PowerFlex DC Stand-Alone Regulator (SAR) Power …literature.rockwellautomation.com/idc/groups/literature/documents/...PowerFlex DC Stand-Alone Regulator ... 8. Unplug the control

Installation Instructions

PowerFlex DC Stand-Alone Regulator (SAR) Power Interface Circuit Board

What This Kit Includes Power interface circuit board Two mounting screws with captive lock washers (for mounting the power

interface circuit board) Four mounting screws with captive lock washers and four stand-offs

(fastened to the power interface circuit board for mounting the switching power supply circuit board)

Static strap Flathead screwdriver for terminal block connections

Tools That You Need Phillips screwdriver Hexalobular screwdriver Flathead screwdriver Nut driver or wrench for hex stand-offs

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 SAR has been removed before performing the following.

ATTENTION: This SAR 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.

23P-IN001A-EN-P

What You Need to Do The list below is an overview of the steps needed to remove and replace the power interface circuit board. See each step for detailed procedures.

1. Remove Power

2. Remove the Covers

3. Remove the Control Circuit Board

4. Remove the Power Interface Circuit Board

5. Remove the Switching Power Supply Circuit Board

6. Install the New Power Interface Circuit Board and Reassemble the SAR

7. Document the Change

Step 1: Remove Power

Remove and lock-out all incoming power to the SAR.

IMPORTANT The SAR has many different cables, wires, and plugs with different connections and routing. For ease of reassembly:

Make note of cable and wire routing between and within the different circuit boards.

Label connectors and plugs with the name of the connection and circuit board from where it was disconnected.

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 systems field devices, causing unintended machine motion

causing an explosion in a hazardous environmentElectrical arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts may create electrical resistance.

L1 L2 L3

O

I

2 Rockwell Automation Publication 23P-IN001A-EN-P - June 2011

Step 2: Remove the Covers

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 SAR, then slide the cover down and off the chassis.

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 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 chassis.

4. Disconnect the HIM communication cable from the control board.

=

Disconnect DPI cable

Tightening torque: 1.5 Nm (13.3.lbin)

When mounting pins fits in keyhole, lift cover off SAR 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.

Rockwell Automation Publication 23P-IN001A-EN-P - June 2011 3

Step 3: Remove the Control Circuit Board

1. Label and disconnect the ribbon cables at connectors XA, XR, and XFCD.

2. Unplug the terminal block connectors (6) from the control board (if wired).

3. Remove the EMI shield mounting screws (5), and save for reassembly.

4. Remove the EMI shield ground screw (1), and save for reassembly.

Note: The control board remains mounted to the EMI shield.

5. Carefully lift the EMI shield and control board (to provide clearance from cabling below), and slide the EMI shield and control board out of the chassis, and carefully set aside.

EMI Shield Mounting Screws (5)Tightening torque:1.0 Nm (8.9 lbin)

Terminal Block Connectors (6)

XA

XR

XFCD

EMI Ground Screw (1)Tightening torque:1.0 Nm (8.9 lbin)


Step 4: Remove the Power Interface Circuit Board

1. Record the DIP switch settings for SW3 and SW4, and the jumper pin locations for J4 and J5.

See the PowerFlex DC Stand-Alone Regulator and Gate Amplifier User Manual, publication 23P-UM001, for more information about these DIP switches and jumpers.

IMPORTANT The power interface circuit board and the switching power supply circuit board are removed together, as an assembly.

