20p-in005_-en-p

8/13/2019 20p-in005_-en-p

1/16

Installation Instructions

PowerFlexDC Drive - Frame A SwitchingPower 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 Phillipsscrewdriver Flathead screwdriver

Nut driver or wrench for hex stand-offs

Phillipsis 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.

8/13/2019 20p-in005_-en-p

2/16

2 PowerFlex 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 PowerSupply boards

Step 5: Install the existing Pulse Transformer board and newSwitching 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 Powerfrom 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 cancause personal injury or property damage by:

sending an erroneous signal to your systems 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

8/13/2019 20p-in005_-en-p

3/16

PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board 3

Step 2: Remove theProtective 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 thedrive until disconnected. See page 4for instructions.

=

Disconnect DPI cable

Tightening torque:1.5 Nm (13.3 lbin)

When metal pin fits in keyhole,

lift cover off drive chassis.

3. 4.

8/13/2019 20p-in005_-en-p

4/16


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.

8/13/2019 20p-in005_-en-p

5/16


Step 3: Remove theControl EMI Shield andControl 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

=

Disconnectcables

XFCD, XA,

and XR

Disconnect I/O

and control

wiring

Note: Control board

shown with

Communication Adapter

and optional boards

removed.

8/13/2019 20p-in005_-en-p

6/16


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

8/13/2019 20p-in005_-en-p

7/16


Step 4: Remove theExisting Pulse Transformerand Switching Power SupplyBoards

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

8/13/2019 20p-in005_-en-p

8/16


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

8/13/2019 20p-in005_-en-p

9/16


Figure 1 Pulse Transformer Circuit Board Layout

XP

1

1

XSW1

X3

1

XSW

1

6

12

33

34

XR

TR2

TR1

XY 1

0V1

T04

T01

T05

T02

T06

T03

T1

T4

T2

T5

T3

T6

K G

KG04K G

KG01

K G

KG05K G

KG02

K G

KG06K G

KG03

K G

KG4

K G

KG1

K G

KG5

K G

KG2

K G

KG6

K G

KG3

XTA

1

TA

U

C

V

W

W V C U

X4

1

78

7935367

576U2V2

XSW1

XSW

X3

XP

TR2

TR1

XR

X4

XY

XCD_

IO TO1

TO4

TO2

TO5

TO3

TO6

KGO1

KGO4

KGO2

KGO5

TO1

TO4

TO2

KGO1

KGO4

KGO2

KGO5

KGO3

KGO6

T5

T3

T6

T1

T4

T2

KG1

KG4

KG2

KG5

KG3

KG6

XT

A

S4

S3

1

1

78

7935367576U2V2

Components shown within dashed lines are only containedon the Pulse Transformer board for regenerative drives.

FIR1

-XXrev.

Pandlower

FIR

1-X

Xrev.

Qandhigher

8/13/2019 20p-in005_-en-p

10/16


2. Remove the plug-in control power terminal block from the Pulse

Transformer circuit board (refer to Figure 1 on page 9for location).

3. Remove the cables from connectors X3, X4 and XP at the top of thePulse Transformer board (refer to Figure 1 on page 9for 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

8/13/2019 20p-in005_-en-p

11/16


4. For Pulse Transformer boards with an armature voltage feedback

terminal block, FIR1-XX, rev Q and higher, remove the connector

from XCD_IO on the upper left corner of the board.

5. Remove the plastic screw near the top of the Pulse Transformer board

and retain for reuse.

XSW1

XSW

X3

XR

X4

XYXCD_IO

Remove connector from XCD_IO

Remove plastic screw

8/13/2019 20p-in005_-en-p

12/16


6. Remove the appropriate gate leads from the Pulse Transformer board

(refer to Figure 1 on page 9for location):

For regenerative drives, remove each pair of (orange and yellow) gate

lead cables from connectors KG01KG06 and KG1KG6 and push

each lead through the appropriate opening in the board.

