installation instructions, powerflex dc drive frame b bimetal ......powerflex® dc drive - frame b...

Installation Instructions

PowerFlex® DC Drive - Frame B Bimetal Thermostat

What This Kit Includes • Bimetal thermostat• Wire leads with connector• Thermal grease• Static strap

Tools That You Need • Phillips® screwdriver• Flathead screwdriver• Nut driver or wrench• Torque wrench

Phillips® is a registered trademark of Phillips Screw Company.

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.

2 PowerFlex® DC Drive - Frame B Bimetal Thermostat

What You Need to Do The Bimetal Thermostat is located on the drive heatsink. To install the Bimetal Thermostat:

❐ Step 1: Remove power from the drive

❐ Step 2: Remove the protective covers and power wiring

❐ Step 3: Remove the Pulse Transformer and Switching Power Supply boards

❐ Step 4: Remove the existing Bimetal Thermostat

❐ Step 5: Install the new Bimetal Thermostat

❐ Step 6: Install the Pulse Transformer board and Switching Power Supply board

❐ Step 7: Replace the protective covers and document the change

Step 1: Remove Power from the Drive

1. Remove and lock-out all incoming power to 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. Worn contacts may create electrical resistance.

L1 L2 L3

O

I

PowerFlex® DC Drive - Frame B Bimetal Thermostat 3

Step 2: Remove the Protective Covers and Power Wiring

1. Remove the screws and washers that secure the plastic shields to the bottom of the drive and remove the shields.

2. Remove the bolts, washers and wiring from the U phase AC input and D power terminals.

3. Disconnect the DPI cable from the HIM assembly (if present).

4. Loosen, but do not remove, the screws that secure the bottom cover to the drive, then slide the cover down and off the drive chassis.

Remove screws and shield Remove screws and shield

U Phase D Terminal

Remove bolts and wiring

Bottom View

=

Disconnect DPI cable

Tightening torque: 1.5 N•m (13.3 lb•in)


5. Loosen, but do not remove, the screws that secure the top cover to the drive, then slide the cover up and off the drive chassis.

Important: The HIM assembly is connected via a cable to the Control board and therefore will not pull free from the drive until disconnected. See step 4 below for instructions.

6. Disconnect the HIM Communication cable from the connector on the upper right corner of the Control board and set the cover aside.

U VC D W

Tightening torque: 1.5 N•m (13.3 lb•in)

Pull tabs out to disconnect cable.


Step 3: Remove the Pulse Transformer and Switching Power Supply Boards

Note: The Switching Power Supply circuit board is located on the back of the Pulse Transformer circuit board. You do not need to remove the Switching Power Supply board from the back of the Pulse Transformer board.

1. Remove the plug-in terminal from the field input block at the top of the drive.

2. Remove the four screws that secure the slotted air flow plate to the top of the drive chassis.

Important: The air flow plate is also secured to the Pulse Transformer circuit board and therefore cannot yet be removed. Instructions for doing so are included later in this procedure.

3. Remove the cable from connector XTA on the Pulse Transformer board.

4. Remove the plug-in terminals from the Control power block on the Pulse Transformer board.

Air flow plate

Remove screws

Remove plug-in terminal

Front of Drive

Remove cable Remove plug-in terminals


5. For Pulse Transformer boards with an armature voltage feedback terminal block, FIR2-XX, rev. “N” and higher, remove the connector from XCD_IO on the lower left corner of the board.

6. Carefully disconnect the cables from connectors XA, XR and XFCD at the top of the Control board.

XCD_IO

C

XTA XM

D

78 79 35 36 75 76 U2 V2

S3 S4

1

Remove connector from XCD_IO

Disconnect cables


7. Loosen the two captive screws at the top of the Control EMI shield and lower the shield.

Important: If the drive is not in a vertical position, the Control EMI shield will not remain open without a means of restraint.

