Manual

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Installation Instructions

PowerFlex

DC Drive - Frame C AC Line

Snubber Board and High Wattage Resistors

What This Kit Includes

• AC Line Snubber circuit board

• Three screws and washers for the AC Line Snubber circuit board

• Six high watt resistors and cables

• Twelve screws for the high watt resistors

• Thermal grease

• Cable ties

• Static strap

Tools That You Need

• Phillips

screwdrivers

• Flathead screwdriver

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 (16 pages)

PAGE 1
Installation Instructions PowerFlex® DC Drive - Frame C AC Line Snubber Board and High Wattage Resistors ! ! ! 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 C AC Line Snubber Board and High Wattage Resistors What You Need to Do The AC Line Snubber board and Resistors are located at the top of the drive chassis behind the Control board and Control EMI Shield and Field Snubber and Pulse Transformer circuit boards.
PAGE 3
PowerFlex® DC Drive - Frame C AC Line Snubber Board and High Wattage Resistors Step 1: Remove Power from 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.
PAGE 4
PowerFlex® DC Drive - Frame C AC Line Snubber Board and High Wattage Resistors 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. = PORT MOD NET A NET B STS Disconnect DPI cable Tightening torque: 1.5 N-m (13.3 lb.-in.) 3.
PAGE 5
PowerFlex® DC Drive - Frame C AC Line Snubber Board and High Wattage Resistors 5 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: Move the EMI Shield and Control Board You must move the Control EMI shield that holds the Control board in order to access the AC Line Snubber circuit board and Resistors. 1.
PAGE 6
PowerFlex® DC Drive - Frame C AC Line Snubber Board and High Wattage Resistors 2. 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. Loosen screws 3. 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.
PAGE 7
PowerFlex® DC Drive - Frame C AC Line Snubber Board and High Wattage Resistors Figure 1 Pulse Transformer Circuit Board Layout T06 KG06 K G X3 KG6 T6 1 K G KG3 T3 K G XCD T03 XUVW C KG03 K G D W V U T05 KG05 K G KG5 T5 K G 1 1 33 34 XTA TA XR T2 KG2 K G T02 KG02 X5 2 1 K G KG04 1 T04 X4 K G 1 XY 1 XSW 6 T4 KG4 1 K G T1 KG1 K G TR2 TR1 T01 XP2 KG01 XP1 K G K2 G2 K1 G1 Components shown within dashed lines are only on the Pulse Transformer boar
PAGE 8
PowerFlex® DC Drive - Frame C AC Line Snubber Board and High Wattage Resistors Step 4: Remove the Pulse Transformer and Field Snubber Circuit Boards You must remove the Pulse Transformer and Field Snubber circuit boards in order to replace the AC Line Snubber circuit board and Resistors. 1. Remove the four screws that secure the slotted air flow plate to the top of the drive and remove the plate.
PAGE 9
PowerFlex® DC Drive - Frame C AC Line Snubber Board and High Wattage Resistors 9 2. Remove the appropriate gate leads: – For non-regenerative drives, remove each pair of (orange and yellow) gate lead cables from connectors KG1 - KG6 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 10
PowerFlex® DC Drive - Frame C AC Line Snubber Board and High Wattage Resistors 4. Remove the (orange and yellow) cables from connectors K1G1 and K2G2 on the Pulse Transformer board (see Figure 1 on page 7 for location). 5. Remove the cables from connectors XTM, X4 and X5 on the Pulse Transformer board (see Figure 1 on page 7 for location). Remove cables 6. Remove the cables from connectors XCD, XUVW and X3 on the Pulse Transformer board (see Figure 1 on page 7 for location).
PAGE 11
PowerFlex® DC Drive - Frame C AC Line Snubber Board and High Wattage Resistors 11 7. Remove the four screws that secure the wire leads (connections 2V1, 2U1 and 2C1 and one unmarked) from the Field Snubber board and set the wires aside. Remove screws, washers and wires Remove screws, washers and wires 8.
PAGE 12
PowerFlex® DC Drive - Frame C AC Line Snubber Board and High Wattage Resistors Important: Mark all connections and wires before removal to avoid Step 5: Remove the incorrect wiring during reassembly. Existing AC Line Snubber Circuit Board and Resistors 1. Remove the bolts and washers that secure the AC Line Snubber board (red and blue) leads and screws and washers that secure the resistor (black) leads to the bus bars and remove the leads.
PAGE 13
PowerFlex® DC Drive - Frame C AC Line Snubber Board and High Wattage Resistors 13 2. Remove the three screws that secure the AC Line Snubber board to the drive frame and remove the board. Remove screws 3. Remove the two screws that secure each resistor (six total) to the drive frame and remove the resistors from the drive.
PAGE 14
PowerFlex® DC Drive - Frame C AC Line Snubber Board and High Wattage Resistors Step 6: Install the New AC Line Snubber Board and Resistors Install the AC Line Snubber boards and Resistors in reverse order of removal and detailed in Step 5: Remove the Existing AC Line Snubber Circuit Board and Resistors on page 12. • Apply thermal grease to the bottom of the resistors before securing them to the heatsink.
PAGE 15
PowerFlex® DC Drive - Frame C AC Line Snubber Board and High Wattage Resistors Step 9: Replace the Protective Covers and Documenting the Change 15 1. Replace the protective covers in the reverse order of removal as described in Step 2: Remove the Protective Covers on page 4. 2. Install DPI cable (if present). 3. Record the installation of the new AC Line Snubber Board and Resistors board and date of installation on the Field Installed Option label on the side of the drive (as shown below).
PAGE 16
Notes: 1S7A10 www.rockwellautomation.com Power, Control and Information Solutions Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.