Schneider Electric Altivar 61 Instruction Sheet

Altivar® 61/71
Adjustable Speed Drives
Spare Parts Kits
Instruction Bulletin
30072-452-80
Retain for future use.
For Frame Size 13:
ATV61HC25N4, ATV61HC31N4, ATV71HC20N4,
ATV71HC25N4, ATV71HC28N4
30072-452-80
04/2009
Contents
© 2009 Schneider Electric All Rights Reserved
Spare Parts Kits for Altivar® 61/71 Drives, Frame Size 13
Contents
Hazard Categories and Special Symbols ................................................ 4
Product Support......................................................................................... 4
Before You Begin....................................................................................... 5
Introduction ................................................................................................ 7
Related Documentation .............................................................................. 8
Receiving, Handling, and Storage............................................................ 9
Electrostatic Precautions ............................................................................ 9
Inspecting the Spare Part Kits .................................................................... 9
Preliminary Recommendations .............................................................. 10
Qualified Personnel ................................................................................... 10
Working Procedures ................................................................................. 10
Tools Required .......................................................................................... 11
Power Removal and Bus Voltage Measurement................................... 12
Discharging Stored Energy in Capacitors ................................................. 13
Parts Locations ........................................................................................ 14
Level 1 Parts ............................................................................................. 14
Level 2 Parts ............................................................................................. 16
Installation Procedures for Level 1 Parts .............................................. 20
Removing and Replacing the Front Cover VY1A1214 .............................. 20
Replacing the Plastic Parts Kit VY1A1403 ................................................ 21
Replacing the Internal Fans VZ3V1213 .................................................... 24
Replacing the Soft Charge Board VX5A1300 ........................................... 25
Replacing the SCR Snubber Board VX4A1200 ........................................ 26
Replacing the Fan Control Board VX5A1400 ........................................... 27
Replacing the Filter Board (VX4A1115) and Motor Current Sensors
(VY1A1108) ........................................................................................... 29
Installation Procedures for Level 2 Parts .............................................. 45
Disassembly Steps for Accessing Level 2 Parts ....................................... 45
Replacing the Power Board VX5A1HC2025, VX5A1HC2531,
VX5A71HC28N4 ................................................................................... 59
Replacing the Gate Driver Boards VX5A1201 and VX5A1202 ................. 64
Replacing the Temperature Sensors, VZ3G1104 ..................................... 70
Replacing the Power IGBT Modules VZ3IM1602M1271, and
VZ3IM1402M1271 ................................................................................. 72
Replacing the Capacitors VY1ADC1112 and VY1ADC1114 .................... 75
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and
Diode Modules (VZ3DM1600M1671) .................................................... 77
Reassembly Steps for Level 2 Parts ......................................................... 91
Wiring...................................................................................................... 104
3
Spare Parts Kits for Altivar® 61/71 Drives, Frame Size 13
Hazard Categories and Special Symbols
Hazard Categories and
Special Symbols
30072-452-80
04/2009
The following symbols and special messages may appear in this document
or on the equipment to warn of potential hazards or to call attention to
information that clarifies or simplifies a procedure.
A lightning bolt or ANSI man symbol in a “Danger” or “Warning” safety label
on the equipment indicates an electrical hazard which, as indicated below,
can or will result in personal injury if the instructions are not followed.
The exclamation point symbol in a safety message in a manual indicates
potential personal injury hazards. Obey all safety messages introduced by
this symbol to avoid possible injury or death.
Symbol
Name
Lightning Bolt
ANSI Man
Exclamation Point
DANGER
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not
avoided, can result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not
avoided, can result in minor or moderate injury.
CAUTION
CAUTION, used without the safety alert symbol, indicates a potentially
hazardous situation which, if not avoided, can result in property damage.
Product Support
For support and assistance, contact the Product Support Group. The
Product Support Group is staffed from Monday through Friday, 8:00 am until
6:00 pm Eastern time, to assist with product selection, start-up, and
diagnosis of product or application problems. Emergency phone support is
available 24 hours a day, 365 days a year.
Toll free: 888-SquareD (888-778-2733)
E-Mail:
[email protected]
Fax:
919-217-6508
4
© 2009 Schneider Electric All Rights Reserved
Spare Parts Kits for Altivar® 61/71 Drives, Frame Size 13
Before You Begin
30072-452-80
04/2009
Before You Begin
Read and follow these precautions before performing any procedure with
this drive.
The word “drive” as used in this bulletin refers to the controller portion of the
adjustable speed drive as defined in the National Electrical Code (NEC).
.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand this manual before installing or operating the
Altivar 61 or 71 drive. Installation, adjustment, repair, and maintenance
must be performed by qualified personnel.
• The user is responsible for compliance with all international and national
electrical code requirements with respect to grounding of all equipment.
• Many parts of this drive, including the printed circuit boards, operate at
the line voltage. DO NOT TOUCH. Use only electrically insulated tools.
• DO NOT touch unshielded components or terminal strip screw
connections with voltage present.
• DO NOT short across terminals PA/+ and PC/– or across the DC bus
capacitors.
• Before servicing the drive:
— Disconnect all power, including external control power that may be
present.
— Place a “DO NOT TURN ON” label on all power disconnects.
— Lock all power disconnects in the open position.
— WAIT 15 MINUTES to allow the DC bus capacitors to discharge.
Then follow the “Bus Voltage Measurement Procedure” on page 12
to verify that the DC voltage is less than 42 V. The drive LED is not
an indicator of the absence of DC bus voltage.
• Install and close all covers before applying power or starting and
stopping the drive.
Failure to follow these instructions will result in death or serious
injury.
© 2009 Schneider Electric All Rights Reserved
5
Spare Parts Kits for Altivar® 61/71 Drives, Frame Size 13
Before You Begin
6
30072-452-80
04/2009
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Introduction
Introduction
This instruction bulletin contains replacement procedures for the
Altivar® 61 and 71 spare parts kits identified in Table 1. Read and
understand the instructions in this document and other referenced
documents before installing the kits.
Table 1:
© 2009 Schneider Electric All Rights Reserved
Altivar® 61 and 71 Spare Parts Kits1
For
Location
of Parts,
See:
Kit Catalog No.
Description
For Use On Drive:
VY1A1214
Front Cover
Assembly
ATV61HC25N4, ATV61HC31N4,
ATV71HC20N4, ATV71HC25N4, page 20
ATV71HC28N4
VY1A1403
Plastic Parts
Kit
ATV61HC25N4, ATV61HC31N4,
pages 14,
ATV71HC20N4, ATV71HC25N4,
15, and 16
ATV71HC28N4
VZ3V1213
Internal Fan
ATV61HC25N4, ATV61HC31N4,
ATV71HC20N4, ATV71HC25N4, page 14
ATV71HC28N4
VX5A1300
Soft Charge
Board
ATV61HC25N4, ATV61HC31N4,
ATV71HC20N4, ATV71HC25N4, page 14
ATV71HC28N4
VX5A1400
Fan Control
Board
ATV61HC25N4, ATV61HC31N4,
ATV71HC20N4, ATV71HC25N4, page 15
ATV71HC28N4
VX4A1115
Filter Board
ATV61HC25N4, ATV61HC31N4,
ATV71HC20N4, ATV71HC25N4, page 15
ATV71HC28N4
VX5A1HC2025
Power Board
ATV61HC25N4, ATV71HC20N4
VX5A1HC2531
Power Board
ATV71HC25N4, ATV61HC31N4
VX5A71HC28N4
Power Board
ATV71HC28N4
VY1A1108
ATV61HC25N4, ATV61HC31N4,
Motor Current
ATV71HC20N4, ATV71HC25N4, page 15
Sensor
ATV71HC28N4
VX5A1201
Gate Driver
Board
ATV61HC25N4, ATV71HC20N4
VX5A1202
Gate Driver
Board
ATV61HC31N4, ATV71HC25N4,
ATV71HC28N4
VZ3G1104
Temperature
Sensors
ATV61HC25N4, ATV61HC31N4,
ATV71HC20N4, ATV71HC25N4, page 18
ATV71HC28N4
VZ3IM1402M1271
Power IGBT2
ATV61HC25N4, ATV71HC20N4
Module
VZ3IM1602M1271
Power IGBT2
Module
ATV61HC31N4, ATV71HC25N4,
ATV71HC28N4
VY1ADV1109
Screw Kit
ATV61HC25N4, ATV61HC31N4,
ATV71HC20N4, ATV71HC25N4, —
ATV71HC28N4
VY1ADC1112
Capacitors
VY1ADC1114
Capacitors
VX4A1200
ATV61HC25N4, ATV61HC31N4,
SCR Snubber
ATV71HC20N4, ATV71HC25N4, page 15
Board
ATV71HC28N4
VZ3TM1425M1671
SCR3 Module ATV61HC25N4, ATV71HC20N4
VZ3TM1600M1671
SCR3 Module
page 16
page 17
page 18
ATV61HC31N4, ATV71HC25N4,
ATV71HC28N4
page 18
ATV61HC25N4, ATV71HC20N4
ATV61HC31N4, ATV71HC25N4, page 19
ATV71HC28N4
7
Introduction
Related Documentation
30072-452-80
04/2009
Table 1:
Altivar® 61 and 71 Spare Parts Kits1 (continued)
Kit Catalog No.
Description
For Use On Drive:
For
Location
of Parts,
See:
ATV61HC25N4, ATV61HC31N4,
VZ3DM1600M1671 Diode Module ATV71HC20N4, ATV71HC25N4, page 19
ATV71HC28N4
VZ3N1318
Related Documentation
Wire Kit
ATV61HC25N4, ATV61HC31N4,
ATV71HC20N4, ATV71HC25N4, —
ATV71HC28N4
1
For kit contents, refer to document 30072-452-44.
2
IGBT: Insulated-gate bipolar transistor
3
SCR: Silicon controlled rectifier
For drive installation instructions, refer to the following documents:
•
•
Altivar® 61 Installation Manual 0.5 to 100 HP, module no. 1760643
•
•
Altivar® 61 Installation Manual 75 to 800 HP, module no. 1760655
•
•
Altivar® 71 Installation Manual 0.5 to 100 HP, module no. 1755843
Supplementary Instructions to ATV61 Variable Speed Drives Installation
Manual—Low Horsepower, document no. 30072-451-50
Addendum to ATV61 Variable Speed Drives Installation Manual—High
Horsepower, document no. 30072-451-57
Altivar® 71 Installation Manual 75 to 700 HP, module no. 1755849
All documentation referenced in this bulletin is provided with the drive or on
the CD-ROM included with the spare parts kits. You can also downIoad the
documentation from the Technical Library at www.schneider-electric.us.
8
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Receiving, Handling, and Storage
Electrostatic Precautions
Receiving, Handling, and
Storage
Electrostatic Precautions
CAUTION
STATIC SENSITIVE COMPONENTS
Circuit boards and option cards can be damaged by static electricity.
Observe the electrostatic precautions below when handling controller
circuit boards or testing components.
Failure to follow these instructions can result in injury or equipment
damage.
Observe the following precautions for handling static-sensitive components:
Inspecting the Spare Part Kits
•
Keep static-producing material such as plastic, upholstery, and
carpeting out of the immediate work area.
•
Store static-sensitive components in protective packaging when they are
not installed in the drive.
•
When handling a static-sensitive component, wear a conductive wrist
strap connected to the component or drive through a minimum of
1 megohm resistance.
•
Avoid touching exposed conductors and component leads with skin or
clothing.
After receiving the ATV61/ATV71 spare parts kit:
•
Ensure that the catalog number printed on the kit label is the same as
that on the packing slip and corresponding purchase order. Contact your
Schneider Electric representative if there are any errors.
•
Remove the kit from its packaging and inspect it for damage. If any
damage is found, notify the carrier and your Schneider Electric
representative.
•
To store the kit, replace any static-sensitive parts in their protective
packaging and store them at -25 to +70 °C (-13 to +158 °F).
WARNING
DAMAGED EQUIPMENT
Do not install or operate any equipment that appears damaged.
Failure to follow these instructions can result in death, serious
injury, or equipment damage.
© 2009 Schneider Electric All Rights Reserved
9
Preliminary Recommendations
Qualified Personnel
30072-452-80
04/2009
Preliminary
Recommendations
Before beginning the installation procedures, read and understand all the
information in this section.
Qualified Personnel
For the protection of personnel and equipment, a qualified person must
perform the procedures detailed in this instruction bulletin.
A qualified person is one who has skills and knowledge related to the
construction and operation of this electrical equipment and the installation,
and has received safety training to recognize and avoid the hazards
involved. Refer to the most current release of NFPA 70E®, “Standard for
Electrical Safety in the Workplace,” for safety training requirements.
In addition, the person must be:
Working Procedures
10
•
Able to read, interpret, and follow the instructions and precautions in this
instruction bulletin and the other documentation referenced.
•
Able to use the required tools listed in this instruction bulletin in a safe
and correct manner.
Observe the following working procedures:
•
Use only the components provided with the kits listed in Table 1
beginning on page 7. Do not attempt to repair the drive with other spare
parts or equipment.
•
If the part being replaced includes labels, ensure that the labels are
applied to the replacement part. If the labels are not available in the kit,
contact your Schneider Electric representative.
•
Mount the spare parts only in the locations specified in the installation
procedures.
•
Route and position the wires as shown in the instructions. Use the wires
and cables provided with the spare parts kits or with the drive. Do not
modify the wires and cables. Do not route wires and cables outside of
the drive enclosure.
•
Install the power terminal shield as specified on pages 21–22, the filter
board shield as specified on pages 41–42, and the SCR assembly shield
as specified on page 99 of the installation procedures.
•
Observe the hardware and torque requirements specified in the
installation procedures. Do not substitute hardware. Carefully segregate
and label all removed hardware and parts for use in reassembly of the
drive.
•
Mount all panels and covers as specified in the installation procedures.
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Tools Required
Preliminary Recommendations
Tools Required
•
•
•
•
Needle-nose pliers
Torque wrench, 0–45 N•m (0–398 lb-in)
Voltmeter, 1–1000 Vdc
Driver bits:
— T-10 Torx® driver
— T-20 Torx® driver
— T-30 Torx® driver
— T-30 Torx® right-angle driver
— Size 2 magnetic tip Phillips® driver
— Size 3 magnetic tip Phillips® driver
•
Socket wrenches:
— 7 mm
— 10 mm
— 13 mm
— 16 mm
•
Open-end wrenches:
— 18 mm
— 21 mm
© 2009 Schneider Electric All Rights Reserved
11
Power Removal and Bus Voltage Measurement
30072-452-80
04/2009
Power Removal and
Bus Voltage Measurement
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
Failure to follow these instructions will result in death or serious
injury.
The DC bus voltage can exceed 1,000 Vdc. Use a properly rated
voltage-sensing device when performing this procedure. To measure the
DC bus voltage:
1. Disconnect all power.
2. Wait 15 minutes to allow the DC bus to discharge.
3. Measure the voltage of the DC bus between the PA/+ and PC/–
terminals to ensure that the voltage is less than 42 Vdc.These terminals
are clearly labeled on each drive.
