Rockwell Automation Allen-Bradley PowerFlex 4M User manual

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
O
I

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
UV
CD
W
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
Flat washer
Bolt (30mm long)
Bolt (30mm long)
Flat washer
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

PowerFlex® DC Drive - Frame C Bimetal Thermostat 11
9. Remove the bolts and washers that secure the horizontal bus bars to the
C and D (vertical) power terminal bus bars. Note the size and location
of the bolts and the order in which the washers are placed on the bolts.
10. Remove the bolts and washers that secure the horizontal bus bars to the
SCR modules and remove the bus bars.
Continue with Remove the SCR Modules and Bimetal Thermostat on
page 12.
Remove bolts, lock washers, flat washers
Left to right, flat washers,
lock washers and nuts
Left to right, bolts and
flat washers
Bolt Size and Washer Order
Remove bolts and washers and bus bars

12 PowerFlex® DC Drive - Frame C Bimetal Thermostat
Remove the SCR Modules and Bimetal Thermostat
1. Remove the remaining bolts, washers and metal plates (for
Regenerative drives only) from the tops of the appropriate SCR
modules. Note the order of the washers on the bolts.
Important: Mark all connections and wires before removal to avoid
incorrect wiring during reassembly.
2. Remove the gate leads that connect the SCR modules to the Pulse
Transformer circuit board from the Pulse Transformer circuit board end.
Remove bolts and metal plates
Note: Regenerative drive shown.
Bolt (32 mm long)
Lock washer
Flat washer
SCR module

PowerFlex® DC Drive - Frame C Bimetal Thermostat 13
3. Remove the four screws that secure each SCR module to the heatsink
and remove the SCR modules. Note the order of the washers on the bolt.
4. Remove the wires connected to the Bimetal Thermostat from connector
X4 on the Pulse Transformer circuit board.
5. Remove the solder from the connections on the two leads of the Bimetal
Thermostat.
6. Remove the Bimetal Thermostat from the heatsink by unscrewing them
at the base.
Remove four screws
Remove solder and
Bimetal Thermostat

14 PowerFlex® DC Drive - Frame C Bimetal Thermostat
Step 4: Install the New
Bimetal Thermostat
Install the new Bimetal Thermostat in reverse order of removal as detailed
in Step 3: Remove the Existing Bimetal Thermostat on page 4.
•Apply thermal grease 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
screws that secure the SCR modules 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:
!ATTENTION: Thermal grease must be applied to the bottom
of the Bimetal Thermostat before securing it to the heatsink or
damage to the drive may occur.
230V AC Input
Drive Current
Rating Code DC Amps AC Line Amps HP Final Torque
521 521 426 150 6 Nm (53 lb.-in.)
460V AC Input
Drive Current
Rating Code DC Amps AC Line Amps HP Final Torque
495 495 404.4 300 4.5 - 5.5 Nm (40 - 48.7 lb.-in.)
667 667 544.9 400 6 Nm (53 lb.-in.)
230V AC Input
Drive Current
Rating Code DC Amps AC Line Amps HP Final Torque
521 521 426 150 11 - 13 Nm (97.4 - 115 lb.-in.)
460V AC Input
Drive Current
Rating Code DC Amps AC Line Amps HP Final Torque
495 495 404.4 300 11 - 13 Nm (97.4 - 115 lb.-in.)
667 667 544.9 400

PowerFlex® DC Drive - Frame C Bimetal Thermostat 15
Step 5: 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 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 document
Publication
Number
In depth information regarding the
operation of PowerFlex Digital DC
drives
User Manual - PowerFlex Digital DC Drives 20P-UM001…

Publication 20P-IN034A-EN-P - March 2009
Copyright © 2009 Rockwell Automation. All rights reserved. Printed in USA.
www.rockwellautomation.com
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