8. Remove the two screws that secure the air flow plate to the top of the Pulse Transformer board and lift the plate off the drive chassis. The air flow plate cannot be completely removed due to the fuse connections at FU1 and FV1.

Loosen screws

Remove screws

Fuse connections


9. Remove the cables from connectors X3, X4 and XP on the Pulse Transformer board.

10. Remove the ground connection at the left side of the Pulse Transformer board.

Remove cableRemove cable Remove cable

Remove ground connection


11. Remove the appropriate gate leads:

– 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.

– For regenerative drive, 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.

Important: Remove the gate leads by grasping the connector and pulling up. DO NOT pull the gate leads off by pulling on the wires.

For non-regenerative drives, remove six gate leads and route through openings in board

For regenerative drives, remove 12 gate leads and route through openings in board


12. Remove the seven screws that secure the board to the stand-offs on the drive chassis and remove the boards from the drive.

Step 4: Remove the Existing Bimetal Thermostat

1. Remove the appropriate bus bars in order to access the Bimetal Thermostat.

– If removing the bus bars from a Regenerative drive, refer to Remove the Bus Bars from a Regenerative Drive on page 11.

– If removing the bus bars from a Non-Regenerative drive, refer to Remove the Bus Bars from a Non-Regenerative Drive on page 13.

Remove screws

Note: Regenerative Drive Shown


Remove the Bus Bars from a Regenerative Drive

2. Remove the bolts and washers that secure the connecting bus bar to the U phase SCR modules and remove the bus bars.

3. Remove the bolt and washer that secures the U phase terminal bus bar to the terminal isolation bar.

=

3. Remove bolt and washer from isolation bar

2. Remove bolts and washers

2. Remove bus bars


4. Remove the screw and washer that secures the wire to the bus bar and the bolt and washer that secures the U phase bus bar to the SCR module and remove the bus bar.

5. Remove the bolt and washers that secure the D terminal bus bar to the terminal isolation bar.

Continue with Remove the Bimetal Thermostat on page 14.

5. Remove bolt and washer from isolation bar

4. Remove bolt, screw and washers

4. Remove bus bar


Remove the Bus Bars from a Non-Regenerative Drive

2. Remove the three bolts and washers that secure the U Phase and D power terminals to the isolation bar.

3. Remove the bolts and washers that secure the wires and bus bars to the U phase SCR Module and D power terminal and remove the bus bars.

Continue with Remove the Bimetal Thermostat on page 14.

=

Remove bolts, washers and wires

Non-Regenerative Drive U Phase Terminal D Terminal

Non-Regenerative Drive

Remove bolts, washers and wires


Remove the Bimetal Thermostat

1. Remove the solder from the connections on the two leads of the bimetal thermostat.

2. Unscrew the base and remove the bimetal thermostat from the heatsink.

Step 5: Install the New Bimetal Thermostat

Install the new Bimetal Thermostat in reverse order of removal as detailed in Step 4: Remove the Existing Bimetal Thermostat on page 10.

Important: Thermal grease must be applied to the bottom of the Bimetal Thermostat before securing it to the heatsink.

• Use the following table to determine the proper tightening torque for the bolts that secure the bus bars to the SCR Modules:

Remove solder and bimetal thermostat

Regenerative Drive Shown

230V AC InputDrive Current Rating Code DC Amps AC Line Amps HP Final Torque146 146 119 40

4.5…5.5 N•m (40…48.7 lb•in)180 180 147 50218 218 178 60265 265 217 75

11…13 N•m (97.4…115 lb•in)360 360 294 100434 434 355 125

460V AC InputDrive Current Rating Code DC Amps AC Line Amps HP Final Torque167 167 136.4 100

4.5…5.5 N•m (40…48.7 lb•in)207 207 169.1 125250 250 204.3 150

11…13 N•m (97.4…115 lb•in)330 330 269.6 200412 412 336.6 250


Step 6: Install the Pulse Transformer Board and Switching Power Supply Board

1. Install the Pulse Transformer board and Switching Power Supply board in reverse order of removal as detailed in Step 3: Remove the Pulse Transformer and Switching Power Supply Boards on page 5.

