Bulletin No.

30072-450-35
April 2001
Instruction Bulletin Raleigh, NC, USA

ALTIVAR® 58 Power Board Kits

VX5A58D28M2U, VX5A58D33M2U, VX5A58D46M2U, VX5A58D54N4U, VX5A58D64N4U,
VX5A58D79N4U
Retain for future use.

INTRODUCTION This bulletin contains installation instructions for the ALTIVAR 58 (ATV58)
Power Board Kits VX5A58D28M2U, VX5A58D33M2U, VX5A58D46M2U,
VX5A58D54N4U, VX5A58D64N4U, VX5A58D79N4U. The kits are for use
on ATV58 frame size 7 drive controllers. Refer to Table 1 for drive catalog
Table 1: ATV58 Frame Size 7 Controllers numbers. Before installing the kits, perform the bus voltage measurement
Drive Controller Catalog Number procedure described on page 2. You will need the following tools for the
Frame Size procedures in this bulletin:
(ATV58•••••)

7
D28M2, D33M2, D46M2, D54N4, D64N4, • Flat-blade screwdriver
D79N4
• Phillips head screwdriver
• Set of metric hex key wrenches
• Voltmeter
• Torque wrench
• T-20 hex head bit

Table 2: Kit Contents

Qty Description Qty Description

6 M4 x 10 screws (extra screws) 1 Insulator for power board
15 M5 x 10 screws 1 Current sensor
6 M5 x 45 screws 1 J18 cable
6 5 x 12 washers 1 J31 cable
1 Filter board 1 J33 cable
1 Power board 1 J5 cable

HANDLING PRECAUTIONS
CAUTION
STATIC SENSITIVE COMPONENTS
The power board can be damaged by static electricity. Observe the
electrostatic precautions below when handling circuit boards or testing
components.
Failure to follow this instruction can result in equipment damage.

Observe the following precautions when handling static sensitive

components:
• Keep static producing material (plastic, upholstery, carpeting) out of the
immediate work area.
• Store the power board in its protective packaging when it is not installed
in the drive controller.
• When handling the power board, wear a conductive wrist strap that is
connected to the power board through a minimum of one megohm
resistance.
• Avoid touching exposed conductors and component leads with skin or
clothing.

© 2001 Schneider Electric All Rights Reserved 1

ALTIVAR 58 Power Board Kits Bulletin No. 30072-450-35
VX5A58D28M2U, VX5A58D33M2U, VX5A58D46M2U, VX5A58D54N4U, VX5A58D64N4U, VX5A58D79N4U April 2001

BUS VOLTAGE MEASUREMENT

DANGER
HAZARDOUS VOLTAGE
• Disconnect all power including external control power that may be
present before servicing the drive controller. WAIT THREE MINUTES
for the DC bus capacitors to discharge. Then follow the DC bus
voltage measurement procedure to verify that the DC voltage is less
than 45 V. The drive controller LEDs are not accurate indicators of the
absence of DC bus voltage.
• Read and understand the bus voltage measurement procedure
before performing the procedure. Measurement of bus capacitor
voltage must be performed by qualified personnel.
• DO NOT short across DC bus capacitors or touch unshielded
components or terminal strip screw connections with voltage present.
• Many parts in this drive controller, including printed wiring boards,
operate at line voltage. DO NOT TOUCH. Use only electrically
insulated tools.
Electric shock will result in death or serious injury.

To measure the DC bus capacitor voltage:

1. Disconnect all power from the drive controller including external control
power that may be present on the control board and the option board
terminals.
2. Wait three minutes for the DC bus capacitors to discharge.
3. Remove the door of the drive controller.
4. Set the voltmeter to the 1000 Vdc scale. Measure the voltage between
terminals J2 (+) and J2 (-) identified in Figure 1. Verify that the DC bus
voltage has discharged below 45 V before servicing the drive controller.
5. If the DC bus capacitors will not discharge below 45 V, contact your local
Square D representative. Do not operate the drive controller.

