• Topic ID: id_16157505
  • Version: 4.0
  • Date: Jan 20, 2020 8:34:29 PM

Inverter Mid Power Assembly Replacement

Prerequisites

Overview

To replace the Inverter Mid Power Assembly:

  • If possible, upload JEDI database (from JEDI to console)

  • Remove power unit mounting screws

  • Replace power unit

  • Verify system operation

1 Inverter Mid Power Assembly Removal

Procedure

  1. Remove the power unit according to Power Unit Replacement.
  2. Remove the heat sink as follows:
    1. With the Power Unit standing on end, unscrew seven bolts holding the heat sink.
    2. Loosen two bolts holding the HV Tank through the heat sink.
    3. Place the heat sink down on the floor.
    4. Remove top and side covers of the PI filter box.
    5. Disconnect J2 cable connector from PI Filter box.

      Figure 1. PI Filter Box

      6. Notice Image
      • notice
      • Ensure that the two cables are marked. The Inverter will be damaged if the + and – DC Bus cables are reversed.
    6. Using a 10 mm socket wrench, disconnect the two DC cables :–DC, +DC from the Pi Filter board. And retain the locking washers.

      Figure 2. Disconnect DC Cables

    7. Remove the remaining two HV Tank retaining bolts from the bottom of the heat sink.

      Figure 3. Bolts of HV Tank

    8. Separate the Power Unit.
  3. Remove covers from the Power Unit as follows:
    1. Unscrew twelve 5.5 mm hex head screws from three sides, and loosen four 5.5 mm hex head screws, then remove the front cover.
    2. Unscrew and remove the lifting bracket plate.

      Figure 4. Front Cover and Lifting Bracket Plate

      note:

      All the 5.5 mm hex head screws on the Jedi generator are 8 mm long, except for the fourteen screws holding the lifting bracket, which are 12 mm long.

    3. Unscrew and remove the fan (with bracket), but don’t remove the fan from its bracket.
    4. Unscrew and remove the lateral L shape cover.

      Figure 5. Fan and Lateral L Shape Cover

  4. Remove the Capacitor assembly as follows:
    1. Disconnect the short ribbon cable from the KV Measure board to the Gate Command board.
    2. Disconnect the measure current cable from the Capacitor assembly.

      Figure 6. Ribbon Cable and Measure Current Cable

    3. Cut tie-wraps.
    4. Unscrew six 8mm nuts and two 8mm screws using 8mm socket wrench.
    5. Unscrew ten 5.5mm hex head screws.

      Figure 7. Capacitor Assembly Removal

    6. Unscrew a 8mm nut and remove the DC cable.

      Figure 8. Disconnect DC Cable

    7. Pull and slide the capacitor assembly, and remove it.

      Figure 9. Capacitor Assembly Removal

  5. Remove the Inverter Mid Power Assembly as follows:
    1. Unscrew the 5.5 mm hex head screws and remove the lateral cover. (The inverter is now mechanically free).

      Figure 10. Lateral Cover Removal

    2. Disconnect the flat cable and the current measure cable from the gate command board.
    3. Pull and slide the entire block, and separate the inverter mid power assembly from the tank and frame.

      Figure 11. Flat Cable and Current Measure Cable

2 Inverter Mid Power Assembly Installation

Procedure

  1. Put the new inverter power assembly (see the image) in the position of the old inverter.

    Figure 12. Inverter Power Assembly

  2. Re-install the lateral cover.

    Figure 13. Lateral L Cover Installation

    note:

    Do not place any screws.

  3. Connect the flat cable to the gate command board.
  4. Re-install the capacitor assembly as follows:
    1. Add tie-wraps in the position as shown in illustration below.

      Figure 14. Tie-wrap on Capacitor Assembly

    2. Put the Capacitor assembly over the inverter frame but do not insert it.
    3. Connect the cable of the current measure in the Gate Command board.
    4. Insert the Capacitor assembly taking care of the cable of the DC bus.

      Figure 15. Capacitor Assembly Installation

    5. Put in place and screw the serial inductor cable.

      Figure 16. Serial Inductor Cable

    6. Install and tighten all the 5.5 mm hex head screws to fix the capacitor assembly to the frame.
    7. Connect all cables of capacitor assembly, and tighten all the 8mm screws and nuts (see Torque Wrench Information) as shown in illustration below.

      Figure 17. Cable Connection of Capacitor Assembly

      8. Notice Image
      • notice
      • The two flat cables with white bands on them go to the position (1) and (3) of the Capacitor Assembly.
    8. Close and tight the tie-wraps, and cut the useful extremity of the tie-wraps.

3 Reassemble the Power Unit

Procedure

  1. Position the heat sink while passing the two DC cables through the hole.

    Figure 18. DC Cables

  2. Re-install the heat sink.
    3. Notice Image
    • notice
    • ENSURE POLARITY IS OBSERVED. AN INVERSION WOULD DESTROY THE INVERTER AND PI FILTER BOARD AT POWER-UP.
  3. Attach + and – wires of the DC cables to the Pi Filter board.

    Figure 19. DC Cable Connection

  4. Insert the screw and grower washer, then tighten to torque 4Nm on U3 and U4. These torques are written on the label: 4Nm (40kg.cm)

    Figure 20. Torque Label

  5. Put the complete assembly in the vertical position.
  6. Re-install the following covers and unit, and ensure that proper torque specifications (see Torque Wrench Information) are followed for all fasteners.

    • Lateral L Shape Cover (see Figure 5).

    • Fan (with bracket) (see Figure 5).

    • Lifting Bracket Plate (see Figure 4).

    • Pi Filter Cover.

  7. Lift the power unit back on to the gantry and attach it.
    8. Notice Image
    • notice
    • ENSURE POLARITY OF CABLES IS OBSERVED. AN INVERSION WOULD DESTROY THE INVERTER AND TUBE AT POWER-UP.
  8. Reconnect all cables.
  9. Remount the covers.

4 Finalization

Procedure

  1. Run System Scanning Test verify that the system is operational.