SW3 SW4

J5 J40VI RCTXCT

MSB LSBON

Off

On

Burden Resistor Jumpers

External Burden Resistor Terminal Block (XCT)

Binary Gain Amp DIP Switches


http://literature.rockwellautomation.com/idc/groups/literature/documents/um/23p-um001_-en-p.pdf

2. Label and disconnect the plugs at connectors X3 and X4.

3. Label and disconnect the plugs at connectors XCD and XCD_IO.

4. Label and disconnect the ribbon cable at XPT1.

5. Label and disconnect the plugs at TH-CT and XF.

6. Label and disconnect the plugs at connectors at XP1 and XP2.

7. Label and disconnect the plug from connector XUVW.

8. Unplug the control power and relay terminal blocks.

9. Label and disconnect any external burden resistor circuit wires from the XCT terminal.

10. Remove the mounting screws (2).

X3

X4

XCD

XCD_IOXPT1

TH-CT

XF

XP1 and XP2(respectively)

XUVW

Control Power and Relay Terminal Block

XCT TerminalMounting Screws (2)Tightening torque:1.0 Nm (8.9 lbin)

XR


11. Remove the cooling vent mounting screws (4) on top of the stand-alone regulator, and save for reassembly.

12. Disconnect the fan plug from the XV connector on the switching power supply circuit board.

13. Remove the cooling vent and fan assembly.

14. Carefully slide the power interface circuit board and the switching power supply circuit board assembly out of the chassis.

15. Label and remove the ribbon cable at connector XR and save to reuse on the new power interface circuit board.

16. Continue with Remove the Switching Power Supply Circuit Board on page 8.

Cooling Vent Mounting Screws (4)Tightening torque:1.0 Nm (8.9 lbin)

Fan plug XV connector (behind cooling vent)


Step 5: Remove the Switching Power Supply Circuit Board

1. Remove the stand-off mounting screw (1) next to the XR ribbon cable connector on the power interface circuit board, and save for reassembly.

2. Label and disconnect the plug at connector XUV.

3. Remove the mounting screws (4), and save for reassembly.

4. Carefully pull the two boards apart, pulling the XSW and XSW1 plugs on the switching power supply circuit board out of the pins on the power interface circuit board.

5. Save the switching power supply circuit board for reassembly.

6. Dispose of the power interface circuit board properly.

Step 6: Install the New Power Interface Circuit Board and Reassemble the SAR

1. Install the switching power supply circuit board onto the new power interface circuit board in reverse order of removal. See Remove the Switching Power Supply Circuit Board on page 8.

2. Install the new power interface circuit board in reverse order of removal. See Remove the Power Interface Circuit Board on page 5.

3. Install the control circuit board in reverse order of removal. See Remove the Control Circuit Board on page 4.

Mounting Screws (4)Tightening torque:1.0 Nm (8.9 lbin)

XUV

Stand-off mounting screw (1) is removed at XR on the power interface circuit board

IMPORTANTXSW and XSW1 plugs on the switching power supply circuit board fit into the pins on the power interface circuit board.

XA


Step 7: Document the Change

1. Record the installation of the new power interface circuit board and date of installation on the field installed option label on the side of the SAR (as shown below).

2. Replace the SAR covers in the reverse order of removal. See Remove the Covers on page 3.

3. Install DPI cable (if present).

Additional Resources

These documents contain additional information concerning related Rockwell Automation products.

You can view or download publications athttp://www.rockwellautomation.com/literature. To order paper copies of technical documentation, contact your local Rockwell Automation distributor or sales representative.

Resource Description

PowerFlex DC Stand-Alone Regulator and Gate Amplifier User Manual, publication 23P-UM001

Provides installation instructions and connection and configuration information for the PowerFlex DC Stand-Alone Regulator (SAR).

PowerFlex Digital DC Drive User Manual, publication 20D-UM001 Provides additional installation, configuration, and programming information for the PowerFlex DC Stand-Alone Regulator (SAR).

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1

Provides general guidelines for installing a Rockwell Automation industrial system.

