Allen-Bradley PowerFlex 4M User manual

Publication 20P-IN050A-EN-P
PowerFlex® DC Drive
Frame D Pulse Transformer Circuit Board
Installation Instructions
What This Kit Includes •Pulse transformer circuit board
•Six screws and washers
•6 gate lead cables with connectors (for non-regenerative drives only)
•12 gate lead cables with connectors (for regenerative drives only)
•Static strap
Tools That You Need •Phillips®screwdriver
•Hexalobular screwdriver
•Nut driver or wrench
Phillips®is a registered trademark of Phillips Screw Company.
What You Need to Do To install the switching power supply board:
❐ Step 1: Remove power from the drive
❐ Step 2: Remove the protective covers
❐ Step 3: Remove the switching power supply board
❐ Step 4: Remove the existing pulse transformer board
❐ Step 5: Install the new pulse transformer board
❐ Step 6: Install the switching power supply board
❐ Step 7: Replace the protective covers and document the change
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.

Publication 20P-IN050A-EN-P
2
Step 1: Remove Power
from the Drive
1. Remove and lock-out all incoming power to the drive.
Step 2: Remove the
Protective Covers
1. Loosen, but do not remove, the four hexalobular screws that secure the top
control pan cover to the drive, then slide the cover up and off the drive
chassis (see Figure 1 on page 3). Tightening torque is noted in the
illustration for reassembly.
2. Disconnect the DPI cable from the HIM assembly (if present) (see Figure
1 on page 3).
Important:A communication cable is connected to the back of the HIM
assembly and to the Control board mounted on the control pan.
Therefore, the bottom control pan cover and HIM assembly
cannot be fully removed from the drive until the cable is
disconnected. Step 4 details this connection.
3. Loosen, but do not remove, the four hexalobular screws that secure the
bottom control pan cover to the drive, then slide the cover up and off the
drive chassis (see Figure 1 on page 3). Tightening torque is noted in the
illustration for reassembly.
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. An electrical arc can
cause personal injury or property damage by:
•sending an erroneous signal to your system’s field devices,
causing unintended machine motion
•causing an explosion in a hazardous environment
Electrical arcing causes excessive wear to contacts on both the
module and its mating connector. Worn contacts may create electrical
resistance.
L1 L2 L3
O
I

3
Publication 20P-IN050A-EN-P
Figure 1 Cover Removal
4. Disconnect the HIM communication cable from the connector on the upper
right corner of the Control board and remove the bottom cover.
Disconnect
DPI cable
Top control
pan cover
Bottom control
pan cover
Tightening torque:
1.5 N•m (13 lb•in)
T15
=
Pull tabs out
to disconnect
cable.

Publication 20P-IN050A-EN-P
4
Step 3: Remove the
Switching Power Supply
Board
1. Loosen the eight hexalobular screws that secure the protective plastic cover
to the control pan and remove the cover.
Important: Mark all connections and wires before removal to avoid
incorrect wiring during reassembly.
2. Disconnect the cables from connector XA and XUV on the switching power
supply board (see Figure 2 below). Also, carefully remove the ribbon cable
from XA from the cable standoffs on the pulse transformer board.
3. Remove the five screws that secure the board to the control EMI shield and
remove the board.
Important:The switching power supply board is directly connected to the
pulse transformer board at connectors XSW and XSW1. Be sure
to carefully pull the board straight up during removal.
PFC-XX
Loosen
screws
Loosen
screws
Loosen
screw
Loosen
screw
Pulse Transformer board
Switching Power
Supply board

5
Publication 20P-IN050A-EN-P
Figure 2 Switching Power Supply Circuit Board Layout
Step 4: Remove the
Existing Pulse Transformer
Board
1. Disconnect the (red and white) gate leads from connectors XP1 and XP2 at
the top-left corner of the board.
2. Disconnect the appropriate gate leads from the pulse transformer board (see
Figure 3 below):
–For non-regenerative drives, each pair of (red and white) gate lead cables
from connectors KG1…KG6.
–For regenerative drives, each pair of (red and white) gate lead cables from
connectors KG1…KG6 and KG01…KG06.
3. Disconnect the cables from the following connectors: XUV, XCD_IO,
XUVW, XCD, XR, XTA, X4 and XSPF. Also, carefully remove the ribbon
cable (from XR) from the cable standoff on the board.
4. Remove the plug-in terminal block at the bottom of the pulse transformer
board.
5. Remove the two hexagonal standoffs and washers from the pulse
transformer board.
6. Remove the six hexalobular screws that secure the pulse transformer board
to the control pan and remove the board.
XA
1
2
15
16 XSW
14
XSW1
14
XV
F1
1C2
1D2
XUV
16
T15
Tightening torque:
1.0…1.2 N•m
(9…10.5 lb•in)

