PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board

Transcription

1 Installation Instructions PowerFlex DC Drive - Frame A Switching Power Supply 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. 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 , uarding Against Electrostatic Damage or any other applicable ESD protection handbook. What This it 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 Phillips screwdriver Flathead screwdriver Nut driver or wrench for hex stand-offs Phillips is a registered trademark of Phillips Screw Company.

2 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: Step 2: Step 3: Step 4: Step 5: Step 6: Step 7: Remove power from the drive Remove the protective covers Remove the Control EMI Shield and Control board Remove the existing Pulse Transformer and Switching Power Supply boards Install the existing Pulse Transformer board and new Switching Power Supply board Install the Control EMI Shield and Control board Replace the protective covers and document the change 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. 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. 1. Remove and lock-out all incoming power to the drive. L1 L2 L3 I O

3 PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board 3 Step 2: Remove the Protective 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. = Disconnect DPI cable Tightening torque: 1.5 N m (13.3 lb in) 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 the drive until disconnected. See page 4 for instructions When metal pin fits in keyhole, lift cover off drive chassis.

4 4 PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board 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.

5 PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board 5 Step 3: Remove the Control EMI Shield and Control 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 Disconnect cables XFCD, XA, and XR = Disconnect I/O and control wiring Note: Control board shown with Communication Adapter and optional boards removed.

6 6 PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board 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

7 PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board 7 Step 4: Remove the Existing Pulse Transformer and Switching Power Supply Boards 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 230V AC input and 35A, 45A, and 52A 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 8 PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board 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. = Remove screw Air flow plate Remove screw Important: Mark all connections and wires before removal to avoid incorrect wiring during reassembly.

9 PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board 9 Figure 1 Pulse Transformer Circuit Board Layout Components shown within dashed lines are only contained on the Pulse Transformer board for regenerative drives. XSW XP X3 XSW1 TR2 TR1 X4 XR XCD_IO XY TO1 TO4 TO2 TO5 TO3 TO6 O1 O4 O2 O5 O3 O6 T1 T4 T2 T5 T3 T XTA S U2 V2 FIR1-XX rev. Q and higher S3 U C V W T04 T T1 T4 1 4 W V C U X3 1 XSW1 1 XSW 6 1 XP 1 TR2 TR1 X4 2 XR V1 XY 1 T02 T05 T03 T T2 T3 T5 T FIR1-XX rev. P and lower 06 XTA 1 TA U2 V2

10 10 PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board 2. Remove the plug-in control power terminal block from the Pulse Transformer circuit board (refer to Figure 1 on page 9 for location). Remove plug-in terminal block 3. Remove the cables from connectors X3, X4 and XP at the top of the Pulse Transformer board (refer to Figure 1 on page 9 for location). Note: Connector X4 contains a jumper for drives without a fan - leave in place. Remove cables from X3, X4 and XSW

11 PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board 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. X3 XSW1 XSW X4 Remove connector from XCD_IO XR XCD_IO XY 5. Remove the plastic screw near the top of the Pulse Transformer board and retain for reuse. Remove plastic screw

12 12 PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board 6. Remove the appropriate gate leads from the Pulse Transformer board (refer to Figure 1 on page 9 for location): For regenerative drives, remove each pair of (orange and yellow) gate lead cables from connectors and 1 6 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 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 9 for location). For regenerative drives, remove 12 gate leads and push through holes in board Remove cable from XTA For non-regenerative drives, remove six gate leads and push through holes in board Remove cable from XTA

13 PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board 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 slide through 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

14 14 PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board Figure 2 Switching Power Supply Circuit Board Layout XUV 1C2 6 1 XSW 4 1 XV 4 1 XSW1 F XA 1 2 1D2 XY1 9. Remove the cable from connector XUV on the left side of the Switching Power Supply board (refer to Figure 2 above 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. Remove cable Remove screws

15 PowerFlex DC Drive - Frame A Switching Power Supply Circuit Board Remove the plastic stand-off and nut that secures the Switching Power Supply board to the back of the Pulse Transformer board. Secure nut Remove stand-off Step 5: Install the Existing Pulse Transformer Board and New Switching Power Supply 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 14 above for location). Step 6: Install the Control EMI 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.

16 Step 7: 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 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 at For... Read this document Publication Number In depth information regarding the User Manual - PowerFlex Digital DC Drives 20P-UM001 operation of PowerFlex Digital DC drives 1S7A01 Power, Control and Information Solutions Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI USA, Tel: (1) , Fax: (1) Europe/Middle East/Africa: Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) , Fax: (32) Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong ong, Tel: (852) , Fax: (852) Publication 20P-IN005B-EN-P - December 2009 Supersedes 20P-IN005A-EN-P - March 2009 Copyright 2009 Rockwell Automation. All rights reserved. Printed in USA.