PowerFlex DC Stand-Alone Regulator (SAR) Bimetal
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PowerFlex DC Stand-Alone Regulator (SAR) Bimetal Thermostat
Installation InstructionsPowerFlex DC Stand-Alone Regulator (SAR)
Bimetal Thermostat
What This Kit Includes • One bimetal thermostat with wire harness •
Static strap
Tools That You Need • Phillips® screwdriver • Hexalobular
screwdriver • Nut driver or wrench for hex stand-offs and bimetal
thermostat • Isopropyl alcohol • Thermal grease
Phillips® is a registered trademark of Phillips Screw
Company.
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 SAR has been removed before performing the following.
ATTENTION: This SAR 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.
23P-IN007A-EN-P
What You Need to Do The list below is an overview of the steps
needed to remove and replace the bimetal thermostat. See each step
for detailed procedures.
1. Remove Power
3. Remove the Control Circuit Board
4. Remove the Power Interface Circuit Board and Switching Power
Supply Circuit Board
5. Remove the Field Circuit Board
6. Remove the Bimetal Thermostat
7. Install the New Bimental Thermostat and Reassemble the SAR
8. Document the Change
Step 1: Remove Power
Remove and lock-out all incoming power to the SAR.
IMPORTANT The SAR has many different cables, wires, and plugs with
different connections and routing. For ease of reassembly:
• Make note of cable and wire routing between and within the
different circuit boards.
• Label connectors and plugs with the name of the connection and
circuit board from where it was disconnected.
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
Step 2: Remove the Covers
1. Disconnect the Device Peripheral Interface (DPI) cable from the
HIM assembly (if present).
2. Loosen the captive screws that secure the bottom front cover to
the SAR, then slide the cover down and off the chassis.
3. Press in on the sides at the bottom edge of the top cover and
pull the cover toward you until the cover is partially off the
chassis. Then pull the top of the cover toward you until the
mounting pins align with the keyholes in the top of the cover. Then
carefully lift the cover off of the chassis.
=
Tightening torque: 1.5 N•m (13.3.lb•in)
When mounting pins fits in keyhole, lift cover off SAR
chassis.
IMPORTANT The HIM assembly is connected to the control board via a
communication cable. Carefully set the top cover down next to the
chassis.
Rockwell Automation Publication 23P-IN007A-EN-P - June 2011 3
Step 3: Remove the Control Circuit Board
1. Label and disconnect the ribbon cables at connectors XA, XR, and
XFCD.
2. Unplug the terminal block connectors (6) from the control board
(if wired).
3. Remove the EMI shield mounting screws (5), and save for
reassembly.
4. Remove the EMI shield ground screw (1), and save for
reassembly.
Note: The control board remains mounted to the EMI shield.
5. Carefully lift the EMI shield and control board (to provide
clearance from cabling below), and slide the EMI shield and control
board out of the chassis, and carefully set aside.
EMI Shield Mounting Screws (5) Tightening torque: 1.0 N•m (8.9
lb•in)
Terminal Block Connectors (6)
XA
XR
XFCD
EMI Ground Screw (1) Tightening torque: 1.0 N•m (8.9 lb•in)
4 Rockwell Automation Publication 23P-IN007A-EN-P - June 2011
Step 4: Remove the Power Interface Circuit Board and Switching
Power Supply Circuit Board
1. Label and disconnect the plugs at connectors X3 and X4.
2. Label and disconnect the plugs at connectors XCD and
XCD_IO.
3. Label and disconnect the ribbon cable at XPT1.
4. Label and disconnect the plugs at TH-CT and XF.
5. Label and disconnect the plugs at connectors at XP1 and
XP2.
6. Label and disconnect the plug from connector XUVW.
7. Unplug the control power and relay terminal block.
8. Label and disconnect any external burden resistor circuit wires
from the XCT terminal.
9. Remove the mounting screws (2), and save for reassembly.
IMPORTANT The power interface circuit board and the switching power
supply circuit board are removed together, as an assembly.
X3
X4
XCD
Control Power and Relay Terminal Block
XCT Terminal Mounting Screws (2) Tightening torque: 1.0 N•m (8.9
lb•in)
XR
Rockwell Automation Publication 23P-IN007A-EN-P - June 2011 5
10. Remove the cooling vent mounting screws (4) on top of the
stand-alone regulator, and save for reassembly.
11. Disconnect the fan plug from the XV connector on the switching
power supply circuit board.
12. Remove the cooling vent and fan assembly.
13. Carefully slide the power interface circuit board and the
switching power supply circuit board assembly out of the
chassis.
Step 5: Remove the Field Circuit Board
1. Label and disconnect the plug at X3.
Cooling Vent Mounting Screws (4) Tightening torque: 1.0 N•m (8.9
lb•in)
Fan plug XV connector (behind cooling vent)
IMPORTANT The screws for the field circuit board are different
lengths. Be sure to replace the correct length screw back to the
correct fastener location when reinstalling the field circuit
board.