For non-regenerative drives, remove each pair of (orange and yellow)

gate lead cables from connectors KG01KG06 and push each lead

through the appropriate opening in the board.

Important: Carefully remove the gate leads by grasping the connector.

DO NOT pull the gate leads off by pulling on the wires.

7. Remove the cable from connectors XTA on the Pulse Transformer

board (refer to Figure 1 on page 9for location).

Remove cable

from XTA

For regenerative

drives, remove 12

gate leads and

push through holes

in board

Remove cable

from XTA

Fornon-regenerative

drives, remove six

gate leads and push

through holes in

board

8/13/2019 20p-in005_-en-p

13/16


8. Remove the six screws that secure the bottom of the Pulse Transformer

board to the drive and, while lifting up slightly on the board, slide it

toward the top of the drive and out of the chassis. Note that on some

drives there is an isolation sheet below the board; do not remove this

sheet.

Important: The cables from connectors XSW and XTA must slidethrough the openings in the board as it is lifted out of the

drive chassis. Take care not to damage these cables and

connectors.

Remove six screws

Carefully route cables through

openings as the board is removed.

Isolation sheet

Note: Regenerative drive shown

8/13/2019 20p-in005_-en-p

14/16


Figure 2 Switching Power Supply Circuit Board Layout

9. Remove the cable from connector XUV on the left side of the SwitchingPower Supply board (refer to Figure 2above for location).

10. Remove the four screws that secure the Switching Power Supply board

to four of the stand-offs on the back of the Pulse Transformer board and

remove the Switching Power Supply board.

XA

1

2

15

16

6 1

XSW

XY1

14

XSW114

XV

F1

1C2

1D2

XUV

Remove screwsRemove cable

8/13/2019 20p-in005_-en-p

15/16


11. Remove the plastic stand-off and nut that secures the Switching Power

Supply board to the back of the Pulse Transformer board.

Step 5: Install the ExistingPulse Transformer Boardand New Switching PowerSupply Board

Install the existing Pulse Transformer board and new Switching Power

Supply board in reverse order of removal as detailed in Step 4: Remove the

Existing Pulse Transformer and Switching Power Supply Boards on page 7.

Replace the 16 pin cable connected to connector XA on the Switching

Power Supply board with the new cable provided (refer to Figure 2 on

page 14above for location).

Step 6: Install the ControlEMI Shield and Control

Board

Install the Control EMI Shield and Control board in the reverse order of

removal as detailed in Step 3: Remove the Control EMI Shield and Control

Board on page 5.

Secure nut

Remove stand-off

8/13/2019 20p-in005_-en-p

16/16

Publication 20P-IN005B-EN-P - December 2009

Supersedes 20P-IN005A-EN-P - March 2009 Copyright 2009 Rockwell Automation. All rights reserved. Printed in USA.

www.rockwellautomation.com

Americas:RockwellAutomation,1201SouthSecondStreet,Milwaukee,WI53204-2496USA,Tel:(1) 414.382.2000,Fax:(1) 414.382.4444Europe/Middle East/Africa:RockwellAutomationSA/NV,Vorstlaan/Boulevard du Souverain36,1170 Brussels,Belgium,Tel:(32) 2 6630600,Fax:(32) 2 663 0640AsiaPacific:RockwellAutomation,Level 14,Core F,Cyberport 3,100 Cyberport Road,HongKong,Tel:(852) 2887 4788,Fax:(852) 2508 1846

Power, Control and Information Solutions

1S7A01

Step 7: Replace theProtective Covers andDocumenting 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 the DPI cable (if present).

3. Record the installation of the new Switching Power Supply 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 atwww.rockwellautomation.com/literature.

For . . . Read this documentPublicationNumber

In depth information regarding theoperation of PowerFlex Digital DC drives

User Manual - PowerFlex Digital DC Drives 20P-UM001

20p-in005_-en-p

Documents