Allen-Bradley PowerFlex SK-20P-S725804 User manual

Installation Instructions
Original Instructions
PowerFlex DC Drive – Frame D, Series C to Series C Fan
Replacement
Catalog Number SK-20P-S725804
Identify Frame D, Series C
Drive
Verify that you are working on a Frame D, series C 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: C
Frame: D
6.2
8.2
I/O: 24VDC (Standard)
Ind. Cont.
Listed
C
R
US
max. 1 Phase
Hz 1.0/0.5A 1 Phase
Eq. 31KF
N223

2Rockwell Automation Publication 20P-IN076B-EN-P - May 2016
PowerFlex DC Drive Frame D Series C to Series C Fan Replacement
What This Kit Includes •Fan assembly (includes fan and mounting bracket)
Tools That You Need •T20 hexalobular screwdriver
•3.5 mm x 0.8 mm screwdriver
•13 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 front top airflow plate.
Step 3: Remove the existing fan assembly.
Step 4: Install the series C fan assembly.
Step 5: Install the series C front top airflow plate.
Step 6: Install the series C top protection cover airflow plate.
Step 7: Document the change.
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 environment
Electric arcing causes excessive wear to contacts on both the module and its mating
connector. Worn contacts can create electrical resistance.

Rockwell Automation Publication 20P-IN076B-EN-P - May 2016 3
PowerFlex DC Drive Frame D Series C to Series C Fan Replacement
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. If installed, remove the bus bar extensions.
3. Loosen, but do not remove, the four hexalobular screws that secure the
front top airflow plate to the drive, remove the central hexalobular screw,
and slide the plate forward to lift it off of the screws.
The tightening torque is noted in the illustration for reassembly.
L1 L2 L3
O
I
Top Protective Cover
Tool size: T20
1.5 N•m (13 lb•in)
=
Tool size: T20
1.5 N•m (13 lb•in)
Pull plate forward to lift off screws.
Top View of Drive
Fan Loss Detection Board
Loosen screws. Loosen screws.
Remove Central Screw

4Rockwell Automation Publication 20P-IN076B-EN-P - May 2016
PowerFlex DC Drive Frame D Series C to Series C Fan Replacement
Step 3: Remove the Existing
Fan Assembly
1. Remove the wires that are connected to the terminal blocks at XF and XF2
on the three-phase fan loss detection circuit board (located at the top of
the drive, to the left of the fan blower).
2. 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.
Remove wires from
terminal blocks
XF and XF2.
Loosen nuts - two each
side of bracket.
Lift bracket and fan and
pull out of drive.
Tool size: 13 mm
18.0 N•m (159.3 lb•in)

Rockwell Automation Publication 20P-IN076B-EN-P - May 2016 5
PowerFlex DC Drive Frame D Series C to Series C Fan Replacement
Step 4: Install the Series C
Fan Assembly
1. Install the series C fan assembly in the reverse order of removal as detailed
in step 3, Remove the Existing Fan Assembly.
IMPORTANT
In step 3.1, reconnect both XF and XF2 connectors of the three-phase fan loss
detection board to the motor using the following diagram.
FNLS3
31 32 PE W3 V3 U3
TB TB PE W3F V3F U3F Z3F Y3F X3F
Fan Fault Fan Supply 3 Phase 400V AC, 50 Hz 400...460V AC, 60 Hz
To Fan Motor
White White Yellow/Green Black Gray Red Orange Blue Brown

6Rockwell Automation Publication 20P-IN076B-EN-P - May 2016
PowerFlex DC Drive Frame D Series C to Series C Fan Replacement
Step 5: Install the Series C
Front Top Airflow Plate
1. Install the series C front airflow plate, tightening the four screws loosened
in Step 2.2. Add and tighten a new hexalobular screw in the center.
Step 6: 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.
Tool size: T20
1.5 N•m (13.2 lb•in)
Tighten.
Front Top Airflow Plate
Rear Top Airflow Plate
Tool size: T20
1.5 N•m (13.2 lb•in)
Tighten.

Rockwell Automation Publication 20P-IN076B-EN-P - May 2016 7
PowerFlex DC Drive Frame D Series C to Series C Fan Replacement
Step 7: Document the
Change
1. Record the installation of the new fan assembly and date of installation on
the Field Installed Option label on the side of the drive (as shown below).
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.

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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.
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Publication 20P-IN076B-EN-P- May 2016
Supersedes Publication 20P-IN076A-EN-P - March 2016 Copyright © 2016 Rockwell Automation, Inc. All rights reserved. Printed in UIF64".
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