20p-in008_-en-p

8/13/2019 20p-in008_-en-p

1/20

Installation Instructions

PowerFlex DC Drive - Frame A PulseTransformer Circuit Board

What This Kit Includes Pulse Transformer circuit board Six screws with washers 6 gate lead cables with connectors (for non-regenerative drives only) 12 gate lead cables with connectors (for regenerative drives only) Cables for connectors X3 (2 pin) and XP (34 pin) Cables for connector X4 (for drives with a fan only) Plug-in terminal block with 1k ohm resistor @ terminals 78-79 Isolation sheet Flathead screwdriver for terminal block connections Static strap

Tools That You Need Phillips screwdriver Flathead screwdriver Nut driver or wrench for hex stand-offs Multimeter (capable of reading to a thousandth of an Ohm) Wire Cutter

Phillips is a registered trademark of Phillips Screw Company.

ATTENTION: Only qualified personnel familiar with DCdrives and associated machinery should plan or implement theinstallation, start-up and subsequent maintenance of the system.Failure to comply may result in personal injury and/or equipmentdamage.

ATTENTION: To avoid an electric shock hazard, ensure that allpower to the drive has been removed before performing thefollowing.

ATTENTION: This drive contains ESD (ElectrostaticDischarge) sensitive parts and assemblies. Static controlprecautions are required when installing, testing, servicing orrepairing this assembly. Component damage may result if ESDcontrol procedures are not followed. If you are not familiar withstatic control procedures, reference A-B publication 8000-4.5.2,Guarding Against Electrostatic Damage or any otherapplicable ESD protection handbook.

8/13/2019 20p-in008_-en-p

2/20

8/13/2019 20p-in008_-en-p

3/20

PowerFlex DC Drive - Frame A Pulse Transformer 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 slidethe cover down and off the drive chassis.

3. Press in on the sides at the bottom edge of the top cover and at the sametime 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, untilthe pins fit in the keyhole in the top of the cover, then carefully lift thecover 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 4 for 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-in008_-en-p

4/20

8/13/2019 20p-in008_-en-p

5/20


Step 3: Remove theControl EMI Shield andControl Board

1. Carefully disconnect the cables from connectors XFCD, XA and XR onthe 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

=

DisconnectcablesXFCD, XA,and XR

Disconnect I/Oand controlwiring

Note: Control boardshown withCommunication Adapterand optional boardsremoved.

8/13/2019 20p-in008_-en-p

6/20

8/13/2019 20p-in008_-en-p

7/20


1. Remove the slotted air flow plate from the top of the drive:

For 38A and 55A drives @ 230V AC input and 35A, 45A, and 52Adrives @ 460V AC input, remove the four screws that secure theslotted air flow plate to the top of the drive, remove the fan cable fromconnector XV on the Switching Power Supply board and remove the

plate and connected fan.

For all other drives, remove the two screws that secure the slotted airflow plate to the top of the drive and remove the plate.

= Remove screws

=

Air flow plate

Remove screw

Remove screw

8/13/2019 20p-in008_-en-p

8/20

8 PowerFlex DC Drive - Frame A Pulse Transformer Circuit Board

Figure 1 Pulse Transformer Circuit Board Layout

X P

1

1

X S W 1

X 3

1

X S W

1

6

1 2

3 3

3 4

X R

T R 2

T R 1

X Y 1

0 V 1

T 0 4

T 0 1

T 0 5

T 0 2

T 0 6

T 0 3

T 1

T 4

T 2

T 5

T 3

T 6

K G

K G 0 4

K G

K G 0 1

K G

K G 0 5

K G

K G 0 2

K G

K G 0 6

K G

K G 0 3

K G

K G 4

K G

K G 1

K G

K G 5

K G

K G 2

K G

K G 6

K G

K G 3

X T A

1

T A

U

C

V

W

W V C U

X 4

1

7 8 7 9 3

5 3 6

7 5 7 6 U 2 V 2

X S

W 1

X S

W

X 3

X P

T R 2

T R 1

X R

X 4

X Y

X C D

_ I O

T O 1

T O 4

T O 2

T O 5

T O 3

T O 6

K G O 1

K G O 4

K G O 2

K G O 5

T O 1

T O 4

T O 2

K G O 1

K G O 4

K G O 2

K G O 5

K G O 3

K G O 6

T 5

T 3

T 6

T 1

T 4

T 2

K G 1

K G 4

K G 2

K G 5

K G 3

K G 6

X T A

S 4

S 3

1

1

7 8 7 9 3

5 3

6 7 5 7 6 U 2 V 2

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

F I R 1

- X X r e v .

P a n

d l o w e r

F I R 1

- X X r e v .

Q a n

d h i g h e r

8/13/2019 20p-in008_-en-p

9/20

8/13/2019 20p-in008_-en-p

10/20

8/13/2019 20p-in008_-en-p

11/20


7. Remove the six screws that secure the bottom of the Pulse Transformerboard to the drive and, while lifting up slightly on the board, slide ittoward the top of the drive and out of the chassis.

