Installation Instructions, PowerFlex 755 Common DC Input ... · See step 3 of Remove the DC Precharge Left-front Cover and Disconnect Switch Handle and Handle Shaft on page 5 for

Installation Instructions

PowerFlex 755 Common DC Input Drives, Frames 8...10 Interlock Assembly and Precharge Assembly Left-front Cover Retrofit KitCatalog Numbers 20G14x, 21G14x

This retrofit kit can be used to improve the access to the molded case switch (SW1) on common DC input drives for lock-out, tag-out procedures. Install this kit only on DC input with precharge modules with catalog numbers20-750-P5-C770D740 and 20-750-P5-E510F500.

General Precautions

Before You Begin Before you install the retrofit kit, complete these tasks:• Review the parts list and verify that you have all items that are listed, page

2• Gather the tools that are required to install the kit, page 2

Topic Page

General Precautions 1

Before You Begin 1

Install the Retrofit Kit 2

Additional Resources 11

ATTENTION:

• Only qualified personnel familiar with adjustable frequency AC 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.

• This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when you install, test, service, or repair this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference Guarding Against Electrostatic Damage, publication 8000-4.5.2 or any other applicable ESD protection handbook.

PowerFlex 755 Common DC Input Drives, Frames 8...10 Interlock Assembly and Precharge Assembly Left-front Cover Retrofit Kit

Kit Parts List

This kit contains the following parts.• DC precharge left-front cover with access panel• DC bus guard• Interlock assembly• L-bracket and two M5 x 14 mm hexalobular screws

Required Tools

Install the Retrofit Kit

Follow theses steps to install the interlock assembly and precharge assembly, left cover retrofit kit.

Remove Power from the Drive

1. Turn off and lock out all input power, including any external power sources (such as an AFE or other DC power source).

2. Wait 15 minutes and verify that there is no voltage at the drive input-power terminals.

Tool Description Details

Allen socket wrench 2.5 mm

ESD-protected place of work Work surface, Floor cover, seat, and ground connections

ESD-protective clothing Wrist wrap, shoes, overall clothing (coat)

Flash light –

Hexalobular screw driver/bit #20, #25

Multi-meter Digital multi-meter, capable of AC and DC voltage, continuity, resistance, capacitance measurements, and forward diode bias tests. Fluke model 87 III or equivalent.

Nose pliers –

Phillips screw driver / bit #1

ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing. Measure the DC bus voltage at the -DC and +DC TESTPOINT sockets on the front of the power module (show in the illustration in step 3).Remove power before you remove or make cable connections. When you remove or insert a cable connector with power applied, an electrical arc may occur. An electrical arc may cause these system events, which can cause personal injury or property damage.• An erroneous signal to system field devices, which can cause unintended

machine motion• An explosion in a hazardous environmentElectrical arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts can create electrical resistance.

2 Rockwell Automation Publication 750-IN037A-EN-P - June 2015


3. Measure the DC bus voltage at the -DC and +DC TESTPOINT sockets on the front of the power module.

Rockwell Automation Publication 750-IN037A-EN-P - June 2015 3


4. Turn off and lock the drive circuit breaker SW5 (if used).

5. Turn off the drive disconnect switch SW2.

ATTENTION: To avoid an electric shock hazard when servicing the drive, a means for Lockout/Tagout of the external, single-phase 120/240V and, if present, 120V uninterruptible power supply sources must be provided.

Frame 9 Common DC Input Drive Shown

SW2

SW5



Remove the DC Precharge Left-front Cover and Disconnect Switch Handle and Handle Shaft

1. Remove only the four M5 x 14 mm screws that secure the DC precharge left-front cover to the assembly and remove the cover and top and left guards.

2. Remove the four M5 x 14 mm screws that secure the top and left guards to the cover, and remove the guards. Retain the guards and screws for reuse.

3. Remove the two M4 x 12 mm hexalobular screws and washers that secure the rotary disconnect on/off handle to the front cover and remove the handle. Retain the handle, screws, and washers for reuse.

T252.8 N•m (25 lb•in)

1

2

2

=

T201.8 N•m (16 lb•in)



4. Loosen the hexagonal screw that secures the disconnect handle shaft to the disconnect switch and remove the handle.

Install the New Disconnect Switch Interlock Assembly1. Complete steps a.…d to install the interlock assembly on the disconnect

handle shaft.a. Position the interlock rod (A) under the clamp assembly (as shown in

the illustration).b. Position the set screw (B) to the right of the clamp assembly.c. Position the pins (C) on the disconnect handle shaft vertically and slide

the base of the shaft through the square opening in the clamp assembly.

2.5 mm0.6 N•m (5.4 lb•in)

A

C

B



d. Position the back of the interlock clamp assembly 34 mm (1.33 in.) from the base of the shaft and tighten the M3 x 1.5 mm set screw.

2. With the interlock rod (D) positioned below the handle shaft, fully insert the handle shaft (E) into the receptacle on the disconnect switch.

3. Secure the handle shaft in place by using the set screw on the disconnect switch.

See step 4 of Remove the DC Precharge Left-front Cover and Disconnect Switch Handle and Handle Shaft on page 5 for recommended torque.