Product Certifications website, http://ab.rockwellautomation.com Provides declarations of conformity, certificates, and other certification details.


http://literature.rockwellautomation.com/idc/groups/literature/documents/um/20p-um001_-en-p.pdfhttp://literature.rockwellautomation.com/idc/groups/literature/documents/um/23p-um001_-en-p.pdfhttp://literature.rockwellautomation.com/idc/groups/literature/documents/in/1770-in041_-en-p.pdfhttp://ab.rockwellautomation.com/http://www.rockwellautomation.com/literature

1S7A73

Publication 23P-IN001A-EN-P - June 2011

Copyright 2011 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

Power, Control and Information Solutions HeadquartersAmericas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444Europe/Middle East/Africa: Rockwell Automation NV, Pegasus Park, De Kleetlaan 12a, 1831 Diegem, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846

www.rockwel lautomation.com

U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, E-mail: [email protected], Online: www.ab.com/support/abdrives

PowerFlex DC Stand-Alone Regulator (SAR)Power Interface Circuit Board Installation InstructionsWhat This Kit IncludesTools That You NeedWhat You Need to DoStep 1: Remove PowerStep 2: Remove the CoversStep 3: Remove the Control Circuit BoardStep 4: Remove the Power Interface Circuit BoardStep 5: Remove the Switching Power Supply Circuit BoardStep 6: Install the New Power Interface Circuit Board and Reassemble the SARStep 7: Document the ChangeAdditional Resources

Back Cover

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Introduction_Catagory Types

This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards. It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printing.Find your publication type in the first section below. Use the assigned Printing Category information to determine the standard print specifications for that document type. The Printing Categories are defined below the Publication Type section. Note there may be slightly different print specifications for the categories, depending on the region (EMEA or Americas).For more information on Global Sales and Marketing Printing Standards, see publication RA-CO004 in DocMan.

Publication Type and Print Category

Publication TypeOff Set Print Category Spec. (See table below)JIT Spec. (See table below)DescriptionOrder Min **Order Max **Life Cycle Usage / Release Option

ADNA - PuttmanNAAdvertisement Reprint ColourNANAPresale / Internal

APA3D2Application Solution or Customer Success Story5100Presale / External

ARNANAArticle/Editorial/BylineNANAPresale / Internal

(press releases should not be checked into DocMan or printed)

ATB3, B4D5Application techniques5100Presale / External

BRA2 Primary, A1NABrochures5100Presale / External

CAC2 Primary, C1NACatalogue150Presale / External

CGNANACatalogue Guide150Presale / External

CLNANACollection550Presale / External

COA5, A6, A9D5Company Confidential InformationNANANA / Confidential

CPE-onlyE-only, D5Competitive Information550NA / Confidential

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DMNANAProduct Demo550Presale / Internal

DSB3D5Dimensions Sheet15Post / External

DUB3D5Document Update15Post / External

GRB2D6Getting Results15Post / External

INB3 Primary, B2D5, D6Installation instructions15Post / External

LMNANALaunch Materials550Presale / Internal

PCB3D5Packaging Contents

PLE-only primary, B3E-onlyPrice List550Presale / Internal

PMB2D6Programming Manual15Post / External

PPA3D1Profile (Single Product or Service). NOTE: Application Solutions are to be assigned the AP pub type.5100Presale / External

QRB2 primary, B3, B5D5, D6Quick Reference15Post / External

QSB2 primary, B3, B5D5, D6Quick Start15Post / External

RMB2D5, D6Reference Manual15Post / External

RNB3D5Release Notes15Post / External

SGB1 Primary, B4D5, D6Selection Guide Colour550Presale / External

SGB2D5, D6Selection Guide B/W550Presale / External

SPA1, A2, A3, A4NASales Promotion NOTE: Service profiles are to be assigned the PP pub type.5100Presale / Internal

SRB2, B3D5, D6Specification Rating Sheet5100Presale / External

TDB2 Primary B3, B4, B5D5, D6Technical Data550Presale / External

TGB2, B3D6Troubleshooting Guide15Post / External

UMB2 Primary, B4D6User Manual B/W15Post / External

WDB3D5Wiring Diagrams / Dwgs15Post / Internal

WPB3 Primary, B5D5White Paper550Presale / External

** Minimum order quantities on all JIT items are based on the publication length. **

Publication lengthMinimum Order Quantity

77 or more pages1 (no shrink wrap required)

