Allen-Bradley PowerFlex User manual

Installation Instructions
PowerFlex®DC Drive - Frame A Switching
Power Supply Circuit Board
What This Kit Includes •Switching Power Supply circuit board
•16 Pin ribbon cable
•Four screws with captive lock washers
•One plastic stand-off
•One plastic screw
•One plastic nut
•Static strap
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.

2PowerFlex® DC Drive - Frame A Switching Power Supply Circuit Board
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 Control EMI Shield and Control board
❐ Step 4: Remove the existing Pulse Transformer and Switching Power
Supply boards
❐ Step 5: Install the existing Pulse Transformer board and new
Switching Power Supply board
❐ Step 6: Install the Control EMI Shield and Control board
❐ Step 7: Replace the protective covers and document the change
Step 1: Remove Power
from the Drive
1. Remove and lock-out all incoming power to 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. 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

PowerFlex® DC Drive - Frame A Switching Power Supply Circuit Board 3
Step 2: Remove the
Protective Covers
1. Disconnect the DPI cable from the HIM assembly (if present).
2. Remove the screws that secure the bottom cover to the drive, then slide
the cover down and off the drive chassis.
3. 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.
4. 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.
Important:The HIM assembly is connected via a cable to the
Control board and therefore will not pull free from the
drive until disconnected. See page 4 for instructions.
=
Disconnect DPI cable
Tightening torque:
1.5 N•m (13.3 lb•in)
When metal pin fits in keyhole,
lift cover off drive chassis.
3. 4.

4PowerFlex® DC Drive - Frame A Switching Power Supply Circuit Board
5. 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.

PowerFlex® DC Drive - Frame A Switching Power Supply Circuit Board 5
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. Remove all appropriate I/O and control wiring including:
–digital and analog I/O plug-in terminal blocks on the Control board
–analog tachometer terminal block on the Control board
–encoder terminal block on the Control board
–cable shields that are grounded to the Control EMI shield
–I/O terminal blocks on the I/O Expansion board
–I/O terminal blocks on the 115V AC to 24V DC I/O Converter board
=
Disconnect
cables
XFCD, XA,
and XR
Disconnect I/O
and control
wiring
Note: Control board
shown with
Communication Adapter
and optional boards
removed.

6PowerFlex® DC Drive - Frame A Switching Power Supply Circuit Board
3. Remove the five screws that secure the ground wire (in the lower left
corner) and Control EMI shield 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.
Remove
screws
Remove
screw and
ground wire

PowerFlex® DC Drive - Frame A Switching Power Supply Circuit Board 7
Step 4: Remove the
Existing Pulse Transformer
and Switching Power Supply
Boards
Note: The Switching Power Supply circuit board is mounted on the back of
the Pulse Transformer circuit board. You must remove both boards in order
to replace the Switching Power Supply 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 and connected fan.
=Remove screws

8PowerFlex® DC Drive - Frame A Switching Power Supply Circuit Board
–For all other size drives, remove the two screws that secure the slotted
air flow plate to the top of the drive and remove the plate.
Important: Mark all connections and wires before removal to avoid
incorrect wiring during reassembly.
=
Air flow plate
Remove screw
Remove screw

PowerFlex® DC Drive - Frame A Switching Power Supply Circuit Board 9
Figure 1 Pulse Transformer Circuit Board Layout
XP
11
XSW1
X3
1XSW
16
1 2
33 34
XR
TR2 TR1
XY
1
0V1
T04
T01
T05T02 T06T03
T1
T4
T2
T5
T3
T6
K G
KG04
K G
KG01
K G
KG05
K G
KG02
K G
KG06
K G
KG03
K G
KG4
K G
KG1
K G
KG5
K G
KG2
K G
KG6
K G
KG3
XTA
1
TA
UCVW
W V C U
X4
1
7879 35 36 75 76 U2 V2
XSW1
XSW
X3
XP
TR2 TR1
XR
X4
XY
XCD_IO
TO1 TO4 TO2 TO5 TO3TO6
KGO1 KGO4
KGO2
KGO5
TO1 TO4 TO2
KGO1 KGO4
KGO2
KGO5 KGO3KGO6
T5 T3T6T1 T4 T2
KG1 KG4 KG2 KG5 KG3KG6
XTA
S4
S3
11
7879 35 36 75 76 U2 V2
Components shown within dashed lines are only contained
on the Pulse Transformer board for regenerative drives.
FIR1-XX rev. “P” and lowerFIR1-XX rev. “Q” and higher

10 PowerFlex® DC Drive - Frame A Switching Power Supply 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).
3. Remove the cables from connectors X3, X4 and XP at the top of the
Pulse Transformer board (refer to Figure 1 on page 9 for location).
Note: Connector X4 contains a jumper for drives without a fan - leave in
place.
Remove
plug-in
terminal
block
Remove cables from X3, X4 and XSW