33.8 mm(1.33 in.)

P11.13 N•m (10 lb•in)

D

E



Replace the DC Bus Guard

1. By using a pliers, remove the four cable tie mounts, which secure the resistor wires, from the back of the existing DC bus guard.

2. Loosen the two M4 x 12 mm hexalobular screws that secure the clear, plastic shield to the front of the DC bus guard and remove the plastic panel. Retain this panel for reuse.

3. Loosen the two M4 x 12 mm hexlobular screws that secure the sheet metal DC bus guard to the resistor assembly and remove and discard the guard.

4. Place the new sheet metal DC bus guard on the resistor assembly and secure the guard by tightening the two existing screws.

5. Place the clear, plastic shield on the new DC bus guard and secure the shield by tightening the existing screws.

6. Fully insert the four cable tie mounts, which secure the resistor wires, into the holes on the new DC bus guard.

1

T202.8 N•m (25 lb•in)

T201.8 N•m (16 lb•in)3

2

4

5

6

T201.8 N•m (16 lb•in)

T202.8 N•m (25 lb•in)



Install the Rotary Disconnect Handle and New DC Precharge Cover

1. Secure the existing rotary on/off disconnect handle to the new DC precharge assembly left front cover by using the two M4 x 8 mm long screws and washers.


2. Secure the two clear plastic guards to the new DC precharge assembly left front cover by using the four existing M5 x 14 mm screws.


3. Set the rotary on/off handle and the disconnect handle shaft to the “off ” position.

The disconnect handle shaft is in the “off ” position when the pins on the end of the shaft are oriented horizontally.

4. Align the rotary disconnect handle and shaft and place the new front cover on the DC precharge unit.

5. Secure the front cover by using the existing screws.




Install the Interlock Bracket

1. Loosen the two hexalobular screws that secure the circuit-breaker access door to the left front cover and lower the door.

2. Position the L-bracket with the square opening on top and the screw holes to the front and flush with the back of the cover.

IMPORTANT The interlock rod behind the cover must fit into the square opening on the top of the L-bracket (as shown in the illustration).

1

T201.8 N•m (16 lb•in)

2

T202.8 N•m (25 lb•in)



3. Secure the L-bracket by using the two M5 x 14 mm hexalobular screws that are provided in the kit.

4. Close and secure the circuit-breaker access door.

5. Move the disconnect handle to the “ON” position.

6. Verify that the circuit- breaker access door cannot be opened.

7. Secure the circuit-breaker access door by tightening the two hexalobular screws.

Additional Resources These documents contain additional information concerning related products from Rockwell Automation.

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.

Resource Description

PowerFlex® 750-Series AC Drives, Frame 8 and Larger Hardware Service Manual, publication 750-TG001

Provides a recommended preventative maintenance schedule, major component test and hardware replacement procedures, and schematic diagrams for frame 8 and larger PowerFlex 750-Series AC drives.

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


http://literature.rockwellautomation.com/idc/groups/literature/documents/tg/750-tg001_-en-p.pdfhttp://www.ab.comhttp://www.rockwellautomation.com/literature/

Rockwell Automation SupportRockwell Automation provides technical information on the Web to assist you in using its products.At http://www.rockwellautomation.com/support you can find technical and application notes, sample code, and links to software service packs. You can also visit our Support Center at https://rockwellautomation.custhelp.com/ for software updates, support chats and forums, technical information, FAQs, and to sign up for product notification updates.

In addition, we offer multiple support programs for installation, configuration, and troubleshooting. For more information, contact your local distributor or Rockwell Automation representative, or visithttp://www.rockwellautomation.com/services/online-phone.

Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running.

New Product Satisfaction Return

Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.

Documentation Feedback Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete this form, publication RA-DU002, available at http://www.rockwellautomation.com/literature/.

United States or Canada 1.440.646.3434

Outside United States or Canada Use the Worldwide Locator at http://www.rockwellautomation.com/rockwellautomation/support/overview.page, or contact your local Rockwell Automation representative.

United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor to complete the return process.

Outside United States Please contact your local Rockwell Automation representative for the return procedure.

Publication 750-IN037A-EN-P - June 2015 PN-318377Copyright © 2015 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

Rockwell Automation maintains current product environmental information on its website athttp://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page.

Allen-Bradley, PowerFlex, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc.Trademarks not belonging to Rockwell Automation are property of their respective companies.

