Remove and Install the Control Pod (XT) for Frame 7

Replace a control pod assembly with kit catalog number 20-750-MCPOD3-F7M (regenerative drive or bus supply) or 20-750-MCPOD4-F7M (low harmonic drive). Follow these steps to remove and install the control pod assembly.
  1. Review the product advisories in Before You Begin.
  2. Remove power from the system.
  3. Open the enclosure door.
  4. Remove the protective guard. See Remove and Install the Protective Guard for Frame 7.
  5. Remove the control pod cover. See Remove and Install the Control Pod Cover for Frame 7.
  6. If a human interface module (HIM) is installed in the HIM cradle, remove the HIM.
  7. If used, disconnect the
    DPI™
     cable from the connector on the bottom of the HIM cradle.
    example of how to remove the DPI cable from the HIM cradle with XT
    TIP: The inner control pod chassis is shown removed from the outer control pod chassis for clarity only.
    TIP: If a cable is not connected to the
    DPI™
     port on the HIM cradle, be sure to leave the protective cover installed.
  8. If used, remove the fiber-optic cables from the cable management devices (A in illustration) in the control pod.
    IMPORTANT: The minimum inside bend radius for fiber-optic cable is 50 mm (2 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable. Signal attenuation increases as inside bend radius is decreased.
    fiber-optic cable bend radius example
  9. Loosen the two captive thumbscrews that secure each of the fiber transceiver circuit boards to the chassis and remove the boards with cables. Retain the fiber transceiver boards for reuse.
    TIP: It is easier to remove the fiber transceiver circuit board from the pod before removing the fiber-optic cables. However, it is possible to remove the fiber-optic cables without removing the boards.
    IMPORTANT: The edge connectors on a fiber transceiver circuit board with enhanced protection contain dielectric grease. If you do not intend to replace a fiber transceiver circuit board, do not touch the edge connectors on the board.
    example of how to remove a fiber transceiver circuit board from the control pod
    TIP: The control pod is shown separated from the enclosure to clarify the instructions only.
  10. Remove the fiber-optic cables from the applicable ports on the fiber transceiver boards.
    • AC precharge circuit board fiber-optic cable from the ACPC port.
    • If present, torque accuracy module fiber-optic cable from the TAM port.
    • Line side converter power module fiber-optic cables from the L0 port.
    • Motor side inverter power module fiber-optic cable from the M0 port.
    fiber transceiver circuit board fiber-optic port identification
  11. Route the fiber optic cables through the grommets in the bottom of the control pod carefully, and coil the fiber-optic cable and secure in a protected location. Follow the minimum bend radius requirement.
  12. If an option module is installed, complete these steps:
    1. Disconnect the plug-in terminal blocks.
    2. Loosen the two captive thumb screws that secure the option module to the control pod chassis and remove the option module. Final torque for re-assembly is 0.45 N•m (4 lb•in).
  13. Record any settings made on these main control board selectors or jumpers (B in the illustration):
    • Control selector
    • Embedded
      EtherNet/IP™
       address selectors
    • Safety enable jumper
    • Hardware enable jumper
  14. Disconnect any Ethernet cables from the Ethernet ports on the bottom of the main control board.
  15. Disconnect the plug-in terminal block (TB1) on the bottom of the main control board.
    example of the control pod Ethernet ports and terminal block TB1 locations on the main control circuit board with XT
    TIP: The inner control pod chassis is shown removed from the outer control pod chassis for clarity only.
  16. Disconnect connector P14 from connector J14 on the fiber-optic interface board.
  17. If installed, disconnect the customer supplied 24V supply power wire connector P13 from connector J13 on the fiber-optic interface board.
  18. Route all control cables through the grommets (C) in the bottom of the control pod.
    example of the 24V DC and control pod fan connection locations on the fiber interface circuit board
  19. Loosen the M5.5 x 13 mm Torx screw that secures the control pod assembly to the chassis.
  20. Loosen the two M5 captive screws that secure the bottom of the control pod assembly to the side panel and rotate the control pod assembly out from the enclosure.
    example of how to rotate the frame 7 control pod assembly
  21. While supporting the control pod assembly, remove the three M5.5 x 13 mm Torx screws that secure the hinged mounting bracket to the inside edge of the enclosure and remove the control pod assembly.
    example of how to remove the frame 7 control pod and mounting bracket
  22. Install the hinged mounting bracket on the new control pod assembly by using the five M5 x 12 mm Torx screws provided with the kit.
    example of how to install the frame 7 control pod and mounting bracket
  23. Install the control pod in the reverse order of removal.
    IMPORTANT: Do not remove protective covers from wire harnesses, circuit board connectors, terminal blocks, and fiber-optic transceivers and ports unless used at the time of installation. For the product to meet the corrosive atmosphere rating, protective covers must remain installed in unused connectors during storage and operation.
  24. Make any necessary changes to the settings on these main control board selectors or jumpers:
    • Control selector
    • Embedded
      EtherNet/IP™
       address selectors
    • Safety enable jumper
    • Hardware enable jumper
  25. For each fiber transceiver board, open the transceiver latch and pull the transceiver out of the connector on the board.
    TIP: If the latch is obstructed and you cannot use your fingers to open it, use a small, screwdriver or other long, narrow tool to open the latch.
    example of how to remove the fiber transceiver from a fiber-optic port
  26. Without bending the cable to a radius less than 50 mm (2 in.), fully insert the fiber-optic cable into the transceiver.
    IMPORTANT: The end of the transceiver that connects to the inside of the fiber port contains dielectric grease. Do not touch the end of the transceiver.
    example of how to insert a fiber-optic cable into a transceiver
  27. Insert the transceiver and fiber-optic cable into the connector on the board, until you hear an audible ‘click.’
    IMPORTANT: If before you install the new board, grease is removed from an edge connector or is contaminated, do not install the circuit board. You must clean and reapply grease to the affected edge connector or connectors. See Clean and Apply Dielectric Grease to a Fiber Transceiver Edge Connector (XT).
    example of how to insert a fiber transceiver with fiber-topic cable into the fiber port on the fiber transceiver board with XT
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