(SPS) Board - Rockwell Automation
Contents
1. AJ3 20 pin connector AJ5 2 pin connector Bae E dia eS e a D D e q Soret le za AMI Le SUNS ol ah TS e El EE pE 00 BET DECH eo J J ae Ale A Tol E9 9 erya g A anil al Z relie OL OFOt 00 00020 6 pE N bal 19 Check that all of the cables are properly seated including the cables on the power board that are close to the SPS board PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board 11 Putting the Drive Back 1 Place the control tray over the circuit boards and plug the ribbon cable Together Frame G back into the control board In order for the control tray to seat properly the large ferrite on the ribbon cable needs to be routed to the right of transformer ET9 on the power board The control ribbon cable slack should be pushed down inside the drive 2 With a torque2. TY o Op O6 o E 3 3 AJ2 5 pin fan connector P L Lo H AJ1 5 pin fan connector JE l oH eo AJ9 3 pin fan connector Q ye gt e o o 5 AJ10 3 pin fan connector Ca e l o eT AJ7 3 pin fan connector a C AJ8 3 pin fan connector oh A DEO L a A kW oO 6 fv 4 m J eee Ts AJ3 20 pin connector i ae EE BE gy El BE gfe ae o i a P 8 o o 9 O ie 2 Tt eral ee pote reellel el 6 0 a Oooo aE oO O oTe hed aed Mea eid ea ea ea ee AJ5 2 pin connector Nei e AJ11 3 pin connector Cable tie 20 Check that all of the cables are properly seated including the cables on the power board that are close to the SPS board Putting the Drive Back Together Frame H PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board 19 1 Place the control tray over the circuit boards and plug the ribbon cable back into the control board The ribbon cable needs to go through a hole in the control tray The control ribbon cable slack should be pushed down inside the drive Install the three shorter M4 screws with a torque of 1 4 1 6 N m 12 2 13 9 Ib in and two M5 screws with a torque of 2 5 2 9 N m 21 7 26 0 Ib in back in to secure the control tray
3. 5 Remove the two M5 screws for the top choke cover and set them aside 6 Remove the choke cover and set it aside 7 Disconnect the ribbon cable from the control board 8 Remove the four M4 screws for the control tray and set them aside 9 Remove the control tray and set it aside Choke cover Ribbon cable M it A WN M F 6 PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board Checking the SPS board 1 Locate and compare the transformers AT3 AT4 and ATS on the current Frame G SPS board with the ones on the new SPS board Transformers Capacitors AC59 _ EA through to AC64 SPS board Power board The good board has larger AT3 AT4 and AT5 transformers Each of these transformers is labeled with a date code in the format yyww where yy represents the year and ww represents the week For example a date code of 0801 means the transformer was dated in the first week of the year 2008 If the transformer has a date code of 0801 or later it is not defective Date code on transformers 2 Locate and compare the capacitors AC59 through AC64 on the current SPS board with the ones on the new SPS board The good board has smaller capacitors at AC59 through AC64 If the SPS board does not need to be replaced skip to Putting the Drive Back Together Frame G on page 11 PowerFlex 400 Frame G a
4. Place the plastic guard over the terminal block and install the four longer M4 screws Torque the screws to about 1 2 1 4 N m 10 4 12 2 Ib in Place the choke cover over the choke at the top of the drive Tighten the six captive screws with a torque of 1 2 1 4 N m 10 4 12 2 1b in to secure the choke cover Install the front cover and torque the four captive screws to about 1 2 1 8 N m 10 4 12 2 Ib in Proceed to Packaging the Drive on page 20 if you need to package the drive Packaging the Drive If the drive is to be packaged do the following 1 Wrap the plastic bag around the drive and secure with tape 2 Place the user manual and lifting instructions back on top of the drive 3 Place the foam and box cover back on the drive 4 Strap the box cover to the pallet of the drive 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 4444 Europe Middle East Africa Rockwell Automation SA NV Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 22C SB001B EN P June 2008 Copyright 2008 Rockwell Automation All rights reserved Printed in Taiwan
5. E W ni PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board 13 Remove the four M4 screws for the clear plastic guard Remove the plastic guard and set it aside Disconnect the ribbon cable from the control board P N A p Remove the three M4 and two M5 screws for the control tray and set them aside Remove the control tray and set it aside M4 P0 7 Ribbon cable M5 P0 8 ____ M4 P0 7 Control tray M4 P0 7_ ______ D a SS I On i Lag M4 P0 7 _ gt i 7 be 7 il Q O C D i f ALI QI j Vey 2 gt eo 5 G i f i J ONICO a j NRY z Y SA XY FHA 4i K YV A RQ DY lw Fal Hy YA Q _ 8 Aa DE gt i ll A Z e s 2 gt a ae pp il i g LA G y i 14 PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board Checking the SPS board 1 Locate and compare the transformers AT3 AT4 and ATS on the current Frame H SPS board with the ones on the new SPS board Cable tie Capacitors AC59 through to AC64 SPS board Power board The good board has larger AT3 AT4 and ATS transformers Each of these transformers is labeled with a date code in the format yyww where yy represents the year and ww represents the week For example a d