Important: The cables from connectors X4 and XTA must slide throughthe openings in the board as it is lifted out of the drive

chassis. Take care not to damage these cables andconnectors.

Remove six screws

Carefully route cables throughopenings as the board is removed.

Regenerative drive shown

8/13/2019 20p-in008_-en-p

12/20


8. Remove the cable from connector XUV on the Switching Power Supplyboard.

9. Remove the five screws from the Pulse Transformer board that secure thestand-offs connected to the Switching Power Supply board and removethe Switching Power Supply board from the back of the PulseTransformer board.

Remove cable at XUV Switching Power Supply board on back of Pulse Transformer board.

Remove screws

8/13/2019 20p-in008_-en-p

13/20


Step 5: Configure the NewPulse Transformer Board

The Pulse Transformer circuit board must be configured to match the drivesize (armature output current and HP rating). The steps required to completethe configuration are different based on the revision code of the board. Seeeither, Pulse Transformer Board FIR1-XX Rev. P and Lower below, orPulse Transformer Board FIR1-XX Rev. Q and Higher on page 17 .

Pulse Transformer Board FIR1-XX Rev. P and Lower

Important: This step requires a multimeter that measures resistance tothousandths of an ohm.

1. Cut and remove the appropriate sizing resistor(s) (if necessary) from thePulse Transformer board based on the drive size. Refer to Table A orTable B in the Sizing Resistor Configuration section on page 14 for theappropriate configuration.

=

Sizing resistors are located on the lower right

corner of the Pulse Transformer circuit board.

8/13/2019 20p-in008_-en-p

14/20


Sizing Resistor Configuration

Table A and Table B below indicate the value of the designated resistor(R1R5) when left in place on the Pulse Transformer board, or indicateRemove when the resistor should be cut off and removed from the board. in a cell in the tables below indicates that this resistor is not contained

on the Pulse Transformer board for the designated drive size.Table A 230V AC Input Drives

Table B 460V AC Input Drives

Drive CurrentRating Code

DCAmps

AC LineAmps HP R1 R2 R3 R4 R5

7P0 7 5.7 1.5 Remove 27.4 Remove Remove 9P0 9 7.4 2 Remove Remove 39.2 Remove 012 12 9.8 3 Remove 27.4 Remove Remove 020 20 16 5 56.2 Remove Remove Remove 029 29 24 7.5 Remove Remove 39.2 Remove 038 38 31 10 Remove 27.4 Remove Remove 055 55 45 15 56.2 27.4 Remove Remove 073 73 60 20 Remove 27.4 39.2 Remove

093 93 76 25 Remove Remove Remove 6.98

110 110 90 30 Remove Remove Remove 6.98


DCAmps

AC LineAmps HP R1 R2 R3 R4 R5

4P1 4.1 3.3 2 56.2 Remove Remove Remove 6P0 6 4.9 3 Remove Remove 39.2 Remove 010 10 8.2 5 Remove Remove 39.2 Remove 014 14 11.4 7.5 Remove 27.4 Remove Remove 019 19 15.5 10 56.2 Remove Remove Remove 027 27 22.1 15 Remove Remove 39.2 Remove 035 35 28.6 20 Remove 27.4 Remove Remove

045 45 36.8 25 56.2 Remove 39.2 Remove 052 52 42.5 30 56.2 27.4 Remove Remove 073 73 59.6 40 Remove 27.4 39.2 Remove 086 86 70.3 50 Remove Remove Remove 6.98 100 100 81.7 60 Remove Remove Remove 6.98 129 129 105.4 75 Remove Remove Remove 6.98

8/13/2019 20p-in008_-en-p

15/20


2. Connect the leads of a multimeter to pins 13 and 14 of connector XR onthe Pulse Transformer circuit board (polarity is not important) and, usingthe TA potentiometer on the lower right corner of the Pulse Transformercircuit board, set the total resistance (RTA) to the appropriate value asindicated in Table C or Table D in the Total Resistance Values section onpage 16 .

1 . . . . . . . . . . . . . .13 . . . . . . . . . . . . . . . . . . . .33

2 . . . . . . . . . . . . . 14 . . . . . . . . . . . . . . . . . . .34 XR

=

The XR connector is located onthe upper right corner of thePulse Transformer circuit board.

The TA potentiometer is located on the lower rightcorner of the Pulse Transformer circuit board nextto the control power terminal block. Shown sealed.

8/13/2019 20p-in008_-en-p

16/20


Total Resistance Values

Table C 230V AC Input Drives

Table D 460V AC Input Drives

3. Seal the TA potentiometer using RV (silicon).

Continue with Step 6: Install the New Pulse Transformer Board andExisting Switching Power Supply Board on page 18 .