2. Verify that the four plastic board stabilizers mounted on the top air flow plate are placed one on either side of each of the Pulse Transformer and Switching Power Supply boards.

ATTENTION: Each gate lead cable must be connected to the exact connector from which it was removed on the Pulse Transformer circuit board or damage to the drive may occur.

One plastic stabilizer should be on either side of each boardAir flow plate

Plastic stabilizers

Top view of Pulse Transformer boardSide cut-away view

Pulse Transformer board

Switching Power Supply board

Step 7: Replace the Protective Covers and Documenting the Change

1. Replace the protective covers in the reverse order of removal as described in Step 2: Remove the Protective Covers and Power Wiring on page 3.

2. Install 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).

Related Documentation Allen-Bradley publications are available on the internet at www.rockwellautomation.com/literature.

For . . . Read this documentPublication Number

In depth information regarding the operation of PowerFlex Digital DC drives

User Manual - PowerFlex Digital DC Drives 20P-UM001…

Publication 20P-IN033B-EN-P - December 2009Supersedes 20P-IN033A-EN-P - March 2009 Copyright © 2009 Rockwell Automation. All rights reserved. Printed in USA.

www.rockwellautomation.com

Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444Europe/Middle East/Africa: Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846

Power, Control and Information Solutions

1S7A22

Front CoverWhat This Kit IncludesTools That You NeedWhat You Need to DoStep 1: Remove Power from the DriveStep 2: Remove the Protective Covers and Power WiringStep 3: Remove the Pulse Transformer and Switching Power Supply BoardsStep 4: Remove the Existing Bimetal ThermostatStep 5: Install the New Bimetal ThermostatStep 6: Install the Pulse Transformer Board and Switching Power Supply BoardStep 7: Replace the Protective Covers and Documenting the ChangeRelated DocumentationPublication 20P-IN033B-EN-P - December 2009

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Introduction_Catagory Types

This tab summarizes Rockwell Automation Global Sales and Marketing preferred printing standards. It also provides guidance on whether a publication should be released as JIT (print on demand) or if it requires an RFQ for offset printing.Find your publication type in the first section below. Use the assigned Printing Category information to determine the standard print specifications for that document type. The Printing Categories are defined below the Publication Type section. Note there may be slightly different print specifications for the categories, depending on the region (EMEA or Americas).For more information on Global Sales and Marketing Printing Standards, see publication RA-CO004 in DocMan.

Publication Type and Print Category

Publication TypeOff Set Print Category Spec. (See table below)JIT Spec. (See table below)DescriptionOrder Min **Order Max **Life Cycle Usage / Release Option

ADNA - PuttmanNAAdvertisement Reprint ColourNANAPresale / Internal

APA3D2Application Solution or Customer Success Story5100Presale / External

ARNANAArticle/Editorial/BylineNANAPresale / Internal

(press releases should not be checked into DocMan or printed)

ATB3, B4D5Application techniques5100Presale / External

BRA2 Primary, A1NABrochures5100Presale / External

CAC2 Primary, C1NACatalogue150Presale / External

CGNANACatalogue Guide150Presale / External

CLNANACollection550Presale / External

COA5, A6, A9D5Company Confidential InformationNANANA / Confidential

CPE-onlyE-only, D5Competitive Information550NA / Confidential

DCE-onlyE-onlyDiscount SchedulesNANAPresale / Internal

DIA1, A3NADirect Mail5100Presale / Internal

DMNANAProduct Demo550Presale / Internal

DSB3D5Dimensions Sheet15Post / External

DUB3D5Document Update15Post / External

GRB2D6Getting Results15Post / External

INB3 Primary, B2D5, D6Installation instructions15Post / External

LMNANALaunch Materials550Presale / Internal

PCB3D5Packaging Contents

PLE-only primary, B3E-onlyPrice List550Presale / Internal

PMB2D6Programming Manual15Post / External

PPA3D1Profile (Single Product or Service). NOTE: Application Solutions are to be assigned the AP pub type.5100Presale / External