Also, note the location of the mounting points for the transducer
cable for reassembly.
Field Power Terminal Screws (4, long)
X3
Dual Diode Module Bus Screws (3, medium)
Field SCR Module Bus Screws (3, medium)
Stand-off
Ribbon Cable Removed from Hoop Harness
Note: Tightening torque for all screws: 2.5 N•m (22.0 lb•in)
6 Rockwell Automation Publication 23P-IN007A-EN-P - June 2011
2. Remove the ribbon cable from its plastic hoop harness (if needed
to make more room for removing the mounting screws).
3. Remove the mounting screws (4, long) to the field power
terminals, and save for reassembly.
4. Remove the mounting screws (3, medium) from the dual diode
module, and save for reassembly.
5. Remove the mounting screws (3, medium) from the field SCR
module, and save for reassembly.
6. Remove the mounting screw (1, short) for the transducer cable to
the glastic stand-off. Save the transducer cable and mounting screw
for reassembly.
7. Remove the stand-off and washer from the heatsink, and save for
reassembly.
8. Lift the front edge of the field circuit board up at an angle
and carefully pass the mounting screw wells over the glastic spacer
stack, and remove the field circuit board.
IMPORTANT Lift the Front of the Field Circuit Board at an Angle
Until you can Pull the Mounting Screw Wells Over the Glastic Spacer
Stack.
Rockwell Automation Publication 23P-IN007A-EN-P - June 2011 7
Step 6: Remove the Bimetal Thermostat
1. Remove the stand-off and washer from the heatsink (if needed for
additional clearance).
2. Remove the bimetal thermostat from the heatsink and dispose of
properly.
Step 7: Install the New Bimental Thermostat and Reassemble the
SAR
1. Install the new bimetal thermostat in reverse order of removal.
See Remove the Bimetal Thermostat on page 8.
2. Install the field circuit board in reverse order of removal. See
Remove the Field Circuit Board on page 6.
3. Install the power interface circuit board and switching power
supply circuit board in reverse order of removal. See Remove the
Power Interface Circuit Board and Switching Power Supply Circuit
Board on page 5.
4. Install the control circuit board in reverse order of removal.
See Remove the Control Circuit Board on page 4.
Stand-off
Bimetal Thermostat Tightening Torque: 1.0 N•m (8.9 lb•in)
IMPORTANT Thermal grease must be applied to the bottom of the
bimetal thermostat before securing it to the heatsink. Clean the
surface of the heatsink and the new bimetal thermostat with
isopropyl alcohol, then apply a thin coat of thermal grease to the
bimetal thermostat.
8 Rockwell Automation Publication 23P-IN007A-EN-P - June 2011
Step 8: Document the Change 1. Record the installation of the new
bimetal thermostat and date of installation on the field installed
option label on the side of the SAR (as shown below).
2. Replace the SAR covers in the reverse order of removal. See
Remove the Covers on page 3.
3. Install DPI cable (if present).
Additional Resources These documents contain additional information
concerning related Rockwell Automation products.
You can view or download publications at
http://www.rockwellautomation.com/literature. To order paper copies
of technical documentation, contact your local Rockwell Automation
distributor or sales representative.
Resource Description
PowerFlex DC Stand-Alone Regulator and Gate Amplifier User Manual,
publication 23P-UM001
Provides installation instructions and connection and configuration
information for the PowerFlex DC Stand-Alone Regulator (SAR).
PowerFlex Digital DC Drive User Manual, publication 20D-UM001
Provides additional installation, configuration, and programming
information for the PowerFlex DC Stand-Alone Regulator (SAR).
Industrial Automation Wiring and Grounding Guidelines, publication
1770-4.1
Provides general guidelines for installing a Rockwell Automation
industrial system.
Product Certifications website, http://ab.rockwellautomation.com
Provides declarations of conformity, certificates, and other
certification details.
Rockwell Automation Publication 23P-IN007A-EN-P - June 2011 9
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Printed in the U.S.A.
Power, Control and Information Solutions Headquarters Americas:
Rockwell Automation, 1201 South Second Street, Milwaukee, WI
53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
Europe/Middle East/Africa: Rockwell Automation NV, Pegasus Park, De
Kleetlaan 12a, 1831 Diegem, Belgium, Tel: (32) 2 663 0600, Fax:
(32) 2 663 0640 Asia Pacific: Rockwell Automation, Level 14, Core
F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887
4788, Fax: (852) 2508 1846
www.rockwel lautomation.com
What This Kit Includes
Tools That You Need
Step 1: Remove Power
Step 3: Remove the Control Circuit Board
Step 4: Remove the Power Interface Circuit Board and Switching
Power Supply Circuit Board
Step 5: Remove the Field Circuit Board
Step 6: Remove the Bimetal Thermostat
Step 7: Install the New Bimental Thermostat and Reassemble the
SAR
Step 8: Document the Change
Additional Resources
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PowerFlex DC Stand-Alone Regulator (SAR) Bimetal Thermostat
Installation Instructions
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