Rockwell Automation Single Precharge Contactor Replacement User Manual

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Single Precharge Contactor Replacement Kit

for LiquiFlo 2.0 AC Frame 3 Drive Assembly

Numbers 179910-903-xxx and 179910-905-xxx

(Replaces Obsolete 100-B400ND3 Contactor)

Instruction Manual D2-8100

ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and

understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: Do not install or remove modification kits with power applied to the drive. Disconnect and lock out incoming power before attempting such installation or removal. Failure to observe this

precaution could result in severe bodily injury or loss of life.

ATTENTION: DC Bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge and then

check the voltage with a voltmeter to ensure that the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the

equipment.

ATTENTION: The drive contains ESD- (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing the drive. Erratic machine

operation and damage to, or destruction of, equipment can result if this procedure is not followed. Failure to observe this precaution could result in severe bodily injury or loss of life.

What the Kit Contains

Single Precharge Contactor Kit M/N SK-181778-A01 can be used only with LiquiFlo

2.0 AC Frame 3 drives, assembly numbers: 179910-903-xxx and 179910-905-xxx.

Quantity Part Number Description

1 181777-C01 Contactor Bracket

3 181783-C01 Contactor Upper Bus Bar

3 181784-C01 Contactor Lower Bus Bar

2 328858-C34 262 MCM cable, 29.0 inches long

4 328858-C36 262 MCM cable, 35.5 inches long

2 419063-201SM M12 Hex Nut with Conical Washer

NOTE: Contactor 100-D630ED11 to be purchased separately.

2 Instruction Manual D2-8100

Tools That You Need

What You Need to Do

• 10 mm hex bit socket

• 17 mm socket

• 18 mm socket

• 7/16 inch socket

• 17 mm combination wrench (open / box end)

• Socket ratchet wrench

• 3 inch long socket extension

• 6 inch long socket extension

• Torque wrench (capable of 600 lb.-in. / 50 lb.-ft.)

• Phillips

To install the single precharge contactor kit you need to:

❐ Step 1: Disconnect and lock out input power at the branch circuit.

❐ Step 2: Turn off the drive cabinet circuit breaker.

❐ Step 3: Verify that DC bus capacitors are discharged.

❐ Step 4: Remove the cables, bus bars, stand-offs, and old contactor.

❐ Step 5: Install the new contactor bracket.

#2 screwdriver

❐ Step 6: Install the new lower bus bars.

❐ Step 7: Install the new upper bus bars.

❐ Step 8: Reinstall the cabling and precharge resistor wiring.

❐ Step 9: Verify the precharge resistor wiring.

Instruction Manual D2-8100 3

Step 1: Disconnect Power at the Branch Circuit

Step 2: Turn Off Drive Cabinet Circuit Breaker

Step 3: Verify that DC Bus Capacitors are Discharged

Disconnect input power upstream of the drive assembly cabinet. Follow required safety procedures to lock out circuit during the repair.

Turn off the drive cabinet circuit breaker and open the drive cabinet doors.

ATTENTION: DC Bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting

input power, wait five (5) minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure that the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

Task Description

Turn off and lock out input power. Wait five minutes.

Verify that there is no voltage at the drive’s input power terminals.

Remove top cover.

Measure the DC bus potential with a voltmeter while standing on a non-conductive surface

and wearing insulated gloves (1000V).

L1 L2 L3

Neg

(-)

DC Bus Measurement Points on

Laminated Bus Assembly

(0.25 x 0.32 in. male Faston).

Accessible by removal of top cover.

Pos

(+)

Top Cover (Removed)

Front View of Inverter

Right Side View of Inverter

+ 7 hidden pages