4. If the DC bus capacitors do not discharge completely, contact your local
Schneider Electric representative. Do not repair or operate the drive.
CAUTION
IMPROPER DRIVE OPERATION
• If no power is applied to the drive for a long period, the performance of
its electrolytic capacitors will be reduced.
• If the drive is not in active service, apply power to the drive every two
years using the following procedure. Do not initially connect the drive
directly to full line voltage. Without a motor connected to the drive,
gradually increase the voltage using an adjustable AC source
connected between drive terminals L1 and L2:
— 25% of rated voltage for 30 minutes
— 50% of rated voltage for 30 minutes
— 75% of rated voltage for 30 minutes
— 100% of rated voltage for at least 5 hours
• Check drive operation before placing the drive into service.
Failure to follow these instructions can result in injury or equipment
damage.
12
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Power Removal and Bus Voltage Measurement
Discharging Stored Energy in Capacitors
Discharging Stored Energy in
Capacitors
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• When the controller is damaged, voltage may remain on certain energy
storage capacitors after de-energization of the controller and discharge
of the main capacitor bank.
• Before working on or near assemblies containing energy storage
capacitors, verify that the capacitor voltages are less than 42 Vdc.
• The following assemblies have energy-storing capacitors:
— Filter board
— SCR snubber board
• Always check for the presence of voltage using a voltmeter set to the
1000 Vdc scale. When voltage is present, allow the voltmeter to
discharge the capacitor’s stored charge.
Failure to follow these instructions will result in death or serious
injury.
Capacitors are used throughout the drive as energy storage devices. Some
of the capacitors can store potentially lethal amounts of energy during
normal controller operation.
When power is removed from an undamaged controller, the stored energy
in these capacitors is automatically discharged to nonhazardous levels.
However, the discharge mechanisms in a damaged controller may not be
operating properly, and stored energy may be present on printed circuit
boards.
Do not touch traces on printed circuit boards, such as the line filter board
and SCR snubber board, unless you have first checked for voltage with a
voltmeter!
To discharge the filter board and SCR snubber board capacitors, use a
voltmeter set to the 1000 Vdc scale. It will take approximately 6.6 minutes
for a 10 megohm input impedance voltmeter to discharge a 10 microfarad
capacitor from 700 V to less than 42 V. It will take approximately 40 seconds
for a 1 megohm input impedance voltmeter to discharge a 10 microfarad
capacitor from 700 V to less than 50 V.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Do not use a voltmeter to discharge stored energy on the DC bus
capacitors.
• If the energy on the DC bus capacitors remains greater than 42 Vdc
after 15 minutes, contact Product Support.
Failure to follow these instructions will result in death or serious
injury.
© 2009 Schneider Electric All Rights Reserved
13
Parts Locations
Level 1 Parts
Parts Locations
Level 1 Parts
30072-452-80
04/2009
Refer to the figures in this section to familiarize yourself with the layout of
the drive and the location of the parts before performing the installation
procedures.
Figure 1:
Level 1 Parts
Internal
fan (x2)
Soft charge
board
Plastic
parts kit,
EMC tray
Plastic
parts kit,
power
terminal
shield
Plastic
parts kit,
conduit
tray
14
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Parts Locations
Level 1 Parts
Figure 2:
Level 1 Parts (continued)
SCR
snubber
board
Fan
control
board
Plastic
parts kit,
filter board
shield
Filter
board
© 2009 Schneider Electric All Rights Reserved
Motor current
sensors (x3)
15
Parts Locations
Level 2 Parts
Level 2 Parts
30072-452-80
04/2009
Figure 3:
SCR Assembly Shield and Power Board
Plastic
parts kit,
SCR assy
shield
Power
board
16
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Parts Locations
Level 2 Parts
Figure 4:
Gate Driver Boards
Gate driver
boards (x3)
© 2009 Schneider Electric All Rights Reserved
17
Parts Locations
Level 2 Parts
30072-452-80
04/2009
Figure 5:
Temperature Sensors, Power IGBT Modules, and
Capacitors
Temperature
sensors
(x3)
Power IGBT
modules (x12)
Capacitors
(x12)
18
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Parts Locations
Level 2 Parts
Figure 6:
SCR Modules and Diode Modules
SCR module
(x3)
Diode module
(x3)
© 2009 Schneider Electric All Rights Reserved
19
Installation Procedures for Level 1 Parts
Removing and Replacing the Front Cover VY1A1214
Installation Procedures for
Level 1 Parts
30072-452-80
04/2009
Level 1 parts consist of the front cover and parts that are accessible directly
under the front cover. They are:
Front cover
Power terminal shield (plastic kit)
Conduit tray (plastic kit)
EMC tray (plastic kit)
Internal fans
Soft charge board
Removing and Replacing the
Front Cover VY1A1214
Fan control board
Motor current sensors
Filter board
Filter board shield (plastic kit)
SCR snubber board
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
All of the procedures in this manual require removal and replacement of the
front cover. See Figure 7.
•
To remove the front cover, using a size 2 Phillips driver, remove nine
screws and take the front cover off the drive.
•
To replace the front cover, using a size 2 Phillips driver secure the front
cover with nine screws. Tighten the screws to 5.5 N•m (48.7 lb-in).
Figure 7:
Front Cover
x9
20
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 1 Parts
Replacing the Plastic Parts Kit VY1A1403
Replacing the Plastic Parts Kit
VY1A1403
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
The replacement steps for some parts of the plastic kit are covered in other
procedures. See Table 2.
Table 2:
Plastic Kit Contents
Description
For replacement steps, see
Power terminal shield
“Replacing the Power Terminal Shield” beginning on
page 21
Conduit tray
“Replacing the Filter Board (VX4A1115) and Motor
Current Sensors (VY1A1108)” beginning on page 29
EMC tray
“Replacing the EMC Tray” beginning on page 23
Filter board shield
“Replacing the Filter Board (VX4A1115) and Motor
Current Sensors (VY1A1108)” beginning on page 29
SCR assembly shield
“Replacing the SCR Modules (VZ3TM1425M1671,
VZ3TM1600M1671) and Diode Modules
(VZ3DM1600M1671)” beginning on page 77
Remove the Front Cover
Using a size 2 Phillips driver, remove nine screws and take the front cover
off the drive. See Figure 7 on page 20.
Replacing the Power Terminal Shield
If the transparent power terminal shield is cracked, broken, or damaged,
replace it as follows.
1. The power terminal shield has two retaining tabs (A, Figure 8 on
page 22) on the right that fit into slots on the conduit tray, and three
mounting holes (B, Figure 8 on page 22) on the left that fit over posts on
the side panel of the drive. Disengage the shield from the retaining tabs
and mounting slots and remove it from the drive.
NEXT STEP: If you are also replacing the EMC tray, perform the steps in
“Replacing the EMC Tray” beginning on page 23 before installing the
new power terminal shield.
2. If you are only replacing the power terminal shield, install the new shield
as shown in Figures 8 and 9 on page 22.
Labels for the new shield are included in the plastic kit. Add the new
labels in the same positions as on the old shield.
3. Replace the front cover. Using a size 2 Phillips driver, secure the front
cover with nine screws. See Figure 7 on page 20. Tighten the screws to
5.5 N•m (48.7 lb-in).
© 2009 Schneider Electric All Rights Reserved
21
Installation Procedures for Level 1 Parts
Replacing the Plastic Parts Kit VY1A1403
30072-452-80
04/2009
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Install the power terminal shield as shown in Figures 8 and 9.
• Before installing the shield, ensure that it has no tears or cracks. If the
shield is damaged, install a new piece from the plastic kit. See page 21.
• Do not install a damaged shield.
Failure to follow these instructions will result in death or serious
injury.
Figure 8:
Power Terminal Shield
A
A
Figure 9:
Power Terminal Shield Retaining Posts
B
22
B
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 1 Parts
Replacing the Plastic Parts Kit VY1A1403
Replacing the EMC Tray
Replace the EMC tray as follows.
1. Using a T-20 Torx driver, remove three screws (A) securing the EMC
tray to the control module mounting plate and remove the tray from the
drive. See Figure 10.
Figure 10:
Table 3:
EMC Tray
EMC Tray Hardware Torque
Values
A (x3)
Torque Range
Item
Description
A
(3) T-20 screws 0.4–0.6
3.5–5.3
B
(1) Size 2
Phillips screw
(20 mm length)
0.4–0.6
3.5–5.3
C
(2) Size 2
Phillips screws
(10 mm length)
0.4–0.6
N•m
lb-in
B
3.5–5.3
C
C
2. Using a size 2 Phillips driver, remove three screws (B and C) securing
the cable clamps to the metal EMC plate, and remove the clamps from
the plate. See Figure 10.
NOTE: Note the differences in the cable clamps and screws. The
screw (B) in the large clamp is longer than the screws (C) in the two
shorter clamps.
3. Remove the metal EMC plate from the plastic tray and discard the
plastic tray.
4. Place the metal EMC plate into the new plastic tray.
5. Using a size 2 Phillips driver, install the cable clamps on the EMC plate
with three screws (B and C). See Figure 10.
6. Using a T-20 Torx driver, secure the plastic EMC tray to the control
module mounting plate with mounting three screws (A). See Figure 10.
7. Tighten the hardware to the torque values listed in Table 3.
Replace the Power Terminal Shield
Replace the power terminal shield as illustrated in Step 2 of “Replacing the
Power Terminal Shield” on page 21.
Replace the Front Cover
Replace the front cover. Using a size 2 Phillips driver, secure the front cover
with nine screws. See Figure 7 on page 20. Tighten the screws to 5.5 N•m
(48.7 lb-in).
© 2009 Schneider Electric All Rights Reserved
23
Installation Procedures for Level 1 Parts
Replacing the Internal Fans VZ3V1213
30072-452-80
04/2009
Replacing the Internal Fans
VZ3V1213
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
Remove the Front Cover
1. Using a size 2 Phillips driver, remove nine screws and take the front
cover off the drive. See Figure 7 on page 20.
Replace the Internal Fan
2. Remove the internal fan you are replacing as follows. See Figure 11.
— Using needle-nose pliers, carefully unplug the fan’s 2-pin connector
(A) from the top bracket.
— Using a T-20 Torx driver, remove four screws (B) securing the fan to
the top bracket and remove the fan from the drive.
Figure 11:
B (x4)
Internal Fans
A
A
B (x4)
3. Install the new fan as follows. See Figure 11.
— Using a T-20 Torx driver, secure the fan to the top bracket with four
screws (B). Tighten the screws to 1.1–1.7 N•m (9.7–15 lb-in).
— Plug the fan’s 2-pin connector (A) into the terminal on the top
bracket.
Replace the Front Cover
24
4. Replace the front cover. Using a size 2 Phillips driver, secure the front
cover with nine screws. See Figure 7 on page 20. Tighten the screws to
5.5 N•m (48.7 lb-in).
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 1 Parts
Replacing the Soft Charge Board VX5A1300
Replacing the Soft Charge Board
VX5A1300
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
1. Using a size 2 Phillips driver, remove nine screws and take the front
cover off the drive. See Figure 7 on page 20.
2. Using needle-nose pliers, carefully remove the following connections.
See Table 4 and Figure 12 for connector locations.
Table 4:
Soft Charge Board Wiring
Wire
No.1
Terminal
No.
Description
To:
E110
CN2A
9-pin, red
PB2 X30 (9-pin)
E109
E108
SCR3
CNL3G
2-pin,
violet/black
3
Terms. 4 & 5
CNL2G
2-pin,
green/black
SCR 2
Terms. 4 & 5
E107
CNL1G
2-pin,
yellow/black
SCR 1
Terms. 4 & 5
E111
CN7A
2-pin, black
PB X31
1
See the schematic on page 106 for complete drive wiring.
Wire numbers are given for cross referencing the wires with
the wiring table and the schematic. The numbers do not
appear on the wires.
2
PB: Power board
3
SCR: Silicon controlled rectifier
— At the top of the soft charge board, from left to right remove: the
9-pin connector from terminal CN2A, the 2-pin connector from
terminal CNL3G, the 2-pin connector from terminal CNL2G, and the
2-pin connector from terminal CNL1G.
— At the left side of the board, remove the 2-pin connector from
terminal CN7A.
Figure 12:
Soft Charge Board
A (x4)
CN2A
CNL3G
CNL1G
CNL2G
CN7A
3. Using needle-nose pliers, compress the four plastic mounting posts (A,
Figure 12), one at a time, while lifting the soft charge board off the posts.
Remove the soft charge board from the drive.
4. Press the new soft charge board down over the four mounting posts (A,
Figure 12) until it is securely seated.
5. Install five connections on the new soft charge board. See Table 4 and
Figure 12 for connector locations.
6. Replace the front cover. Using a size 2 Phillips driver, secure the front
cover with nine screws. See Figure 7 on page 20. Tighten the screws to
5.5 N•m (48.7 lb-in).
© 2009 Schneider Electric All Rights Reserved
25
Installation Procedures for Level 1 Parts
Replacing the SCR Snubber Board VX4A1200
30072-452-80
04/2009
Replacing the SCR Snubber
Board VX4A1200
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• When the controller is damaged, voltage may remain on certain energy
storage capacitors after de-energization of the controller and discharge
of the main capacitor bank.
• Before working on or near assemblies containing energy storage
capacitors, verify that the capacitor voltages are less than 42 Vdc.
• The following assemblies have energy-storing capacitors:
— SCR snubber board. See Figure 14 on page 27.
• Always check for the presence of voltage using a voltmeter set to the
1000 Vdc scale. When voltage is present, allow the voltmeter to
discharge the capacitor’s stored charge. Refer to “Discharging Stored
Energy in Capacitors” on page 13.
Failure to follow these instructions will result in death or serious
injury.
1. Using a size 2 Phillips driver, remove nine screws and take the front
cover off the drive. See Figure 7 on page 20.
SCR Snubber Board Wiring
Wire
No.1
Terminal
Description To:
No.
E131
X1
E130
X4
Red
PO/+ bus bar
E133
X5
Black
PC/- bus bar
E126
X10
Red,
0.25 in.,
1-pin
PB2 RFS+X10
E171
X11
Red,
0.19 in.,
1-pin
PB RFS+X11
1
See the schematic on page 106 for complete drive wiring.
Wire numbers are given for cross referencing the wires
with the wiring table and the schematic. The numbers do
not appear on the wires.
2
PB: Power board
26
Figure 13:
SCR Snubber Board Layout
L1 bus bar
X1
X4
X5
X11
Green
2. Using needle-nose pliers, carefully remove all connections from the
SCR snubber board. See Table 5 and Figure 13 for the connection
locations.
X10
Table 5:
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 1 Parts
Replacing the Fan Control Board VX5A1400
3. Using a 7 mm socket wrench, remove two nuts (A, Figure 14) securing
the SCR snubber board to the standoffs on the SCR L2 and L3 bus bars
and remove the snubber board from the drive.
Figure 14:
Table 6:
SCR Snubber Board Hardware
Torque Values
SCR Snubber Board
A
A
Torque Range
Item
A
Description
(2) 7 mm nuts
N•m
lb-in
1.1–1.7
9.7–15
4. Using a 7 mm socket wrench, secure the new SCR snubber board to the
standoffs on the SCR L2 and L3 bus bars with two nuts (A, Figure 14).