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

Rockwell Otomasyon Ticaret A.Ş., Kar Plaza İş Merkezi E Blok Kat:6 34752 İçerenköy, İstanbul, Tel: +90 (216) 5698400

http://www.rockwellautomation.com/rockwellautomation/distributor-locator/sales-locator.pagehttp://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.pagewww.ab.com/support/abdriveshttp://www.rockwellautomation.com/supporthttps://rockwellautomation.custhelp.com/http://literature.rockwellautomation.com/idc/groups/literature/documents/du/ra-du002_-en-e.pdfhttp://www.rockwellautomation.com/literature/http://www.rockwellautomation.com/services/online-phone

PowerFlex 755 Common DC Input Drives, Frames 8...10 Interlock Assembly and Precharge Assembly Left-front Cover Retrofit Kit, Installation InstructionsGeneral PrecautionsBefore You BeginKit Parts ListRequired ToolsInstall the Retrofit KitRemove Power from the DriveRemove the DC Precharge Left-front Cover and Disconnect Switch Handle and Handle ShaftInstall the New Disconnect Switch Interlock AssemblyReplace the DC Bus GuardInstall the Rotary Disconnect Handle and New DC Precharge CoverInstall the Interlock Bracket

Additional ResourcesBack Cover

Introduction_Category 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

DCE-onlyE-onlyDiscount SchedulesNANAPresale / Internal

DIA1, A3NADirect Mail5100Presale / Internal

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-QR005J-EN-P - 6/14/2013

Printing SpecificationYOUR DATA HEREInstructionsNO

(required) Publication Number:750-IN037A-EN-PSample: 2030-SP001B-EN-P11” x 17”LOOSE -Loose LeafYESPre-sale / MarketingTOP

Use Legacy Number:NOYES or NO8.5” x 11”PERFECT - Perfect BoundA1LEFT

Legacy Number if applicable:Sample Legacy Number: 0160-5.338.375” x 10.875SADDLE - Saddle StitchA2RIGHTCORNER

Publication Title:PowerFlex 755 Common DC Input Drives, Frames 8...10 Interlock Assembly andPrecharge Assembly Left-front Cover Retrofit Kit, Installation InstructionsSample: ElectroGuard Selling Brief80 character limit - must match DocMan Title8.25” x 11” (RA product profile std)PLASTCOIL - Plastic Coil (Coil Bound)A4BOTTOMSIDE

Used in Manufacturing:YESYES or NO - If Yes, must have Part No. listed below8.25” x 10.875”STAPLED1 -1 positionA3

Part Number:PN-318377If SAP Part Number, be sure to enter PN- before the number7.385” x 9” (RSI Std)STAPLED1B - bottom 1 positionA5

(required) CategoryD5Select Print Category A,B,C or D from category list, on "Introduction_Category Types" tab6” x 4”STAPLED2 - 2 positionsA6

Paper Stock Color:White is assumed. For color options contact your vendor5.5” x 8.5” (half-size)THERMAL - Thermal bound (Tape bound)A7

Ink Color:One color assumes BLACK / 4 color assume CMYK / Indicate PMS number here4.75” x 7.75”THERMALO - Thermal Bound (Tape bound - offline)A8

(required) Page Count ofPublication:12Total page count including cover. Enter PAGE count, not SHEET count4.75” x 7” (slightly smaller half-size)A9

(required) Finished Trim Size Width:8.5” x 11”This is sheet size, before folding4.25" x 5.50"Post Sale / Technical Communication

Fold:NoneReview key below. Leave blank if folded for saddle stitching4” x 6”B1

Finished Fold Size:This is size after folding is completed3” x 5”B2

Binding/Stitching:STAPLED2 - 2 positionsReview key below9” x 12” (Folder)B3None

Stitching Location:SIDEBlank, Corner or SideA4 (8 ¼” x 11 ¾”) (210 x 297 mm)B4Half or V or Single Fold

Drill Hole (Yes/No):NOAll drilled publications use the 5-hole standard, 5/16 inch-size hole and a minimum of ¼ inch from the inner page border.A5 (5.83” x 8.26”) (148 x 210 mm)B5C or Tri-Fold

Number of Tabs Needed:5 tab in stock at RR Donnelley36” x 24” PosterCatalogsDbleParll

Number of Pages per Pad:Average sheets of paper. 25, 50 75,100 Max24” x 36” PosterC1Sample

Glue Location on Pad:Glue location on pads18” x 24” PosterC2Short (must specify dimensions between folds in Comments)

(required) Business Group:Marketing CommercialAs entered in DocManJIT/PODZ or Accordian Fold

(required) Cost Center:19134 - Power CIf your Business Unit is Marketing Commercial, add the appropriate division name after 19134 using the chart on the right. All other Business Units: Enter only the number as in DocMan, no description. Example - 1902119134 - Commerc 19134 - OEM 19134 - Compone 19134 - Power C19134 - Global 19134 - Process 19134 - IA 19134 - Service 19134 - IMC 19134 - Safety 19134 - Industr 19134 - Softwar19134 - Mkt Dig 19134 - US MarkeD1Microfold or French Fold - designate no. of folds in Comments - intended for single sheet only to be put in box for manufacturing

Comments:D2Double Gate

FoldsHalf, V, Single C or Tri

Dble Parll

Z or Accordian Microfold or French

Double Gate

Short FoldSaddle-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)D3

D4

D5

D6

D7

D8

D9

MBD000B0209.bin

MBD000B020B.bin

MBD000B020C.bin

MBD000B020A.bin

MBD000B0205.bin

MBD000B0207.bin

MBD000B0208.bin

MBD000B0206.bin

MBD000B0203.bin

MBD000B0204.bin

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Installation Instructions, PowerFlex 755 Common DC Input ... · See step 3 of Remove the DC Precharge Left-front Cover and Disconnect Switch Handle and Handle Shaft on page 5 for