Instruction Manual

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Publication 20P-IN061A-EN-P

PowerFlex® DC Drive

Frame D Bimetal Thermostat

Installation Instructions

What This Kit Includes

• Bimetal thermostat and cable with connector

• Thermal grease

Tools That You Need

• Flathead screwdriver

• Hexalobular screwdriver

• Torque wrench

What You Need to Do

The bimetal thermostat is located on the heatsink of the U phase SCR leg

assembly in the drive. To install the bimetal thermostat:

❐ Step 1: Remove power from the drive

❐ Step 2: Remove the protective cover and open the control panel

❐ Step 3: Remove the existing bimetal thermostat

❐ Step 4: Install the new bimetal thermostat

❐ Step 5: Install the protective cover, close the control panel 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.

Summary of content (10 pages)

PAGE 1
PowerFlex® DC Drive Frame D Bimetal Thermostat Installation Instructions 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
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. An electrical arc can cause personal injury or property damage by: • sending an erroneous signal to your system’s field devices, causing unintended machine motion • causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector.
PAGE 3
Step 2: Remove the Protective Cover and Open the Control Panel 1. Loosen, but do not remove, the six hexalobular screws that secure the bottom protective cover to the drive, then slide the cover down and off the drive chassis. Tightening torque for reassembly is noted in the illustration below. = T15 Tightening torque: 1.5 N•m (13 lb•in) Bottom protective cover 2. Disconnect the DPI cable from the HIM (if necessary). 3.
PAGE 4
Note: Regenerative drives have two sets of terminals (front and back) on each Step 3: Remove the Existing Bimetal Thermostat SCR module for each input phase (U, V, and W). Non-Regenerative drives only have one terminal for each input phase. 1. Disconnect the gate lead wires from the connector at the top the U phase (left) SCR leg assembly (for regenerative drives, there are two sets of gate leads and connectors). 2.
PAGE 5
Important: Note the terminal number on the fuse switch to which the signal wires are connected for proper re-installation. 4. Remove the signal wires from the fuse switch connectors and secure the wires in a position above the input terminals. 5. Loosen the lower bolt and washer that secures the bottom of the leg fuse to the Phase U SCR module leg input terminal. 6.
PAGE 6
7. Remove the bolts and washers that secure the bottom SCR assembly terminal to the output terminal at the bottom of the drive (regenerative drives contain two SCR assembly terminals and therefore, eight bolts and washers).
PAGE 7
Important: Prior to removing the SCR assembly, ensure that the area around the drive is clear of equipment. Only lift the assembly using the handles provided. 8. Loosen the six hexalobular screws that secure the phase U SCR module leg assembly to the back wall of the drive chassis. 9. Using the two handles, lift the SCR assembly up and off the mounting screws and lift the assembly up and forward so that the output terminals clear the holes in the bottom of the drive frame.
PAGE 8
10. Place the SCR leg assembly right side down on a work surface and disconnect the wires from the connector mounted on the middle, left-side of the assembly. 11. Remove the two hexalobular screws that secure the thermostat to the heat sink and remove the thermostat. Disconnect wires from connector Step 4: Install the New Bimetal Thermostat Remove screws Install the new bimetal thermostat in the reverse order of removal as detailed in Step 3: Remove the Existing Bimetal Thermostat on page 4.
PAGE 9
Step 5: Close the Control Panel, Install the Protective Cover and Document the Change Related Documentation 1. Close the control panel and install the protective cover in the reverse order as detailed in Step 2: Remove the Protective Cover and Open the Control Panel on page 3. 2. 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). Allen-Bradley publications are available on the internet at www.
PAGE 10
1S7A65 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.