DCAmps

AC LineAmps HP

Set RTA Value UsingTA Potentiometer

(Ohms)7P0 7 5.7 1.5 34.9719P0 9 7.4 2 45.333012 12 9.8 3 34020 20 16 5 61.2029 29 24 7.5 42.207038 38 31 10 32.211055 55 45 15 22.255073 73 60 20 16.767093 93 76 25 13.161110 110 90 30 11.127

Drive CurrentRating Code DCAmps AC LineAmps HP

Set RTA Value Using

TA Potentiometer(Ohms)4P1 4.1 3.3 2 59.7076P0 6 4.9 3 40.8010 10 8.2 5 40.8014 14 11.4 7.5 29.143019 19 15.5 10 64.421027 27 22.1 15 45.333035 35 28.6 20 34.971045 45 36.8 25 27.2052 52 42.5 30 23.538073 73 59.6 40 16.767086 86 70.3 50 14.233100 100 81.7 60 12.24129 129 105.4 75 9.488

8/13/2019 20p-in008_-en-p

17/20


Pulse Transformer Board FIR1-XX Rev. Q and Higher

Set DIP switches S3 and S4, located on the Pulse Transformer board (seeFigure 1 on page 8 for location), to the correct settings based on theappropriate table below.

Important: A blank cell below a switch in Tables E and F below indicatethat the setting is OFF.

Table E 230V AC Input Drives

Table F 460V AC Input Drives

DriveCurrentRatingCode

DCAmps

ACLineAmps 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 S4-87P0 7 5.7 1.5 ON ON ON9P0 9 7.4 2 ON ON ON012 12 9.8 3 ON ON ON020 20 16 5 ON ON ON029 29 24 7.5 ON ON ON038 38 31 10 ON ON055 55 45 15 ON ON ON ON073 73 60 20 ON ON ON ON093 93 76 25 ON ON ON ON110 110 90 30 ON ON ON ON

DriveCurrentRatingCode

DCAmps

ACLineAmps 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 S4-84P1 4.1 3.3 2 ON ON ON6P0 6 4.9 3 ON ON ON010 10 8.2 5 ON ON ON014 14 11.4 7.5 ON ON ON019 19 15.5 10 ON ON ON027 27 22.1 15 ON ON ON035 35 28.6 20 ON ON ON045 45 36.8 25 ON ON ON ON052 52 42.5 30 ON ON ON ON073 73 59.6 40 ON ON ON ON086 86 70.3 50 ON ON ON100 100 81.7 60 ON ON ON ON129 129 105.4 75 ON ON ON ON

8/13/2019 20p-in008_-en-p

18/20


Step 6: Install the NewPulse Transformer Boardand Existing SwitchingPower Supply Board

1. Install the new Pulse Transformer board and existing Switching PowerSupply board in reverse order of removal as detailed in Step 4: Removethe Pulse Transformer and Switching Power Supply Boards on page 6 .

2. Install the new Isolation sheet (if present) before installing the PulseTransformer and Switching Power Supply boards.

3. Replace the gate lead cables with the new cables provided.

4. Inspect the existing connection cables for burn marks, cracks or looseconnectors. If necessary, replace the cables connected to connector X3,X4 (for drives with a fan) and XP on the Pulse Transformer board withthe new cables provided.

Step 7: Install the ControlEMI Shield and ControlBoard

Install the Control EMI Shield and Control board in reverse order ofremoval.

ATTENTION: Failure to install the Isolation sheet below thePulse Transformer and Switching Power Supply boards mayresult in damage to the drive.

ATTENTION: Each gate lead cable must be connected to theexact connector from which it was removed on the PulseTransformer circuit board or damage to the drive may occur.

8/13/2019 20p-in008_-en-p

19/20


Step 8: Replace theProtective Covers andDocumenting the Change

1. Replace the protective covers in the reverse order of removal asdescribed in Step 2: Remove the Protective Covers on page 3 .

2. Install the DPI cable (if present).

3. Record the installation of the new Pulse Transformer board and date ofinstallation on the Field Installed Option label on the side of the drive (asshown 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

8/13/2019 20p-in008_-en-p

20/20

Publication 20P-IN008B-EN-P - December 2009

www.rockwellautomation.com

Americas: Rockwell Automation,1201 South Second Street,Milwaukee, WI 53204-2496 USA, Tel:(1) 414.382.2000 , Fax: (1) 414.382.4444Europe/Middle East/Africa:Rockwell Automation SA/NV,Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel:(32) 2 663 0600, Fax:(32) 2 663 0640

Asia Pacific:Rockwell Automation,Level 14,Core F,Cyberport 3,100 Cyberport Road, Hong Kong,Tel:(852) 2887 4788,Fax: (852) 2508 1846

Power, Control and Information Solutions

1S 7A04

20p-in008_-en-p

Documents