed in Step 5-e,

secure the power wire coming from FU-6 to the right hand inductor connection, the power wire coming from FU-5 to the center inductor connection, and the power wire coming from FU-4 to the left hand inductor connection (see Figure 6). Tighten to 30…35 lb•ft (40.7…47.5 N•m).

g. Connect the free lead from the 1 μF Capacitor to the terminal on the capacitor bank assembly.

h. Insure that the surge trap style SPD, shown in the “Precheck” section on page 3, is installed and reconnected properly.

Figure 6 - Power Wire Connections

ATTENTION: Upon installing the assembly and hardware, sharp edges may be encountered. Use work gloves to protect your hands.

Rockwell PN-109107 Power Wire to FU6

Bleeder Resistor Harness



Resistor Mounting Hardware (12x) M3 x 8 pan head screws



Figure 7 - Replacement Filter Capacitor Assembly (shown installed on drive)

Step 8: Power Up the Drive and Filter Capacitor Assembly Replacement

Normal power-up and recommissioning procedures should be followed to ensure electrical integrity prior to applying power and verifying drive operation.

a. Verify that all tools, hardware, and cardboard or covers have been removed from the drive enclosure.

b. Re-install the left side panel to the enclosure.c. Complete normal pre-power-up checks.d. With the drive enclosure door closed, remove the lock and tag, and

apply power to the drive enclosure.e. Turn on the drive enclosure circuit breaker.f. Verify normal drive operation.

New Filter Capacitor Assembly


Mounting Hardware (3x) M6 hex nuts

Surge Trap Location



Publication 20L-IN016A-EN-P - February 2012 PN-129876 - Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, E-mail: [email protected]: www.ab.com/support/abdrives

Filter Capacitor Replacement Kit SK-L1-CAP2-D1250 for PowerFlex 700L Frame 3B 480V AC DrivesAdditional ResourcesWhat the Kit ContainsKit Weight

Tools That You NeedPrecheckWhat You Need To DoStep 1: Disconnect and Lock Out Input Power at the Branch CircuitStep 2: Turn Off the Drive Enclosure Circuit BreakerStep 3: Verify that DC Bus Capacitors are DischargedStep 4: Prepare for the ReplacementStep 5: Remove the Existing Filter Capacitor AssemblyStep 6: Remove Existing Mounting Brackets and Install New Kit BracketsStep 7: Install the New Filter Capacitor AssemblyStep 8: Power Up the Drive and Filter Capacitor Assembly ReplacementBack Page / Publication 20L-IN016A-EN-P February 2012

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Filter Capacitor Replacement Kit SK-L1-CAP2-D1250 for ......Filter Capacitor Replacement Kit SK-L1-CAP2-D1250 for PowerFlex 700L Frame 3B 480V AC Drives Catalog Number SK-L1-CAP2-D1250