QRB2 primary, B3, B5D5, D6Quick Reference15Post / External

QSB2 primary, B3, B5D5, D6Quick Start15Post / External

RMB2D5, D6Reference Manual15Post / External

RNB3D5Release Notes15Post / External

SGB1 Primary, B4D5, D6Selection Guide Colour550Presale / External

SGB2D5, D6Selection Guide B/W550Presale / External

SPA1, A2, A3, A4NASales Promotion NOTE: Service profiles are to be assigned the PP pub type.5100Presale / Internal

SRB2, B3D5, D6Specification Rating Sheet5100Presale / External

TDB2 Primary B3, B4, B5D5, D6Technical Data550Presale / External

TGB2, B3D6Troubleshooting Guide15Post / External

UMB2 Primary, B4D6User Manual B/W15Post / External

WDB3D5Wiring Diagrams / Dwgs15Post / Internal

WPB3 Primary, B5D5White Paper550Presale / External

** Minimum order quantities on all JIT items are based on the publication length. **

Publication lengthMinimum Order Quantity

77 or more pages1 (no shrink wrap required)

33 to 76 pages25

3 to 32 pages50

1 or 2 pages100

Pre-sale / MarketingAll paper in this category is White Brightness, 90% or better. Opacity 90% or better

CategoryColor OptionsAP, EMEA Paper RequirementsCanada, LA, US Paper Requirements

A14 color170 gsm 2pp100# gloss cover, 100# gloss text

A24 color170 gsm , folded, 4pp100# gloss cover, 80# gloss text

A34 colorCover 170 gsm with Body 120 gsm, > 4pp80# gloss cover, 80# gloss text

A42 color170gsm Silk – 120gsm Silk80# gloss cover, 80# gloss text

A52 color170gsm Silk – 120gsm Silk80# gloss cover, 80# matt sheet text

A61 color170gsm Silk – 120gsm Silk80# gloss cover, 80# matt sheet text

A74 color cover2 color textSelection GuideCategory being deleted10 Point Cover C2S50# matte sheet text

A84 color coverCategory being deleted50# matte sheet text, self cover

2 color text

Selection Guide

A92 color100gsm bond50# matte sheet text, self cover

Selection Guide

Gray shading indicates Obsolete Print Catagories

Post Sale / Technical Communication


B14 color cover270gsm Gloss 100gsm bond10 Point Cover C2S

2 color text50# matte sheet text

B21 color160gsm Colortech & 100gsm Bond90# Cover50# matte sheet text

B31 color100gsm bond50# matte sheet text, self cover

B42 color160gsm Colortech & 100gsm Bond90# Cover50# matte sheet text

B52 color100gsm bond50# matte sheet text, self cover

Catalogs


C14 color cover270gsm Gloss 90gsm silk10 Point Cover C2S

4 color text45# Coated Sheet

C24 color cover270gsm Gloss 80gsm silk10 Point Cover C2S

2 color text32#-33# Coated Sheet

JIT / PODAll paper in this category is White Brightness, 82% or better. Opacity 88% or better


D14 color170gsm white silk80# gloss cover, coated 2 sides

D24 color120gsm white silk80# gloss text, coated 2 sides, self cover

D34 colorCover 170gsm with Body 120gsm80# gloss cover, 80# gloss text coated 2 sides

D41 color160gsm tab90# index

D51 color80gsm bond20# bond, self cover

D61 colorCover 160gsm tab with Body 80gsm bond90# index, 20# bond

D72 color160gsm tab90# index

D82 color80gsm bond20# bond, self cover

D92 colorCover 160gsm tab with Body 80gsm bond90# index, 20# bond

D10Combination: 4 color cover, with 2 color bodyCover 160gsm with Body 80gsm90# index, 20# bond