Tighten the nuts to the torque values shown in Table 6.
5. Replace all connections to the SCR snubber board. See Table 5 and
Figure 13 on page 26 for the connection locations.
6. Replace the front cover. Using a size 2 Phillips driver, secure the front
cover with nine screws. See Figure 7 on page 20. Tighten the screws to
5.5 N•m (48.7 lb-in).
Replacing the Fan Control Board
VX5A1400
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
1. Using a size 2 Phillips driver, remove nine screws and take off the front
cover of the drive. See Figure 7 on page 20.
2. Remove the power terminal shield as described in Step 1 of “Replacing
the Power Terminal Shield” on page 21.
© 2009 Schneider Electric All Rights Reserved
27
Installation Procedures for Level 1 Parts
Replacing the Fan Control Board VX5A1400
Table 7:
Fan Control Board Wiring
Wire
No.1
Terminal
No.
Description
To:
E124
X4
5-pin,
violet/green/
yellow
Fan control
terminal block
TB1
X1
5-pin,
violet/green/
yellow
X2
3-pin,
yellow
E114
X3
9-pin,
black/white/
brown/blue with
yellow and
green ground
wire
FB X11 & X12
—
X6
Not used
—
E118
E105
FB2 X1
FB X2
FB X3
PB3 X14
30072-452-80
04/2009
3. Remove the following connections from the fan control board. See
Table 7 and Figure 15 for connector locations.
— From the top of the board, remove from left to right: the 5-pin
connector from terminal X4, the 5-pin connector from terminal X1,
and the 3-pin connector from terminal X2.
— From the bottom left of the board, remove the 9-pin connector from
terminal X3.
4. Using a T-10 Torx driver, remove 1 screw (A, Figure 15) from the board
between connectors X1 and X4.
5. Using needle-nose pliers, compress the four plastic mounting posts (B,
Figure 15), one at a time, while lifting the board off the posts. Remove
the board from the drive.
Figure 15:
1
See the schematic on page 105 for complete drive wiring.
Wire numbers are given for cross referencing the wires with
the wiring table and the schematic. The numbers do not
appear on the wires.
2
FB: Filter board
3
PB: Power board
Fan Control Board
X4
X3
X1
A
X2
B (x4)
6. Press the new fan control board down over the four mounting posts until
it is securely seated.
7. Using a T-10 Torx driver secure the board with one screw (A, Figure 15).
Tighten the screw to 0.8 N•m (7.1 lb-in).
8. Install the four connections on the new fan control board. See Table 7
and Figure 15 for connector locations.
9. Replace the power terminal shield as illustrated in Step 2 on page 27.
10. Replace the front cover. Using a size 2 Phillips driver, secure the front
cover with nine screws. See Figure 7 on page 20. Tighten the screws to
5.5 N•m (48.7 lb-in).
28
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Replacing the Filter Board
(VX4A1115) and Motor Current
Sensors (VY1A1108)
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• When the controller is damaged, voltage may remain on certain energy
storage capacitors after de-energization of the controller and discharge
of the main capacitor bank.
• Before working on or near assemblies containing energy storage
capacitors, verify that the capacitor voltages are less than 42 Vdc.
• The following assemblies have energy-storing capacitors:
— Filter board. See Figure 19 on page 31.
• Always check for the presence of voltage using a voltmeter set to the
1000 Vdc scale. When voltage is present, allow the voltmeter to
discharge the capacitor’s stored charge. Refer to “Discharging Stored
Energy in Capacitors” on page 13.
Failure to follow these instructions will result in death or serious
injury.
© 2009 Schneider Electric All Rights Reserved
29
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
30072-452-80
04/2009
Remove the Front Cover
1. Using a size 2 Phillips driver, remove nine screws and take the front
cover off the drive. See Figure 7 on page 20.
Remove the Power Terminal Shield
2. The power terminal shield has two retaining tabs (A, Figure 16) on the
right that fit into slots on the conduit tray, and three mounting holes
(B, Figure 17) on the left that fit over posts on the side panel of the drive.
Disengage the shield from the retaining tabs and mounting slots and
remove it from the drive.
Figure 16:
Power Terminal Shield
A
A
Figure 17:
Power Terminal Shield Retaining Posts
B
30
B
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Remove the EMC Tray
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
3. Using a T-20 Torx driver, remove three screws (A) securing the EMC
tray to the control module mounting plate and remove the tray from the
drive. See Figure 18.
Figure 18:
EMC Tray
A
(x3)
Remove the Filter Board Shield
4. Remove the filter board shield as follows.
— Using a T-30 Torx driver, remove six screws (A, Figure 19) securing
the filter board shield to the output bus bars.
Figure 19:
Filter Board Shield
Filter board shield
Filter board
A (x6)
© 2009 Schneider Electric All Rights Reserved
31
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
30072-452-80
04/2009
— Disconnect the cable (wire E103) from terminal X11 of the power
board, remove it from the cable clamp, and route it under the TB1
bracket and through the hole in the filter board shield. See Figures
20 and 21.
— Remove the filter board shield from the drive.
Figure 20:
Power Board Connection X11
TB1
bracket
Clamp
X11
(wire E103)
Figure 21:
Filter Board Shield
Filter board shield
Wire E103
32
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Loosen the Output Bus Bars
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
5. Loosen the output bus bars as follows.
— Using a T-30 Torx driver, remove three screws and washers
(A, Figure 22) securing the output bus bars to the red insulators at
terminals U/T1, V/T2, and W/T3.
— Using an 18 mm socket wrench, remove three bolts with two
washers each (B, Figure 22) securing the output bus bars to the DC
bus plates.
Figure 22:
Output Bus Bars
B
B
A
© 2009 Schneider Electric All Rights Reserved
B
A
A
33
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
Remove the Conduit Tray
30072-452-80
04/2009
6. Remove the conduit tray as follows. See Figure 23.
— Rotate the T3 bus bar to the right as shown in Figure 23.
— Using a 10 mm socket wrench, remove two nuts securing the conduit
tray to the drive frame and remove the tray.
Figure 23:
Conduit Tray
Conduit tray
T3 bus bar
10 mm
nuts (x2)
34
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
Remove the Filter Board and Fan
Connections
7. Using needle-nose pliers, remove the six 1-pin connections from the
filter board. See Table 8 and Figure 24 for connector locations.
Table 8:
Figure 24:
Wire
No.1
Filter Board Wiring
Terminal
No.
Description
X1
Yellow, 0.25 in.
connector
X2
Green, 0.25 in.
connector
X3
Violet, 0.25 in.
connector
X11
Yellow, 0.19 in.
connector
X12
Green, 0.19 in.
connector
X13
Violet, 0.19 in.
connector
E115
A7/X11
Black sleeve,
9-pin
Heatsink fan 1
E125
A7/X12
Black sleeve,
9-pin
Heatsink fan 2
E118
E120
Filter Board Connections
To:
FCB2 X1
PB3 X7
1
See the schematic on page 105 for complete drive wiring.
Wire numbers are given for cross referencing the wires with
the wiring table and the schematic. The numbers do not
appear on the wires.
2
FCB: Fan control board
3
PB: Power board
8. Disconnect the 9-pin fan connectors from terminals A7/X11 and A7/X12.
See Figure 25.
Figure 25:
Filter Board Fan Connections
A7/X11
© 2009 Schneider Electric All Rights Reserved
A7/X12
35
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
Remove the Filter Board
30072-452-80
04/2009
9. Remove the filter board as follows.
— Using a T-30 Torx driver, remove six screws (A, Figure 26) securing
the filter board to the input bus bars.
— Using a 7 mm socket wrench, remove one nut (B, Figure 26)
securing the filter board to the bracket on the drive frame.
— Using a size 3 Phillips driver, remove the grounding screw and
washer (C, Figure 26) securing the filter board to the drive frame.
NOTE: Note whether the screw is installed in the grounded or nongrounded position for reinstallation. Figure 26 shows the screw in the
grounded position.
— Gently press in on the tabs at the top and bottom of the fan
connectors at terminals A7/X11 and A7/X12 and push the
connectors down through the cutouts in the board. See Figure 27.
— Remove the filter board from the drive. The output bus bar segments
come out with the board.
Figure 26:
A (x6)
Figure 27:
36
Filter Board Mounting Hardware
C (grounded)
C (non-grounded)
B
Fan Connector Detail
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
Remove the Motor Current Sensors
10. Remove the motor current sensors from the filter board as follows:
— Remove the E103 cable connections from the motor current sensors.
See Figure 28.
— Slide the output bus bars out of the motor current sensors.
— Using a T-20 Torx driver, remove six screws (E, Figure 28) securing
the motor current sensors to the filter board, and using a 7 mm
socket wrench, remove six nuts (F, Figure 29) from the back of the
filter board.
Figure 28:
Table 9:
Filter Board Front
Motor Current Sensor
Hardware Torque Values
E103
Torque Range
Item
Description
N•m
lb-in
E
(6) T-20 screws 1.2
10.6
F
(6) 7 mm nuts
10.6
1.2
Motor current
sensor (x3)
E (x6)
Output bus bar (x3)
Figure 29:
Filter Board Back
F (x6)
NEXT STEP: In the next steps you can install a new filter board, install
new motor current sensors, or both. If you are installing new motor
current sensors, you must replace all three current sensors.
Install the Motor Current Sensors
11. Install the motor current sensors as follows.
— Install the motor current sensors on the filter board and secure them
with six T-20 Torx screws (E, Figure 28) and six 7 mm nuts (F,
Figure 29) each. Tighten the hardware to the values specified in
Table 9.
— Slide the output bus bars through the motor current sensors as
illustrated in Figure 28.
NOTE: Note the markings on the output bus bars and install them in the
positions shown in Figure 28. U/T1 (left), V/T2 (center), W/T3 (right).
© 2009 Schneider Electric All Rights Reserved
37
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
30072-452-80
04/2009
— Connect cable E103 to the motor current sensors. See Figure 28 on
page 37.
NOTE: Note the position of the wires. T1: yellow/red/black;
T2: green/red/black; T3: violet/red/black.
Install the Filter Board
12. Install the filter board as follows:
— Position the filter board and output bus bars in the drive as shown in
Figure 30. Gently press the top and bottom tabs on the fan
connectors (Figure 31 on page 39) and push them up through the
cutouts on the filter board.
— Using a T-30 Torx driver, secure the filter board to the input bus bars
with six screws (A, Figure 30).
— Using a 7 mm socket wrench, secure the right edge of the filter board
to the bracket on the drive frame with one nut (B, Figure 30).
— Using a size 3 Phillips driver, install the grounding screw and washer
(C, Figure 30).
NOTE: Be sure to install the size 3 Phillips screw and washer (C) in the
original position. Figure 30 shows the screw in the grounded position.
— Tighten the hardware to the torque values specified in Table 10.
Figure 30:
Table 10:
Filter Board Hardware Torque
Values
A (x6)
Filter Board Mounting Hardware
C (grounded)
C (non-grounded)
B
Torque Range
Item
Description
A
(6) T-30 screws 5.5
48.7
B
(1) 7 mm nut
1.2
10.6
C
(1) Size 3
Phillips screw
5.5
48.7
N•m
38
lb-in
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
Figure 31:
Replace the Filter Board and Fan
Connections
Fan Connector Detail
13. Replace the fan and filter board connections as follows.
— Connect the 9-pin fan connectors at terminals A7/X11 and A7/X12.
See Figure 32.
— Replace the six 1-pin connections on the filter board. See Table 11
and Figure 33 for connector locations.
Table 11:
Wire
No.1
Filter Board Wiring
Figure 32:
Terminal
No.
Description
X1
Yellow, 0.25 in.
connector
X2
Green, 0.25 in.
connector
X3
Violet, 0.25 in.
connector
X11
Yellow, 0.19 in.
connector
X12
Green, 0.19 in.
connector
X13
Violet, 0.19 in.
connector
E115
A7/X11
Black sleeve,
9-pin
Heatsink fan 1
E125
A7/X12
Black sleeve,
9-pin
Heatsink fan 2
E118
E120
Filter Board Fan Connections
To:
FCB2 X1
PB3 X7
A7/X11
Figure 33:
1
See the schematic on page 105 for complete drive wiring.
Wire numbers are given for cross referencing the wires with
the wiring table and the schematic. The numbers do not
appear on the wires.
2
FCB: Fan control board
3
PB: Power board
© 2009 Schneider Electric All Rights Reserved
A7/X12
Filter Board Connections
39
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
Replace the Conduit Tray
30072-452-80
04/2009
14. Replace the conduit tray as follows. If the tray is cracked, broken, or
damaged, replace it with a new piece from the plastic kit. See page 20.
— Turn the T3 bus bar to the right as shown in Figure 34.
— Using a 10 mm socket wrench, secure the conduit tray to the drive
frame with two nuts. See Figure 34. Tighten the nuts to 5.5 N•m
(48.7 lb-in).
— Straighten the T3 bus bar to its correct position.
Figure 34:
Conduit Tray
Conduit tray
T3 bus bar
10 mm
nuts (x2)
40
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
Secure the Output Bus Bars
15. Secure the output bus bars as follows.
— Using a 18 mm socket wrench, secure the output bus bars to the DC
bus plates with three bolts (B, Figure 35).
— Using a Torx T-30 driver, secure the output bus bars to the red
insulators at terminals U/T1, V/T2, and W/T3 with three screws
(A, Figure 35).
— Tighten the hardware to the torque values specified in Table 12.
Table 12:
Output Bus Bar Hardware
Torque Values
Figure 35:
Output Bus Bars
B
B
B
Torque Range
Item
Description
N•m
lb-in
A
(3) T-30 screws
5.5
and washers
48.7
B
(3) 18 mm bolts 45
398
A
Replace the Filter Board Shield
A
A
16. Replace the filter Board shield as follows.
— If the shield is cracked, broken, or damaged, replace it with a new
piece from the plastic kit. See page 20.
DANGER
HAZARD OF ELECTRIC SHOCK,
EXPLOSION, OR ARC FLASH
• Install the filter board shield as shown in
Figure 37 on page 42.
• Before installing the shield, ensure that it has
no tears or cracks. If the shield is damaged,
install a new piece from the plastic kit. See
page 21.
— Route the cable from the motor current sensors (wire E103) through
the hole in the filter board shield and under the TB1 bracket. See
Figure 36 and Figure 38 on page 42.
Figure 36:
Filter Board Shield
Filter board shield
Wire E103
• Do not install a damaged shield.
Failure to follow these instructions will
result in death or serious injury.
© 2009 Schneider Electric All Rights Reserved
41
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
30072-452-80
04/2009
— Using a T-30 Torx driver, secure the filter board shield to the output
bus bars with six screws (A, Figure 37). Tighten the screws to the
torque values specified in Table 13.
