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Table Of Contents

Installation Instructions

PowerFlex

DC Drive - Frame B AC Line

Snubber Board and High Wattage Resistors

What This Kit Includes

• AC Line Snubber circuit board

• Three screws for AC Line Snubber circuit board

• Six high watt resistors and wire leads

• Twelve screws for high watt resistors

• Thermal grease

• Cables ties

• Static strap

Tools That You Need

• Phillips

screwdrivers

• Flathead screwdriver

• Torque wrench (1…12 N•m)

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 (18 pages)

PAGE 1
Installation Instructions PowerFlex® DC Drive - Frame B AC Line Snubber Board and High Wattage Resistors 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 B AC Line Snubber Board and High Wattage Resistors What You Need to Do The AC Line Snubber board and Resistors are located at the top of the drive chassis behind the Control board and Control EMI Shield and Field and Pulse Transformer circuit boards. Field board Pulse Transformer board AC Line Snubber board and Resistors behind Field and Pulse Transformer boards Note: Drive shown with front covers removed and Control EMI shield lowered.
PAGE 3
PowerFlex® DC Drive - Frame B AC Line Snubber Board and High Wattage Resistors 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 B AC Line Snubber Board and High Wattage Resistors Step 2: Remove the Protective Covers 1. Disconnect the DPI cable from the HIM assembly (if present). 2. Loosen, but do not 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) 3.
PAGE 5
PowerFlex® DC Drive - Frame B AC Line Snubber Board and High Wattage Resistors 5 4. 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. Step 3: Remove the Pulse Transformer and Switching Power Supply Boards Note: The Switching Power Supply circuit board is located on the back of the Pulse Transformer circuit board. 1.
PAGE 6
PE1 KG1 PE KG4 KGO1 U X3 T1 T4 TO1 XCD_IO KGO4 TO4 KG5 XTA T5 TO2 KGO5 V XM XY TR2 D T3 KG3 T6 TR1 XP 78 79 35 36 75 76 U2 V2 XCT FIR2-XX rev. “N” and higher C KG2 T2 KGO2 TO5 X4 XR XSW1 1 KG6 S3 TO6 TO3 S4 W 1U2 1V2 KGO6 KGO3 XI2CA PE1 KG1 PE KG4 KGO1 U X3 T1 T4 TO1 XCD_IO KGO4 TO4 KG5 XTA T5 TO2 KGO5 V XM XY TR2 D T3 KG3 T6 TR1 XP 78 79 35 36 75 76 U2 V2 XCT FIR2-XX rev.
PAGE 7
PowerFlex® DC Drive - Frame B AC Line Snubber Board and High Wattage Resistors 7 3. Remove the cable from connector XTA on the Pulse Transformer board (see Figure 1 on page 6 for location). 4. Remove the plug-in terminals from the Control power block on the Pulse Transformer board. = Remove cable Remove plug-in terminals 5. For Pulse Transformer boards with an armature voltage feedback terminal block, FIR2-XX, rev. “N” and higher, remove the connector from XCD_IO on the lower left corner of the board.
PAGE 8
PowerFlex® DC Drive - Frame B AC Line Snubber Board and High Wattage Resistors 6. Carefully disconnect the cables from connectors XA, XR and XFCD at the top of the Control board. Disconnect cables 7. Loosen the two captive screws at the top of the Control EMI shield and lower the shield. Important: If the drive is not in a vertical position, the Control EMI shield will not remain open without a means of restraint.
PAGE 9
PowerFlex® DC Drive - Frame B AC Line Snubber Board and High Wattage Resistors 9 8. Remove the two screws that secure the air flow plate to the top of the Pulse Transformer board and lift the plate off the drive chassis. The air flow plate cannot be completely removed due to the fuse connections at FU1 and FV1. Remove screws Fuse connections 9. Remove the cables from connectors X3, X4 and XP on the Pulse Transformer board (see Figure 1 on page 6 for location).
PAGE 10
PowerFlex® DC Drive - Frame B AC Line Snubber Board and High Wattage Resistors 10. Remove the ground connection at the left side of the Pulse Transformer board.
PAGE 11
PowerFlex® DC Drive - Frame B AC Line Snubber Board and High Wattage Resistors 11 11. Remove the appropriate gate leads (see Figure 1 on page 6 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.
PAGE 12
PowerFlex® DC Drive - Frame B AC Line Snubber Board and High Wattage Resistors 12. Remove the seven screws that secure the board to the stand-offs on the drive chassis and remove the Pulse Transformer and Switching Power Supply boards from the drive. Note: Regenerative Drive Shown.
PAGE 13
PowerFlex® DC Drive - Frame B AC Line Snubber Board and High Wattage Resistors Step 4: Remove the Field Circuit Board 1. Remove the wires from connectors UF, UF1, VF and VF1. 2. Remove the six screws that secure the Field board to the Field SCR and Dual Diode Modules and remove the Field board.
PAGE 14
PowerFlex® DC Drive - Frame B AC Line Snubber Board and High Wattage Resistors Step 5: Remove the Existing AC Line Snubber Board and Resistors 1. Remove the screws and washers and/or bolts and washers that secure the (red, blue and black) wires from the AC Line Snubber board and resistors to the bus bars and remove the wires.
PAGE 15
PowerFlex® DC Drive - Frame B AC Line Snubber Board and High Wattage Resistors 15 2. Remove the three screws that secure the AC Line Snubber board to the drive frame and lift the board. Note: The wires from the resistors are connected to the board. Therefore, the board cannot be removed until the resistors are removed. Remove screws 3. Remove the two screws that secure each resistor (six total) to the drive heat sink and remove the resistors and AC Line Snubber board from the drive.
PAGE 16
PowerFlex® DC Drive - Frame B AC Line Snubber Board and High Wattage Resistors Step 6: Install the New AC Line Snubber Board and Resistors Install the new AC Line Snubber board and resistors in reverse order of removal as detailed in Step 5: Remove the Existing AC Line Snubber Board and Resistors on page 14. • Apply thermal grease to the bottom of the resistors before securing them to the heatsink.
PAGE 17
PowerFlex® DC Drive - Frame B AC Line Snubber Board and High Wattage Resistors Step 8: Install the Pulse Transformer and Switching Power Supply Boards 17 Install the Pulse Transformer and Switching Power Supply boards in reverse order of removal as detailed in Step 3: Remove the Pulse Transformer and Switching Power Supply Boards on page 5.
PAGE 18
Step 9: 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 4. 2. Install DPI cable (if present). 3. Record the installation of the new AC Line Snubber board and Resistors 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.