Remove and Install a Power Module for Frames 8...15

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-MI1-CnnnDnnn, 20-750-MI1-EnnnFnnn, 20-750-MI2-CnnnDnnn, 20-750-MI2-EnnnFnnn, 20-750-MI3-CnnnDnnn, or 20-750-MI3-EnnnFnnn. The power module catalog number is included on the nameplate that is on the front of the module as shown in this illustration.
Frame 8...15 Power Module Nameplate Location
frame 8…15 power module data nameplate location
Follow these steps to remove and install a power module from the enclosure.
  1. Review the product advisories in Before You Begin.
  2. Remove power from the system.
  3. Open the corresponding enclosure door.
  4. If a DC link fuse assembly is installed, remove the upper guard from the enclosure.
  5. If a DC precharge module is installed, loosen the two M6 x 16 mm Torx screws that secure the bottom guard to the enclosure, and remove the bottom guard.
    example of how to remove the DC precharge module bottom guard.
  6. TIP: A power module with DC link fuse assembly is shown throughout this procedure. The remaining steps are the same when a DC precharge module is installed.
  7. Loosen the thumb screw that secures the connections cover to the front of the power module.
  8. Use the screw to lift the connections cover up and off the power module chassis.
    example of how to remove the connections cover from a power module
  9. 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
  10. 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 layer interface circuit board.
  11. 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.
  12. Carefully remove the cable from the power module chassis and, observing the minimum bend radius, secure the fiber-optic cables in a protected location.
    example of how to remove the fiber-optic cables from the power layer interface circuit board on the power module
  13. TIP: If the latch is obstructed and you cannot use your fingers to open it, use a small, flat-blade screwdriver or other long, narrow tool to open the latch.
  14. 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
  15. IMPORTANT: 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. See Protective Covers on Kits with XT on page 27 for details on protective covers.
  16. If present, disconnect the cable connector P1 from connector J1 on the I/O panel in the power module remove the cable from the power module chassis.
  17. If present, disconnect the cable connector P2 from connector J2 on the I/O panel in the power module remove the cable from the power module chassis.
  18. Disconnect the cable connector P3 from connector J3 on the I/O panel in the power module remove the cable from the power module chassis.
  19. Disconnect the cable connector P4 from connector J4 on the I/O panel in the power module remove the cable from the power module chassis.
    example of how to remove the wire harnesses from the I/O panel on the power module
  20. TIP: The power module and assemblies are shown removed from the enclosure for clarity only.
    ATTENTION:
    Risk of equipment damage exists.
    Equipment damage can occur if the PE-B1 jumper is installed in the connected (IN) position for these applications:
    • The power module is used as a regenerative front-end converter. Do not install the PE-B1 jumper in the connected (IN) position for this application.
    • The power module is used as a common bus inverter with a regenerative front-end converter. Do not install the PE-B1 jumper in the connected (IN) position for this application.
    The PE-B1 jumper can be installed in the connected (IN) position when the power module is used as a common bus inverter with a non-regenerative front-end converter.
  21. Record the position of the PE-B1 jumper on the power interface circuit board in the power module. The PE-B1 jumper on the new power module must be installed in the same position.
    PE-B1 power jumper location on a frame 8…15 power module
  22. Item
    Description
    A
    PE-B1 jumper in the "IN" position
    B
    PE-B1 jumper in the "OUT" position (default)
    TIP: The protective cover (at A) shown in the illustration is not present on all existing power modules. If present, the protective cover must remain installed in the unused jumper connector J5 or J6. See Protective Covers on Kits with XT on page 27 for details on protective covers.
  23. Loosen the two M10 x 10 mm hex nuts and bolts that secure the power module DC input terminals to the DC precharge module or DC link fuse terminals.
  24. Remove the two M10 x 20 mm Torx screws that secure the power module chassis to the control bus frame.
  25. Leave the two M10 x 20 mm screws that secure the power module chassis to the floor mounting bracket while preparing the
    PowerFlex®
     750-Series service cart or service ramp.
    example of how to remove the power module from the enclosure
  26. To remove the module by using the service cart, follow the detailed instructions in the
    PowerFlex®
     750-Series Service Cart and DCPC Module Lift Installation Instructions, publication 750-IN105. To remove the module using PowerFlex 755TM service ramp, follow the procedures that are detailed in the
    PowerFlex®
     755T Module Service Ramp Instructions, publication 750-IN108.
  27. To release the power module from the enclosure, remove the two remaining M10 x 20 mm screws.
  28. Remove the power module from the enclosure.
  29. Verify that the jumper PE-B1 is installed in the correct position on the new power module.
  30. IMPORTANT: The protective cover provided in connector J5 on the power interface circuit board in the new power module must be installed in the unused PE-B1 jumper connector, position J5 or J6.
  31. Install the power module into the enclosure in the reverse order of removal.
  32. Connect the existing wire harnesses to the I/O penal on the power module.
    protective covers in connectors on the power module I/O panel
  33. IMPORTANT: Do not remove the protective covers (C) from connectors J2 and J3 on the power module I/O panel unless used at the time of installation. Do not remove the protective cover from the fiber-optic port PDI on the power layer interface circuit board unless used at the time of installation.
    IMPORTANT: Retain protective covers for power and LCL filter modules for reuse. Install protective covers on connectors when a module is removed and stored.
  34. If used, remove the protective cover from the PDI fiber optic port on the power layer interface circuit board.
    example of how to remove the cover from the fiber-optic transceiver port with XT protection
  35. TIP: This illustration represents a fiber-optic transceiver port on an example circuit board only.
  36. Without bending the cable to a radius less than 50 mm (2 in.), fully insert the fiber-optic cable into the transceiver.
    example of how to insert a fiber-optic cable into a transceiver
  37. 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
Provide Feedback
Have questions or feedback about this documentation? Please submit your feedback here.
Normal