Figure 37:
Table 13:
Filter Board Shield
Filter board shield
Filter Board Shield Hardware
Torque Values
Torque Range
Item
Description
N•m
A
(6) T-30 screws 5.5
lb-in
48.7
A (x6)
— Route the cable from the motor current sensors (wire E103) through
the hole in the filter board, connect it to terminal X11 of the power
board, and secure it in the cable clamp on the power board. See
Figures 37 and 38.
Figure 38:
Power Board Connection X11
TB1
bracket
Clamp
X11
(wire E103)
42
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Replace the EMC Tray
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
17. Using a T-20 Torx driver, securing the EMC tray to the control module
plate with three screws. See Figure 39. Tighten the screws to
1.1–1.7 N•m (9.7–15.0 lb-in).
Figure 39:
EMC Tray
A
(x2)
© 2009 Schneider Electric All Rights Reserved
43
Installation Procedures for Level 1 Parts
Replacing the Filter Board (VX4A1115) and Motor Current Sensors (VY1A1108)
Replace the Power Terminal Shield
30072-452-80
04/2009
18. Replace the power terminal shield as follows.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Install the power terminal shield as shown in Figures 40 and 41.
• Before installing the shield, ensure that it has no tears or cracks. If the
shield is damaged, install a new piece from the plastic kit. See page 21.
• Do not install a damaged shield.
Failure to follow these instructions will result in death or serious
injury.
— Hook the mounting holes on the left side of the shield over the posts
on the side panel of the drive (B, Figure 40).
— Insert the retaining tabs on the right side of the shield in the slots on
the conduit tray (A, Figure 41).
Figure 40:
Power Terminal Shield Retaining Posts
B
Figure 41:
B
Power Terminal Shield
A
A
Replace the Front Cover
44
19. Replace the front cover. Using a size 2 Phillips driver, secure the front
cover with nine screws. See Figure 7 on page 20. Tighten the screws to
5.5 N•m (48.7 lb-in).
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for
Level 2 Parts
Installation Procedures for Level 2 Parts
Disassembly Steps for Accessing Level 2 Parts
The level 2 parts are under the control module assembly, the bus assembly,
or the fan plate. They are:
Power board
Capacitors
Gate driver boards
SCR assembly shield (plastic kit)
Temperature sensors
SCR modules
Power IGBT modules
Diode modules
You must remove equipment from the drive as described in the following
section to access the level 2 parts.
Disassembly Steps for Accessing
Level 2 Parts
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
This section contains instructions for removing the following parts from the
drive:
© 2009 Schneider Electric All Rights Reserved
❏
Front cover
❏
Power board connections
❏
Power terminal shield
❏
Soft charge board connections
❏
EMC tray
❏
Fan control board connections
❏
Control module assembly
❏
Bus plate assembly
❏
Top crossbrace
❏
Gate driver boards
❏
Fan plate
❏
DC bus plate
❏
SCR assembly shield
45
Installation Procedures for Level 2 Parts
Disassembly Steps for Accessing Level 2 Parts
30072-452-80
04/2009
You must perform some or all of the steps in this section to access the
level 2 parts. Consult Table 14 for the disassembly steps that must be
performed to access the spare parts you are replacing.
Table 14:
Disassembly Steps
If you are replacing:
Steps 1–6
“Replacing the Power Board
VX5A1HC2025, VX5A1HC2531,
VX5A71HC28N4” beginning on
page 59
Gate driver boards
VX5A1201 and
VX5A1202
Steps 1–16
“Replacing the Gate Driver
Boards VX5A1201 and
VX5A1202” beginning on
page 64
Temperature sensors
VZ3G1104
Steps 1–19
“Replacing the Temperature
Sensors, VZ3G1104” beginning
on page 70
Power IGBT modules
VZ3IM1602M1271
VZ3IM1402M1271
Steps 1–20
“Replacing the Power IGBT
Modules VZ3IM1602M1271, and
VZ3IM1402M1271” beginning on
page 72
Capacitors
VY1ADC1112
VY1ADC1114
Steps 1–20
“Replacing the Capacitors
VY1ADC1112 and VY1ADC1114”
beginning on page 75
Steps 1–12
“Replacing the SCR Modules
(VZ3TM1425M1671,
VZ3TM1600M1671) and Diode
Modules (VZ3DM1600M1671)”
beginning on page 77
Power boards
VX5A1HC2025
VX5A1HC2531
VX5A71HC28N4
SCR modules
VZ3TM1425M1671
VZ3TM1600M1671
Diode modules
VZ3DM1600M1671
46
Perform
Then follow
disassembly steps: procedure:
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Disassembly Steps for Accessing Level 2 Parts
Remove the Front Cover
1. Using a size 2 Phillips driver, remove nine screws and take the front
cover off the drive. See Figure 7 on page 20.
Remove the Power Terminal Shield
2. The power terminal shield has two retaining tabs (A, Figure 42) on the
right that fit into slots on the conduit tray, and three mounting holes (B,
Figure 43) on the left that fit over posts on the side panel of the drive.
Disengage the shield from the retaining tabs and mounting slots and
remove it from the drive.
Figure 42:
Power Terminal Shield
A
A
Figure 43:
Power Terminal Shield Retaining Posts
B
© 2009 Schneider Electric All Rights Reserved
B
47
Installation Procedures for Level 2 Parts
Disassembly Steps for Accessing Level 2 Parts
Remove the EMC Tray
30072-452-80
04/2009
3. Using a T-20 Torx driver, remove three screws (A) securing the EMC
tray to the control module mounting plate and remove the tray from the
drive. See Figure 44.
Figure 44:
EMC Tray
A (x3)
Remove the Control Module Assembly
4. Remove the following connections.
— Remove the 5-pin connector from fan control board terminal X4. See
Figure 45.
— Remove the 26-pin ribbon cable from motor control board terminal
X3. See Figure 46 on page 49.
Figure 45:
Fan Control Board Terminal X4
X4
48
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Disassembly Steps for Accessing Level 2 Parts
Figure 46:
Control Module Assembly Front
X3
10 mm
nut
10 mm
nut
5. Using a 10 mm socket wrench, remove two nuts securing the control
module assembly to the drive frame. See Figure 46.
6. Turn the assembly over, disconnect the ribbon cable from the back
(wire E112, Figure 47), and remove the assembly from the drive.
Figure 47:
Control Module Assembly Back
Wire
E112
NEXT STEP: If you are replacing the power board, skip to “Replacing
the Power Board VX5A1HC2025, VX5A1HC2531, VX5A71HC28N4”
beginning on page 59.
© 2009 Schneider Electric All Rights Reserved
49
Installation Procedures for Level 2 Parts
Disassembly Steps for Accessing Level 2 Parts
Remove the Top Crossbrace
30072-452-80
04/2009
7. Using a 10 mm socket wrench, remove six nuts (A, Figure 48) securing
the top crossbrace to the fan plate and the drive frame, and remove the
crossbrace.
Figure 48:
Fan Plate and Crossbrace
B (x4)
Fan Plate
A (x6)
Crossbrace
Remove the Fan Plate
8. Using a T-30 Torx driver, remove four screws (B, Figure 48) securing
the fan plate to the drive frame.
9. Using a T-30 Torx right-angle driver, remove three screws (C, Figure 49)
from the right sides of the three red insulators at the PO, PA/+, and PC/terminals.
10. Using an 18 mm socket wrench, remove five nuts and bolts from the PO,
PA/+, and PC bus bars (D, Figure 49). Each bolt has two flat washers
and one lock washer.
11. Remove the internal fan connections from the back of the fan plate, and
remove the fan plate from the drive. See Figure 50 on page 51.
Figure 49:
Fan Plate with Bus Bar Detail
D (x5)
C (x3)
50
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Disassembly Steps for Accessing Level 2 Parts
Figure 50:
Internal Fan Connections
Internal fan connections
Remove the SCR Assembly Shield
12. Remove the transparent shield over the SCR assembly. See Figure 51.
Figure 51:
SCR Assembly Shield
SCR assembly shield
NEXT STEP: If you are replacing the SCR modules or Diode modules,
skip to “Replacing the SCR Modules (VZ3TM1425M1671,
VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)”
beginning on page 77.
© 2009 Schneider Electric All Rights Reserved
51
Installation Procedures for Level 2 Parts
Disassembly Steps for Accessing Level 2 Parts
30072-452-80
04/2009
Remove the Power Board Connections
NOTE: Take care not to damage the LED (see Figure 52) when
removing, handling, or installing the power board.
13. Using needle-nose pliers, carefully remove the power board connections
listed in Table 15. See Figure 52 for the connection locations.
Table 15:
Power Board Wiring
Figure 52:
Wire
No.1
Terminal
No.
Description To:
E103
X11
9-pin, multi
color
Motor current
sensors
X14
3-pin, yellow
FCB2
E136
UD0
1-pin,
blue
Phase U
DC bus plate
E141
UD -R1
1-pin,
white
Bleeder resistor
X93
E139
UD +R1
1-pin,
white
Bleeder resistor
UD+R1
E105
X2
X6
X30
X7
X2
X5
X91
RFS+X10
X1
X31
3
RFS +X11
1-pin,
red
SCR snubber
board X11
E126
RFS +X10
1-pin,
red
SCR snubber
board X10
E143
X5
GDB4 U X2,
6-pin,
yellow/green/ GDB V X2,
violet
GDB W X2
E120
X7
6-pin,
Filter board
yellow/green/
X11, X12, X13
violet
—
X2
10-pin,
gray
Motor control
board X2
E129
X93
1-pin,
violet
Dynamic braking
board X205
E142
X3
18-pin,
gray
GDB W X31
E100
X8
10-pin,
white
GDB V X81
E106
X21
2-pin,
red/black
Internal fan
E106
X22
2-pin,
red/black
Internal fan
E112
X4
10-pin, gray
Control module
—
X16
Not used
—
—
X91
Not used
—
—
X92
Not used
—
1
See the schematic on page 106 for complete drive wiring.
Wire numbers are given for cross referencing the wires
with the wiring table and the schematic. The numbers do
not appear on the wires.
2
FCB: Fan control board
3
SCR: Silicon controlled rectifier
4
GDB: Gate driver board
5
The optional dynamic braking board may not be present in
the drive.
X8
X16
RFS+X11
X22 X21
E171
52
Power Board Connections
X4
X3
UD0
X11
UD-R1
X14
X92
FRAGILE
(LED with sleeving)
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Remove the Soft Charge Board
Connections
Installation Procedures for Level 2 Parts
Disassembly Steps for Accessing Level 2 Parts
14. Using needle-nose pliers, remove soft charge board connections
CNL1G, CNL2G, and CNL3G. See Figure 53 for terminal locations.
Figure 53:
Soft Charge Board Connections
CNL2G
CNL3G CNL1G
Remove the Fan Control Board
Connections
15. Remove the connections from terminals X1 and X3 of the fan control
board. See Figure 54 for terminal locations.
Figure 54:
Fan Control Board Connections X1 and X3
X3
© 2009 Schneider Electric All Rights Reserved
X1
53
Installation Procedures for Level 2 Parts
Disassembly Steps for Accessing Level 2 Parts
Remove the Bus Plate Assembly
30072-452-80
04/2009
16. Remove the bus plate assembly as follows. See Figure 55.
— Using a Using a T-30 Torx driver, remove one screw and washer (A)
securing the bus plate assembly to the red insulator on the drive
frame.
— Using a 16 mm socket wrench, remove two bolts (B) securing the
bus plate assembly to the PC/- bus.
— Using a 16 mm socket wrench, remove two bolts (C) securing the
bus plate assembly to the PA/+ bus.
— Using a 13 mm socket wrench, remove four screws (D) securing the
bus plate assembly to the phase W positive and negative buses.
— Using a 13 mm socket wrench, remove four screws (E) securing the
bus plate assembly to the phase V positive and negative buses.
— Using a 13 mm socket wrench, remove four screws (F) securing the
bus plate assembly to the phase U positive and negative buses.
— Remove the bus plate assembly from the drive.
Figure 55:
Bus Plate Assembly
C
B
A
F
E
D
NEXT STEP: If you are replacing a gate driver board, skip to
“Replacing the Gate Driver Boards VX5A1201 and VX5A1202” on
page 64.
54
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Remove the Gate Driver Board
NOTE: Perform the steps in this section only if
you are removing a gate driver board to access
parts under the DC bus plate.
If you are replacing a gate driver board, skip to
“Replacing the Gate Driver Boards VX5A1201
and VX5A1202” on page 64.
If you are removing equipment to make repairs
in phase U, remove the left gate driver board.
Begin with Step 17 on this page.
Installation Procedures for Level 2 Parts
Disassembly Steps for Accessing Level 2 Parts
17. If you are removing gate driver board U, perform these steps to remove
the L1, L2, and L3 bus bars. If you removing gate driver boards V or W,
skip to Step 18 on page 56.
— Remove the connections from terminals X4 and X5 on the SCR
snubber board. See Figure 56.
— Using an 18 mm socket wrench, remove three bolts (A, Figure 57)
joining the L1, L2, and L3 bus bars to the lower bus segments.
— Using an 18 mm socket wrench, remove three bolts (B, Figure 57)
joining the L1, L2, and L3 bus bars to the SCR bus segments and
remove the bus bars. See Figure 57.
Figure 56:
SCR Snubber Board
If you are removing equipment to make repairs
in phase V, remove the center gate driver
board. Begin with Step 18 on page 56.
X4
If you are removing equipment to make repairs
in phase W, remove the right gate driver board.
Begin with Step 18 on page 56.
X5
Figure 57:
L1, L2, L3 Bus Bars
B
(x3)
L1
bar
L2
bar
L3
bar
A
(x3)
© 2009 Schneider Electric All Rights Reserved
55
Installation Procedures for Level 2 Parts
Disassembly Steps for Accessing Level 2 Parts
30072-452-80
04/2009
18. Remove the connections from the gate driver board that you are
removing. See Table 16 and Figure 58 on page 57.
19. Using a 7 mm socket wrench, remove 12 nuts securing the gate driver
board you are removing to the DC bus plate, and remove the gate driver
board from the drive. See Figure 58 on page 57.
NEXT STEP: If you are replacing a temperature sensor, skip to
“Replacing the Temperature Sensors, VZ3G1104” beginning on
page 70.
Table 16:
Wire No.1
Gate Driver Board Wiring
Terminal No.
Description
To:
1-pin, yellow
Power board X5
Gate Driver Board U (Left)
E143
X2
E144
X4
2-pin, black
Temperature sensor U
E138
X32
18-pin, gray
GDB2 V X31
E129
X51
1-pin, blue
DBB X203
E127
X52
1-pin, blue
GDB V, X51
E100
X82
10-pin, white
GDB V X81
—
X31
Not used
—
—
X81
Not used
—
Power board X5
Gate Driver Board V (Center)
E143
X2
1-pin, green
E127
X51
1-pin, blue
GDB U, X52
E123
X52
1-pin, blue
GDB W, X51
E100
X81
10-pin, white
GDB U, X82, PB-X8
E102
X82
10-pin, white
GDB W, X81
E138
X31
18-pin, gray
GDB U, X32
E142
X32
18-pin, gray
GDB W, X31
E128
X4
2-pin, black
Temperature sensor V
Gate Driver Board W (Right)
56
E143
X2
1-pin, violet
Power board X5
E145
X4
2-pin, black
Temperature sensor W
E123
X51
1-pin, blue
GDB V, X52
E132
X52
1-pin, blue
Neutral on W power bus
E102
X81
10-pin, white
GDB V, X82
E142
X31
18-pin, gray
GDB V, X32 & PB X3
—
X32
Not used
—
—
X82
Not used
—
1
See the schematic on page 106 for complete drive wiring. Wire numbers are given for cross
referencing the wires with the wiring table and the schematic. The numbers do not appear on
the wires.
