PowerFlex DC Drive – Frame D, Series A to Series C Fan … · 2016. 6. 3. · 1. Place the new terminal identification label where the old terminal identification label was located

Installation Instructions

Original Instructions

PowerFlex DC Drive – Frame D, Series A to Series C Fan ReplacementCatalog Number SK-20P-S725806

Identify Frame D, Series A Drive

Verify that you are working on a Frame D, series A drive by checking the data nameplate label on the lower right side of the drive. The frame size is printed just above the serial number in the lower right corner of the label. The series letter is printed on the upper right corner of the label.

ATTENTION: Only qualified personnel familiar with DC drives and associated machinery must plan or implement the installation, startup, and subsequent maintenance of the system. Failure to comply can result in personal injury and/or equipment damage.

ATTENTION: To avoid an electric shock hazard, make sure that all power to the drive is 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. If ESD control procedures are not followed, component damage can result. If you are not familiar with static control procedures, reference Allen-Bradley publication 8000-4.5.2, ‘Guarding Against Electrostatic Damage’ or any other applicable ESD protection handbook.

EXAMPLE ONLY

A0NNN

500HP

3 Phase Original Firmware V. 5.007

Serial Number: D23E0042

Series: A

Frame: D

6.28.2

I/O: 24VDC (Standard)

Ind. Cont.Listed

C R US

max. 1 Phase

Hz 1.0/0.5A 1 Phase

Eq. 31KF

N223

PowerFlex DC Drive Frame D Series A to Series C Fan Replacement

What This Kit Includes • Fan assembly (includes fan and mounting bracket)• The terminal identification label with the new three-phase fan loss

detection board terminal names• Three-phase fan loss detection board and support• Front and rear top airflow plates and a T20 hexalobular screw M4x8• Top protection cover airflow plate• Top panel with fan inlet• Top insulator bar

Tools That You Need • T20 hexalobular screwdriver• T10 hexalobular screwdriver• Phillips PH2 screwdriver• 3.5 mm x 0.8 mm screwdriver• 8 mm wrench• 13 mm socket wrench• 19 mm socket wrench• Cable ties• Wire cutter

What You Need to Do To replace the existing fan assembly:Step 1: Remove power from the drive.Step 2: Remove the protective cover and top airflow plate.Step 3: Remove the existing fan assembly.Step 4: Remove the existing fan loss detection board.Step 5: Remove the existing fan starting capacitor.Step 6: Remove the top insulator bar. Step 7: Remove the top panel with fan inlet and input bus bars.Step 8: Install the three-phase fan loss detection board.Step 9: Install the series C top panel with fan inlet and reinstall input

bus bars.Step 10: Install the series C top insulator bar. Step 11: Install the series C rear top airflow plate.Step 12: Install the series C fan assembly.Step 13: Install the series C front top airflow plate.Step 14: Install the series C top protection cover airflow plate.Step 15: Document the change.

2 Rockwell Automation Publication 20P-IN077B-EN-P - May 2016


Step 1: Remove Power from the Drive

Remove and lockout all incoming power to the drive.

IMPORTANT The Frame D, series C drive cooling fan requires three-phase (50/60 Hz), 400…460V AC input power. If sourced from the main three-phase AC input, the power supply connections must be taken from the primary side of the installed isolation transformer or line reactor (clean power).

WARNING: Remove power before making or breaking cable connections. When you remove or insert a cable connector with power applied, an electric arc can occur. An electric arc can cause personal injury or property damage by:

• Sending an erroneous signal to the field devices on your system, causing unintended machine motion

• Causing an explosion in a hazardous environmentElectric arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts can create electrical resistance.

L1 L2 L3

O

I

Rockwell Automation Publication 20P-IN077B-EN-P - May 2016 3


Step 2: Remove the Protective Cover and Top Airflow Plate

1. Loosen, but do not remove, the four hexalobular screws that secure the top protective cover to the drive, and slide the cover up and off the drive chassis.

The tightening torque is noted in the illustration for reassembly.

2. Remove the AC input wiring.

3. If installed, remove the bus bar extensions.

4. Loosen, but do not remove, the six hexalobular screws that secure the top airflow plate to the drive, and slide the plate forward to lift it off the screws.


= Top Protective Cover

Tool size: T20 1.5 N•m (13 lb•in)

Tool size: T201.5 N•m (13 lb•in)

Pull plate forward to lift off screws.

Top View of Drive

Fan Loss Detection Board

Loosen screws. Loosen screws.



Step 3: Remove the Existing Fan Assembly

1. Remove the wires that are connected to the terminal block at XF on the fan loss detection circuit board (at the top of the drive, to the left of the fan blower).

