Rockwell Automation 20P-RES-A0 User Manual

PowerFlex® DC Drive and Stand-Alone Regulator (SAR) Control Circuit Board

Installation Instructions

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.

What This Kit Includes

What This Option Provides

Tools That You Need

• Control circuit board

• Five screws with captive lock washers

• Static strap

• Flathead screwdriver for terminal block connections

The Control circuit board is the main drive-mounted board that controls the drive and provides these Input/Output (I/O) signals:

• Eight Digital Inputs

• Four Digital Outputs

• Three Analog Inputs

• Two Analog Outputs

• Digital Encoder Input

• DC Analog Tachometer Input

• Phillips® screwdriver

• Hexalobular screwdriver

• Flathead screwdriver

• Nut driver or wrench for hex stand-offs

Phillips

is a registered trademark of Phillips Screw Company.

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What You Need to Do

Step 1: Save the Parameter Configuration

Step 2: Remove Power from the Drive

To install the Control board:

❐ Step 1: Save the Parameter Configuration ❐ Step 2: Remove Power from the Drive ❐ Step 3: Remove the Drive Covers ❐ Step 4: Remove the Communication Adapter and EMI Shield ❐ Step 5: Remove the Existing Connections and Option Board(s) ❐ Step 6: Remove the Existing Control Board ❐ Step 7: Install the New Control Board ❐ Step 8: Wire the Control Board ❐ Step 9: Document the Change

If possible, save the drive and adapter parameter configuration to a Human Interface Module (HIM) Set or by up loading the drive and adapter parameters to an offline database file using DriveExecutive™. Refer to the PowerF lex DC Digital Drive User Manual, publication 20P-UM001 the HIM or the on-line Help provided with DriveExecutive.

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:

, for information on using

• 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.

L1 L2 L3

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Step 3: Remove the Drive Covers

• To open frame A drives and the stand-alone regulator, see Frame A Drives

and the Stand-Alone Regulator below.

• To open frame B and C drives see Frame B and C Drives

• To open frame D drives see Frame D Drives

on page 5.

on page 4.

Frame A Drives and the Stand-Alone Regulator

1. Disconnect the Device Peripheral Interface (DPI) cable from the HIM

assembly (if present).

2. Loosen the captive screws that secure the bottom front 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 pull the cover

toward you until the cover is partially off the drive chassis. Then pull the top of the cover toward you until the mounting pins align with the keyholes in the top of the cover. Then carefully lift the cover off of the drive chassis.

Important: The HIM assembly is connected to the control board via a

communication cable. Carefully set the top cover down next to the chassis.

4. Continue with Disconnect the HIM Communication Cable

on page 6.

When mounting pins fits in keyhole, lift cover off drive chassis.

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Frame B and C Drives

1. Disconnect the DPI cable from the HIM (if present).

2. Loosen, but do not remove, the screws that secure the top and bottom front

covers to the drive, then slide the covers off the drive chassis.

Important: The HIM assembly is connected to the control board via a

communication cable. Carefully set the top cover down next to the chassis.

3. Continue with Disconnect the HIM Communication Cable

Frames B shown

Loosen screws

Disconnect DPI cable.

on page 6.

Tightening torque:

1.5 N•m (13.3.lb•in)

Loosen screws

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Frame D Drives

1. Disconnect the DPI cable from the HIM assembly (if present).

2. Loosen, but do not remove, the four hexalobular screws that secure each of

the three covers to the control pan on the drive, then slide the covers up and off the drive chassis. Tightening torque is noted in the illustration for reassembly.

Important: A communication cable connects the HIM assembly to the

control board mounted on the control pan. Therefore, the middle control pan cover and HIM assembly cannot be fully removed from the drive until the cable is disconnected.

3. Continue with Disconnect the HIM Communication Cable

T15

Tightening torque:

1.5 N•m (13 lb•in)

Loosen screws

on page 6.