2
GDB: Gate driver board
3
DBB: Dynamic braking board. This option may not be present in the drive.
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Figure 58:
Installation Procedures for Level 2 Parts
Disassembly Steps for Accessing Level 2 Parts
Gate Driver Boards
GDB U
© 2009 Schneider Electric All Rights Reserved
7 mm
nuts
(x12)
GDB V
GDB W
57
Installation Procedures for Level 2 Parts
Disassembly Steps for Accessing Level 2 Parts
Remove the DC Bus Plate
NOTE: If you are removing equipment to make
repairs in phase U, remove the left DC bus
plate.
If you are removing equipment to make repairs
in phase V, remove the center DC bus plate.
If you are removing equipment to make repairs
in phase W, remove the right DC bus plate.
30072-452-80
04/2009
20. Remove the DC bus plate as follows. See Figure 59.
— Using an 18 mm socket wrench, remove one bolt (A) securing the
DC bus plate to the output bus bar.
— Using a size 2 Phillips driver, remove two screws securing the DC
bus plate to the IGBT modules (B) and four screws securing the bus
plate to the capacitors (C).
— Using a T-30 Torx driver, remove two 20 mm screws securing the
DC bus plate to the IGBT modules (D) and four 14 mm screws
securing the bus plate to the capacitors (E).
— Using a 10 mm socket wrench, remove two 6 mm standoffs
(F) and two 11 mm standoffs (G).
— Remove the DC bus plate from the drive.
NEXT STEP: If you are replacing the power IGBT modules, skip to
“Replacing the Power IGBT Modules VZ3IM1602M1271, and
VZ3IM1402M1271” beginning on page 72.
If you are replacing the capacitors, skip to “Replacing the Capacitors
VY1ADC1112 and VY1ADC1114” beginning on page 75.
Figure 59:
DC Bus Plate (Phase V Shown)
B
(x2)
F
(x2)
D
(x2)
G
(x2)
E
(x4)
C
(x4)
E
(x4)
A
58
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Replacing the Power Board
VX5A1HC2025, VX5A1HC2531,
VX5A71HC28N4
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
Installation Procedures for Level 2 Parts
Replacing the Power Board VX5A1HC2025, VX5A1HC2531, VX5A71HC28N4
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
Before performing the steps in this procedure, perform Steps 1–6 of
“Disassembly Steps for Accessing Level 2 Parts” beginning on page 45 to
remove the following parts from the drive:
© 2009 Schneider Electric All Rights Reserved
❏
The front cover
❏
The power terminal shield
❏
The EMC tray
❏
The control module assembly
59
Installation Procedures for Level 2 Parts
Replacing the Power Board VX5A1HC2025, VX5A1HC2531, VX5A71HC28N4
Remove the Soft Charge Board
Table 17:
1. Using needle-nose pliers, carefully remove the following connections
from the soft charge board. See Table 17 and Figure 60 for connector
locations.
Soft Charge Board Wiring
Wire
No.1
Terminal
No.
Description
To:
E110
CN2A
9-pin, red
PB2 X30 (9-pin)
E109
CNL3G
2-pin,
violet/black
SCR3 3
Terms. 4 & 5
CNL2G
2-pin,
green/black
SCR 2
Terms. 4 & 5
E107
CNL1G
2-pin,
yellow/black
SCR 1
Terms. 4 & 5
E111
CN7A
2-pin, black
PB X31
E108
30072-452-80
04/2009
1
See the schematic on page 106 for complete drive wiring.
Wire numbers are given for cross referencing the wires with
the wiring table and the schematic. The numbers do not
appear on the wires.
2
PB: Power board
3
SCR: Silicon controlled rectifier
— At the top of the board, from left to right remove: the 9-pin connector
from terminal CN2A, the 2-pin connector from terminal CNL3G, the
2-pin connector from terminal CNL2G, and the 2-pin connector from
terminal CNL1G.
— At the left side of the board, remove the 2-pin connector from
terminal CN7A.
Figure 60:
Soft Charge Board
A (x4)
CN2A
CNL3G
CNL1G
CNL2G
CN7A
2. Using needle-nose pliers, compress the four plastic mounting posts (A,
Figure 60), one at a time, while lifting the soft charge board off the posts.
Remove the soft charge board from the drive.
60
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Replacing the Power Board VX5A1HC2025, VX5A1HC2531, VX5A71HC28N4
Remove the Power Board Connections
NOTE: Take care not to damage the LED (see Figure 61) when
removing, handling, or installing the power board.
Table 18:
Power Board Wiring
Wire
No.1
Terminal
No.
Description To:
E103
X11
9-pin, multi
color
E105
X14
3-pin, yellow FCB2 X2
E136
UD0
1-pin,
blue
Phase U
DC bus plate
E141
UD -R1
1-pin,
white
Bleeder resistor
E139
UD +R1
1-pin,
white
Bleeder resistor
E171
RFS +X11
1-pin,
red
SCR3 snubber
board X11
E126
RFS +X10
1-pin,
red
SCR snubber
board X10
E129
X93
1-pin,
violet
Dynamic braking
board X24
E143
X5
GDB5 U X2,
6-pin,
yellow/green/ GDB V X2,
GDB W X2
violet
E120
X7
6-pin,
Filter board
yellow/green/
X11, X12, X13
violet
—
X2
10-pin,
gray
Motor control
board X2
E142
X3
18-pin,
gray
GDB W X31
E100
X8
10-pin,
white
GDB V X81
E106
X21
2-pin,
red/black
Internal fan
E106
X22
2-pin,
red/black
Internal fan
E112
X4
10-pin, gray
Control module
—
X16
Not used
—
—
X91
Not used
—
—
X92
Not used
—
3. Using needle-nose pliers, carefully remove all connections from the
power board except the connections at terminals X6, X30, and X31.
See Table 18 and Figure 61 for the connections.
Figure 61:
Power Board Connections
Motor current
sensors
X2
X6
X30
X7
X5
X91
X93
RFS+X10
See the schematic on page 106 for complete drive wiring.
Wire numbers are given for cross referencing the wires
with the wiring table and the schematic. The numbers do
not appear on the wires.
2
FCB: Fan control board
3
SCR: Silicon controlled rectifier
4
The optional dynamic braking board may not be present in
the drive.
5
GDB: Gate driver board
© 2009 Schneider Electric All Rights Reserved
X31
X8
X16
RFS+X11
X22 X21
1
X1
UD+R1
X4
X3
UD0
X11
UD-R1
X14
X92
FRAGILE
(LED with sleeving)
61
Installation Procedures for Level 2 Parts
Replacing the Power Board VX5A1HC2025, VX5A1HC2531, VX5A71HC28N4
30072-452-80
04/2009
Remove the Power Board
NOTE: Take care not to damage the LED (see Figure 62) when
removing, handling, or installing the power board.
4. Remove the old power board as follows. See Figure 62.
— Using a T-10 Torx driver, remove four screws (A) securing the power
board to the laminated bus assembly.
— Using needle-nose pliers, gently compress the five plastic mounting
posts (B), one at a time, while lifting the power board off the posts.
Carefully disconnect the connection between the power board and
the motor control board (C) as you remove the power board.
Figure 62:
Power Board
A
(x4)
C
E
(x4)
B
(x5)
D
(x5)
FRAGILE
(LED with sleeving)
Install the New Power Board
5. Transfer the connections from terminals X6, X30, and X31of the old
power board to the corresponding terminals on the new board. See
Figure 61 on page 61 for terminal locations.
6. Transfer the five plastic cable clamps (D, Figure 62) from the old power
board onto the new one as follows.
— To remove a clamp, pinch the clamp on the bottom side of the board
and push it up through the mounting hole.
62
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Replacing the Power Board VX5A1HC2025, VX5A1HC2531, VX5A71HC28N4
— Snap the cable clamps into the mounting holes on the new board.
7. Transfer the four soft charge board mounting posts (E, Figure 62 on
page 62) from from the old power board onto the new one as follows:
— Using a 7 mm socket wrench, remove the plastic nuts securing the
soft charge board mounting posts to the power board. The nuts are
on the back of the board.
— Push the posts into the corresponding mounting holes from the front
of the new power board and secure them at the back with the 7 mm
nuts. Tighten the nuts to 0.4–0.6 N•m (3.5–5.3 lb-in).
8. Gently push the new power board down over the five plastic mounting
posts (B, Figure 62 on page 62) until it is securely seated.
9. Using a T-10 Torx driver, secure the power board to the laminated bus
assembly with four screws (A, Figure 62 on page 62). Tighten the
screws to 0.5–0.7 N•m (4.4–6.2 lb-in).
10. Replace the power board wiring. See Table 18 and Figure 61 on
page 61 for the connection locations.
Replace the Soft Charge Board
11. Replace the soft charge board as follows.
— Press the new soft charge board down over the four mounting posts
(A, Figure 63) until it is securely seated.
— Install five connections to the new soft charge board. See Table 19
and Figure 63 for connector locations.
Table 19:
1
Soft Charge Board Wiring
Figure 63:
Wire
No.1
Terminal
No.
Description
To:
E110
CN2A
9-pin, red
PB2 X30
E109
CNL3G
2-pin,
violet/black
SCR3 3
Terms. 4 & 5
E108
CNL2G
2-pin,
green/black
SCR 2
Terms. 4 & 5
E107
CNL1G
2-pin,
yellow/black
SCR 1
Terms. 4 & 5
E111
CN7A
2-pin, black
PB X31
See the schematic on page 106 for complete drive wiring.
Wire numbers are given for cross referencing the wires with
the wiring table and the schematic. The numbers do not
appear on the wires.
2
PB: Power board
3
SCR: Silicon controlled rectifier
Replace the Front Cover
© 2009 Schneider Electric All Rights Reserved
Soft Charge Board
A (x4)
CN2A
CNL3G
CNL1G
CNL2G
A
12. Replace the front cover. Using a size 2 Phillips driver, secure the front
cover with nine screws. See Figure 7 on page 20. Tighten the screws to
5.5 N•m (48.7 lb-in).
63
Installation Procedures for Level 2 Parts
Replacing the Gate Driver Boards VX5A1201 and VX5A1202
Reassemble the Drive
30072-452-80
04/2009
If you are only replacing the power board, perform Steps 12–17 of
“Reassembly Steps for Level 2 Parts” beginning on page 91 to replace the
following parts:
❏
The control module assembly
❏
The EMC tray
❏
The power terminal shield
❏
The front cover
Replacing the Gate Driver Boards
VX5A1201 and VX5A1202
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
Before performing the steps in this procedure, perform Steps 1–16 of
“Disassembly Steps for Accessing Level 2 Parts” beginning on page 45 to
remove the following parts from the drive:
64
❏
Front cover
❏
SCR assembly shield
❏
Power terminal shield
❏
Power board connections
❏
EMC tray
❏
Soft charge board connections
❏
Control module assembly
❏
Fan control board connections
❏
Top crossbrace
❏
Bus plate assembly
❏
Fan plate
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Remove the Gate Driver Board
Installation Procedures for Level 2 Parts
Replacing the Gate Driver Boards VX5A1201 and VX5A1202
1. If you are replacing gate driver board U, perform these steps to remove
the L1, L2, and L3 bus bars. If you replacing gate driver boards V or W,
skip to Step 2 on page 66.
— Remove the connections from terminals X4 and X5 on the SCR
snubber board. See Figure 64.
— Using an 18 mm socket wrench, remove three bolts joining the L1,
L2, and L3 bus bars to the lower bus segments. See Figure 65.
— Using an 18 mm socket wrench, remove three bolts joining the L1,
L2, and L3 bus bars to the SCR bus segments and remove the bus
bars. See Figure 65.
Figure 64:
SCR Snubber Board
X4
X5
Figure 65:
L1, L2, L3 Bus Bars
B
(x3)
L1
bar
L2
bar
L3
bar
A
(x3)
© 2009 Schneider Electric All Rights Reserved
65
Installation Procedures for Level 2 Parts
Replacing the Gate Driver Boards VX5A1201 and VX5A1202
30072-452-80
04/2009
2. Remove the connections from the gate driver board that you are
replacing. See Table 20 and Figure 66 on page 67.
3. Using a 7 mm socket wrench, remove 12 nuts securing the gate driver
board to the power bus, and remove the board from the drive. See
Figure 66 on page 67.
Table 20:
Wire No.1
Gate Driver Board Wiring
Terminal No.
Description
To:
Gate Driver Board U (Left)
E143
X2
1-pin, yellow
Power board X5
E144
X4
2-pin, black
Temperature sensor U
E138
X32
18-pin, gray
GDB2 V X31
E129
X51
1-pin, blue
DBB X203
E127
X52
1-pin, blue
GDB V, X51
E100
X82
10-pin, white
GDB V X81
—
X31
Not used
—
—
X81
Not used
—
Power board X5
Gate Driver Board V (Center)
E143
X2
1-pin, green
E127
X51
1-pin, blue
GDB U, X52
E123
X52
1-pin, blue
GDB W, X51
E100
X81
10-pin, white
GDB U, X82, PB-X8
E102
X82
10-pin, white
GDB W, X81
E138
X31
18-pin, gray
GDB U, X32
E142
X32
18-pin, gray
GDB W, X31
E128
X4
2-pin, black
Temperature sensor V
Gate Driver Board W (Right)
66
E143
X2
1-pin, violet
Power board X5
E145
X4
2-pin, black
Temperature sensor W
E123
X51
1-pin, blue
GDB V, X52
E132
X52
1-pin, blue
Neutral on W power bus
E102
X81
10-pin, white
GDB V, X82
E142
X31
18-pin, gray
GDB V, X32 & PB X3
—
X32
Not used
—
—
X82
Not used
—
1
See the schematic on page 106 for complete drive wiring. Wire numbers are given for cross
referencing the wires with the wiring table and the schematic. The numbers do not appear on
the wires.
2
GDB: Gate driver board
3
DBB: Dynamic braking board. This option may not be present in the drive.
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Figure 66:
Installation Procedures for Level 2 Parts
Replacing the Gate Driver Boards VX5A1201 and VX5A1202
Gate Driver Boards
GDB U
Cable
clamp
Install the New Gate Driver Board
7 mm
nuts
(x 12)
GDB V
Cable
clamp
GDB W
4. Transfer the two plastic cable clamps (see Figure 66) from the old gate
driver board onto the new one as follows.
— To remove a clamp, pinch the clamp on the bottom side of the board
and push it up through the mounting hole.
— Snap the cable clamps into the mounting holes on the new board.
5. Seat the Gate driver board on the DC bus plate standoffs.
6. Using a 7 mm socket wrench, secure the board with 12 nuts. See
Figure 66. Tighten the nuts to 1.2 N•m (10.6 lb-in).