6. Switching Power Supply SPS Board 13 Plug the ribbon cable back into AJ3 only fit the correct connector the proper way If you find that two ATTENTION All the cable connectors are keyed and should connectors do not fit do not force the connection 14 Plug the three wire cable back into AJ11 and secure the cable with a cable tie 15 Plug the two wire cable routed from DJ2 on the power board into AJ5 on the SPS board 16 Plug the two wire cable that routes from under the circuit boards to AJ4 AJ6 is used for a ground jumper and is normally left open 17 Plug the pair of five wire fan cables into AJ1 and AJ2 18 Plug a pair of three wire fan cables into AJ8 and AJ17 19 Plug the other pair of three wire fan cables into AJ9 and AJ10 AJ4 2 pin connector
7. and power devices to make sure they are fully in contact with each other with no gap in between 10 Place the three new steel clips onto the power devices AD18 AQ3 and AQ4 Make sure the hole on the clip is aligned with the bump on the heat sink Pull on the clip and make sure it will not fall off 11 Tighten the four M4 screws on the bottom of the heat sink with a torque of 1 4 1 6 N m 12 2 13 9 Ib in 12 Plug the ribbon cable back into AJ3 only fit the correct connector the proper way If you find that two ATTENTION All the cable connectors are keyed and should connectors do not fit do not force the connection 10 PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board 13 Plug the three wire cable with the ferrite bead back into AJ11 14 Plug the two wire cable routed from DJ2 on the power board into AJ5 on the SPS board 15 Plug the two wire cable that routes from under the circuit boards to AJ4 AJ6 is used for a ground jumper and is normally left open 16 Plug the pair of five wire fan cables into AJ1 and AJ2 17 Plug a pair of three wire fan cables into AJ8 and AJ17 18 Plug the other pair of three wire fan cables into AJ9 and AJ10 AJ11 3 pin connector AJ4 2 pin connector AJ2 5 pin fan connector AJ1 5 pin fan connector AJ9 3 pin fan connector AJ10 3 pin fan connector AJ7 3 pin fan connector AJ8 3 pin fan connector
8. drive is packaged do the following Package Removing and Locking Out Power 1 Cut the straps holding the box cover to the pallet of the drive 2 Remove the box cover and foam 3 Set aside the user manual and lifting instructions 4 Open the plastic bag surrounding the drive If the drive is in service do the following 1 Turn off and lock out all incoming power to the drive Wait five minutes Li L2 L3 2 O 2 Verify that there is no voltage at the input power terminals 4 PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board Opening the Drive Frame G 1 Loosen the four front cover captive screws 2 Remove the front cover and set it aside voltage on the bus capacitors has discharged before performing any work on the drive Wait five minutes for the capacitors to discharge Then measure the DC bus voltage at the DC and DC terminals or at the DC and P2 terminals on the power terminal block The voltage must be zero ATTENTION To avoid an electric shock hazard verify that the A darkened LCD display and LEDs are not an indication that capacitors have discharged to safe voltage levels 5 PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board 3 Remove the two screws for the clear plastic guard and set them aside 4 Remove the plastic guard and set it aside
9. Service Bulletin PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board Contents This publication provides instructions for replacing the switching power supply SPS board for PowerFlex 400 Frame G and H drives For additional drive information refer to the PowerFlex 400 User Manual publication 22C UMO01 New SPS board Five spare M4 screws to be used for the new SPS board Three new steel clips to be used on power devices AD18 AQ3 and AQ4 A cable tie to be used on loose cables for Frame H only This publication What This Kit Contains Safety Precautions The following general precautions apply to the PowerFlex 400 drive voltage on the bus capacitors has discharged before performing any work on the drive Wait five minutes for the capacitors to discharge Then measure the DC bus voltage at the DC and DC terminals or at the DC and P2 terminals on the power terminal block The voltage must be zero ATTENTION To avoid an electric shock hazard verify that the A darkened LCD display and LEDs are not an indication that capacitors have discharged to safe voltage levels and operation of this equipment and hazards involved should install start and or adjust this equipment Read and understand these instructions in their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life Only qualified electrical personnel familiar
10. ate code of 0801 means the transformer was dated in the first week of the year 2008 If the transformer has a date code of 0801 or later it is not defective Date code on transformers 2 Locate and compare the capacitors AC59 through AC64 on the current SPS board with the ones on the new SPS board The good board has smaller capacitors at AC59 through AC64 If the SPS board does not need to be replaced skip to Putting the Drive Back Together Frame H on page 19 PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board 15 Replacing the SPS board 1 Verify the rubber covers are properly installed on power devices AD 18 Frame H AQ3 and AQ4 on the new SPS board 2 Verify the three nylon standoffs are properly installed on the new SPS board Nylon standoffs 3 On the old SPS board remove the three clips from the heatsinked power devices AD18 AQ3 and AQ4 Pry between the clip and the heatsink using a small straight blade screwdriver to loosen the clips Remove clips 5 ip ae a A hd AB i ZA lt x A ST Had TJRSN WN AAA RA LK RO BM YS il il e 16 PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board 4 Relax the four M5 screws on the bottom of the heat sink 5 Unplug the cables from the old SPS board at AJ11 AJ4 AJ5 the ribbon cable from AJ3 and the six fan cables from AJ1 AJ2 AJ7 AJ8 AJ9 and AJ10 6 Cut t
