Allen-Bradley PowerFlex 4M User manual

Installation Instructions
PowerFlex®DC Drive - Frame C AC Current
Transducers
What This Kit Includes •Two AC Current Transducers (with signal wires)
•Two Screws and washers
•Static strap
Tools That You Need •Phillips®screwdriver
•Flathead screwdriver
•Nut driver or wrench
Phillips®is a registered trademark of Phillips Screw Company.
What You Need to Do To install the AC Current Transducers:
❐ Step 1: Remove power from the drive
❐ Step 2: Remove the protective covers
❐ Step 3: Remove the existing AC Current Transducers
❐ Step 4: Install the new AC Current Transducers
❐ Step 5: 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.

2PowerFlex® DC Drive - Frame C AC Current Transducers
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 C AC Current Transducers 3
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.
3. Loosen, but do not remove, the screws that secure the top cover to the
drive, then slide the cover up and off 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 step 4 below for instructions.
STS
PORT
MOD
NET A
NET B
Disconnect
DPI cable
=
Tightening torque:
1.5 N-m (13.3 lb.-in.)
STS
PORT
MOD
NET A
NET B
FU1 FV1
UV
CD
W
Tightening torque:
1.5 N-m (13.3 lb.-in.)

4PowerFlex® DC Drive - Frame C AC Current Transducers
4. Disconnect the HIM Communication cable from the connector on the
upper right corner of the Control board and set the cover aside.
5. Remove the eight screws and washers that secure the plastic shields to
the bottom of the drive and remove the shields.
6. Remove the power wiring from the U and W Phase AC input power
terminals.
Pull tabs out
to disconnect
cable.
Remove screws and washers Remove screws and washers

PowerFlex® DC Drive - Frame C AC Current Transducers 5
Step 3: Remove the
Existing AC Current
Transducers
1. Remove the screws that secure the ground wires to the PE terminal
(from the Transient Noise Filter board) and U phase power terminal
(from the Pulse Transformer board) and remove the wires.
2. Remove the lower screw that secures the left side AC Current
Transducer to the U phase terminal.
=
Transient Noise Filter board
Remove ground wirePE ground stud Remove screw and wire
Remove screw

6PowerFlex® DC Drive - Frame C AC Current Transducers
3. Remove the two screws and washers that secure the bottom of the
Power Supply Filter circuit board to the drive chassis above the W
phase power terminal.
You must move the Control EMI shield that holds the Control board in order
to access other components within the drive.
4. Carefully disconnect the cables from connectors XFCD and XR on the
Control board.
Remove screws
Power Supply
Filter board
Disconnect
cables

PowerFlex® DC Drive - Frame C AC Current Transducers 7
5. Loosen the two captive screws at the top of the Control EMI shield and
partially lower the shield. The shield will not open to its full extent due
to a cable connection between the Switching Power Supply board and
the Pulse Transformer board.
6. Disconnect the cable from connector XSW on the Switching Power
Supply board and lower the Control EMI shield until it rests on the
drive chassis.
Important: If the drive is not in a vertical position, the Control EMI
shield will not stay open without a means of restraint.
Loosen screws
Remove cable

8PowerFlex® DC Drive - Frame C AC Current Transducers
7. Remove the two screws and washers that secure the top of the Power
Supply Filter board to the drive and carefully lift the board to gain
access to the ground wire connected to the W phase power terminal (see
next step).
8. Temporarily lift the EMI shield and remove the screw that secures the
ground wire (from the Pulse Transformer board) to W phase power
terminal and remove the wire.
Remove screw and washer Remove screw and washer
Remove screw and wire

PowerFlex® DC Drive - Frame C AC Current Transducers 9
9. Remove the lower screw that secures the right side AC Current
Transducer to the W phase power terminal.
10. Move the EMI shield to the lowered position and remove the nuts and
washers that secure the wires to the side of each of the AC Current
Transducers (CTs) and remove the wires.
Remove screw and wire
Note: Left CT and Regenerative drive shown.
Remove
nuts,
washers
and
wires

10 PowerFlex® DC Drive - Frame C AC Current Transducers
11. Remove the upper screw that secures each of the CTs to the U and W
phase power terminals.
12. Remove the bolt(s) and washer(s) that secure the U and W phase power
terminals to the L-shaped bus bar/fuse.
–For Regenerative drives only, remove the two bolts and washers that
secure the U and W phase power terminals to the corresponding
L-shaped bus bars connected to the fuses and while pulling the U and
W phase power terminals down toward the bottom of the drive, slide
the AC Current Transducers off of the terminal bus bar and out of the
drive.
Remove
screw
Note: Left CT and Regenerative drive shown.
Regenerative drive
Remove bolts,
washers and
terminal
Slide AC
Current
Transducers
off of bus bar

PowerFlex® DC Drive - Frame C AC Current Transducers 11
–For Non-Regenerative drives only, remove the bolt and washers that
secure the U and W phase power terminals to the internal armature
circuit fuses and while pulling the U and W phase power terminals up
and into the drive, slide the AC Current Transducers off of the
terminal bus bars and out of the drive.
Step 4: Install the New AC
Current Transducers
Install the new AC Current transducers in reverse order of removal as
detailed in Step 3: .Remove the Existing AC Current Transducers on page 5.
Important:Note the color and location of the signal wires to ensure that
each wire is properly connected during installation. The wires
connected to the left CT are red and white and the wires
connected to the right CT are blue and black.
Non-Regenerative drive
Remove bolts,
washers and
terminal
Slide AC
Current
Transducers
off of bus bars
Left AC Current Transducer Right AC Current Transducer
Left CT - red
and white wires
Right CT - blue
and black wires

Publication 20P-IN027A-EN-P - March 2009
Copyright © 2009 Rockwell Automation. All rights reserved. Printed in USA.
www.rockwellautomation.com
A
mericas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: [phone] , Fax: [phone]
Europe/Middle East/Africa:
Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: [phone], Fax: [phone]
A
sia Pacific: Rockwell Automation, Level 14, Core F, C
y
ber
p
ort 3, 100 C
y
ber
p
ort Road, Hong Kong, Tel: [phone], Fax: [phone]
Power, Control and Information Solutions
1
S
7A16
Step 5: 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 DPI cable (if present).
3. Record the installation of the new AC Current Transducers 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.
For . . . Read this document
Publication
Number
In depth information regarding the
operation of PowerFlex Digital DC drives
User Manual - PowerFlex Digital DC Drives 20P-UM001…