7. Replace the gate driver board wiring. See Table 20 on page 66 and
Figure 66 for the connections.
© 2009 Schneider Electric All Rights Reserved
67
Installation Procedures for Level 2 Parts
Replacing the Gate Driver Boards VX5A1201 and VX5A1202
30072-452-80
04/2009
8. If you are replacing gate driver board U (right board), replace the L1, L2,
and L3 bus bars as follows.
— Using an 18 mm socket wrench, secure the L1, L2, and L3 bus bars
to the SCR bus segments with three bolts (B, Figure 67).
— Using an 18 mm socket wrench, secure the L1, L2, and L3 bus bars
to the lower bus segments with three bolts (A, Figure 67).
— Tighten the hardware to the torque values specified in Table 21.
— Replace the connections to terminals X4 and X5 on the SCR
snubber board. See Figure 68.
Figure 67:
Table 21:
L1, L2, L3 Bus Bars
L1, L2, L3 Bus Bar Hardware
Torque Values
B
(x3)
Torque Range
Item
Description
N•m
lb-in
A
(3) 18 mm bolts 45
398
B
(3) 18 mm bolts 45
398
L1
bar
L2
bar
L3
bar
A
(x3)
Figure 68:
SCR Snubber Board
X4
X5
68
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Reassemble the Drive
© 2009 Schneider Electric All Rights Reserved
Installation Procedures for Level 2 Parts
Replacing the Gate Driver Boards VX5A1201 and VX5A1202
If you are only replacing a gate driver board, perform Steps 5–17 of
“Reassembly Steps for Level 2 Parts” beginning on page 91 to replace the
following parts:
❏
Bus plate assembly
❏
Top crossbrace
❏
Fan control board connections
❏
Control module assembly
❏
Soft charge board connections
❏
EMC tray
❏
Power board connections
❏
Power terminal shield
❏
SCR assembly shield
❏
Front cover
❏
Fan plate
69
Installation Procedures for Level 2 Parts
Replacing the Temperature Sensors, VZ3G1104
30072-452-80
04/2009
Replacing the Temperature
Sensors, VZ3G1104
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
There is one temperature sensor for each phase in the drive. The sensors
are located under the gate driver boards on the DC bus plate.
Before performing the steps in this procedure, perform Steps 1–19 of
“Disassembly Steps for Accessing Level 2 Parts” beginning on page 45 to
remove the following parts from the drive:
❏
Front cover
❏
SCR assembly shield
❏
Power terminal shield
❏
Power board connections
❏
EMC tray
❏
Soft charge board connections
❏
Control module assembly
❏
Fan control board connections
❏
Top crossbrace
❏
Bus plate assembly
❏
Fan plate
❏
Gate driver board
1. Using a T-10 Torx driver, remove one screw securing the temperature
sensor to the DC bus plate. See Figure 69.
2. Replace the temperature sensor and secure it with the T-10 screw.
Tighten the screw to 0.4–0.6 Nm (3.5–5.3 lb-in).
Figure 69:
Temperature Sensor
T-10 screw
70
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Reassemble the Drive
© 2009 Schneider Electric All Rights Reserved
Installation Procedures for Level 2 Parts
Replacing the Temperature Sensors, VZ3G1104
If you are only replacing a temperature sensor, perform Steps 2–17 of
“Reassembly Steps for Level 2 Parts” beginning on page 91 to replace the
following parts:
❏
Gate driver board
❏
Fan plate
❏
Bus plate assembly
❏
Top crossbrace
❏
Fan control board connections
❏
Control module assembly
❏
Soft charge board connections
❏
EMC tray
❏
Power board connections
❏
Power terminal shield
❏
SCR assembly shield
❏
Front cover
71
Installation Procedures for Level 2 Parts
Replacing the Power IGBT Modules VZ3IM1602M1271, and VZ3IM1402M1271
Replacing the Power IGBT
Modules VZ3IM1602M1271, and
VZ3IM1402M1271
30072-452-80
04/2009
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
Before performing the steps in this procedure, perform Steps 1–20 of
“Disassembly Steps for Accessing Level 2 Parts” beginning on page 45 to
remove the following parts from the drive:
❏
Front cover
❏
Power board connections
❏
Power terminal shield
❏
Soft charge board connections
❏
EMC tray
❏
Fan control board connections
❏
Control module assembly
❏
Bus plate assembly
❏
Top crossbrace
❏
Gate driver board
❏
Fan plate
❏
DC bus plate
❏
SCR assembly shield
You must replace the power IGBT modules in pairs as follows. See
Figure 71 on page 73.
•
•
72
Replace modules 1 and 2 together.
Replace modules 3 and 4 together.
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Figure 70:
Installation Procedures for Level 2 Parts
Replacing the Power IGBT Modules VZ3IM1602M1271, and VZ3IM1402M1271
Torque Sequence
(1)
(4)
1. Using a T-30 Torx driver, remove four screws (A) securing the module to
the heatsink and remove the module from the drive.
2. Using a 7 mm socket wrench, remove two standoffs (B) from the old
IGBT module, and install them on terminals E and G of the new module.
Tighten the standoffs to 1.2 N•m (10.6 lb-in).
3. Clean the portion of the heatsink that makes contact with the power
IGBT module.
(3)
(2)
4. Evenly coat the bottom of the new power IGBT module with a thin layer
of thermal compound, included in the kit, and position the module on the
heatsink.
5. Using a T-30 Torx driver, secure the module to the heatsink with four
screws (A). Initially tighten the screws, in the sequence shown in
Figure 70, to 0.7–1.0 N•m (6.2–8.9 lb-in), and then to a final torque of
3.3–4.4 N•m (29.2–38.9 lb-in).
NEXT STEP: If you are also replacing the capacitors, skip to
“Replacing the Capacitors VY1ADC1112 and VY1ADC1114”
beginning on page 75.
If you are only replacing the power IGBT modules, continue with
“Reassemble the Drive” on page 74.
Figure 71:
Power IGBT Modules
1
2
A (x4)
B (x2)
3
© 2009 Schneider Electric All Rights Reserved
4
73
Installation Procedures for Level 2 Parts
Replacing the Power IGBT Modules VZ3IM1602M1271, and VZ3IM1402M1271
Reassemble the Drive
74
30072-452-80
04/2009
If you are only replacing the IGBT modules, perform Steps 1–17 of
“Reassembly Steps for Level 2 Parts” beginning on page 91 to replace the
following parts:
❏
DC bus plate assembly
❏
Fan plate
❏
Gate driver board
❏
Top crossbrace
❏
Bus plate assembly
❏
Control module assembly
❏
Fan control board connections
❏
EMC tray
❏
Soft charge board connections
❏
Power terminal shield
❏
Power board connections
❏
Front cover
❏
SCR assembly shield
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Replacing the Capacitors VY1ADC1112 and VY1ADC1114
Replacing the Capacitors
VY1ADC1112 and VY1ADC1114
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
This kit contains six capacitors. If a capacitor has shorted, you must replace
all of the capacitors in the drive.
Before performing the steps in this procedure, perform Steps 1–20 of
“Disassembly Steps for Accessing Level 2 Parts” beginning on page 45 to
remove the following parts from the drive:
❏
Front cover
❏
Power board connections
❏
Power terminal shield
❏
Soft charge board connections
❏
EMC tray
❏
Fan control board connections
❏
Control module assembly
❏
Bus plate assembly
❏
Top crossbrace
❏
Gate driver board
❏
Fan plate
❏
DC bus plate
❏
SCR assembly shield
1. Replace a capacitor as follows. See Figure 72.
— Unlock the capacitor by turning it counterclockwise, and remove it
from the drive.
— Install the new capacitor and lock it into place.
NOTE: Ensure that the positive terminal (+) is oriented toward the top
of the drive and negative terminal (-) toward the bottom.
Figure 72:
© 2009 Schneider Electric All Rights Reserved
Capacitors, Phase V Shown
75
Installation Procedures for Level 2 Parts
Replacing the Capacitors VY1ADC1112 and VY1ADC1114
Reassemble the Drive
76
30072-452-80
04/2009
If you are only replacing the capacitors, perform Steps 1–17 of “Reassembly
Steps for Level 2 Parts” beginning on page 91 to replace the following
parts:
❏
DC bus plate assembly
❏
Fan plate
❏
Gate driver board
❏
Top crossbrace
❏
Bus plate assembly
❏
Control module assembly
❏
Fan control board connections
❏
EMC tray
❏
Soft charge board connections
❏
Power terminal shield
❏
Power board connections
❏
Front cover
❏
SCR assembly shield
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)
Replacing the SCR Modules
(VZ3TM1425M1671,
VZ3TM1600M1671) and Diode
Modules (VZ3DM1600M1671)
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• When the controller is damaged, voltage may remain on certain energy
storage capacitors after de-energization of the controller and discharge
of the main capacitor bank.
• Before working on or near assemblies containing energy storage
capacitors, verify that the capacitor voltages are less than 42 Vdc.
• The following assemblies have energy-storing capacitors:
— SCR snubber board. See Figure 73 on page 78.
• Always check for the presence of voltage using a voltmeter set to the
1000 Vdc scale. When voltage is present, allow the voltmeter to
discharge the capacitor’s stored charge. Refer to “Discharging Stored
Energy in Capacitors” on page 13.
Failure to follow these instructions will result in death or serious
injury.
Before performing the steps in this procedure, perform Steps 1–12 of
“Disassembly Steps for Accessing Level 2 Parts” beginning on page 45 to
remove the following parts from the drive:
© 2009 Schneider Electric All Rights Reserved
❏
Front cover
❏
Power terminal shield
❏
EMC tray
❏
Control module assembly
❏
Top crossbrace
❏
Fan plate
❏
SCR assembly shield
77
Installation Procedures for Level 2 Parts
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)
Remove the Top Crossbrace
1. Using a 10 mm socket wrench, remove six nuts (A, Figure 48) securing
the top crossbrace to the fan plate and the drive frame, and remove the
crossbrace.
Figure 73:
Fan Plate and Crossbrace
B (x4)
Fan Plate
A (x6)
Crossbrace
SCR snubber board
Remove the Fan Plate
30072-452-80
04/2009
2. Using a T-30 Torx driver, remove four screws (B, Figure 73) securing
the fan plate to the drive frame.
3. Using a T-30 Torx right-angle driver, remove three screws (C, Figure 74)
from the right sides of the red insulators at the PO, PA/+, and PC/terminals.
4. Using an 18 mm socket wrench, remove five nuts and bolts from the PO,
PA/+, and PC bus bars (D, Figure 74).
5. Remove the internal fan connections from the back of the fan plate, and
remove the fan plate from the drive. See Figure 75 on page 79.
Figure 74:
Fan Plate with Bus Bar Detail
D (x5)
C (x3)
78
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)
Figure 75:
Internal Fan Connections
Internal fan connections
Remove the SCR Assembly Shield
6. Remove the transparent shield over the SCR assembly. See Figure 76.
Figure 76:
SCR Assembly Shield
SCR assembly shield
© 2009 Schneider Electric All Rights Reserved
79
Installation Procedures for Level 2 Parts
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)
Remove the PA/+ Bus Assembly
30072-452-80
04/2009
7. Remove the PA/+ bus assembly as follows.
— Using a 16 mm socket wrench, remove two bolts (A, Figure 77)
securing the positive bus plate assembly to the underlying bus bar.
— Using a 16 mm socket wrench, remove two bolts (B, Figure 77)
securing the negative bus plate assembly to the underlying bus bar.
— Using a 18 mm socket wrench, remove three bolts and washers (C,
Figure 77) securing the L1, L2, and L3 bus bars to the underlying
bus bar.
— Using a T-30 Torx driver, remove two screws (D, Figure 77) securing
the PA/+ bus assembly to the red insulators on the PO bus bar and
remove the PA/+ bus assembly.
Figure 77:
PA/+ Bus Assembly
C
D
PA bus assy
B
A
80
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)
Remove the PO Bus Bar
8. Remove the PO bus bar as follows.
— Remove the connections from terminals X4 (red wire) and X5 (black
wire) of the SCR snubber board. See Figure 78.
— Using a 16 mm socket wrench, remove three bolts (A, Figure 78)
securing the PO bus bar to terminal 2 the SCR modules and remove
the bus bar. The red wire from SCR snubber board terminal X4
comes out with the bar.
Figure 78:
PO Bus Bar
PO bus bar
A
A
A
X4
X5
Remove the PC/- Bus Bar
9. Using a 16 mm socket wrench, remove three bolts and washers (B,
Figure 79) securing the PC/- bus bar to the terminal 2 of the diode
modules and remove the bus bar. The black wire from SCR snubber
board terminal X5 comes out with the bar.
Figure 79:
PC/- Bus Bar
PC/- bus bar
B
© 2009 Schneider Electric All Rights Reserved
B
B
81
Installation Procedures for Level 2 Parts
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)
Remove the Phase W SCR Buswork
30072-452-80
04/2009
10. Remove the phase W SCR buswork as follows.
— Using a 16 mm socket wrench, remove two bolts and washers
(A, Figure 80) connecting bus bar X to terminal 1 of the SCR module
and diode module in phase W.
— Using a T-30 Torx driver, remove one screw (B, Figure 80) securing
bus bar X to the red insulator on bus bar Y (see Figure 81 on
page 83) and remove bus bar X.
Figure 80:
SCR Buswork, Phase W
X
B
A
NEXT STEP: If you are only replacing an SCR or diode module in
phase W, skip to Step 13 on page 84 to replace the module.
If you are also replacing an SCR or diode module in phases V or U,
continue with Step 11 below.
82
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)
Remove the Phase V SCR Buswork
11. Remove the phase V SCR buswork as follows.
— Using a 16 mm socket wrench, remove two bolts and washers
(C, Figure 81) connecting bus bar Y to terminal 1 of the SCR module
and diode module in phase V.
— Using a T-30 Torx driver, remove one screw (D, Figure 81) securing
bus bar Y to the red insulator on bus bar Z (see Figure 82 on
page 83) and remove bus bar Y.
Figure 81:
SCR Buswork, Phase V
Y
D
C
NEXT STEP: If you are only replacing an SCR or diode module in
phase V, skip to Step 13 on page 84 to replace the module.
If you are also replacing an SCR or diode module in phase U, continue
with Step 12 below.
Removing the Phase U SCR Buswork
12. Using a 16 mm socket wrench, remove two bolts and washers
(E, Figure 82) connecting bus bar Z to terminal 1 of the SCR module and
diode modules in phase U and remove bus bar Z.
Figure 82:
SCR Buswork, Phase U
E
Z
© 2009 Schneider Electric All Rights Reserved
83
Installation Procedures for Level 2 Parts
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)
Replace the SCR Module
Figure 83:
(1)
Torque Sequence
(4)
30072-452-80
04/2009
13. Replace an SCR module or diode module as follows.
— If you are replacing an SCR module, remove the connections from
terminals 4 and 5. See Figure 84.
— Using a T-20 Torx driver, remove four screws (A) securing the SCR
or diode module to the heatsink and remove the module from the
drive. See Figure 84.
