Owner's manual

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Publication 20P-IN009D-EN-P - February

Installation Instructions

PowerFlex DC Drive Frame B Pulse Transformer Circuit Board

What This Kit Includes

• Pulse Transformer circuit board

• Terminal block with 1k ohm resistor @ terminals 78 & 79

• Seven screws and washers for board

• 6 gate lead cables with connectors (for non-regenerative drives only)

• 12 gate lead cables with connectors (for regenerative drives only)

• 4 cables for connectors X3, X4, XP and XR

• 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 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.

Summary of content (18 pages)

PAGE 1
Installation Instructions PowerFlex DC Drive Frame B Pulse Transformer Circuit Board 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.
PAGE 2
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board What You Need to Do To install the Pulse Transformer board: ❐ Step 1: Remove power from the drive ❐ Step 2: Remove the protective covers ❐ Step 3: Remove the Pulse Transformer and Switching Power Supply boards ❐ Step 4: Configure the new Pulse Transformer board ❐ Step 5: Install the new Pulse Transformer board and existing Switching Power Supply board ❐ Step 6: Replace the protective covers and document the change Step 1: Remove Power
PAGE 3
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board 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. = Disconnect DPI cable Tightening torque: 1.5 N•m (13.3 lb•in) 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.
PAGE 4
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board 4. 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. Step 3: Remove the Pulse Transformer and Switching Power Supply Boards Note: The Switching Power Supply circuit board is located on the back of the Pulse Transformer circuit board. You must remove both boards in order to replace the Pulse Transformer board. 1.
PAGE 5
Rockwell Automation Publication 20P-IN009D-EN-P - February 2012 PE1 KG1 PE KG4 KGO1 U FIR2-XX X3 T1 T4 TO1 XCD_IO KGO4 TO4 N Board revision label KG5 XTA T5 TO2 KGO5 V XM XY TR2 D T3 KG3 T6 TR1 XP 1 KG6 S3 TO6 TO3 S4 W 1U2 1V2 KGO6 KGO3 XI2CA Board configured using DIP switches 78 79 35 36 75 76 U2 V2 XCT FIR2-XX rev.
PAGE 6
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board 3. Remove the cable from connector XTA on the Pulse Transformer board. 4. Remove the plug-in terminal block from the control power block on the Pulse Transformer board. = Remove cable from XTA Remove plug-in terminal block 5. For Pulse Transformer boards with an armature voltage feedback terminal block, FIR2-XX, rev. “N” and higher, remove the connector from XCD_IO on the lower left corner of the board.
PAGE 7
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board 6. Carefully disconnect the cables from connectors XA, XR and XFCD on the Control board. Disconnect cables 7. Loosen the two captive screws at the top of the Control EMI shield and lower the shield. IMPORTANT If the drive is not in a vertical position, the Control EMI shield must be secured in order to remain open.
PAGE 8
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board 8. Remove the two screws that secure the air flow plate to the top of the Pulse Transformer board and lift the plate off the drive chassis. The air flow plate cannot be completely removed due to the field fuse connections at FU1 and FV1. Remove screws Field fuse connections 9. Remove the cables from connectors X3, X4 and XP on the Pulse Transformer board.
PAGE 9
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board 10. Remove the ground connection at the left side of the Pulse Transformer board.
PAGE 10
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board 11. Remove the appropriate gate leads (see Figure 1 - on page 5 for location): • For non-regenerative drives, remove each pair of (orange and yellow) gate lead cables from connectors KG01…KG06 and push each lead through the appropriate opening in the board. • For regenerative drive, remove each pair of (orange and yellow) gate lead cables from connectors KG01…KG06 and KG1…KG6 and push each lead through the appropriate opening in the board.
PAGE 11
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board Note: Regenerative Drive Shown Remove screws Rockwell Automation Publication 20P-IN009D-EN-P - February 2012 11
PAGE 12
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board 13. Turn the Pulse Transformer board over and remove the cables from connectors XV and XUV on the Switching Power Supply board. 14. Remove the six screws that secure the Switching Power Supply board to the stand-offs on the back of the Pulse Transformer board and remove the Switching Power Supply board. Remove cable from XV Remove cable from XUV Remove screws 15. Remove the six stand-offs and washers from the back of the Pulse Transformer board.
PAGE 13
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board Pulse Transformer Board FIR2-XX Rev. “M” and Lower IMPORTANT This procedure requires a multimeter that measures resistance to thousandths of an ohm. 1. Refer to Table 1 - or Table 2 - in the Sizing Resistor Configuration section below for the appropriate configuration. Once you have determined the correct configuration for your drive size, cut and remove the appropriate sizing resistor(s) (if necessary) from the Pulse Transformer board.
PAGE 14
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board 2. Connect the leads of the multimeter to pins 13 and 14 of connector XR on the Pulse Transformer board (polarity is not important) and, using the TA potentiometer on the lower right corner of the Pulse Transformer circuit board, set the total resistance (RTA) to the appropriate value as indicated in Table 3 - or Table 4 - in the Total Resistance Values section on page 15.
PAGE 15
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board Total Resistance Values Table 3 - 230V AC Input Drives Drive Current Rating Code 146 180 218 265 360 434 DC Amps 146 180 218 265 360 434 AC Line Amps 119 147 178 217 294 355 HP 40 50 60 75 100 125 Set RTA Value Using TA Potentiometer (Ohms) 12.575 10.2 8.422 6.928 5.1 4.23 Table 4 - 460V AC Input Drives Drive Current Rating Code 167 207 250 330 412 DC Amps 167 207 250 330 412 AC Line Amps 136.4 169.1 204.3 269.6 336.
PAGE 16
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board Pulse Transformer Board FIR2-XX Rev. “N” and Higher Set DIP switches S3 and S4, located at the bottom right corner of the Pulse Transformer board (see Figure 1 - on page 5 for location), to the correct settings based on the appropriate table below. XP XSW1 TR2 TR1 Dip switches S3 and S4 are located at the bottom, right corner of the board.
PAGE 17
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board Table 7 - 575V AC Input Drives Drive Current Rating Code 67 101 135 270 405 DC Amps AC Line Amps HP 67 101 135 270 405 55.1 82.7 110.3 220.6 330.9 50 75 100 200 300 S3-1 S3-2 ON ON S3-3 DIP Switch S3 S3-4 S3-5 S3-6 S3-7 ON ON ON Step 5: Install the New Pulse Transformer Board and Existing Switching Power Supply Board S3-8 S4-1 ON ON ON ON ON ON S4-2 S4-3 ON ON ON ON ON ON ON DIP Switch S4 S4-4 S4-5 S4-6 S4-7 S4-8 ON ON 1.
PAGE 18
PowerFlex DC Drive Frame B Pulse Transformer Circuit Board 1. Replace the protective covers in the reverse order of removal as described in Step 2: Remove the Protective Covers on page 3. Step 6: Replace the Protective Covers and Documenting the Change Additional Resources 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).