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. 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, uarding Against Electrostatic Damage or any other applicable ESD protection handbook. What This it Includes Pulse Transformer circuit board Terminal block with k ohm resistor @ terminals 78 & 79 Seven screws and washers for board 6 gate lead cables with connectors (for non-regenerative drives only) 2 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. Publication 20P-IN009D-EN-P - February
What You Need to Do To install the Pulse Transformer board: Step : Step 2: Step 3: Step 4: Step 5: Step 6: Remove power from the drive Remove the protective covers Remove the Pulse Transformer and Switching Power Supply boards Configure the new Pulse Transformer board Install the new Pulse Transformer board and existing Switching Power Supply board Replace the protective covers and document the change Step : 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.. Remove and lock-out all incoming power to the drive. L L2 L3 I O 2 Rockwell Automation Publication 20P-IN009D-EN-P - February 202
Step 2: Remove the Protective Covers. 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:.5 N m (3.3 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. 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 step 4 below for instructions. Tightening torque:.5 N m (3.3 lb in) U C V D W Rockwell Automation Publication 20P-IN009D-EN-P - February 202 3
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.. Remove the plug-in terminal from the field input block at the top of the drive. 2. Remove the four screws that secure the slotted air flow plate to the top of the drive chassis. IMPORTANT The air flow plate is also secured to the Pulse Transformer circuit board and therefore cannot yet be removed. Instructions for doing so are included later in this procedure. Remove screws Remove plug-in terminal block Air flow plate Front of Drive 4 Rockwell Automation Publication 20P-IN009D-EN-P - February 202
Figure - Pulse Transformer Circuit Board Layout O XP PE X3 TO4 X3 XSW 6 TR2 TR O4 34 2 33 TO XR 0V 4 XY 06 T4 03 05 02 T T02 T05 T03 T06 04 0 PE T04 T0 T2 T5 U T6 XCD_IO T T4 XSW XP U C V W TR2 TR XI2CA X4 XR 5 X4 2 6 3 4 F3 F2 TA XTA TA 78 79 35 367576U2V2 F FIR2-XX M T3 XY TO5 XCT O5 O2 TO3 TO6 O3 O6 T2 TO2 U2 V2 T6 6 2 T5 5 3 T3 V W D Board revision label S3 S4 C XTA XM 78 79 35 36 75 76 U2 V2 Components shown within dashed lines are only on the Pulse Transformer board for regenerative drives. FIR2-XX rev. M and lower Board revision label Board configured using resistors FIR2-XX N FIR2-XX rev. N and higher Board configured using DIP switches Rockwell Automation Publication 20P-IN009D-EN-P - February 202 5
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. Remove connector from XCD_IO XCD_IO C D S3 S4 XTA XM 78 79 35 36 75 76 U2 V2 6 Rockwell Automation Publication 20P-IN009D-EN-P - February 202
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. Loosen screws Control EMI shield Rockwell Automation Publication 20P-IN009D-EN-P - February 202 7
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 FU and FV. Remove screws Field fuse connections 9. Remove the cables from connectors X3, X4 and XP on the Pulse Transformer board. Remove cable from X3 Remove cable from X4 Remove cable from XP 8 Rockwell Automation Publication 20P-IN009D-EN-P - February 202
0. Remove the ground connection at the left side of the Pulse Transformer board. Remove ground connection Rockwell Automation Publication 20P-IN009D-EN-P - February 202 9