— Clean the portion of the heatsink that makes contact with the SCR or
diode module.
(3)
(2)
— Evenly coat the bottom of the new module with a thin layer of thermal
compound included in the kit.
— Position the new SCR or diode module on the heatsink under the
input bus bar.
— Using a T-20 Torx driver, secure the module with four screws (A).
See Figure 84. Initially tighten the screws, in the sequence shown in
Figure 83, to 0.7–1.0 N•m (6.2–8.9 lb-in), and then to a final torque of
3.3–4.4 N•m (29.2–38.9 lb-in).
— If you are replacing an SCR module, replace the connections to
terminals 4 and 5. See Figure 84.
NOTE: Note the cable positions. The yellow and black twisted cable
goes to SCR module 1, the green and black cable goes to SCR module
2, and the violet and black cable goes to SCR module 3. The black wire
goes on the top terminal of each SCR module.
Figure 84:
SCR and Diode Modules
SCR module
84
A (x4)
Diode module
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)
Replacing the Phase U SCR Buswork
Table 22:
SCR Buswork Hardware
Torque Values
Torque Range
Item
14. Replace the phase U SCR buswork as follows. See Figure 85.
— Using a 16 mm socket wrench, secure bus bar Z to terminal 1 of the
SCR module and diode module with two bolts and washers
(E, Figure 85).
— Tighten the hardware to the torque values specified in Table 22 on
page 85.
Description
N•m
lb-in
A
(2) 16 mm bolts
27
and washers
239
B
(1) T-30 screw
5.5
48.6
C
(2) 16 mm bolts
27
and washers
239
D
(1) T-30 screw
5.5
48.6
E
(2) 16 mm bolts
27
and washers
239
Replacing the Phase V SCR Buswork
Figure 85:
SCR Buswork, Phase U
E
Z
15. Replace the phase V SCR buswork as follows. See Figure 86.
— Using a T-30 Torx driver, secure bus bar Y (Figure 86) to the red
insulator on bus bar Z (Figure 85) with one screw (D, Figure 86).
— Using a 16 mm socket wrench, secure bus bar Y to terminal 1 of the
SCR module and diode module in phase V with two bolts and
washers (C, Figure 86).
— Tighten the hardware to the torque values specified in Table 22.
Figure 86:
SCR Buswork, Phase V
Y
D
© 2009 Schneider Electric All Rights Reserved
C
85
Installation Procedures for Level 2 Parts
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)
Replacing the Phase W SCR Buswork
30072-452-80
04/2009
16. Replace the phase W SCR buswork as follows. See Figure 87.
— Using a T-30 Torx driver, secure bus bar X to the red insulator on
bus bar Y (Figure 86) with one screw (B, Figure 87).
— Using a 16 mm socket wrench, secure bus bar X to terminal 1 of the
SCR module and diode module in phase W with two bolts and
washers (A, Figure 87).
— Tighten the hardware to the torque values specified in Table 22 on
page 85.
Figure 87:
SCR Buswork, Phase W
X
B
86
A
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)
Replace the PC/- Bus Bar
17. Using a 16 mm socket wrench, secure the PC/- bus bar to the terminal 2
of the diode modules with three bolts and washers (B, Figure 88).
Tighten the bolts to the torque values specified in Table 23.
Figure 88:
Table 23:
PC/- Bus Bar
PC/- bus bar
PC/- and PO Bus Bar Hardware
Torque Values
B
B
B
Torque Range
Item
Description
A
(3) 16 mm bolts 27
239
B
(3) 16 mm bolts 27
239
N•m
lb-in
Replace the PO Bus Bar
18. Replace the PO bus bar as follows.
— Using a 16 mm socket wrench, secure the PO bus bar to terminal 2
the SCR modules with three bolts (A, Figure 89).
— Tighten the bolts to the torque values specified in Table 23.
— Replace the connections to terminals X4 (red wire) and X5 (black
wire) of the SCR snubber board. See Figure 89.
Figure 89:
PO Bus Bar
PO bus bar
A
A
A
X4
X5
© 2009 Schneider Electric All Rights Reserved
87
Installation Procedures for Level 2 Parts
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)
Replace the PA/+ Bus Assembly
30072-452-80
04/2009
19. Replace the PA/+ bus assembly as follows.
— Using a T-30 Torx driver, secure the PA/+ bus assembly to the red
insulators on the PO bus bar with two screws (D, Figure 90).
— Using a 18 mm socket wrench, secure the L1, L2, and L3 bus bars to
the SCR/diode line bus bar with three bolts and washers (C,
Figure 90).
— Using a 16 mm socket wrench, secure the negative bus plate
assembly to the DC negative bus bar with two bolts (B, Figure 90).
— Using a 16 mm socket wrench, secure the positive bus plate
assembly to the DC positive bus bar with two bolts (A, Figure 90).
— Tighten the hardware to the torque values shown in Table 24.
Figure 90:
Table 24:
PA/+ Bus Assembly Hardware
Torque Values
PA/+ Bus Assembly
C
D
PA bus assy
B
Torque Range
Item
Description
N•m
lb-in
A
(2) 16 mm bolts 27
239
B
(2) 16 mm bolts 27
239
C
(3) 18 mm bolts
45
and washers
398
D
(2) T-30 screws 5.5
48.6
A
Replace the SCR Assembly Shield
20. Replace the transparent shield over the SCR assembly. See Figure 91.
Figure 91:
DANGER
SCR Assembly Shield
SCR assembly shield
HAZARD OF ELECTRIC SHOCK,
EXPLOSION, OR ARC FLASH
• Install the SCR assembly shield as shown in
Figure 91.
• Before installing the shield, ensure that it has
no tears or cracks. If the shield is damaged,
install a new piece from the plastic kit. See
page 21.
• Do not install a damaged shield.
Failure to follow these instructions will
result in death or serious injury.
88
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)
Replace the Fan Plate
21. Replace the fan plate as follows.
— Replace the internal fan connections on the back of the fan plate,
and position the fan plate in the drive. See Figure 92.
— Using an 18 mm socket wrench, replace five nuts and bolts on the
PO, PA/+, and PC bus bars (D, Figure 93).
— Using a T-30 Torx right-angle driver, secure the PO, PA/+, and PC/bus bars to the red insulators on fan plate with three screws
(C, Figure 93).
— Using a T-30 Torx driver, secure the fan plate to the drive frame with
four screws (B, Figure 94 on page 90).
— Tighten the hardware to the torque values specified in Table 25.
Figure 92:
Internal Fan Connections
Internal fan connections
Figure 93:
Table 25:
Fan Plate Hardware Torque
Values
Fan Plate with Bus Bar Detail
D (x5)
C (x3)
Torque Range
Item
Description
N•m
lb-in
A
(6) 10 mm nuts
5.5
48.6
B
(4) T-30 screws 5.5
48.6
C
(3) T-30 screws 5.5
48.6
D
(5) 18 mm bolts 45
398
© 2009 Schneider Electric All Rights Reserved
89
Installation Procedures for Level 2 Parts
Replacing the SCR Modules (VZ3TM1425M1671, VZ3TM1600M1671) and Diode Modules (VZ3DM1600M1671)
Replace the Top Crossbrace
22. Using a 10 mm socket wrench, secure the top crossbrace to the fan
plate and drive frame with six nuts (A, Figure 94). Tighten the nuts to the
torque values specified in Table 25 on page 89.
Figure 94:
Fan Plate and Crossbrace
Fan Plate
Crossbrace
Reassemble the Drive
90
30072-452-80
04/2009
B (x4)
A (x6)
If you are only replacing the SCR snubber board or the SCR modules,
perform Steps 15–17 of “Reassembly Steps for Level 2 Parts” beginning on
page 91 to replace the following parts:
❏
SCR assembly shield
❏
Fan plate
❏
Top crossbrace
❏
Control module assembly
❏
EMC tray
❏
Power terminal shield
❏
Front cover
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Reassembly Steps for Level 2 Parts
Reassembly Steps for Level 2
Parts
IMPORTANT: Label and retain all removed
hardware and cables for use in reassembly.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand the precautions in “Before You Begin” starting on
page 5 before performing this procedure.
• Before working on this equipment, turn off all power supplying it and
perform the DC bus voltage measurement procedure on page 12.
Failure to follow these instructions will result in death or serious
injury.
This section contains instructions for replacing the following parts in the
drive:
❏
DC bus plate
❏
Fan plate
❏
Gate driver boards
❏
Top crossbrace
❏
Bus plate assembly
❏
Control module assembly
❏
Fan control board connections
❏
EMC tray
❏
Soft charge board connections
❏
Power terminal shield
❏
Power board connections
❏
Front cover
❏
SCR assembly shield
You must perform some or all of the procedures in this section after
replacing the spare parts identified in Table 26. Consult Table 26 for the
reassembly steps that must be performed for the corresponding spare parts.
Table 26:
© 2009 Schneider Electric All Rights Reserved
Reassembly Steps
If you replaced
Perform reassembly steps:
Power board VX5A1HC2025
VX5A1HC2531
VX5A71HC28N4
Steps 12–17
Gate driver board VX5A1201 or VX5A1202
Steps 5–17
Temperature sensors VZ3G1104
Steps 2–17
Power IGBT modules VZ3IM1600M1271
VZ3IM1602M1271
VZ3IM1402M1271
Steps 1–17
Capacitors
VY1ADC1112
VY1ADC1114
Steps 1–17
SCR modules
VZ3TM1425M1671
VZ3TM1600M1671
Steps 15–17
Diode modules
VZ3DM1600M1671
Steps 15–17
91
Installation Procedures for Level 2 Parts
Reassembly Steps for Level 2 Parts
Replace the DC Bus Plate
30072-452-80
04/2009
1. Replace the DC bus plate as follows. See Figure 95.
— Position the DC bus plate in the drive as illustrated in Figure 95.
— Using an 18 mm socket wrench, securing the DC bus plate to the
output bus bar with one bolt (A).
— Using a size 2 Phillips driver, secure the DC bus plate to the IGBT
modules with two screws (B) and secure the plate to the capacitors
with four screws (C).
— Using a T-30 Torx driver, secure the DC bus plate to the IGBT
modules with two 20 mm screws (D) and secure the plate to the
capacitors with four 14 mm screws (E).
— Using a 10 mm socket wrench, install two 6 mm standoffs
(F) and two 11 mm standoffs (G).
— Tighten the hardware to the torque values specified in Table 27.
Figure 95:
Table 27:
DC Bus Plate (Phase V Shown)
B
(x2)
F
(x2)
DC Bus Plate Hardware Torque
Values
Torque Range
Item
Description
N•m
lb-in
A
(1) 18 mm bolts 45
398
B
(2) Size 2
Phillips screws
3.3
29.2
C
(4) Size 2
Phillips screws
3.3
29.2
D
(2) Long T-30
screws
(20 mm length)
3.3
29.2
E
(4) Short T-30
screws
(14 mm length)
3.3
29.2
F
(2) Short 10-mm
standoffs
3.3
(6 mm length)
29.2
G
(2) Long 10 mm
standoffs
3.3
(11 mm length)
29.2
D
(x2)
G
(x2)
E
(x4)
C
(x4)
E
(x4)
A
92
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Replace the Gate Driver Boards
Installation Procedures for Level 2 Parts
Reassembly Steps for Level 2 Parts
2. Replace the gate driver board(s) as follows.
— Using a 7 mm socket wrench, secure the gate driver boards to the
DC bus plate with 12 nuts each. See Figure 96 on page 94. Tighten
the nuts to 1.2 N•m (10.6 lb-in).
3. Replace the gate driver board connections. See Table 28 and Figure 96
on page 94.
Table 28:
Wire No.1
Gate Driver Board Wiring
Terminal No.
Description
To:
Gate Driver Board U (Left)
E143
X2
1-pin, yellow
Power board X5
E144
X4
2-pin, black
Temperature sensor U
E138
X32
18-pin, gray
GDB2 V X31
E129
X51
1-pin, blue
DBB X203
E127
X52
1-pin, blue
GDB V, X51
E100
X82
10-pin, white
GDB V X81
—
X31
Not used
—
—
X81
Not used
—
Gate Driver Board V (Center)
E143
X2
1-pin, green
Power board X5
E127
X51
1-pin, blue
GDB U, X52
E123
X52
1-pin, blue
GDB W, X51
E100
X81
10-pin, white
GDB U, X82, PB-X8
E102
X82
10-pin, white
GDB W, X81
E138
X31
18-pin, gray
GDB U, X32
E142
X32
18-pin, gray
GDB W, X31
E128
X4
2-pin, black
Temperature sensor V
X2
1-pin, violet
Power board X5
Temperature sensor W
Gate Driver Board W (Right)
E143
© 2009 Schneider Electric All Rights Reserved
E145
X4
2-pin, black
E123
X51
1-pin, blue
GDB V, X52
E132
X52
1-pin, blue
Neutral on W power bus
E102
X81
10-pin, white
GDB V, X82
E142
X31
18-pin, gray
GDB V, X32 & PB X3
—
X32
Not used
—
—
X82
Not used
—
1
See the schematic on page 106 for complete drive wiring. Wire numbers are given for cross
referencing the wires with the wiring table and the schematic. The numbers do not appear on
the wires.
2
GDB: Gate driver board
3
DBB: Dynamic braking board. This option may not be present in the drive.
93
Installation Procedures for Level 2 Parts
Reassembly Steps for Level 2 Parts
Figure 96:
Gate Driver Boards
GDB U
94
30072-452-80
04/2009
7 mm
nuts
(x12)
GDB V
GDB W
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Reassembly Steps for Level 2 Parts
4. If you are replacing gate driver board U (right board), replace the L1, L2,
and L3 bus bars as follows.
— Using an 18 mm socket wrench, secure the L1, L2, and L3 bus bars
to the SCR bus segments with three bolts (B, Figure 97).
— Using an 18 mm socket wrench, secure the L1, L2, and L3 bus bars
to the lower bus segments with three bolts (A, Figure 97).
— Tighten the hardware to the torque values specified in Table 29.
— Replace the connections to terminals X4 and X5 on the SCR
snubber board. See Figure 98.
Figure 97:
Table 29:
L1, L2, L3 Bus Bars
L1, L2, L3 Bus Bar Hardware
Torque Values
B
(x3)
Torque Range
Item
Description
N•m
lb-in
A
(3) 18 mm bolts 45
398
B
(3) 18 mm bolts 45
398
L1
bar
L2
bar
L3
bar
A
(x3)
Figure 98:
SCR Snubber Board
X4
X5
© 2009 Schneider Electric All Rights Reserved
95
Installation Procedures for Level 2 Parts
Reassembly Steps for Level 2 Parts
Replace the Bus Plate Assembly
30072-452-80
04/2009
5. Replace the bus plate assembly as follows.
— Position the bus plate assembly in the drive as illustrated in
Figure 99.
— Using a 13 mm socket wrench, secure the bus plate assembly to the
phase U positive and negative buses with four screws (F).
— Using a 13 mm socket wrench, secure the bus plate assembly to the
phase V positive and negative buses with four screws (E).
