Allen-Bradley PowerFlex 4M User manual

Publication 20P-IN050A-EN-P

PowerFlex® DC Drive

Frame D Pulse Transformer Circuit Board

Installation Instructions

What This Kit Includes •Pulse transformer circuit board

•Six screws and washers

•6 gate lead cables with connectors (for non-regenerative drives only)

•12 gate lead cables with connectors (for regenerative drives only)

•Static strap

Tools That You Need •Phillips®screwdriver

•Hexalobular screwdriver

•Nut driver or wrench

Phillips®is a registered trademark of Phillips Screw Company.

What You Need to Do To install the switching power supply board:

❐ Step 1: Remove power from the drive

❐ Step 2: Remove the protective covers

❐ Step 3: Remove the switching power supply board

❐ Step 4: Remove the existing pulse transformer board

❐ Step 5: Install the new pulse transformer board

❐ Step 6: Install the switching power supply board

❐ Step 7: Replace the protective covers and document the change

ATTENTION: Only qualified personnel familiar with DC drives

and associated machinery should plan or implement the installation,

start-up and subsequent maintenance of the system. Failure to comply

may result in personal injury and/or equipment damage.

ATTENTION: To avoid an electric shock hazard, ensure that all

power to the drive has been removed before performing the following.

ATTENTION: This drive contains ESD (Electrostatic Discharge)

sensitive parts and assemblies. Static control precautions are required

when installing, testing, servicing or repairing this assembly.

Component damage may result if ESD control procedures are not

followed. If you are not familiar with static control procedures,

reference A-B publication 8000-4.5.2, “Guarding Against

Electrostatic Damage” or any other applicable ESD protection

handbook.

Publication 20P-IN050A-EN-P

Step 1: Remove Power

from the Drive

1. Remove and lock-out all incoming power to the drive.

Step 2: Remove the

Protective Covers

1. Loosen, but do not remove, the four hexalobular screws that secure the top

control pan cover to the drive, then slide the cover up and off the drive

chassis (see Figure 1 on page 3). Tightening torque is noted in the

illustration for reassembly.

2. Disconnect the DPI cable from the HIM assembly (if present) (see Figure

1 on page 3).

Important:A communication cable is connected to the back of the HIM

assembly and to the Control board mounted on the control pan.

Therefore, the bottom control pan cover and HIM assembly

cannot be fully removed from the drive until the cable is

disconnected. Step 4 details this connection.

3. Loosen, but do not remove, the four hexalobular screws that secure the

bottom control pan cover to the drive, then slide the cover up and off the

drive chassis (see Figure 1 on page 3). Tightening torque is noted in the

illustration for reassembly.

ATTENTION: Remove power before making or breaking cable

connections. When you remove or insert a cable connector with

power applied, an electrical arc may occur. An electrical arc can

cause personal injury or property damage by:

•sending an erroneous signal to your system’s field devices,

causing unintended machine motion

•causing an explosion in a hazardous environment

Electrical arcing causes excessive wear to contacts on both the

module and its mating connector. Worn contacts may create electrical

resistance.

L1 L2 L3

Publication 20P-IN050A-EN-P

Figure 1 Cover Removal

4. Disconnect the HIM communication cable from the connector on the upper

right corner of the Control board and remove the bottom cover.

Disconnect

DPI cable

Top control

pan cover

Bottom control

pan cover

Tightening torque:

1.5 N•m (13 lb•in)

T15

Pull tabs out

to disconnect

cable.

Publication 20P-IN050A-EN-P

Step 3: Remove the

Switching Power Supply

Board

1. Loosen the eight hexalobular screws that secure the protective plastic cover

to the control pan and remove the cover.

Important: Mark all connections and wires before removal to avoid

incorrect wiring during reassembly.

2. Disconnect the cables from connector XA and XUV on the switching power

supply board (see Figure 2 below). Also, carefully remove the ribbon cable

from XA from the cable standoffs on the pulse transformer board.

3. Remove the five screws that secure the board to the control EMI shield and

remove the board.

Important:The switching power supply board is directly connected to the

pulse transformer board at connectors XSW and XSW1. Be sure

to carefully pull the board straight up during removal.

PFC-XX

Loosen

screws

Loosen

screws

Loosen

screw

Loosen

screw

Pulse Transformer board

Switching Power

Supply board

Publication 20P-IN050A-EN-P

Figure 2 Switching Power Supply Circuit Board Layout

Step 4: Remove the

Existing Pulse Transformer

Board

1. Disconnect the (red and white) gate leads from connectors XP1 and XP2 at

the top-left corner of the board.

2. Disconnect the appropriate gate leads from the pulse transformer board (see

Figure 3 below):

–For non-regenerative drives, each pair of (red and white) gate lead cables

from connectors KG1…KG6.

–For regenerative drives, each pair of (red and white) gate lead cables from

connectors KG1…KG6 and KG01…KG06.

3. Disconnect the cables from the following connectors: XUV, XCD_IO,

XUVW, XCD, XR, XTA, X4 and XSPF. Also, carefully remove the ribbon

cable (from XR) from the cable standoff on the board.

4. Remove the plug-in terminal block at the bottom of the pulse transformer

board.