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6
Figure 3 Pulse Transformer Circuit Board Layout
XUV
XSW
XSW1
XCD_IO XUVW
XCD
XR
XSPF
S3
7879 35 36 75 76 81 82 U2 V2
X4 X5 X6
XTA
TR2
TR1
T1
T4
T2
T5
T3
T6
PE
XP1
XP2
KG1
KG4
KG2
KG5
KG3
KG6
KG01
KG04
KG02
KG05
KG03
KG06
T01
T04
T02
T05
T03
T06
XCT
S4
Components shown within dashed lines are only on
the pulse transformer board for regenerative drives.
T15
Tightening torque:
1.0…1.2 N•m
(9…10.5 lb•in)

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Publication 20P-IN050A-EN-P
Step 5: Install the New
Pulse Transformer Board
Install the new pulse transformer board in reverse order of removal as detailed in
Step 4: Remove the Existing Pulse Transformer Board on page 5.
• Inspect the existing gate lead cables for burn marks, cracks or loose
connectors. Replace the cables if necessary with the new cables provided.
• Set DIP switches S3 and S4 on the pulse transformer board (see Figure 3 on
page 6 for location) to the correct settings based on the appropriate table
below.
Important:A blank cell below a switch in tables below indicate that the
setting is “OFF”.
Table 1 230V AC Input Drives
Table 2 460V AC Input Drives
Table 3 575V AC Input Drives
Table 4 690V AC Input Drives
Drive
Current
Rating
Code
DC
Amps
AC
Line
Amps HP
DIP Switch S3 DIP Switch S4
S3-1 S3-2 S3-3 S3-4 S3-5 S3-6 S3-7 S3-8 S4-1 S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8
875 875 718 250 ON ON ON
1050 1050 861 300 ON ON ON ON
Drive
Current
Rating
Code
DC
Amps
AC
Line
Amps HP
DIP Switch S3 DIP Switch S4
S3-1 S3-2 S3-3 S3-4 S3-5 S3-6 S3-7 S3-8 S4-1 S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8
830 830 681 500 ON ON ON
996 996 817 600 ON ON ON
1K1 1162 953 700 ON ON ON ON
1K3 1328 1089 800 ON ON ON ON
1K4 1494 1225 900 ON ON ON ON
Drive
Current
Rating
Code
DC
Amps
AC
Line
Amps HP
DIP Switch S3 DIP Switch S4
S3-1 S3-2 S3-3 S3-4 S3-5 S3-6 S3-7 S3-8 S4-1 S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8
810 810 664 600 ON ON ON
1K0 1080 886 800 ON ON ON ON
1K2 1215 996 900 ON ON ON ON
1K3 1350 1107 1000 ON ON ON ON
1K4 1668 1384 1250 ON ON ON ON
Drive
Current
Rating
Code
DC
Amps
AC
Line
Amps HP
DIP Switch S3 DIP Switch S4
S3-1 S3-2 S3-3 S3-4 S3-5 S3-6 S3-7 S3-8 S4-1 S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8
678 678 556 600 ON ON
791 791 649 700 ON ON ON
904 904 741 800 ON ON ON
1K0 1017 834 900 ON ON ON ON
1K1 1130 927 1000 ON ON ON ON
1K2 1243 1019 1100 ON ON ON ON
1K4 1413 1159 1250 ON ON ON ON
1K5 1582 1297 1400 ON ON ON ON

Publication 20P-IN050A-EN-P - May 2010
Copyright © 2010 Rockwell Automation. All rights reserved. Printed in USA.
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Power, Control and Information Solutions
Step 6: Install the
Switching Power Supply
Board
Install the switching power supply board in reverse order of removal as
detailed in Step 3: Remove the Switching Power Supply Board on page 4.
Step 7: Replace the
Protective Covers and
Document the Change
1. Replace the protective covers in the reverse order of removal as
described in Step 2: Remove the Protective Covers on page 2.
2. Install DPI cable (if present).
3. Record the installation of the new pulse transformer board 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.
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In depth information regarding the
operation of PowerFlex Digital DC drives
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