Component Replacement

How to Replace a Lexium 62 Drive System Component

Before beginning the replacement of specific components, read thoroughly the Prerequisites for Replacing Components and Cables for important safety information.

DANGER
	ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Disconnect all power from all equipment including connected devices prior to removing any covers or doors, or installing or removing any accessories, hardware, cables, or wires. Place a "Do Not Turn On" or equivalent hazard label on all power switches and lock them in the non-energized position. Wait 15 minutes to allow the residual energy of the DC bus capacitors to discharge. Measure the voltage on the DC bus with a properly rated voltage sensing device and verify that the voltage is less than 42.4 Vdc. Do not assume that the DC bus is voltage-free when the DC bus LED is off. Block the motor shaft to prevent rotation prior to performing any type of work on the drive system. Do not create a short-circuit across the DC bus terminals or the DC bus capacitors. Replace and secure all covers, accessories, hardware, cables, and wires and confirm that a proper ground connection exists before applying power to the unit. Use only the specified voltage when operating this equipment and any associated products. Failure to follow these instructions will result in death or serious injury.

DANGER

ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

Disconnect all power from all equipment including connected devices prior to removing any covers or doors, or installing or removing any accessories, hardware, cables, or wires.
Place a "Do Not Turn On" or equivalent hazard label on all power switches and lock them in the non-energized position.
Wait 15 minutes to allow the residual energy of the DC bus capacitors to discharge.
Measure the voltage on the DC bus with a properly rated voltage sensing device and verify that the voltage is less than 42.4 Vdc.
Do not assume that the DC bus is voltage-free when the DC bus LED is off.
Block the motor shaft to prevent rotation prior to performing any type of work on the drive system.
Do not create a short-circuit across the DC bus terminals or the DC bus capacitors.
Replace and secure all covers, accessories, hardware, cables, and wires and confirm that a proper ground connection exists before applying power to the unit.
Use only the specified voltage when operating this equipment and any associated products.

Failure to follow these instructions will result in death or serious injury.

DANGER
	INOPERABLE SAFETY FUNCTION Test the proper functioning of the safety functions after every device replacement and every change of the wiring. Failure to follow these instructions will result in death or serious injury.

Step	Action
1	Disconnect all connection cables on the device that shall be replaced.
2	Loosen the screwed connections on the wiring bus (CN1) of the component that shall be replaced.
3	If present, loosen the screwed connections of the adjacent device on the right-hand side.
4	Push both slides (CN1) to the right.
5	Respectively undo screwed connections to the device mounting on the device rear wall (heat sink) at the top end and bottom end. For important safety information, follow the instructions in the safety messages after this table.
6	If a Lexium 62 DC Link Terminal is present, loosen the screwed connections of the component.
7	Remove the Lexium 62 component and replace it.
8	Install the new Lexium 62 component and tighten the screwed connections on the top and bottom side.
9	Verify whether the terminal cover is attached to the wiring bus (CN1) at the end of a row. For important safety information, follow the instructions in the safety messages after this table.
10	If present, connect the Lexium 62 DC Link Terminal to the Lexium 62 component. For important safety information and the detailed procedure, refer to How to Assemble the Lexium 62 DC Link Terminal.
11	Connect the Lexium 62 component according to the circuit diagram of the machine. For important safety information, follow the instructions in the safety messages after this table.
12	After replacing a Lexium 62 component, proceed as by the first commissioning. For further information, refer to Commissioning.

DANGER
	ELECTRIC SHOCK CAUSED BY HIGH LEAKAGE (TOUCH) VOLTAGE Attach the terminal covers on the extremities of the Bus Bar Module combination. Apply power to the device only if the terminal covers have been attached to the extremities of the Bus Bar Module combination. Failure to follow these instructions will result in death or serious injury.

DANGER
	INCORRECT ASSIGNMENT OF CABLES Verify that the assignment of the cables conforms to their previous connector assignments. Failure to follow these instructions will result in death or serious injury.

DANGER
	FIRE, ELECTRIC SHOCK, OR ARC FLASH WHEN USING LEXIUM 62 DC LINK TERMINAL Thoroughly verify the proper isolation of DC-/DC+ to PE (Protective Earth/ground) with an appropriate measuring instrument before first power on. Verify that the terminals are fully inserted on the Bus Bar Module. Do not connect DC+ to PE, 24 Vdc, 0 V or to DC-. Do not connect DC- to PE, 24 Vdc, 0 V or to DC+. Install the bus terminal connectors in the correct order 1 to 5 as follows: PE (1, green/yellow), DC- (2, black), DC+ (3, black), +24 V (4, blue), and 0 V (5, blue). Always install the full complement of the five connectors and the retaining bracket of the Lexium 62 DC Link Terminal. Always wire at least the PE, DC- and DC+ terminals out of the 5 installed connectors. Verify that the PE (Protective Earth/ground) terminal (1, green/yellow) is always connected to protective ground (earth) using a conductor of at least 10 mm² (AWG 6). Verify compliance with all local and national electrical code requirements as well as all other applicable regulations with respect to grounding of all equipment. Do not insert more than one wire per terminal. Tighten clamping screws of the terminals in conformance with the torque specifications. Only use the cable conductors with the appropriate cross-sections and current carrying capacities. Only use wires of appropriate cross-section as indicated. Failure to follow these instructions will result in death or serious injury.

DANGER

FIRE, ELECTRIC SHOCK, OR ARC FLASH WHEN USING LEXIUM 62 DC LINK TERMINAL

Thoroughly verify the proper isolation of DC-/DC+ to PE (Protective Earth/ground) with an appropriate measuring instrument before first power on.
Verify that the terminals are fully inserted on the Bus Bar Module.
Do not connect DC+ to PE, 24 Vdc, 0 V or to DC-.
Do not connect DC- to PE, 24 Vdc, 0 V or to DC+.
Install the bus terminal connectors in the correct order 1 to 5 as follows: PE (1, green/yellow), DC- (2, black), DC+ (3, black), +24 V (4, blue), and 0 V (5, blue).
Always install the full complement of the five connectors and the retaining bracket of the Lexium 62 DC Link Terminal.
Always wire at least the PE, DC- and DC+ terminals out of the 5 installed connectors.
Verify that the PE (Protective Earth/ground) terminal (1, green/yellow) is always connected to protective ground (earth) using a conductor of at least 10 mm² (AWG 6).
Verify compliance with all local and national electrical code requirements as well as all other applicable regulations with respect to grounding of all equipment.
Do not insert more than one wire per terminal.
Tighten clamping screws of the terminals in conformance with the torque specifications.
Only use the cable conductors with the appropriate cross-sections and current carrying capacities.
Only use wires of appropriate cross-section as indicated.

Failure to follow these instructions will result in death or serious injury.

CAUTION
	FALLING HEAVY OBJECT Do not fully remove the screw connections of the device mounting suspension and prevent the device from falling out and down. Failure to follow these instructions can result in injury or equipment damage.