— Using a 13 mm socket wrench, secure the bus plate assembly to the
phase W positive and negative buses with four screws (D).
— Using a 16 mm socket wrench, secure the bus plate assembly to the
PA/+ bus with two bolts (C).
— Using a 16 mm socket wrench, secure the bus plate assembly to the
PC/- bus with two bolts (B).
— Using a T-30 Torx driver, secure the bus plate assembly to the red
insulator on the drive frame with one screw and washer (A).
— Tighten the hardware to the torque values specified in Table 30.
Figure 99:
Bus Plate Assembly
C
Table 30:
B
A
Bus Plate Assembly Hardware
Torque Values
Torque Range
Item
Description
N•m
lb-in
A
(2) T-30 screws 5.5
48.7
B
(2) 16 mm bolts 27
239
C
(2) 16 mm bolts 27
239
D
(4) 13 mm bolts 13.5
119
E
(4) 13 mm bolts 13.5
119
F
(4) 13 mm bolts 13.5
119
F
E
D
96
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Replace the Fan Control Board
Connections
Installation Procedures for Level 2 Parts
Reassembly Steps for Level 2 Parts
6. Replace the connections on terminals X1 and X3 of the fan control
board. See Figure 100 for terminal locations.
Figure 100: Fan Control Board Connections X1 and X3
X3
Replace the Soft Charge Board
Connections
X1
7. Replace soft charge board connections CNL1G, CNL2G, and CNL3G.
See Figure 101 for terminal locations.
Figure 101: Soft Charge Board Connections
CNL2G
CNL3G CNL1G
© 2009 Schneider Electric All Rights Reserved
97
Installation Procedures for Level 2 Parts
Reassembly Steps for Level 2 Parts
30072-452-80
04/2009
Replace the Power Board Connections
NOTE: Take care not to damage the LED (see Figure 102) when
removing, handling, or installing the power board.
8. Replace the power board connections listed in Table 31. See Figure 102
for the connection locations.
Table 31:
Power Board Wiring
Figure 102: Power Board Connections
Wire
No.1
Terminal
No.
Description To:
E103
X11
9-pin, multi
color
Motor current
sensors
X14
3-pin, yellow
FCB2
E136
UD0
1-pin,
blue
Phase U
DC bus plate
E141
UD -R1
1-pin,
white
Bleeder resistor
X93
E139
UD +R1
1-pin,
white
Bleeder resistor
UD+R1
E105
X30
X7
X2
X5
X91
RFS+X10
X1
X31
3
RFS +X11
1-pin,
red
SCR snubber
board X11
E126
RFS +X10
1-pin,
red
SCR snubber
board X10
E143
X5
GDB4 U X2,
6-pin,
yellow/green/ GDB V X2,
violet
GDB W X2
E120
X7
6-pin,
Filter board
yellow/green/
X11, X12, X13
violet
—
X2
10-pin,
gray
Motor control
board X2
E129
X93
1-pin,
violet
Dynamic braking
board X205
E142
X3
18-pin,
gray
GDB W X31
E100
X8
10-pin,
white
GDB V X81
E106
X21
2-pin,
red/black
Internal fan
E106
X22
2-pin,
red/black
Internal fan
E112
X4
10-pin, gray
Control module
—
X16
Not used
—
—
X91
Not used
—
—
X92
Not used
—
1
See the schematic on page 106 for complete drive wiring.
Wire numbers are given for cross referencing the wires
with the wiring table and the schematic. The numbers do
not appear on the wires.
2
FCB: Fan control board
3
SCR: Silicon controlled rectifier
4
GDB: Gate driver board
5
The optional dynamic braking board may not be present in
the drive.
X8
X16
RFS+X11
X22 X21
E171
98
X2
X6
X4
X3
UD0
X11
UD-R1
X14
X92
FRAGILE
(LED with sleeving)
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Installation Procedures for Level 2 Parts
Reassembly Steps for Level 2 Parts
Replace the SCR Assembly Shield
9. Replace the transparent shield over the SCR assembly. See Figure 103.
Figure 103: SCR Assembly Shield
DANGER
SCR assembly shield
HAZARD OF ELECTRIC SHOCK,
EXPLOSION, OR ARC FLASH
• Install the SCR assembly shield as shown in
Figure 103.
• Before installing the shield, ensure that it has
no tears or cracks. If the shield is damaged,
install a new piece from the plastic kit. See
page 21.
• Do not install a damaged shield.
Failure to follow these instructions will
result in death or serious injury.
Replace the Fan Plate
10. Replace the fan plate as follows.
— Replace the internal fan connections on the back of the fan plate,
and position the fan plate in the drive. See Figure 104.
— Using an 18 mm socket wrench, replace five nuts and bolts on the
PO, PA/+, and PC bus bars (D, Figure 105 on page 100).
— Using a T-30 Torx right-angle driver, secure the PO, PA/+, and PC/bus bars to the red insulators on fan plate with three screws (C,
Figure 105 on page 100).
— Using a T-30 Torx driver, secure the fan plate to the drive frame with
four screws (B,Figure 106 on page 100).
— Tighten the hardware to the torque values specified in Table 32 on
page 100.
Figure 104: Internal Fan Connections
Internal fan connections
© 2009 Schneider Electric All Rights Reserved
99
Installation Procedures for Level 2 Parts
Reassembly Steps for Level 2 Parts
30072-452-80
04/2009
Figure 105: Fan Plate with Bus Bar Detail
Table 32:
Fan Plate Hardware Torque
Values
D (x5)
C (x3)
Torque Range
Item
Description
N•m
lb-in
A
(6) 10 mm nuts
5.5
48.7
B
(4) T-30 screws 5.5
48.7
C
(3) T-30 screws 5.5
48.7
D
(5) 18 mm bolts 45
398
Replace the Top Crossbrace
11. Using a 10 mm socket wrench, secure the top crossbrace to the fan
plate and drive frame with six nuts (A, Figure 106). Tighten the nuts to
the torque values specified in Table 32.
Figure 106: Fan Plate and Crossbrace
Fan Plate
Crossbrace
100
B (x4)
A (x6)
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Replace the Control Module Assembly
Installation Procedures for Level 2 Parts
Reassembly Steps for Level 2 Parts
12. Connect the ribbon cable (wire E112, Figure 107) from power board
terminal X11 to the back of the control module assembly.
Figure 107: Control Module Assembly Back
Wire
E112
13. Using a 10 mm socket wrench, secure the control module assembly to
the drive frame with two nuts (Figure 108). Tighten the nuts to
5.5 N•m (48.7 lb-in).
Figure 108: Control Module Assembly Front
X3
10 mm
nut
10 mm
nut
© 2009 Schneider Electric All Rights Reserved
101
Installation Procedures for Level 2 Parts
Reassembly Steps for Level 2 Parts
30072-452-80
04/2009
14. Replace the following connections.
— Install the 26-pin ribbon cable from the control module assembly to
motor control board terminal X3. See Figure 108 on page 101.
— Install the 5-pin connector from the TB1 bracket to fan control board
terminal X4. See Figure 109.
Figure 109: Fan Control Board Terminal X4
X4
TB1
bracket
Replace the EMC Tray
15. Using a T-20 Torx driver, secure the EMC tray to the control module
plate with three screws. See Figure 110. Tighten the screws to
1.1–1.7 N•m (9.7–15.0 lb-in).
Figure 110: EMC Tray
A (x3)
102
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Replace the Power Terminal Shield
Installation Procedures for Level 2 Parts
Reassembly Steps for Level 2 Parts
16. Replace the power terminal shield as follows.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Install the power terminal shield as shown in Figures 111 and 112.
• Before installing the shield, ensure that it has no tears or cracks. If the
shield is damaged, install a new piece from the plastic kit. See page 21.
• Do not install a damaged shield.
Failure to follow these instructions will result in death or serious
injury.
— Hook the mounting holes on the left side of the shield over the posts
on the side panel of the drive (B, Figure 111).
— Insert the retaining tabs on the right side of the shield in the slots on
the conduit tray (A, Figure 112).
Figure 111: Power Terminal Shield Retaining Posts
B
B
Figure 112: Power Terminal Shield
A
A
Replace the Front Cover
© 2009 Schneider Electric All Rights Reserved
17. Replace the front cover. Using a size 2 Phillips driver, secure the front
cover with nine screws. See Figure 7 on page 20. Tighten the screws to
5.5 N•m (48.7 lb-in).
103
Wiring
Wiring
30072-452-80
04/2009
Table 33:
Wiring Table
From:
Wire
No.1
E100
10-pin, white
Terminal
No.
Component
Terminal
No.
Power board
X8
Gate driver
board V
X81
Gate driver
board V
X81
Gate driver
board U
X82
X81
Component
E102
10-pin, white
Gate driver
board V
X82
Gate driver
board W
E103
9-pin, multi
color
Power board
X11
Motor current
sensors
—
E105
3-pin, yellow
Fan control
board
X2
Power board
X14
E106
2-pin, red/black
Power board
X21, X22
E107
2-pin,
Yellow/black
Soft charge
board
CNL1G
SCR 1
4, 5
E108
2-pin,
green/black
Soft charge
board
CNL2G
SCR 2
4, 5
E109
2-pin,
violet/black
Soft charge
board
CNL3G
SCR 3
4, 5
E110
9-pin, red
Soft charge
board
CN2A
Power board
X30
E111
2-pin, black
Soft charge
board
CN7A
Power board
X31
E112
10-pin, gray
Power board
X4
Control
module
E114
9-pin,
black/white/
brown/blue with
yellow & green
ground wire
Fan control
board
X3
Filter board
X11, X12
E115
9-pin,
black sleeve
Filter board
A7/X11
Heatsink fan
1
—
E118
5-pin,
violet/green/
yellow
Fan control
board
Internal fan
—
—
X1
X1
Filter board
X2
X3
X11
6-pin,
yellow/green/
violet
Power board
E123
E120
104
Description
To:
X7
Filter board
X12
1-pin, blue
Gate driver
board V
X52
Gate driver
board W
X51
E124
5-pin,
violet/green/
yellow
Fan control
board
X4
Fan control
terminal
block TB1
—
E125
9-pin,
black sleeve
Filter board
A7/X12
Heatsink fan
2
—
E126
1-pin, red
SCR snubber
board
X10
Power board RFS +X10
E127
1-pin, blue
Gate driver
board U
X52
Gate driver
board V
E128
2-pin, black
Gate driver
board V
X4
Temperature
sensor V
X13
X51
—
© 2009 Schneider Electric All Rights Reserved
30072-452-80
04/2009
Wiring
Table 33:
Wiring Table (continued)
From:
Wire
No.1
Description
To:
Terminal
No.
1-pin, violet
Power board
X93
Dynamic
braking
board2
X20
1-pin, blue
Dynamic
braking board
X20
Gate driver
board U
X51
E130
1-pin, red
SCR snubber
board
X4
PO/+ bus bar
—
E131
1-pin, green
SCR snubber
board
X1
L1 bus bar
—
E132
1-pin, blue
Gate driver
board W
X52
Neutral on W
DC power
bus plate
—
E133
1-pin, black
SCR snubber
board
X5
PC/- bus bar
—
E136
1-pin, blue
Power board
UD0
U DC bus
plate
—
E138
18-pin, gray
Gate driver
board U
X32
Gate driver
board V
E139
1-pin, white
Power board
UD +R1
Bleeder
resistor
—
E141
1-pin, white
Power board
UD -R1
Bleeder
resistor
—
Gate driver
board V
X32
Gate driver
board W
X31
Gate driver
board W
X31
Power board
X3
Gate driver
board U
X2
Gate driver
board V
X2
Gate driver
board W
X2
E129
E142
E143
© 2009 Schneider Electric All Rights Reserved
Terminal
No.
Component
18-pin, gray
6-pin,
yellow/green/
violet
Power board
X5
Component
X31
E144
2-pin, black
Gate driver
board U
X4
Temperature
sensor U
—
E145
2-pin, black
Gate driver
board W
X4
Temperature
sensor W
—
E161
1-pin, white
R2
—
Bus V
UD+
E162
1-pin, white
R2
—
Bus V
UD-
E171
1-pin, red
SCR snubber
board
X11
Power board RFS +X11
—
10-pin, gray
Power board
X2
Motor control
board
X2
1
Wire numbers are given for cross referencing the wires with the schematic on page 106. The
numbers do not appear on the wires.
2
The optional dynamic braking board may not be present in the drive.
105
SCR-L3_4/5
SCR-L2_4/5
SCR-L1_4/5
E107
A6
Soft
Charge
Board
FAN
FAN
CN2A
CN7A
CNL1G
CNL2G
E108
CNL3G
E109
NOTE: The wiring schematic illustrates connections
between the components in the drive. It does not
illustrate the layout of the various boards or the
connector locations on them.
E111
E110
E106
PHASE U DC BUS PLATE
E105
E105
BLUE
E136
E103
T2
X1
X4
A7
X4
E112
X3
FAN
CONT
BD
X2
X6
X11
X92
X16
E124
X2
X1
X93
X91
X3
X5
UD-R1
UD+R1
X8
RFS+X11
RFS+X10
A1
POWER BOARD
X7
E118
X31
X30
X21
X22
X14
UD0
T3
MOTOR CURRENT SENSORS
T1
TB1
E114
E120
MOTOR
CONTROL
BOARD
X3
CONTROL
MODULE
A2
A10
X2
X1
E129
VIOLET
RED
R1
E139
E126
E171
E100
RED
WHITE
E141
WHITE
E143
E142
E118
X81
X31
X2
X3
A7/X11
X4
X12
E144
X11
FILTER BOARD
A30
X1
A3
X2
X51
A7/X12
E115
E125
E131
X82
X32
FAN
FAN
L1 BUS BAR
E138
E100
X10
X4
X5
E143
E127
X31
X81
X11
X1 A31 SCR
SNUBBER
BOARD
GREEN
X20
TEMP SENSOR U
E126
E171
X13
X52
GATE DRIVE BOARD U
E143
E129
E133
E130
BLACK
RED
A4
X52
E161
E162
E102
E142
UD- BUS V
UD+ BUS V
X32
X82
TEMP SENSOR V
PC/- BUS BAR
PO/+ BUS BAR
E128
X4
X51
GATE DRIVE BOARD V
X2
R2
X81
X31
X2
E145
X4
X51
CAP NEUT BUS W
X32
X82
TEMP SENSOR W
E132
X52
A5
GATE DRIVE BOARD W
E143
E123
© 2009 Schneider Electric All Rights Reserved
106
30072-452-80
04/2009
Wiring
Figure 113: Wiring Schematic
Spare Parts Kits for Altivar® 61/71 Drives, Frame Size 13
Instruction Bulletin
Schneider Electric USA
8001 Knightdale Blvd.
Raleigh, NC 27545 USA
1-888-SquareD
(1-888-778-2733)
www.schneider-electric.us
Altivar® is a registered trademark of Schneider Electric. Other trademarks used herein are the
property of their respective owners.
Electrical equipment should be installed, operated, serviced, and maintained only by qualified
personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of
the use of this material.
30072-452-80 © 2009 Schneider Electric All Rights Reserved
04/2009