Manual

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Installation Instructions

PowerFlex

DC Drive - Frame A Field Circuit

Board

What This Kit Includes

• Field circuit board

• Plug-in terminal block for Field connections

• Two screws for Field circuit board

• Two hexagonal stand-offs

• Two screws for the hexagonal stand-offs

• One plastic stand-off

• Cables for connector X3 and XFCD

• Flathead screwdriver for terminal block connections

• Isolation sheet

• Static strap

Important:It is highly recommended that the Field SCR/Dual Diode

Bridge module be replaced when replacing the Field circuit

board. The Field SCR/Dual Diode Bridge module is sold as a

separate spare part kit.

Tools That You Need

• Phillips

screwdriver

• Flathead screwdriver

• Nut driver or wrench for hex stand-offs

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 (20 pages)

PAGE 1
Installation Instructions PowerFlex® DC Drive - Frame A Field 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 - Frame A Field Circuit Board What You Need to Do The Field circuit board is located at the lower right corner of the drive chassis behind the Control board and Control EMI Shield and the Pulse Transformer board.
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PowerFlex® DC Drive - Frame A Field Circuit Board Step 1: Remove Power from the Drive 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 4
PowerFlex® DC Drive - Frame A Field Circuit Board 2. Disconnect the DPI cable from the HIM assembly (if present). 3. Remove the screws that secure the bottom cover to the drive, then slide the cover down and off the drive chassis. = Disconnect DPI cable Tightening torque: 1.5 N-m (13.3 lb.-in.) 4. Press in on the sides at the bottom edge of the top cover and at the same time pull the cover toward you to pull it partially off the drive chassis. 5.
PAGE 5
PowerFlex® DC Drive - Frame A Field Circuit Board 6. Disconnect the HIM Communication cable from the connector on the upper right corner of the Control board and set the cover aside. Pull tabs out to disconnect cable.
PAGE 6
PowerFlex® DC Drive - Frame A Field Circuit Board Step 3: Remove the Control EMI Shield and Control Board 1. Carefully disconnect the cables from connectors XFCD, XA and XR on the Control board. 2.
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PowerFlex® DC Drive - Frame A Field Circuit Board 3. Remove the four screws (and ground wire on the lower left corner of board) that secure the Control EMI shield and Control board to the chassis and slide the Control EMI shield and Control board up and out of the drive. Important: Be careful when removing the EMI shield not to pull free any of the gate leads or other cables on the Pulse Transformer circuit board below the EMI shield.
PAGE 8
PowerFlex® DC Drive - Frame A Field Circuit Board 1. Remove the air flow plate from the top of the drive: – For 38A and 55A drives @ 230V AC input and 35A, 45A, and 52A drives @ 460V AC input, remove the four screws that secure the slotted air flow plate to the top of the drive, remove the fan cable from connector XV on the Switching Power Supply board and remove the plate.
PAGE 9
T1 KGO1 T4 X4 KGO2 T2 TO2 XSW1 KG2 KGO5 XY KG5 T5 TO5 XR XSW KGO3 T3 TO3 TR2 XP FIR1-XX rev. “Q” and higher TO4 KGO4 KG1 KG4 TO1 XCD_IO X3 T6 S4 1 XTA 1 78 79 35 36 75 76 U2 V2 KG3 KG6 KGO6 TO6 TR1 S3 U C V W KG1 K G T1 KG01 K G C T01 U V K G T4 K G KG04 T04 KG4 W 1 K G T2 1 K G KG02 X4 XSW1 T02 1 1 2 KG5 K G 6 1 XP K G T3 KG03 T03 TR2 KG3 XR K G KG05 T5 T05 1 0V1 XSW XY 1 FIR1-XX rev.
PAGE 10
PowerFlex® DC Drive - Frame A Field Circuit Board 2. Remove the plug-in control power terminal block from the Pulse Transformer circuit board (refer to Figure 1 on page 9 for location). Remove plug-in terminal block 3. Remove the cables from connectors X3 and XP on the Pulse Transformer board (refer to Figure 1 on page 9 for location). 4. For drives with a fan, remove the cable from connector X4 on the Pulse Transformer board.
PAGE 11
PowerFlex® DC Drive - Frame A Field Circuit Board 11 6. Remove the appropriate gate leads (refer to Figure 1 on page 9 for location): – For non-regenerative drives, remove each pair of (orange and yellow) gate lead cables from connectors KG01 - KG06 and push each lead through the appropriate opening in the board. – For regenerative drives, remove each pair of (orange and yellow) gate lead cables from connectors KG01 - KG06 and KG1 - KG6 and push each lead through the appropriate opening in the board.
PAGE 12
PowerFlex® DC Drive - Frame A Field Circuit Board 8. Remove the six screws that secure the Pulse Transformer board (and Switching Power Supply board) to the drive and, while lifting up slightly on the board, slide the Pulse Transformer and Switching Power Supply boards toward the top of the drive and out of the chassis. Important: The cables from connectors X4 (if present) and XTA must slide through the openings in the board as it is lifted out of the drive chassis.
PAGE 13
PowerFlex® DC Drive - Frame A Field Circuit Board Step 5: Remove the Existing Field Circuit Board 13 1. Remove the four bundled wires from the Field SCR/Dual Diode Bridge module. Remove bundled wires = Note: Regenerative drive with bus bars shown.
PAGE 14
PowerFlex® DC Drive - Frame A Field Circuit Board 2. If necessary, remove the power wiring from terminals U, V, W, C, D, and PE. 3. Remove the plug-in field terminal block on the bottom of the drive. Remove plug-in field terminal block Note: Drive with fan shown. 4. Remove the two screws that secure the bottom air flow plate to the power terminal isolation strip. Remove two screws Note: Drive with fan shown.
PAGE 15
PowerFlex® DC Drive - Frame A Field Circuit Board 5. Remove the screws that secure the air flow plate to the bottom of the drive chassis and carefully pull the air flow plate and fan (if present) assembly down and off the drive.
PAGE 16
PowerFlex® DC Drive - Frame A Field Circuit Board 6. Remove the two screws that secure the Field circuit board to the drive chassis and remove the Field board and isolation sheet below the board.
PAGE 17
PowerFlex® DC Drive - Frame A Field Circuit Board Figure 1 Field Circuit Board Layout X3 1 1 VF1 Field fuse connections UF and UF1 XFCD Field fuse connections VF and VF1 UF1 X2 UF VF 7. Remove the wires that connect the Field fuses (UF, UF1, VF, VF1) to the Field circuit board and the cable from connector X3 on the Field board. (Refer to Figure 1 above for connector location.
PAGE 18
PowerFlex® DC Drive - Frame A Field Circuit Board Step 6: Install the New Field Circuit Board Install the new Field board in reverse order of removal as detailed in Step 5: Remove the Existing Field Circuit Board on page 13. ATTENTION: Failure to install the Isolation sheet below the Field board may result in damage to the drive. 1. Replace the cable connected to XFCD on the Field board with the new cable provided. 2.
PAGE 19
PowerFlex® DC Drive - Frame A Field Circuit Board Step 9: Replace the Protective Covers and Documenting the Change 19 1. Replace the protective covers in the reverse order of removal as described in Step 2: Remove the Protective Covers on page 3. 2. Install the DPI cable (if present). 3. Record the installation of the new Field circuit board and date of installation on the Field Installed Option label on the side of the drive (as shown below).
PAGE 20
1S7A07 www.rockwellautomation.com Power, Control and Information Solutions Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.