Rockwell Automation Allen-Bradley PowerFlex 4M Bedienungsanleitung

Installation Instructions

PowerFlex®DC Drive - Frame C 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.

What You Need to Do The Bimetal Thermostats are located on the drive heatsink. To install the

Bimetal Thermostats:

❐ Step 1: Remove power from the drive

❐ Step 2: Remove the protective covers

❐ Step 3: Remove the existing Bimetal Thermostat

❐ Step 4: Install the new Bimetal Thermostat

❐ Step 5: 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.

2PowerFlex® DC Drive - Frame C Bimetal Thermostat

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

PowerFlex® DC Drive - Frame C Bimetal Thermostat 3

Step 2: Remove the

Protective Covers

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

2. 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.

3. 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.

STS

PORT

MOD

NET A

NET B

Disconnect

DPI cable

Tightening torque:

1.5 N-m (13.3 lb.-in.)

STS

PORT

MOD

NET A

NET B

FU1 FV1

Tightening torque:

1.5 N-m (13.3 lb.-in.)

4PowerFlex® DC Drive - Frame C Bimetal Thermostat

Important:Mark all connections and wires before removal to avoid

incorrect wiring during reassembly.

4. Disconnect the HIM Communication cable from the connector on the

upper right corner of the Control board and set the cover aside.

Step 3: Remove the

Existing Bimetal Thermostat

You must move the Control EMI shield that holds the Control board in order

to access the Bimetal Thermostats.

1. Carefully disconnect the cables from connectors XFCD and XR on the

Control board.

Pull tabs out

to disconnect

cable.

Disconnect

cables

PowerFlex® DC Drive - Frame C Bimetal Thermostat 5

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

partially lower the shield. The shield will not open to its full extent due

to a cable connection between the Switching Power Supply board and

the Pulse Transformer board.

3. Disconnect the cable from connector XSW on the Switching Power

Supply board and lower the Control EMI shield until it rests on the

drive chassis.

Important: If the drive is not in a vertical position, the Control EMI

shield will not stay open without a means of restraint.

Loosen screws

Remove cable

6PowerFlex® DC Drive - Frame C Bimetal Thermostat

4. If present, remove the isolation sheet that is secured to the bus bars.

Important: You must remove the bus bars and SCR modules in order

to easily access and remove the Bimetal Thermostats.

5. Remove the appropriate bus bars in order to access the Bimetal

Thermostats in the drive:

–If removing the SCR modules from a Regenerative drive, refer to

Remove the Bus Bars from a Regenerative Drive on page 7.

–If removing the SCR modules from a Non-Regenerative drive, refer to

Remove the Bus Bars from a Non-Regenerative Drive on page 10.

Remove isolation sheet.

PowerFlex® DC Drive - Frame C Bimetal Thermostat 7

Remove the Bus Bars from a Regenerative Drive

6. Remove the six bolts and corresponding washers that secure the

intermediate bus bars to the U and W phase AC input and DC output

(terminals C and D) bus bars. Note the size and location of the bolts and

the order in which the washers are placed on the bolts.

Remove bolts

and washers

Remove bolts

and washers

Nut

Lock washer

Flat washer

Bolt (30mm long)

Flat washer

Lock washer

Nut

Left to right, two (2) bolts

(40mm long) and flat washers

Left to right, two

(2) nuts, lock

washers and flat

washers

Left to right, two (2)

flat washers, lock

washers and nuts

Bolt Size and Washer Order

Left to right, two (2)

flat washers and

bolts (40mm long)

8PowerFlex® DC Drive - Frame C Bimetal Thermostat

7. Remove the bolt (24 mm long) and washers that secure the L-shaped

bus bars to the top of each of the six internal Armature Circuit fuses.

Note the order of the washers on the bolt.

8. Remove the bolts (24mm long) and washers that secure the L-shaped

bus bars to each of the SCR modules and remove the bus bars. Note:

You do not need to remove the wires connected to the metal plate

secured with the L-shaped bus bar.

Remove bolt (24 mm long),

lock washer and flat washer

Bolt (24 mm long)

Lock washer

Flat washer

Fuse

Remove

24mm long

bolts and

washers

Leave wires

in place

PowerFlex® DC Drive - Frame C Bimetal Thermostat 9

9. Remove the four bolts and washers that secure the horizontal bus bars to

the SCR modules and remove the bus bars. Note the order of the

washers on the bolts and the position of the bus bars.

Continue with Remove the SCR Modules and Bimetal Thermostat on

page 12.

Remove bolts Remove bolts

10 PowerFlex® DC Drive - Frame C Bimetal Thermostat

Remove the Bus Bars from a Non-Regenerative Drive

6. Remove the nuts and washers that secure the wires (red and blue) from

the AC Line Snubber board to the bus bars and remove the wires.

7. Remove the bolts and washers that secure the L-shaped bus bars to the

top of each of the three internal Armature Circuit Fuses. Note the order

of the washers on the bolt.

8. Remove the bolts and washers that secure the metal plate and L-shaped

bus bars to each of the SCR modules and remove the bus bars. Note:

You do not need to remove the wires connected to the metal plate

secured with the L-shaped bus bar.

Remove nuts, washers and wires

Bolt

Lock washer

Flat washer

Fuse

9. Remove bolt, lock washer

and flat washer

8. Remove bolt, lock washer,

flat washer, metal plate and

L-shaped bus bar

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