. Remove the appropriate gate leads (see Figure - on page 5 for location): For non-regenerative drives, remove each pair of (orange and yellow) gate lead cables from connectors 0 06 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 0 06 and 6 and push each lead through the appropriate opening in the board. IMPORTANT Remove the gate leads by grasping the connector and pulling up. DO NOT pull the gate leads off by pulling on the wires. For non-regenerative drives, remove six gate leads and route through openings in board For regenerative drives, remove 2 gate leads and route through openings in board 2. Remove the seven screws that secure the board to the stand-offs on the drive chassis and remove the boards from the drive. 0 Rockwell Automation Publication 20P-IN009D-EN-P - February 202
Note: Regenerative Drive Shown Remove screws Rockwell Automation Publication 20P-IN009D-EN-P - February 202
Remove cable from XUV 3. Turn the Pulse Transformer board over and remove the cables from connectors XV and XUV on the Switching Power Supply board. 4. 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 screws 5. Remove the six stand-offs and washers from the back of the Pulse Transformer board. Retain stand-offs and washers for reuse. Step 4: Configure the New Pulse Transformer Board The Pulse Transformer circuit board must be configured to match the drive size (armature output current and HP rating). The steps required to complete the configuration are different based on the revision code of the board. See either, Pulse Transformer Board FIR2-XX Rev. M and Lower below, or Pulse Transformer Board FIR2-XX Rev. N and Higher on page 6. 2 Rockwell Automation Publication 20P-IN009D-EN-P - February 202
Pulse Transformer Board FIR2-XX Rev. M and Lower IMPORTANT This procedure requires a multimeter that measures resistance to thousandths of an ohm.. Refer to Table - 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. Sizing resistors are located near the center of the Pulse Transformer circuit board. X3 XSW 6 TR2 XP TR 2 34 XR 33 X4 XY 0V U C V W 0 04 02 T02 05 T05 03 T03 06 T06 T0 T04 T2 T5 T T4 4 2 5 T3 3 T6 6 F F2 TA XTA F3 78 79 35 367576U2V2 Sizing Resistor Configuration The tables below indicate the value of the designated resistor (R R5) when left in place on the Pulse Transformer board, or Remove when the resistor should be cut off and removed from the board. indicates that there is no resistor in this position on the Pulse Transformer board. Table - 230V AC Input Drives Drive Current DC Amps AC Line HP R R2 R3 R4 R5 Rating Code Amps 46 46 9 40 Remove Remove 5.36Ω Remove 80 80 47 50 Remove Remove 5.36Ω Remove 28 28 78 60 Remove Remove 5.36Ω Remove 265 265 27 75 Remove Remove 5.36Ω 5.36Ω 360 360 294 00 Remove 5.36Ω 5.36Ω 5.36Ω 434 434 355 25 Remove 5.36Ω 5.36Ω 5.36Ω Table 2-460V AC Input Drives Drive Current DC Amps AC Line HP R R2 R3 R4 R5 Rating Code Amps 67 67 36.4 00 Remove 5.36Ω Remove Remove 207 207 69. 25 Remove Remove 5.36Ω Remove 250 250 204.3 50 Remove Remove 5.36Ω 5.36Ω 330 330 269.6 200 Remove 5.36Ω 5.36Ω 5.36Ω 42 42 336.6 250 Remove 5.36Ω 5.36Ω 5.36Ω Rockwell Automation Publication 20P-IN009D-EN-P - February 202 3
2. Connect the leads of the multimeter to pins 3 and 4 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 5. The XR connector is located on the upper right corner of the Pulse Transformer circuit board. = XSW 6 XP X3 TR2 TR 2 34 XR 33 0V X4 XY 2............. 4................... 34 XR U C V W 02 05 03 06 0 04 T02 T05 T03 T06 T0 T04 T2 T5 T T4 T3 T6..............3.................... 33 4 2 5 3 6 F F2 TA XTA F3 TA 78 79 35 367576U2V2 The TA potentiometer is located on the lower right corner of the Pulse Transformer circuit board next to the control power terminal block. 4 Rockwell Automation Publication 20P-IN009D-EN-P - February 202
Total Resistance Values Table 3-230V AC Input Drives Drive Current DC AC Line HP Set RTA Value Using TA Rating Code Amps Amps Potentiometer (Ohms) 46 46 9 40 2.575 80 80 47 50 0.2 28 28 78 60 8.422 265 265 27 75 6.928 360 360 294 00 5. 434 434 355 25 4.23 Table 4-460V AC Input Drives Drive Current DC AC Line HP Set RTA Value Using TA Rating Code Amps Amps Potentiometer (Ohms) 67 67 36.4 00 0.994 207 207 69. 25 8.87 250 250 204.3 50 7.344 330 330 269.6 200 5.564 42 42 336.6 250 4.456 3. Seal the TA potentiometer in place using RV (silicon). Continue with Step 5: Install the New Pulse Transformer Board and Existing Switching Power Supply Board on page 7. Rockwell Automation Publication 20P-IN009D-EN-P - February 202 5
