Manual

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Installation Instructions

PowerFlex

DC Drive - Frame A SCR Modules

for Drives with Bus Bars

What This Kit Includes

• SCR modules (3 for non-regenerative drives, 6 for regenerative drives)

• Mounting screws and washers (6 for non-regenerative drives, 12 for

regenerative drives)

• Gate leads (6 for non-regenerative drives, 12 for regenerative drives)

• Thermal Grease

• Static strap

Important:The SCR Modules supplied with this kit should only be used in

the following Frame A drives:

Tools That You Need

• Phillips

screwdriver

• Flathead screwdriver

• Nut driver or wrench for hex stand-offs

• Torque wrench

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.

230V AC Input 460V AC Input

Drive Current

Rating Code DC Amps

AC Line

Amps HP

Drive Current

Rating Code DC Amps

AC Line

Amps HP

073 73 60 20 073 73 59.6 40

093 93 76 25 086 86 70.3 50

110 110 90 30 100 100 81.7 60

129 129 105.4 75

Summary of content (18 pages)

PAGE 1
Installation Instructions PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars 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 SCR Modules for Drives with Bus Bars What You Need to Do The SCR modules are located on the heat sink of the drive chassis, below all circuit boards and components.
PAGE 3
PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars Step 2: Remove the Protective Covers 3 1. Remove the two screws that secure the power terminal cover to the drive and slide the cover down and off the drive chassis. 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.
PAGE 4
PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars 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. 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 - Frame A SCR Modules for Drives with Bus Bars Step 3: Remove the Control EMI Shield and Control Board 5 Note: The SCR Modules are located on the heat sink of the drive, behind the Control, Pulse Transformer, Switching Power Supply and Power Traces boards. All of these boards must be removed in order to replace the SCR Modules. 1. Carefully disconnect the cables from connectors XA, XR and XFCD on the Control board. 2.
PAGE 6
PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars 3. Remove the five 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 7
PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars Step 4: Remove the Pulse Transformer and Switching Power Supply Boards Note: The Switching Power Supply circuit board is secured to the back of the Pulse Transformer circuit board. 1. Remove the two screws that secure the slotted air flow plate to the top of the drive and remove the plate. = Remove screw Air flow plate Remove screw Important: Mark all connections and wires before removal to avoid incorrect wiring during reassembly. 2.
PAGE 8
PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars 3. Remove the cables from connectors X3, X4 and XP on the Pulse Transformer board. Remove cables from X3 and XP 4. For Pulse Transformer boards with an armature voltage feedback terminal block, FIR1-XX, rev “Q” and higher, remove the connector from XCD_IO on the upper left corner of the board.
PAGE 9
PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars 9 5. Remove the appropriate gate leads: – 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. – 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.
PAGE 10
PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars 7. 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 11
PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars Step 5: Remove the Bus Bars 11 1. Remove the isolation sheet. Remove isolation sheet = 2. Remove the screws that secure the U, V, W, C, and D terminal bus bars to the power terminal isolation strip at the bottom of the drive.
PAGE 12
PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars 3. For regenerative drives only, remove the screws and washers that secure the connecting bus bars to the anodes of the corresponding SCR Modules and remove the bus bars. In addition, remove the U, V and W phase terminal bus bars from the drive. Important: The screws that secure these bus bars to the SCR Modules are M5 x 16. Retain for reuse with these bus bars only.
PAGE 13
PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars 13 4. Remove the four screws and washers that secure the C and D terminal bus bars to the horizontal bus bars and remove the C and D terminal bus bars. Important: For regenerative drives only, the screws that secure these bus bars to the SCR Modules are M5 x 16. Retain for reuse with these bus bars only.
PAGE 14
PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars 5. Remove the screws and washers that secure the connecting bus bars to the SCR Modules and remove the bus bars.
PAGE 15
PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars 6. For non-regenerative drives only, remove the screws and washers that secure the U, V and W terminal bus bars to the SCR Modules and remove the bus bars.
PAGE 16
PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars Step 6: Remove the Existing SCR Modules 1. Remove the two screws and washers that secure each SCR Module to the heatsink and remove the SCR Modules. Non-Regenerative drive = Remove screws Regenerative drive Remove screws Step 7: Install the New SCR Modules Install the new SCR modules in reverse order of removal as detailed in Step 6: Remove the Existing SCR Modules above.
PAGE 17
PowerFlex® DC Drive - Frame A SCR Modules for Drives with Bus Bars Step 8: Install the Bus Bars 17 Install the bus bars in reverse order of removal as detailed in Step 5: Remove the Bus Bars on page 11. Use the following table to determine the proper tightening torque for the bus bars to SCR Modules connections. 230V AC Input Part Number SK-20P-S7F46 SK-20P-S7F47 Step 9: Install the Pulse Transformer and Switching Power Supply Boards Final Torque 2.5…4 N•m (22…35.4 lb•in) 2.5…4 N•m (22…35.
PAGE 18
Step 11: Replace the Protective Covers and Documenting the Change 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 SCR Modules 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.