Remove and Install a Power Module for Frame 7

ATTENTION:
Risk of injury, death, or equipment damage exists.
IGBT power and LCL filter modules have a high center of gravity and may pose a tip-over hazard. To guard against death, serious personal injury, or equipment damage, do not subject the module to high rates of acceleration or deceleration while transporting. Do not push or pull above the points that are indicated on the module.
Equipment is available that is designed to help you safely handle the power modules. The following equipment is recommended:
  • PowerFlex®
     750-Series module service cart, catalog number 20-750-MCART1. See the PowerFlex 750-Series Service Cart and DC Precharge Module Life Instructions, publication 750-IN105.
  • PowerFlex®
     750TM power and LCL filter module storage hardware, catalog number 20-750-MINV-ATIP. See the PowerFlex 755TM Power and Filter Module Storage Hardware Installation Instructions, publication 750-IN106.
  • PowerFlex®
     755T power module service ramp, catalog number 20-750-MRAMP1. See the PowerFlex 755T Power Module Service Ramp Instructions, publication 750-IN108.
IMPORTANT: The service ramp is used only with power module when the cabinet is mounted directly to the floor. Do not use the ramp to remove LCL filter modules from the cabinet. Review service ramp instructions before using.
Replace the power module with the appropriate catalog number: 20-750-MI4-CnnnDnnn or 20-750-MI4-EnnnFnn. The power module catalog number is included on the nameplate that is on the front of the module as shown in this illustration.
Frame 7 Power Module Nameplate Location
Frame 7 power module data nameplate location
Follow these steps to remove a power module from the enclosure.
  1. Review the product advisories in Before You Begin.
  2. Remove power from the system.
  3. Open the enclosure door.
  4. Remove the protective guard. See Remove and Install the Protective Guard for Frame 7.
  5. Loosen the thumbscrew that secures the connection cover to the front of the power module.
  6. Use the screw to lift the connections cover up and off the power module chassis.
    example of how to remove the frame 7 power module connections cover
  7. IMPORTANT: The minimum inside bend radius for fiber-optic cable is 50 mm (2 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable. Signal attenuation increases as inside bend radius is decreased.
    fiber-optic cable bend radius example
  8. Without bending the cable to a radius less than 50 mm (2 in.), remove the fiber-optic cables from the transceiver in the CTL and PDI (if used) ports on the power interface circuit board.
  9. IMPORTANT: The end of the transceiver that connects to the inside of the fiber port contains dielectric grease. Do not touch the end of the transceiver.
  10. Carefully remove the cable from the power module chassis and, observing the minimum bend radius, secure the fiber-optic cable in a protected location.
  11. For the CTL and PDI (if used) fiber-optic ports on the power layer interface board, open the transceiver latch and pull the transceiver out of the connector on the board.
    example of how to remove the fiber transceiver from a fiber-optic port
  12. TIP: If the latch is obstructed and you cannot use your fingers to open it, use a small, screwdriver, or other long, narrow tool to open the latch.
    IMPORTANT: For line side converter power module replacement, retain the PDI fiber-optic transceiver for reuse. When the power module is removed to replace the power layer interface circuit board only, retain the CTL and PDI (if used) fiber-optic transceivers for reuse. If present, do not remove the protective cover from the PDI fiber-optic port.
  13. For line side converter power modules, disconnect the DC fuse wire harness connector P1 from connector J1 on the I/O panel on the power module.
  14. For line side converter power modules, disconnect the 24V DC signal wire harness connector P3 from J3 on the I/O panel on the power module.
  15. Disconnect the 240V AC and optional 24V DC power supply wire harness connector P4 from J4 on the I/O panel on the power module.
    frame 7 power module wire harness connections
  16. Record the position of the DR jumper on the top of the power module. The DR jumper on the new power module must be installed in the same position.
    frame 7 power module DR jumper positions
  17. Item
    Description
    A
    DR jumper in the "IN" position
    B
    DR jumper in the "OUT" position
  18. Remove the two M12 nuts (C) that secure the top of the DC fuses to the DC bus terminals on the line side converter power module. For bus supplies, remove the DC link/fuses.
  19. For drives only, remove the two M10 nuts that secure the DC link bus bars to the DC terminals on the motor side inverter power module and remove the DC link/fuse assembly.
    example of how to remove the DC link fuses from a frame 7 power module
  20. For the line side converter power module, remove the six M8 x 30 mm Torx screws that secure the AC input flexible bus bars to the AC input terminals on the power module, and remove the flexible bus bars.
    example of how to remove the AC flexible bus bars from a frame 7 power module
  21. For the motor side inverter module, remove the six M8 x 30 mm Torx screws that secure the AC output flexible bus bars to the AC output terminals on the power module, and remove the flexible bus bars.
    example of how to remove the AC output flexible bus bars from a frame 7 power nodule
  22. Remove the two M10 x 20 mm Torx screws (E) that secure the upper power module chassis to the module support bracket.
  23. While you prepare and secure the
    PowerFlex®
     750-Series service cart or service ramp to the enclosure, leave the two M10 x 20 mm screws that secure the power module chassis to the floor mounting bracket.
  24. To release the power module, remove the two remaining M10 screws (F).
    example of how to remove the screws that secure the frame 7 power module to the enclosure
  25. On the new power module, verify that the jumper DR is installed in the same position as the old power module.
  26. Install the power module into the enclosure in the reverse order of removal.
  27. IMPORTANT: For motor side inverter power modules, do not remove the protective covers (G) from connector J3 on the I/O panel and the fiber-optic port PDI on the power layer interface circuit board. Retain protective covers for power and LCL filter modules for reuse. Install protective covers on connectors when a module is removed and stored.
    example of the protective covers on the frame 7 power module i/o connections panel
  28. Remove the protective covers from the CTL and PDI (if used) fiber-optic ports on the power layer interface circuit board.
    example of how to remove the cover from the fiber-optic transceiver port with XT protection
  29. TIP: This illustration represents a fiber-optic transceiver port on an example circuit board only.
  30. Remove the new transceiver supplied with the kit from the packing materials.
  31. Remove the protective covers from the transceiver.
    example of how to remove the covers from the ends of a fiber-optic transceiver with XT protection
  32. Without bending the cable to a radius less than 50 mm (2 in.), fully insert the fiber-optic cable into the transceiver.
    IMPORTANT: The end of the transceiver that connects to the inside of the fiber port contains dielectric grease. Do not touch the end of the transceiver.
    example of how to insert a fiber-optic cable into a transceiver
  33. Insert the transceiver and fiber-optic cable into the port on the board, until you hear an audible ‘click.’
    example of how to insert a fiber-optic cable and transceiver into a fiber-optic port
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