2. Cut the cable ties that secure the fan blower motor wires to the fan capacitor wires.

3. Use a 13 mm socket wrench to loosen the 4 nuts (2 on each side) that secure the fan assembly bracket to the drive frame, and lift the fan assembly bracket up to clear the fan blower inlet. Remove the bracket and fan assembly from the drive.

IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly.

ATTENTION: The edges of the blades on the fan blower can be sharp. Take precautions to help protect against personal injury when handling the fan assembly.

V2

V1

C1

PE

XF XC

XE

K1

Remove wires fromterminal block XF.



Step 4: Remove the Existing Fan Loss Detection Board

1. Remove the wires that are connected to terminal block at XE on the fan loss detection circuit board.

2. Remove the wires that are connected to the terminal block at XC from the fan loss detection board.

3. Disconnect the ground wire from connector PE.

4. Remove the four hexalobular screws that secure the fan loss detection board to the insulator and remove the board.


5. Remove the fan loss board support.

Loosen nuts - two eachside of bracket.

Lift bracket and fan andpull out of drive.

Tool size: 13 mm 18.0 N•m (159.3 lb•in)




Step 5: Remove the Existing Fan Starting Capacitor

1. Unscrew the fan capacitor from the back of the drive frame, and remove the capacitor.

V2

V1

C1

PE

XF XC

XE

K1

Tool size: T100.7 N•m(6.20 lb•in)

XF XC

Unscrew capacitor from drive motor.

Fan Loss Detection Board

=



Step 6: Remove Top Insulator Bar

1. Remove the four bolts and washers that secure the top insulator bar, over the AC input terminal bus bars, to the drive frame and remove the top insulator bar.


Step 7: Remove Top Panel with Fan Inlet and Input Bus Bar

1. Remove the 2 nuts and washers that secure the signal wires to the terminals on each of the AC current transducers and remove the wires.


2. Loosen, but do not remove, the 2 screws that secure each of the current transducers to the U- and W-phase terminal bus bar. The current transducers will be loose on the bus bars.


XF XC

Remove. Top Insulator bar





3. Remove the bolt and washer that secures each of the U-, V-, and W-phase AC input terminal bus bars to the rear insulator bar and then remove the terminal identification label.


Remove nut, washer, and signal wires.

Loosen two screws on current transducers.


P20.6 N•m (5.3 lb•in)

XF XC

Remove.Remove label.




4. Use a T20 hexalobular screwdriver to remove the 10 screws that secure the top panel to the fan inlet.


5. Remove the 4 M12 bolts and washers that secure each of the U-, V-, and W-phase AC input terminal bus bars to the fuse bus bars.


6. Remove the U-, V-, and W-phase bus bars and current transducers.

Remove.

Tool size: T20 1.5 N•m (13 lb•in)

U-phase bus bar V-phase bus bar W-phase bus bar Signal wire Remove bolts and washers from U-, V-, and W-phase bus bars.

Tool size: 19 mm 25 N•m (221 lb•in)



7. Tilt the panel and remove it by sliding the panel through the side wall channels.

Step 8: Install the New Three-Phase Fan Loss Detection Board

1. Place the new terminal identification label where the old terminal identification label was located. The new terminal identification label shows the new three-phase fan loss detection board terminal names.

2. Install the support for the three-phase fan loss detection board.

Use a T20 screwdriver to torque the screws to 1 N•m (9 lb•in).

3. Install the three-phase fan loss detection board.

Use a T10 screwdriver to torque the screws to 0.7 N•m (6.2 lb•in).

4. Remove the TB1 (XF2) and TB2 (XF) connectors from the fan loss detection board.

5. Connect the fan wires to terminal blocks TB1 (XF2) and TB2 (XF) using the following diagram.

6. Connect three-phase (50/60 Hz), 400…460V AC input power to terminal block TB3 (XE) on the fan loss detection board.

Slide panel through the side wall channels.

IMPORTANT When wiring the external power connection of the three-phase fan loss detection board, pay attention to the proper phase sequence to obtain the proper fan direction. See the label on the fan.



Step 9: Install the Series C Top Panel with Fan Inlet and Reinstall Input Bus Bars

Install the series C top panel with fan inlet and reinstall input bus bars in the reverse order of removal as detailed in step 7, Remove Top Panel with Fan Inlet and Input Bus Bar on page 8.

• During Step 7.6, reconnect signal wires.• During Step 7.2, secure the AC current transducer cables to the panel

using cable ties.

Step 10: Install the Series C Top Insulator Bar

Install the series C top insulator bar in reverse order of removal as detailed in step 6, Remove Top Insulator Bar on page 8.