33 to 76 pages25

3 to 32 pages50

1 or 2 pages100

Pre-sale / MarketingAll paper in this category is White Brightness, 90% or better. Opacity 90% or better

CategoryColor OptionsAP, EMEA Paper RequirementsCanada, LA, US Paper Requirements

A14 color170 gsm 2pp100# gloss cover, 100# gloss text

A24 color170 gsm , folded, 4pp100# gloss cover, 80# gloss text

A34 colorCover 170 gsm with Body 120 gsm, > 4pp80# gloss cover, 80# gloss text

A42 color170gsm Silk 120gsm Silk80# gloss cover, 80# gloss text

A52 color170gsm Silk 120gsm Silk80# gloss cover, 80# matt sheet text

A61 color170gsm Silk 120gsm Silk80# gloss cover, 80# matt sheet text

A74 color cover2 color textSelection GuideCategory being deleted10 Point Cover C2S50# matte sheet text

A84 color coverCategory being deleted50# matte sheet text, self cover

2 color text

Selection Guide

A92 color100gsm bond50# matte sheet text, self cover

Selection Guide

Gray shading indicates Obsolete Print Catagories

Post Sale / Technical Communication


B14 color cover270gsm Gloss 100gsm bond10 Point Cover C2S

2 color text50# matte sheet text

B21 color160gsm Colortech & 100gsm Bond90# Cover50# matte sheet text

B31 color100gsm bond50# matte sheet text, self cover

B42 color160gsm Colortech & 100gsm Bond90# Cover50# matte sheet text

B52 color100gsm bond50# matte sheet text, self cover

Catalogs


C14 color cover270gsm Gloss 90gsm silk10 Point Cover C2S

4 color text45# Coated Sheet

C24 color cover270gsm Gloss 80gsm silk10 Point Cover C2S

2 color text32#-33# Coated Sheet

JIT / PODAll paper in this category is White Brightness, 82% or better. Opacity 88% or better


D14 color170gsm white silk80# gloss cover, coated 2 sides

D24 color120gsm white silk80# gloss text, coated 2 sides, self cover

D34 colorCover 170gsm with Body 120gsm80# gloss cover, 80# gloss text coated 2 sides

D41 color160gsm tab90# index

D51 color80gsm bond20# bond, self cover

D61 colorCover 160gsm tab with Body 80gsm bond90# index, 20# bond

D72 color160gsm tab90# index

D82 color80gsm bond20# bond, self cover

D92 colorCover 160gsm tab with Body 80gsm bond90# index, 20# bond

D10Combination: 4 color cover, with 2 color bodyCover 160gsm with Body 80gsm90# index, 20# bond

Gray shading indicates Obsolete Print Catagories

Just In Time (JIT) or Off Set (OS)?

Use these guidelines to determine if your publication should be JIT (just in time/print on demand) or if it would be more economical to print OS (offset/on a press). OS print jobs require an RFQ (Request For Quote) in US. If your job fits into the Either category, an RFQ is recommended, but not required. In the US, RA Strategic Sourcing will discourage or reject RFQs for jobs that fall within the JIT category. Guidelines differ for black & white and color printing, so be sure to check the correct tables.

Black & White Printing

Color Printing

Color Printing

Print Spec Sheet

JIT Printing SpecificationsRA-QR005G-EN-P - 3/29/2010

Printing SpecificationYOUR DATA HEREInstructionsNO

(required) Category:JIT / PODSelect Print Category A,B,C or D from category list, on "Introduction_Catagory Types" tab11 x 17LOOSE -Loose LeafYESPre-sale / MarketingTOP

(required) Finished Trim Size Width:8.5 x 118.5 x 11PERFECT - Perfect BoundA1LEFT