5. Remove the two hexagonal standoffs and washers from the pulse

transformer board.

6. Remove the six hexalobular screws that secure the pulse transformer board

to the control pan and remove the board.

16 XSW

XSW1

1C2

1D2

XUV

T15

Tightening torque:

1.0…1.2 N•m

(9…10.5 lb•in)

Publication 20P-IN050A-EN-P

Figure 3 Pulse Transformer Circuit Board Layout

XUV

XSW

XSW1

XCD_IO XUVW

XCD

XSPF

7879 35 36 75 76 81 82 U2 V2

X4 X5 X6

XTA

TR2

TR1

XP1

XP2

KG1

KG4

KG2

KG5

KG3

KG6

KG01

KG04

KG02

KG05

KG03

KG06

T01

T04

T02

T05

T03

T06

XCT

Components shown within dashed lines are only on

the pulse transformer board for regenerative drives.

T15

Tightening torque:

1.0…1.2 N•m

(9…10.5 lb•in)

Publication 20P-IN050A-EN-P

Step 5: Install the New

Pulse Transformer Board

Install the new pulse transformer board in reverse order of removal as detailed in

Step 4: Remove the Existing Pulse Transformer Board on page 5.

• Inspect the existing gate lead cables for burn marks, cracks or loose

connectors. Replace the cables if necessary with the new cables provided.

• Set DIP switches S3 and S4 on the pulse transformer board (see Figure 3 on

page 6 for location) to the correct settings based on the appropriate table

below.

Important:A blank cell below a switch in tables below indicate that the

setting is “OFF”.

Table 1 230V AC Input Drives

Table 2 460V AC Input Drives

Table 3 575V AC Input Drives

Table 4 690V AC Input Drives

Drive

Current

Rating

Code

Amps

Line

Amps HP

DIP Switch S3 DIP Switch S4

S3-1 S3-2 S3-3 S3-4 S3-5 S3-6 S3-7 S3-8 S4-1 S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8

875 875 718 250 ON ON ON

1050 1050 861 300 ON ON ON ON

Drive

Current

Rating

Code

Amps

Line

Amps HP

DIP Switch S3 DIP Switch S4

S3-1 S3-2 S3-3 S3-4 S3-5 S3-6 S3-7 S3-8 S4-1 S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8

830 830 681 500 ON ON ON

996 996 817 600 ON ON ON

1K1 1162 953 700 ON ON ON ON

1K3 1328 1089 800 ON ON ON ON

1K4 1494 1225 900 ON ON ON ON

Drive

Current

Rating

Code

Amps

Line

Amps HP

DIP Switch S3 DIP Switch S4

S3-1 S3-2 S3-3 S3-4 S3-5 S3-6 S3-7 S3-8 S4-1 S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8

810 810 664 600 ON ON ON

1K0 1080 886 800 ON ON ON ON

1K2 1215 996 900 ON ON ON ON

1K3 1350 1107 1000 ON ON ON ON

1K4 1668 1384 1250 ON ON ON ON

Drive

Current

Rating

Code

Amps

Line

Amps HP

DIP Switch S3 DIP Switch S4

S3-1 S3-2 S3-3 S3-4 S3-5 S3-6 S3-7 S3-8 S4-1 S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8

678 678 556 600 ON ON

791 791 649 700 ON ON ON

904 904 741 800 ON ON ON

1K0 1017 834 900 ON ON ON ON

1K1 1130 927 1000 ON ON ON ON

1K2 1243 1019 1100 ON ON ON ON

1K4 1413 1159 1250 ON ON ON ON

1K5 1582 1297 1400 ON ON ON ON

Publication 20P-IN050A-EN-P - May 2010

www.rockwellautomation.com

mericas:

Rockwell

Automation,

1201

South

Second

Street,

Milwaukee,

53204-2496

USA,

Tel:

(1) 414.382.2000

Fax:

(1)

414.382.4444

Europe/Middle East/Africa:

Rockwell

Automation

SA/NV,

Vorstlaan/Boulevard

du Souverain

36,

1170 Brussels,

Belgium,

Tel:

(32) 2 663

0600,

Fax:

(32) 2 663 0640

sia

Pacific:

Rockwell

Automation,

Level 14,

Core F,

Cyberport 3,

100 Cyberport Road,

Hong

Kong,

Tel:

(852) 2887 4788,

Fax:

(852) 2508 1846

Power, Control and Information Solutions

Step 6: Install the

Switching Power Supply

Board

Install the switching power supply board in reverse order of removal as

detailed in Step 3: Remove the Switching Power Supply Board on page 4.

Step 7: Replace the

Protective Covers and

Document the Change

1. Replace the protective covers in the reverse order of removal as

described in Step 2: Remove the Protective Covers on page 2.

2. Install DPI cable (if present).

3. Record the installation of the new pulse transformer board and date of

installation on the Field Installed Option label on the side of the drive

(as shown below).

Related Documentation Allen-Bradley publications are available on the internet at

www.rockwellautomation.com/literature.

For . . . Read this document

Publication

Number

In depth information regarding the

operation of PowerFlex Digital DC drives

User Manual - PowerFlex Digital DC Drives 20P-UM001…

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