Manual

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Installation Instructions

23P-IN008A-EN-P

PowerFlex DC Stand-Alone Regulator (SAR)

In-Rush Limiting Resistor

What This Kit Includes

• One in-rush limiting resistor

• Four screws with captive lock washers

• Static strap

Tools That You Need

• Phillips

screwdriver

• Hexalobular screwdriver

• Nut driver or wrench for hex stand-offs

• Wire cutter/stripper

• Soldering iron and solder supplies

• Isopropyl alcohol

• Thermal grease

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 SAR has been removed before performing the following.

ATTENTION: This SAR 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 Stand-Alone Regulator (SAR) In-Rush Limiting Resistor 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 SAR has been removed before performing the following.
PAGE 2
What You Need to Do The list below is an overview of the steps needed to remove and replace the in-rush limiting resistor. See each step for detailed procedures. IMPORTANT The SAR has many different cables, wires, and plugs with different connections and routing. For ease of reassembly: • Make note of cable and wire routing between and within the different circuit boards. • Label connectors and plugs with the name of the connection and circuit board from where it was disconnected. 1. Remove Power 2.
PAGE 3
Step 2: Remove the Covers 1. Disconnect the Device Peripheral Interface (DPI) cable from the HIM assembly (if present). 2. Loosen the captive screws that secure the bottom front cover to the SAR, then slide the cover down and off the chassis. = Disconnect DPI cable Tightening torque: 1.5 N•m (13.3.lb•in) 3. Press in on the sides at the bottom edge of the top cover and pull the cover toward you until the cover is partially off the chassis.
PAGE 4
Step 3: Remove the Control Circuit Board 1. Label and disconnect the ribbon cables at connectors XA, XR, and XFCD. 2. Unplug the terminal block connectors (6) from the control board (if wired). 3. Remove the EMI shield mounting screws (5), and save for reassembly. 4. Remove the EMI shield ground screw (1), and save for reassembly. Note: The control board remains mounted to the EMI shield. EMI Shield Mounting Screws (5) Tightening torque: 1.0 N•m (8.
PAGE 5
Step 4: Remove the Power Interface Circuit Board and Switching Power Supply Circuit Board IMPORTANT The power interface circuit board and the switching power supply circuit board are removed together, as an assembly. 1. Label and disconnect the plugs at connectors X3 and X4. X3 X4 XR XCD XCD_IO XPT1 XP1 and XP2 (respectively) TH-CT XF XUVW Mounting Screws (2) Tightening torque: 1.0 N•m (8.9 lb•in) XCT Terminal Control Power and Relay Terminal Block 2.
PAGE 6
10. Remove the cooling vent mounting screws (4) on top of the stand-alone regulator, and save for reassembly. Fan plug XV connector (behind cooling vent) Cooling Vent Mounting Screws (4) Tightening torque: 1.0 N•m (8.9 lb•in) 11. Disconnect the fan plug from the XV connector on the switching power supply circuit board. 12. Remove the cooling vent and fan assembly. 13. Carefully slide the power interface circuit board and the switching power supply circuit board assembly out of the chassis.
PAGE 7
Step 5: Remove the In-Rush Limiting Resistor 1. Remove the mounting screws (4). 2. Cut the wire at each soldered terminal directly behind the terminal. Leave as much wire as possible for reassembly. In-rush Limiting Resistor (1) Mounting Screws (4). Tightening torque: 2.5…4 N•m (22…35.4 lb•in) Soldered Terminals (2). Cut the wire directly behind the terminal. 3. Dispose of the in-rush limiting resistor properly. Step 6: Install the New In-Rush Limiting Resistor and Reassemble the SAR 1.
PAGE 8
Step 7: Document the Change 1. Record the installation of the new in-rush limiting resistor and date of installation on the field installed option label on the side of the SAR (as shown below). 2. Replace the SAR covers in the reverse order of removal. See Remove the Covers on page 3. 3. Install DPI cable (if present). Additional Resources These documents contain additional information concerning related Rockwell Automation products.
PAGE 9
Notes: Rockwell Automation Publication 23P-IN008A-EN-P - June 2011 9
PAGE 10
1S7A80 U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, E-mail: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives www.rockwel lautomation.com Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.