(required) Publication Number :23P-IN001A-EN-PSample: 2030-SP001B-EN-P3 x 5SADDLE - Saddle StitchA2RIGHTCORNER

Use Legacy NumberYES or NO18 x 24 PosterPLASTCOIL - Plastic Coil (Coil Bound)A4BOTTOMSIDE

Legacy Number if applicable:Sample Legacy Number: 0160-5.3324 x 36 PosterSTAPLED1 -1 positionA3

Publication Title:PowerFlex DC Stand-Alone Regulator (SAR) Power Interface Circuit Board Installation InstructionsSample: ElectroGuard Selling Brief80 character limit - must match DocMan Title36 x 24 PosterSTAPLED1B - bottom 1 positionA5

(required) Business Group:Marketing CommercialAs entered in DocMan4 x 6STAPLED2 - 2 positionsA6

(required) Cost Center:19010As entered in DocMan - enter number only, no description. Example - 19021CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 191054.75 x 7 (slightly smaller half-size)THERMAL - Thermal bound (Tape bound)A7

Binding/Stitching:STAPLED1 -1 positionReview key on right...Saddle-Stitch Items All page quantities must be divisible by 4.Note: Stitching is implied for Saddle-Stitch - no need to specify in Stitching Location.80 pgs max. on 20# (text and cover)76 pgs max. on 20# (text) and 24# (cover)72 pgs max. on 24# (text and cover)

Perfect Bound Items940 pgs max. w/cover (90# index unless indicated otherwise)70 pgs. min. for spine without words200 pgs min. for spine with words

Plastcoil Bound Items530 pgs max. of 20# (if adding cover deduct equivalent number of pages to equal cover thickness) (90# index unless indicated otherwise)

Tape Bound Items250 pgs max. on 20# no cover240 pgs max. w/cover (90# index unless indicated otherwise)4.75 x 7.75THERMALO - Thermal Bound (Tape bound - offline)A8

(required) Page Count of Publication:10Total page count including cover5.5 x 8.5 (half-size)A9

Paper Stock Color:White is assumed. For color options contact your vendor.6 x 4Post Sale / Technical Communication

Number of Tabs Needed:5 tab in stock at RR Donnelley7.385 x 9 (RSI Std)B1

Stitching Location:CORNERBlank, Corner or Side8.25 x 10.875B2

Drill Hole YES/NONOAll drilled publications use the 5-hole standard, 5/16 inch-size hole and a minimum of inch from the inner page border.8.25 x 11 (RA product profile std)B3None

Glue Location on Pad:Glue location on pads8.375 x 10.875B4Half or V or Single Fold

Number of Pages per Pad:Average sheets of paper.. 25, 50 75,100 Max9 x 12 (Folder)B5C or Tri-Fold

Ink ColorOne colorOne color assumes BLACK / 4 color assume CMYK / Indicate PMS number hereA4 (8 x 11 ) (210 x 297 mm)CatalogsDbleParll

Used in Manufacturing:NOA5 (5.83 x 8.26) (148 x 210 mm)C1Sample

Fold:NoneReview key on right...Short (must specify dimensions between folds in Comments)

Comments:C2Z or Accordian Fold

Part Number:JIT / PODMicrofold or French Fold - designate no. of folds in Comments - intended for single sheet only to be put in box for manufacturing

D1Double Gate

D2

FoldsHalf, V, Single C or Tri

Dble Parll

Z or Accordian Microfold or French

Double Gate

Short FoldD3

D4

D5

D6

D7

D8

D9

MBD000CCD74.bin

MBD000D141F.bin

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MBD000D05AE.bin

MBD000B37AA.bin

MBD000C2CF0.bin

MBD000CBFEF.bin

MBD000B71E5.bin

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MBD000AF7AA.bin

Documents

PowerFlex DC Stand-Alone Regulator (SAR) Power …literature.rockwellautomation.com/idc/groups/literature/documents/...PowerFlex DC Stand-Alone Regulator ... 8. Unplug the control