Loosen screws

Disconnect DPI cable

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Disconnect the HIM Communication Cable

For all drives, disconnect the HIM communication cable from the connector on the upper right corner of the control board and set the cover aside.

All Frames (Frame A shown)

Pull tabs out to disconnect cable.

Step 4: Remove the Communication Adapter and EMI Shield

If a communication adapter is not installed, continue with step 4 on page 7.

1. Disconnect the interface cable from the adapter and set it aside.

2. Disconnect any network cables from the adapter and set them aside.

Disconnect interface cable

Disconnect network cables

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3. Remove the four screws that secure the adapter to the EMI shield and

remove the adapter.

Remove four screws Tightening torque:

0.9 N•m (8 lb•in)

4. Remove the three screws that secure the EMI shield to the stand-offs on the

control board and remove the EMI shield.

Remove three screws Tightening torque:

1.0 N•m (8.9 lb•in)

5. Remove the three stand-offs from the control board.

Remove three standoffs Tightening torque:

1.0 N•m (8.9 lb•in)

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Step 5: Remove the Existing Connections and Option Board(s)

If the optional resolver feedback module, I/O expansion, and 115V AC to 24V DC converter boards are not installed on the control board, continue with Step 6: Remove the Existing Control Board

on page 13.

Important:Mark all connections and wires before removing to avoid incorrect

wiring during reassembly.

Step 5A: Remove the Resolver Feedback Module

If the optional resolver feedback module is not installed, continue with Step 5B:

Remove the Optional I/O Expansion Board on page 10.

Important:The resolver feedback module can only be used with PowerFlex DC

drives with firmware version 5.002 or higher.

Important:The resolver feedback module consists of an interface board and a

feedback board. For this procedure, both boards of the resolver feedback module are removed together, as an assembly.

1. Remove the three plug-in I/O terminal blocks from the resolver feedback

module assembly.

2. Remove the four mounting screws for the resolver interface board.

Resolver feedback board

Resolver interface board

Remove four screws (resolver interface board) Tightening torque is

0.7 N•m (6.2 lb•in)

Plug-in I/O terminal blocks

XP3

J1 J2

P2 P3

XRE

S21

TB1 TB2

S15

XFCD

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3. Carefully lift the resolver interface module off of the control board, pulling

the stacker connector out of the XRE connectors on the control board.

Important: Lift the resolver interface board straight up so that the stacker

connector pins do not bend or break.

Resolver interface board

XRE connector

Side view

Control board

Stacker

connector

XRE

connector

Resolver interface board

Capped pins to right

Control board

Bottom view

4. Remove the four stand-offs and washers that support the resolver interface

board on the control board.

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Step 5B: Remove the Optional I/O Expansion Board

If the optional I/O expansion board is not installed, continue with Step 5C:

Remove the 115V AC to 24V DC Converter Board on page 12.

1. Remove the plug-in I/O terminal blocks.

2. Remove the two screws that secure the board to the stand-offs on the control

board.

3. Carefully remove the I/O expansion board from the control board.

Pins connected to connector XBB

Lift board straight up and off control board

Remove two screws Tightening torque:

1.0 N•m (8.9 lb•in)

Important: Lift the board straight up so that the connector pins on the

I/O expansion board do not bend or break.

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4. Remove the two stand-offs and washers that support the I/O expansion

board on the control board.

Remove two stand-offs Tightening torque:

1.0 N•m (8.9 lb•in)

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Step 5C: Remove the 115V AC to 24V DC Converter Board

If the optional 115V AC to 24V DC converter board is not installed, continue with Step 6: Remove the Existing Control Board

1. Remove the plug-in I/O terminal blocks.

2. Remove the two screws that secure the I/O converter board to the stand-offs

on the control board and remove the converter board.

on page 13.

Remove two screws Tightening torque:

1.0 N•m (8.9 lb•in)

3. Remove the two stand-offs and washers that support the converter board on

the control board.