Flexible
Shield

+
Main Control – } ATV58•D16M2–D46M2
ATV58•D28N4–D79N4
Board
L1 L2 L3 + – PA PB U V W

Power
Terminal
Block

Figure 1: DC Bus Measurement Terminals

2 © 2001 Schneider Electric All Rights Reserved

Bulletin No. 30072-450-35
April 2001 VX5A58D28M2U, VX5A58D33M2U, VX5A58D46M2U, VX5A58D54N4U, VX5A58D64N4U, VX5A58D79N4U
REMOVING THE POWER BOARD
NOTE: Before replacing the power board,
record the drive controller configuration and
save it to an open file in Menu 7.
© 2001 Schneider Electric All Rights Reserved
ALTIVAR 58 Power Board Kits
Follow the procedure below to remove the power board from the drive
controller. Refer to Figure 2 on page 4 for the lettered items.
1. Perform the bus voltage measurement procedure on page 2 of this
bulletin.
2. Loosen two captive screws on the drive controller door (A) and remove
the door.
3. Loosen one screw and remove the plastic cover (B) at the top of the drive
controller. Retain the hardware for reinstallation.
NOTE: this screw is mounted in the center tab at the very back of the
plastic cover, but it is visible and accessible from the front of the drive
controller. You will need a long flat-blade screwdriver to reach it.
4. Remove two screws from the panel (C) above the drive controller door
and lift it up and off. Retain the hardware for reinstallation.
5. Remove four screws and remove the metal plate (D) installed under the
top panel. Retain the hardware for reinstallation.
6. Remove the control board (E):
a. Remove the J18 cable on the front of the control board.
b. Remove four mounting screws to release the control board from its
mounting frame (F). Retain the screws for reinstallation.
c. Remove the J5 cable on the back of the control board. Pull the cable
straight off to prevent the pins from bending.
d. Remove the control board from the drive controller.
7. Remove six screws from the left side and one screw from the top grille of
the drive controller, then lift off the left side grille (H). Retain the grille and
hardware for reinstallation.
8. Remove six screws from the right side and one screw from the top grille
of the drive controller, then lift off the right side grille (I). Retain the grille
and hardware for reinstallation.
9. Note carefully how the fan cable (K) is routed through the controller for
replacement, then unplug the connector from terminal J29 on the power
board (L).
10. Remove the control board support bracket (F) from the drive controller.
11. Remove seven cable connections from the power board (L). Refer to
Figure 5 on page 6 for the connection locations.
a. Unplug J26 and J31 from the right side of the power board.
b. Unplug J27, J28, J30, and J33 from the left side of the power board.
c. Unplug J10 from the left side of the power board.
12. Remove nine or eleven M5 x 10 screws securing the power board (L) to
the DC bus.
13. Remove six M5 x 45 screws securing the current sensor bus bars (M).
Note the arrangement of the washers for reinstallation: the conical
washer goes on first, the flat washer on second.
14. Pull the bus out of the current sensors (N).
15. Remove the power board (L) and insulator (P) from the drive controller.
When removing the power board, pull it straight up taking care not to bend
the connector pins.
16. Remove four screws (M5 x 10) and lift the filter board (O) from the drive
controller.
17. Remove and discard the J31 and J33 cables.
3
ALTIVAR 58 Power Board Kits Bulletin No. 30072-450-35
VX5A58D28M2U, VX5A58D33M2U, VX5A58D46M2U, VX5A58D54N4U, VX5A58D64N4U, VX5A58D79N4U April 2001

C
A

E
L

K
F

B
H F
O

Top

I
Bottom
See Detail “R”

N Right Side
R
J40
J41
J42
J43

Figure 2: Replacing the Power Board

4 © 2001 Schneider Electric All Rights Reserved

Bulletin No. 30072-450-35 ALTIVAR 58 Power Board Kits
April 2001 VX5A58D28M2U, VX5A58D33M2U, VX5A58D46M2U, VX5A58D54N4U, VX5A58D64N4U, VX5A58D79N4U