32 31 PE W3 V3 U3TB3

TB1TB2

PE

TB TB PE W3F V3F U3F Z3F Y3F X3FXF XF2

XE

FNLS3

31 32 PE W3

V3 U3

TB TB PE W3F

V3F

U3F

Z3F

Y3F

X3F

Fan

Faul

t

Fan

Supp

ly 3

Pha

se

400V

AC,

50

Hz

400.

..460

V AC

, 60

Hz

To Fan Motor

Whi

te

Whi

te

Yello

w/G

reen

Blac

k

Gray

Red

Ora

nge

Blue

Brow

n

Tool size: T100.7 N•m (6.2 lb•in)

IMPORTANT Do not fully tighten screws until all screws have been initially tightened to 1/3 (33%) of the final torque value to avoid mechanical tension on the bus bars.



Step 11: Install the Series C Rear Top Airflow Plate

Install the series C rear top airflow plate by tightening only the two rear screws. Do not tighten the other two screws.

Step 12: Install the Series C Fan Assembly

Install the series C fan assembly in the reverse order of removal as detailed in step 3, Remove the Existing Fan Assembly on page 5.

Step 13: Install the Series C Front Top Airflow Plate

Install the series C front airflow plate by tightening the four screws that were loosened in Step 2.4 and adding a new hexalobular screw in the center.

Tighten.

Do not tighten.


IMPORTANT In step 3.1, reconnect both XF and XF2 connectors to the three-phase fan loss detection board.


Tighten.



Step 14: Install the Series C Top Protective Cover

Install the series C top protective cover by tightening the four screws loosened in Step 2.1.

IMPORTANT The front top airflow plate has to be placed over the rear top airflow plate.

Front Top Airflow Plate

Rear Top Airflow Plate

Tool size: T201.5 N•m (13.2 lb•in)Tighten.



Step 15: Document the Change

Record the installation of the new fan assembly and date of installation on the Field Installed Option label on the side of the drive.

Additional Resources These documents contain additional information concerning related products from Rockwell Automation.

You can view or download publications at http://www.rockwellautomation.com/literature/. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.

Resource Description

PowerFlex® Digital DC Drive User Manual, publication 20P-UM001

Provides the basic information to install, start up, and troubleshoot PowerFlex DC drives.

PowerFlex Digital DC Drive Frame D Hardware Service Manual, publication 20P-TG004

Provides hardware service information for frame D PowerFlex DC drives.

Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and other certification details.


http://literature.rockwellautomation.com/idc/groups/literature/documents/um/20p-um001_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/tg/20p-tg004_-en-p.pdf

http://www.ab.com

http://www.rockwellautomation.com/literature/

Rockwell Automation SupportRockwell Automation provides technical information on the Web to assist you in using its products.At http://www.rockwellautomation.com/support you can find technical and application notes, sample code, and links to software service packs. You can also visit our Support Center at https://rockwellautomation.custhelp.com/ for software updates, support chats and forums, technical information, FAQs, and to sign up for product notification updates.

In addition, we offer multiple support programs for installation, configuration, and troubleshooting. For more information, contact your local distributor or Rockwell Automation representative, or visithttp://www.rockwellautomation.com/services/online-phone.

Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running.

New Product Satisfaction Return

Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.

Documentation Feedback Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete this form, publication RA-DU002, available at http://www.rockwellautomation.com/literature/.

United States or Canada 1.440.646.3434

Outside United States or Canada Use the Worldwide Locator at http://www.rockwellautomation.com/rockwellautomation/support/overview.page, or contact your local Rockwell Automation representative.

United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor to complete the return process.

Outside United States Please contact your local Rockwell Automation representative for the return procedure.

Publication 20P-IN077B-EN-P- May 2016Supersedes Publication 20P-IN077A-EN-P - March 2016 Copyright © 2016 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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Allen-Bradley, PowerFlex, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc.Trademarks not belonging to Rockwell Automation are property of their respective companies.

Rockwell Otomasyon Ticaret A.Ş., Kar Plaza İş Merkezi E Blok Kat:6 34752 İçerenköy, İstanbul, Tel: +90 (216) 5698400

http://www.rockwellautomation.com/services/online-phone

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http://www.rockwellautomation.com/support

https://rockwellautomation.custhelp.com/

http://literature.rockwellautomation.com/idc/groups/literature/documents/du/ra-du002_-en-e.pdf

http://www.rockwellautomation.com/literature/

Documents

PowerFlex DC Drive – Frame D, Series A to Series C Fan … · 2016. 6. 3. · 1. Place the new terminal identification label where the old terminal identification label was located