Remove two stand-offs Tightening torque:

1.0 N•m (8.9 lb•in)

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Step 6: Remove the Existing Control Board

S14

S20

1 2 3 4 5 6 7 8

- A B C +

1. Record the DIP switch and jumper settings on the control board.

1 2 3 4 5 6 7 8

S14

S20

S10

21 22 23 24 25 26 27 28 29 30

1 2 3 4 5 6 7 8 9 10

31 32 33 34 35 36 37 38 39 40

11 12 13 14 15 16 17 18 19 20

DEBUG

S21

ENC_5 ENC_12

S11 S9

A+ A- B+ B- Z+ Z- COM +V

S15

1 2 3 4 5 6 7 8

RST ACT RUN PWR

S15

S21

S9, S10, S11

Jumper/ Switch Function Setting

S4 Configures the input voltage of the DC analog tachometer. S9 Configures the input signal of Analog Input 1 (terminals 1 and 2):

Note: The input signal type must also be programmed accordingly using parameter 71 [Anlg In1 Config].

S10 Configures the input signal of Analog Input 2 (terminal 3 and 4):

Note: The input signal type must also be programmed accordingly using parameter 76 [Anlg In2 Config].

S11 Configures the input signal of Analog Input 3 (terminals 5 and 6):

Note: The input signal type must also be programmed accordingly using parameter 81 [Anlg In3 Config].

S14 Field current resistors setting.

Important: In addition, the value selected with switch S14 must be entered in parameter 374 [Drv Fld Brdg Cur] in the

control software when the drive is commissioned.

S14-1 = S14-2 = S14-3 = S14-4 = S14-5 = S14-6 = S14-7 = (not used) S14-8 = (not used)

S15 Configuration of the control circuit board to the appropriate drive size. This value is set to the appropriate size at the

factory.

S15-1 = S15-2 = S15-3 = S15-4 = S15-5 = S15-6 = S15-7 =

S15-8 = S20 Monitoring of the Z channel of the digital encoder on connector XE2: S21 Encoder power supply voltage and input adaptation selection:

Note: When control power is supplied to the drive, the appropriate LED lights to indicate the selection of the switch.

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2. Carefully disconnect the cables from connectors XFCD, XA, and XR on the

control board.

3. Remove the plug-in I/O and control terminal blocks with the wiring kept in

place.

Disconnect cables

Disconnect I/O and control wiring

Remove screws Tightening torque:

1.0 N•m (8.9 lb•in)

4. Remove the five screws that secure the control board to the control EMI

shield and remove the board from the drive.

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Step 7: Install the New Control Board

Step 8: Wire the Control Board

1. Install the new control board in the reverse order of removal as detailed in

Step 6: Remove the Existing Control Board

on page 13.

2. Verify that all DIP switch and jumper settings match those recorded in the

chart on page 13 publication 20P-UM001

. Refer to the PowerFlex DC Digital Drive User Manual,

, for detailed information on DIP switch and

jumper settings.

Install the I/O and control wiring in reverse order of removal.

Figure 1 I/O and Control Wire Routing

Route I/O and control wiring between bottom front cover and power terminal cover/shield.

(Frame A shown)

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Step 9: Document the Change

1. Record the installation of the new control board and date of installation on

the field installed option label on the side of the drive (as shown below).

2. Replace the drive covers in the reverse order of removal as described in Step

3: Remove the Drive Covers

on page 3.

3. Install DPI cable (if present).

4. Down load the parameter configuration back into the drive.

Frame A Shown

Rockwell Automation 20P-RES-A0 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

What This Kit Includes

What This Option Provides

Tools That You Need

What You Need to Do

Step 1: Save the Parameter Configuration

Step 2: Remove Power from the Drive

Step 3: Remove the Drive Covers

Step 4: Remove the Communication Adapter and EMI Shield

Step 5: Remove the Existing Connections and Option Board(s)

Step 6: Remove the Existing Control Board

Step 7: Install the New Control Board

Step 8: Wire the Control Board

Step 9: Document the Change

Related Documentation