INSTALLING THE POWER BOARD Follow the procedure below to install the power board. Refer to Figure 2 on
page 4 for lettered items.
1. The power board removal may have loosened the torque on three
Black standoffs (R). Check the torque and retighten if necessary.
Red 2. Install the new J31 and J33 cables on the power board. Note the color of
6 the IPM near the connection point. If the IPM is white, refer to Figure 3
5
for the J31 and J33 pin-outs. If the IPM is black, refer to Figure 4. See
4
White
3
J31 Figure 5 on page 6 for connection locations.
Red 2 3. Install the filter board (O) and secure it with four M5 x 10 screws. Tighten
1 the screws to 22 lb-in (2.5 N•m).
Blue
4. Position the power board insulator (P) over the DC bus.
Red
5. Set the power board (L) in place, firmly but carefully pushing down at J40,
J41, J42, J43 (T) to engage the connector pins.
7 6. Install the current sensor (M):
Red
Blue
a. Ensure that the bus bars are through the ferrite as illustrated in
J33 Figure 2 (N), then insert the bus bars into the current sensor.
Red b. Position the current sensor assembly over the holes on the DC bus
2
1 c. Secure the current sensor with six M5 x 45 screws and 12 washers.
Install the conical washer first, then the flat washer. Tighten the
Figure 3: J31 and J33 Cable Pin-Outs screws to 22 lb-in (2.5 N•m).
White IPM 7. Secure the board with nine or eleven screws. Tighten the screws to
22 lb-in (2.5 N•m).
8. Replace nine cables on the power board (refer to Figure 5 for the power
Red
board connections):
Black
6 a. Plug in J10 at the left side of the power board.
5
b. Plug in J27, J28, J30, and J33 at the left side of the power board.
4
Red J31
3 NOTE: J27 is a 3-wire connector. J28 and J30 can connect in either of the
White 2 two position connectors.
1
c. Plug in J31 and J26 at the right side of the power board.
Red
d. Plug J18 and J5 into the power board.
Blue
NOTE: Connect the short end of the J5 cable (G) to the power board.
9. Replace the control board support bracket (F).
7
Red 10. Connect the fan cable (K) to J29 on the power board (L). Refer to Figure
Blue 5 on page 6 for connection locations. Route the cable around the stand
J33 off.
Red
2 11. Replace the left side grille (H) and secure it with six M4 x 10 screws at the
1 side and one M4 x 10 screw at the top of the drive controller. Tighten the
screws to 13.3 lb-in (1.5 N•m).
Figure 4: J31 and J33 Cable Pin Outs 12. Install the control board (E):
Black IPM
— Route the J18 cable through the opening in the mounting frame (F).
— Connect the long end of cable J5 (G) to the control board.
— Set the control board onto the mounting frame (F).
— Secure the control board with four M4 screws. Tighten the screws to
8.8 lb-in (1.0 N•m).
e. Connect cable J18 to the control board.
13. Replace the right side grille (I) and secure it with six M4 x 10 screws at
the side and one M4 x 10 screw at the top of the drive controller. Tighten
the screws to 13.3 lb-in (1.5 N•m).
14. Replace the metal plate (D) and secure it with four screws. Tighten the
screws to 13.3 lb-in (1.5 N•m).

© 2001 Schneider Electric All Rights Reserved 5

ALTIVAR 58 Power Board Kits Bulletin No. 30072-450-35
VX5A58D28M2U, VX5A58D33M2U, VX5A58D46M2U, VX5A58D54N4U, VX5A58D64N4U, VX5A58D79N4U April 2001

15. Replace the top panel of the drive controller (C). First engage the two
plastic tabs at the top of the panel in the receiving grooves on the drive
J29
controller, then set the bottom of the panel in place. Secure the panel with
two screws. Tighten the screws to 13.3 lb-in (1.5 N•m).
16. Replace the top cover of the drive controller (B) and secure it with one
screw. Tighten the screw to 13.3 lb-in (1.5 N•m).
J18
17. Replace and close the drive controller door (A) and secure with two
J19 screws.

J10 J31

J26

J33

J40 J41 J42 J43

J27
J5
J28

J30

Figure 5: Power Board Connections

6 © 2001 Schneider Electric All Rights Reserved

Bulletin No. 30072-450-35 ALTIVAR 58 Power Board Kits
April 2001 VX5A58D28M2U, VX5A58D33M2U, VX5A58D46M2U, VX5A58D54N4U, VX5A58D64N4U, VX5A58D79N4U

© 2001 Schneider Electric All Rights Reserved 7

ALTIVAR 58 Bulletin No. 30072-450-35
VX5A58D28M2U, VX5A58D33M2U, VX5A58D46M2U, VX5A58D54N4U, VX5A58D64N4U, VX5A58D79N4U April 2001

Square D Company
8001 Hwy 64 East
Knightdale, NC 27545 Electrical equipment should be serviced only by qualified personnel. No responsibility is assumed
1-888-SquareD (1-888-778-2733) by Schneider Electric for any consequences arising out of the use of this material. This document
www.SquareD.com is not intended as an instruction manual for untrained persons.

8 © 2001 Schneider Electric All Rights Reserved