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 - on page 5 for location), to the correct settings based on the appropriate table below. XSW XP X3 TR2 TR XI2CA Dip switches S3 and S4 are located at the bottom, right corner of the board. XR TO4 X4 XY TO5 XCT TO3 O4 O5 O3 O O2 TO6 O6 D TO T2 TO2 U2 V2 S3 S4 4 T4 2 T5 T6 6 T 5 79 35 36 75 76 U2 V2 3 PE T3 PE U V W XCD_IO D C S3 S4 XTA XM 78 79 35 36 75 76 U2 V2 IMPORTANT A blank cell below a switch in the following tables indicate that the setting is OFF. Drive Current Rating Code DC Amps AC Line Amps Table 5-230V AC Input Drives HP DIP Switch S3 DIP Switch S4 S3- S3-2 S3-3 S3-4 S3-5 S3-6 S3-7 S3-8 S4- S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8 46 46 9 40 ON ON ON 80 80 47 50 ON ON ON ON 28 28 78 60 ON ON ON ON 265 265 27 75 ON ON ON ON 360 360 294 00 ON ON ON 434 434 355 25 ON ON ON ON Drive Current Rating Code DC Amps AC Line Amps Table 6-460V AC Input Drives HP DIP Switch S3 DIP Switch S4 S3- S3-2 S3-3 S3-4 S3-5 S3-6 S3-7 S3-8 S4- S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8 67 67 36.4 00 ON ON ON ON 207 207 69. 25 ON ON ON 250 250 204.3 50 ON ON ON ON 330 330 269.6 200 ON ON ON 42 42 336.6 250 ON ON ON ON 6 Rockwell Automation Publication 20P-IN009D-EN-P - February 202
Drive Current Rating Code DC Amps AC Line Amps Table 7-575V AC Input Drives HP DIP Switch S3 DIP Switch S4 S3- S3-2 S3-3 S3-4 S3-5 S3-6 S3-7 S3-8 S4- S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8 67 67 55. 50 ON ON ON ON 0 0 82.7 75 ON ON ON ON 35 35 0.3 00 ON ON ON ON 270 270 220.6 200 ON ON ON ON 405 405 330.9 300 ON ON ON ON Step 5: Install the New Pulse Transformer Board and Existing Switching Power Supply Board. Install the new Pulse Transformer board and existing Switching Power Supply board in reverse order of removal. 2. Replace the cables connected to connector X3, X4, XP and XR on the Pulse Transformer board and the gate lead cables with the new cables provided. ATTENTION: Each gate lead cable must be connected to the exact connector from which it was removed on the Pulse Transformer circuit board or damage to the drive may occur. Side cut-away view 3. Verify that the four plastic board stabilizers mounted on the top air flow plate are placed one on either side of each of the Pulse Transformer and Switching Power Supply boards. Top view of Pulse Transformer board Air flow plate One plastic stabilizer should be on either side of each board Pulse Transformer board Switching Power Supply board Plastic stabilizers Rockwell Automation Publication 20P-IN009D-EN-P - February 202 7
Step 6: Replace the Protective Covers and Documenting the Change. Replace the protective covers in the reverse order of removal as described in Step 2: Remove the Protective Covers on page 3. 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). Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource PowerFlex Digital DC Drive Use Manual, publication number 20P-UM00 Product Certifications website, http://www.ab.com Description Provides basic information needed to install, start-up and troubleshoot the PowerFlex DC drive. Provides declarations of conformity, certificates, and other certification details. You can view or download publications at http:// www.rockwellautomation.com/literature/. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative. U.S. Allen-Bradley Drives Technical Support - Tel: () 262.52.876, Fax: () 262.52.2222, E-mail: support@drives.ra.rockwell.com Online: www.ab.com/support/abdrives Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. S7A05 Publication 20P-IN009D-EN-P - February 202 Supersedes Publication Supersedes Publication 20P-IN009C-EN-P - February 20 Copyright 202 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.