Rockwell Automation PowerFlex

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Installation Instructions

PowerFlex

DC Drive - Cooling Fan for Frame A

Drives Rated 73A and Higher with 230V and

460V AC Input

What This Kit Includes

• Cooling fan

• Fan cover plate

• Fan terminal block and screw

• Static strap

Tools That You Need

• Phillips

screwdriver

• Flathead screwdriver

Phillips

is a registered trademark of Phillips Screw Company.

What You Need to Do

To install the Cooling Fan:

❐ Step 1: Remove power from the drive

❐ Step 2: Remove the air flow plate

❐ Step 3: Remove the existing fan

❐ Step 4: Install the new fan

❐ Step 5: Install the air flow plate

❐ Step 6: 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.

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Summary

Installation Procedure

Step 1: Remove Power from the Drive

Ensure all power to the drive is removed before making or breaking cable connections to prevent electrical arcs and potential injury.

Step 2: Remove the Air Flow Plate

Remove the bottom protective cover by loosening two screws and sliding it off the drive chassis.

Step 3: Remove the Existing Fan

Carefully remove the fan cover plate using a flathead screwdriver and slide the existing fan out of its housing.

Step 4: Install the New Fan

Install the new cooling fan in the reverse order of removal, ensuring the air flow arrow points inward towards the drive top.

Step 5: Install the Air Flow Plate

Install the air flow plate in the reverse order of its removal.

Step 6: Document the Change

Record the installation of the new cooling fan and the date on the drive's Field Installed Option label.

This document describes the installation of a cooling fan for PowerFlex® DC Drives, specifically for Frame A drives rated 73A and higher with 230V and 460V AC input. The kit includes the cooling fan, a fan cover plate, a fan terminal block and screw, and a static strap. Tools required for installation are a Phillips® screwdriver and a flathead screwdriver.

Function Description:

The cooling fan is an essential component for maintaining the operational temperature of the PowerFlex® DC Drive. It ensures proper airflow to dissipate heat generated during the drive's operation, preventing overheating and potential damage to internal components. This specific fan is designed as an upgrade or replacement for Frame A drives that operate at higher current ratings (73A and above) and utilize 230V or 460V AC input, where increased heat generation necessitates enhanced cooling. The fan works by drawing air into the drive chassis, facilitating heat exchange, and expelling warmer air, thereby maintaining the drive within its optimal operating temperature range. Proper cooling is critical for the longevity and reliable performance of the DC drive, especially in demanding industrial environments.

Important Technical Specifications:

While specific fan technical specifications like CFM (cubic feet per minute) or power consumption are not explicitly detailed in this document, the context implies it is a specialized fan designed to meet the thermal requirements of PowerFlex® DC Drive Frame A units at higher current ratings. The installation process involves a tightening torque of 1.5 N•m (13.3 lb•in) for certain screws, indicating precision in assembly. The drive itself operates with 230V and 460V AC input, which implies the fan's power requirements are compatible with the drive's internal power supply. The fan's design is integrated into the drive's airflow plate and chassis, suggesting a custom fit for the PowerFlex® DC Drive architecture. The importance of proper air flow direction, with the arrow pointing inward towards the top of the drive, highlights a critical design aspect for effective cooling.

Usage Features:

The cooling fan is an internal component of the PowerFlex® DC Drive, meaning its "usage" is primarily in its function within the drive's overall operation. It operates continuously or as needed to regulate the drive's internal temperature. The drive itself is used in various industrial applications to control DC motors, offering precise speed and torque control. The fan's role is to support the reliable operation of the drive in these applications by preventing thermal overload. The documentation emphasizes the importance of proper installation to ensure the fan functions correctly, including marking connections and wires to avoid incorrect reassembly. The fan's integration into the drive's design means it operates automatically as part of the drive's thermal management system, requiring no direct user interaction during normal operation.

Maintenance Features:

The document outlines a clear procedure for installing the cooling fan, which can also be interpreted as a guide for replacement or maintenance. Key maintenance features include:

Replacement Procedure: A step-by-step guide is provided for removing the existing fan and installing the new one. This includes removing power, disassembling protective covers and air flow plates, disconnecting wiring, and carefully extracting the old fan.
ESD Precautions: The document explicitly warns about ESD (Electrostatic Discharge) sensitive parts and assemblies within the drive. This highlights a critical maintenance consideration, requiring static control precautions (e.g., static strap, proper handling procedures) to prevent damage to sensitive electronic components during fan replacement.
Wiring and Connection Guidance: Instructions emphasize marking all connections and wires before removal to ensure correct reassembly, preventing wiring errors that could lead to malfunction or damage.
Airflow Direction Verification: A crucial step in installation is to verify that the air flow arrow on the fan is pointed inward, toward the top of the drive. This ensures the fan is installed in the correct orientation for optimal cooling performance.
Documentation of Change: The final step involves recording the installation of the new cooling fan and the date of installation on the "Field Installed Option" label on the side of the drive. This provides a clear maintenance record, which is valuable for future servicing, troubleshooting, and warranty purposes.
Qualified Personnel Requirement: The document stresses that only qualified personnel familiar with DC drives should perform the installation and maintenance. This ensures safety and proper execution of the procedure, minimizing risks of personal injury or equipment damage.
Power Removal and Lock-out: A fundamental safety and maintenance practice emphasized is the removal and lock-out of all incoming power to the drive before any work is performed. This prevents electrical shock hazards and protects both personnel and equipment.

Overall, the cooling fan is a critical component for the PowerFlex® DC Drive, and its proper installation and maintenance, as detailed in this document, are essential for the drive's safe, reliable, and long-term operation.