Manual

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Installation Instructions

PowerFlex

DC Drive Analog and Digital I/O

Expansion Circuit Board

What This Kit Includes

• I/O Expansion circuit board

• Two stand-offs

• Two spring washers

• Two flat washers

• Two screws with captive lock washers

What This Option Provides

The I/O Expansion Card is a drive mounted board that provides these

additional I/O signals.

• Four (4) Digital Inputs

• Four (4) Digital Outputs

• Two (2) Analog Outputs

Tools That You Need

• Phillips

screwdriver

• Nut driver or wrench for hex stand-offs

• Flathead screwdriver

Phillips

is a registered trademark of Phillips Screw Company.

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.

Summary of content (10 pages)

PAGE 1
Installation Instructions PowerFlex® DC Drive Analog and Digital I/O Expansion Circuit Board ! ! ! 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.
PAGE 2
PowerFlex® DC Drive Analog and Digital I/O Expansion Circuit Board What You Need to Do To install the I/O Expansion board: ❐ Step 1: ❐ Step 2: ❐ Step 3: ❐ Step 4: ❐ Step 5: Step 1: Removing Power from the Drive Remove power from the drive Open the drive Install the I/O Expansion board Wire the I/O Expansion board Document the change 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.
PAGE 3
PowerFlex® DC Drive Analog and Digital I/O Expansion Circuit Board Step 2: Opening the Drive 3 1. Disconnect the DPI cable from the HIM (if present). 2. Remove the bottom front cover from the drive: a. On frame A drives, remove the screws that secure the bottom front cover to the drive, then slide the cover down and off the drive chassis. Frame A = Disconnect DPI cable Tightening torque: 1.5 N-m (13.3 lb.-in.) b.
PAGE 4
PowerFlex® DC Drive Analog and Digital I/O Expansion Circuit Board 3. Remove the top front cover from the drive: a. For frame A drives, press in on the sides at the bottom edge of the cover and at the same time pull the cover toward you to pull it partially off the drive chassis. Next, at the top of the drive, pull the cover forward, away from the drive, until the pins fit in the keyhole in the top of the cover, then carefully lift the cover off of the drive chassis.
PAGE 5
PowerFlex® DC Drive Analog and Digital I/O Expansion Circuit Board 5 b. On frame B and C drives, loosen, but do not remove, the screws that secure the top front cover to the drive, then slide the cover up and off the drive chassis. Important: The HIM assembly is connected via a cable to the Control board and therefore will not pull free from the drive until disconnected. See page 5 for instructions. Frames B & C (Frame B shown) = Tightening torque: 1.5 N-m (13.3 lb.-in.) U C V D W 4.
PAGE 6
PowerFlex® DC Drive Analog and Digital I/O Expansion Circuit Board Step 3: Installing the I/O Expansion Board 1. Remove the screw in the lower left corner of the Control circuit board. = Remove screw 2. Place the two (2) flat washers and two (2) spring washers between the stand-offs and the Control board and install and tighten the stand-offs on the Control board. Important: Do not over tighten the stand-offs or circuit board damage may occur.
PAGE 7
PowerFlex® DC Drive Analog and Digital I/O Expansion Circuit Board 3. Carefully insert the connector pins on the back of the I/O Expansion board into connector XBB on the Control board and push the board down until it makes contact with the stand-offs. Important: Push the board straight down so that the pins on the I/O Expansion board do not bend or break. = Insert pins into connector XBB 4. Secure the I/O Expansion board to the stand-offs on the Control board using the two screws provided.
PAGE 8
PowerFlex® DC Drive Analog and Digital I/O Expansion Circuit Board Step 4: Wiring the I/O Expansion Board Table 1 Recommended Signal Wire Size Wire Type and Size Flexible (mm2) multi-core (mm2) 0.14 - 1.5 0.14 - 1.5 AWG 28-16 Tightening Torque N-m (lb.-in.) 0.4 (3.5) A 75 x 2.5 x 0.4 mm (3.0 x 0.1 x 0.02 in.) flathead screwdriver is recommended for connecting wire to the terminal block inputs. Strip the ends of the cables to a length of 6.5 mm (0.26 in.).
PAGE 9
PowerFlex® DC Drive Analog and Digital I/O Expansion Circuit Board 9 Figure 3 I/O Expansion Board Wiring Diagram 1 4 2 3 5 4 5 6 6 7 7 8 8 9 9 10 11 19 10 11 12 13 + 24 V 0V Figure 4 I/O Wire Routing (Frame A shown) Route I/O wiring between bottom front cover and power terminal cover/shield.
PAGE 10
Step 5: Documenting the Change 1. Record the installation of the Analog and Digital I/O Expansion circuit board and date of installation on the Field Installed Option label on the side of the drive (as shown below). 2. Replace the drive covers in the reverse order of removal as described in Step 2: Opening the Drive on page 3. 3. Install DPI cable (if present). Frame A Shown Related Documentation Allen-Bradley publications are available on the internet at www.rockwellautomation.com/literature.