Gray shading indicates Obsolete Print Catagories

Print Spec Sheet

JIT Printing SpecificationsRA-QR005F-EN-P - 8/07/2009

Printing SpecificationYOUR DATA HEREInstructionsNO

(required) Category:D5Select Print Category A,B,C or D from category list, on "Introduction_Catagory Types" tab11” x 17”LOOSE -Loose LeafYESPre-sale / MarketingTOP

(required) Finished Trim Size Width:8.5” x 11”8.5” x 11”PERFECT - Perfect BoundA1LEFT

(required) Publication Number :20P-IN036B-EN-PSample: 2030-SP001B-EN-P3” x 5”SADDLE - Saddle StitchA2RIGHTCORNER

Use Legacy NumberNOYES or NO18” x 24” PosterPLASTCOIL - Plastic Coil (Coil Bound)A4BOTTOMSIDE

Legacy Number if applicable:Sample Legacy Number: 0160-5.3324” x 36” PosterSTAPLED1 -1 positionA3

Publication Title:PowerFlexDC Frame B Switching Power Supply Circuit Board Fuse ReplacementSample: ElectroGuard Selling Brief36” x 24” PosterSTAPLED1B - bottom 1 positionA5

(required) Business Group:Marketing CommercialAs entered in DocMan4” x 6”STAPLED2 - 2 positionsA6

(required) Cost Center:19010As entered in DocMan - enter number only, no description. Example - 19021CMKMKE CM Integrated Arch - 19021CMKMKE Market Access Program - 191054.75” x 7” (slightly smaller half-size)THERMAL - Thermal bound (Tape bound)A7

Binding/Stitching:LOOSE -Loose LeafReview key on right...Saddle-Stitch Items All page quantities must be divisible by 4.80 pgs max. on 20# (text and cover)76 pgs max. on 20# (text) and 24# (cover)72 pgs max. on 24# (text and cover)

Perfect Bound Items940 pgs max. w/cover (90# index unless indicated otherwise)

Coil Bound Items580 pgs max. of 20# (if adding cover deduct equivalent number of pages to equal cover thickness) (90# index unless indicated otherwise)

Tape Bound Items250 pgs max. on 20# no cover240 pgs max. w/cover (90# index unless indicated otherwise)

Double Wire Bound Items80 pgs max. on 20# (if adding cover deduct equivalent number of pages to equal cover thickness) (90# index unless indicated otherwise)4.75” x 7.75”THERMALO - Thermal Bound (Tape bound - offline)A8

(required) Page Count of Publication:2Total page count including cover5.5” x 8.5” (half-size)Wire O - Double Wire Bound (offline)A9

Paper Stock Color:White is assumed. For color options contact your vendor.6” x 4”Post Sale / Technical Communication

Number of Tabs Needed:5 tab in stock at RR Donnelley7.385” x 9” (RSI Std)B1

Stitching Location:Blank, Corner or Side8.25” x 10.875”B2

Drill Hole YES/NONOAll drilled publications use the 5-hole standard, 5/16 inch-size hole and a minimum of ¼ inch from the inner page border.8.25” x 11” (RA product profile std)B3None

Glue Location on Pad:Glue location on pads8.375” x 10.875B4Half

Number of Pages per Pad:Average sheets of paper.. 25, 50 75,100 Max9” x 12” (Folder)B5C

Ink ColorOne color assumes BLACK / 4 color assume CMYK / Indicate PMS number here…A4 (8 ¼” x 11 ¾”) (210 x 297 mm)CatalogsDbleParll

Used in Manufacturing:NOA5 (5.83” x 8.26”) (148 x 210 mm)C1Offset Z

Fold:NoneSample

Comments:C2Short

Part Number:JIT / PODV

D1Z

D2Microfold

D3

D4

D5

D6

D7

D8

D9

installation instructions, powerflex dc drive frame b bimetal ......powerflex® dc drive - frame b...

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