11. he cable tie by using a pair of diagonal cutting pliers AD18 Cable tie AJG ASS AJ11 PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board 17 7 Remove the five M4 screws holding the SPS board and lift the SPS board out of the drive N N N SS N T SE fs SA p L ALKA N SZA A vil d AD gt L A lt gt ri ZA SZ A o amp S JN Z SES A SJ x gt Sa ia WA a A L A A LA A A e Z A ee BK va Z A 7 P gt 7 A f gt N g Vi Zo f f MAR f D f y D Q ea a gt 9 Zo ZY rae f Oo Pa Z B L a 7 Oo i A pe 7 ra ZZ ao X a A ao oa oe ras A Oo 1 j A Z 8 Place the new SPS board where the old one was 9 Place the five M4 screws back in to secure the SPS board Use a torque of about 1 2 1 8 N m 10 4 12 2 Ib in 10 Adjust the heat sink and power devices to make sure they are fully in contact with each other with no gap in between 11 Place the three new steel clips onto the power devices AD18 AQ3 and AQ4 Make sure the hole on the clip is aligned with the bump on the heat sink Pull on the clip and make sure it will not fall off 12 Tighten the four M5 screws on the bottom of the heat sink with a torque of 2 5 2 9 N m 21 7 26 0 Ib in 18 PowerFlex 400 Frame G and H Replacement Procedure for
12. nd H Replacement Procedure for Switching Power Supply SPS Board 7 Replacing the SPS board 1 Verify the rubber covers are properly installed on power devices AD 18 Frame G AQ3 and AQ4 on the new SPS board 2 Verify the three nylon standoffs are properly installed on the new SPS board Nylon standoffs 3 On the old SPS board remove the three steel clips from the heatsinked power devices AD18 AQ3 and AQ4 Pry between the clip and the heat sink using a small straight blade screwdriver to loosen the clips Steel clips 4 Relax the four M4 screws on the bottom of the heat sink PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board 5 Unplug the cables from the old SPS board at AJ11 AJ4 AJ5 the ribbon cable from AJ3 and the six fan cables from AJ1 AJ2 AJ7 AJ8 AJ9 and AJ10 AD18 AJ4 AJ6 PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board 9 6 Remove the five M4 screws holding the SPS board and lift the SPS board out of the drive M4 P0 7 M4 P0 7 M4 P0 7 M4 P0 7 M4 P0 7 7 Place the new SPS board where the old one was Be careful to make sure the black plastic insulator wraps around the edges of the SPS board and that it is not pinched 8 Place the five M4 screws back in to secure the SPS board Use a torque of about 0 9 1 1 N m 7 8 9 6 Ib in 9 Adjust the heat sink
13. of 1 4 1 6 N m 12 2 13 9 lb in install the four M4 screws back in to secure the control tray 3 Place the choke cover over the choke at the top of the drive 4 With a torque of 2 5 2 9 N m 21 7 26 0 lb in install the two M5 screws back in to secure the choke cover 5 Install the clear plastic guard over the loosened M4 screws by the terminal block Torque the screws to about 1 2 1 4 N m 10 4 12 2 Ib in 6 Install the front cover and torque the four captive screws to about 1 3 1 5 N m 11 3 13 0 Ib in Proceed to Packaging the Drive on page 20 if you need to package the drive 12 PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board Opening the Drive Frame H 1 Loosen the four front cover captive screws 2 Remove the front cover and set it aside ATTENTION To avoid an electric shock hazard verify that the AN voltage on the bus capacitors has discharged before performing any work on the drive Wait five minutes for the capacitors to discharge Then measure the DC bus voltage at the DC and DC terminals or at the DC and P2 terminals on the power terminal block The voltage must be zero A darkened LCD display and LEDs are not an indication that capacitors have discharged to safe voltage levels 3 Remove the six captive screws for the top choke cover 4 Remove the choke cover and set it aside Choke cover a FI
14. with the construction 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 Il wih ATTENTION This drive contains ESD Electrostatic 2 PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board What You Need e A 1 Phillips screwdriver e A small straight blade screwdriver e A pair of diagonal cutting pliers Replacement Procedure The replacement procedure for the SPS board is described in the following sections LI Removing the Drive from the Package on page 3 I Removing and Locking Out Power on page 3 C Opening the Drive Frame G on page 4 LI Checking the SPS board Frame G on page 6 I Replacing the SPS board Frame G on page 7 I Putting the Drive Back Together Frame G on page 11 I Opening the Drive Frame H on page 12 I Checking the SPS board Frame H on page 14 I Replacing the SPS board Frame H on page 15 C Putting the Drive Back Together Frame H on page 19 LI Packaging the Drive on page 20 PowerFlex 400 Frame G and H Replacement Procedure for Switching Power Supply SPS Board 3 Removing the Drive fromthe If the
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