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Installation Instructions

PowerFlex

DC Drive - Frame A Bimetal

Thermostat

What This Kit Includes

• Bimetal Thermostat

• Two screws

• Wire leads with connector

• Thermal grease

• Static strap

Tools That You Need

• Phillips

screwdriver

• Flathead screwdriver

Phillips

is a registered trademark of Phillips Screw Company.

What You Need to Do

To install the Bimetal Thermostat:

❐ Step 1: Remove power from the drive

❐ Step 2: Remove the protective covers

❐ Step 3: Remove the Control EMI shield and Control board

❐ Step 4: Remove the Pulse Transformer and Switching Power Supply

boards

❐ Step 5: Remove the existing Bimetal Thermostat

❐ Step 6: Install the new Bimetal Thermostat

❐ Step 7; Install the Pulse Transformer board and Switching Power

Supply board

❐ Step 8: Install the Control EMI Shield and Control board

❐ Step 9: Replace the protective covers and document the change

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 drive has been removed before performing the

following.

ATTENTION: This drive 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.

Summary of content (12 pages)

PAGE 1
Installation Instructions PowerFlex® DC Drive - Frame A Bimetal Thermostat 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 drive has been removed before performing the following.
PAGE 2
PowerFlex® DC Drive - Frame A Bimetal Thermostat Step 1: Remove Power from the Drive 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.
PAGE 3
PowerFlex® DC Drive - Frame A Bimetal Thermostat 3 3. Press in on the sides at the bottom edge of the top cover and at the same time pull the cover toward you to pull it partially off the drive chassis. 4. At the top of the drive, pull the cover forward, away from the drive, until the pins fit in the keyhole in the top of the cover, then carefully lift the cover off of the drive chassis.
PAGE 4
PowerFlex® DC Drive - Frame A Bimetal Thermostat Step 3: Remove the Control EMI Shield and Control Board 1. Carefully disconnect the cables from connectors XFCD, XA and XR on the Control board. 2.
PAGE 5
PowerFlex® DC Drive - Frame A Bimetal Thermostat 5 3. Remove the five screws that secure the ground wire (in the lower left corner) and Control EMI shield to the chassis and slide the Control EMI shield and Control board up and out of the drive. Important: Be careful when removing the EMI shield not to pull free any of the gate leads or other cables on the Pulse Transformer circuit board below the EMI shield.
PAGE 6
PowerFlex® DC Drive - Frame A Bimetal Thermostat 1. Remove the slotted air flow plate from the top of the drive: – For 38A and 55A drives @ 230V AC input and 35A, 45A, and 52A drives @ 460V AC input, remove the four screws that secure the slotted air flow plate to the top of the drive, remove the fan cable from connector XV on the Switching Power Supply board and remove the plate.
PAGE 7
PowerFlex® DC Drive - Frame A Bimetal Thermostat 7 2. Remove the plug-in control power terminal block from the Pulse Transformer circuit board. Remove plug-in terminal block 3. Remove the cables from connectors X3 and XP on the Pulse Transformer board. 4. For drives with a fan, remove the cable from connector X4 on the Pulse Transformer board. Remove cables from X3 and XP Remove cable from X4 for drives with a fan 5.
PAGE 8
PowerFlex® DC Drive - Frame A Bimetal Thermostat 6. Remove the appropriate gate leads: – For regenerative drives, remove each pair of (orange and yellow) gate lead cables from connectors KG01…KG06 and KG1…KG6 and push each lead through the appropriate opening in the board. – For non-regenerative drives, remove each pair of (orange and yellow) gate lead cables from connectors KG01…KG06 and push each lead through the appropriate opening in the board.
PAGE 9
PowerFlex® DC Drive - Frame A Bimetal Thermostat 9 8. Remove the six screws that secure the bottom of the Pulse Transformer board to the drive and, while lifting up slightly on the board, slide it toward the top of the drive and out of the chassis. Important: The cables from connectors X4 and XTA must slide through the openings in the board as it is lifted out of the drive chassis. Take care not to damage these cables and connectors.
PAGE 10
PowerFlex® DC Drive - Frame A Bimetal Thermostat Remove the two screws that secure the thermostat to the drive heat sink and Step 5: Remove the Existing Bimetal Thermostat remove the thermostat and connected wires from the drive. Remove screws Step 6: Install the New Bimetal Thermostat • Install the Bimetal Thermostat in reverse order of removal as detailed in Step 5: Remove the Existing Bimetal Thermostat above.
PAGE 11
PowerFlex® DC Drive - Frame A Bimetal Thermostat Step 9: Replace the Protective Covers and Documenting the Change 11 1. Replace the protective covers in the reverse order of removal as described in Step 2: Remove the Protective Covers on page 2. 2. Install the DPI cable (if present). 3. Record the installation of the new Bimetal Thermostat and date of installation on the Field Installed Option label on the side of the drive (as shown below).
PAGE 12
1S7A21 www.rockwellautomation.com Power, Control and Information Solutions Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.