ACE Variable Frequency Drive System IF 1619 Installation & Maintenance Information

ACE Variable Frequency Drive System IF 1619 Installation & Maintenance Information
ACE Variable Frequency Drive System
Installation & Maintenance Information
IF 1619
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE
Designated Space for Additional
DIN Rail Mountable Terminals/
Relays
Shroud
Shrouds
Manifold
Blower Cooling
Intake
Warning Plate
Blower
Product Nameplate
with Critical
Markings
Baffle
Control Pad
Viewing Window
Indicating Lights
Control
Pad Button
Assembly
Explosionproof Filter
(pre-filters removed
for clarity)
Data Nameplate
Including Torque
Information
Disconnect
Operating
Handle
Control Pad
Assembly
External
Ground
Internal
Ground
Disconnect
Switch
VFD
Warning Plate
table of contents
1.Safety Instructions
1.1 Approved Applications
1.2 Electrical Safety
1.3 Blower Safety
1.4 Hot Surfaces
1.5 Enclosure Safety
Page 2
Page 2
Page 2
Page 2
Page 3
2. Mechanical Installation
2.1 Airflow Provisions - Installation Drawing
2.2 Weights
2.3 Lifting
2.4 Dimensional Drawings
2.5 Mounting
2.6 Shroud Installation
2.7 Pre-filter Installation
5.Maintenance
5.1 Drive Maintenance
5.2 Cooling System Maintenance
5.3 Periodic Mechanical Maintenance (Torque Verification,
Pushbutton Lubrication, Window Cleaning)
5.4 Status Indication - Filter Maintenance
5.5 Explosive Event Required Maintenance
Page 3
Page 4
Page 4
Page 5
Page 6
Page 6
Page 6
6.Technical Data
6.1 Technical Data Chart
6.2 Power Loss (Heat Dissipation)
6.3 Derating Factors and Curves (Ambient Temperature,
Altitude, Switching Frequency)
7.Crouse-Hinds Drive Parameters
7.1 Parameter Table
3.Electrical Installation
3.1 Enclosure Grounding - Internal/External
3.2 Line Feed
3.3 Load Feed and Shield Grounding to Drive
3.4 Control Wire Routing
3.5 Blower and Signal Schematic
3.6 Communication Modules
Page 6
Page 6
Page 6
Page 6
Page 7
Page 8
8. Replacement Parts
8.1 Pre-filter Kit
8.1.1 Pre-filter Installation Instructions
Page 11
Page 11
8.2 Sintered Filter Kit
8.2.1 Sintered Filter Installation Instructions
Page 11
Page 11
8.3 Blower Kit
8.3.1 Blower Installation Instructions
Page 12
Page 12
Page 8
Page 9
Page 9
8.4 Pushbutton Operator Kit
8.4.1 Pushbutton Installation Instructions
Page 13
Page 13
4.
General Operation
4.1 Keypad Interface
4.2 Disconnect and Lockout/Tagout
4.3 Potentiometer Settings
IF 1619 • 01/14
Copyright© 2014, Eaton’s Crouse-Hinds Business
Page 9
Page 9
Page 10
Page 10
Page 10
Page 10
Page 10
Page 10
Page 11
Page 1
1. safety instructions
The ACE Explosionproof VFD should be installed, inspected, and maintained by qualified
and competent personnel.
1.1 Approved applications
The ACE Explosionproof VFD is classified Class I, Divisions 1 and 2 for use in hazardous
environments, and is designed to match the strict requirements of pumps, compressors,
fans, separators, and mixers in such process industries as:
• Oil and gas / refineries
• OEM skid builders
• Petrochemical
• Water / waste water
• Pharmaceutical
• Food and beverage manufacturing
warning
1.2 Electrical safety
warning: high voltage
Electrical power must be OFF before and during inspection or service. Ensure
electrical supply to the enclosure is disconnected, locked out and tagged out.
Personnel injury or damage to equipment can occur if all power upstream from the
enclosure is not fully disconnected prior to opening.
Before commissioning the drive and putting it into service, make sure that the
motor and all driven equipment are suitable for operation throughout the speed
range provided by the drive. The drive can be adjusted to operate the motor at
speeds above and below the speed provided by connecting the motor directly to
the line power.
caution
To ensure safety and VFD performance, grounding provisions for the enclosure,
blower, and VFD must be made before operating.
To avoid cooling system malfunction, cooling system failure, and personnel injury,
remove all loose debris and deposits before energizing.
These blowers comply with EN 61800-5-1 safety standards.
The blower is non-serviceable. Refer to ACE KIT 3, Section 8.3, for replacement instructions.
1.4 hot surfaces
WARNING: burn hazard
To avoid personnel injury, use appropriate personnel protective equipment before
handling and operating the device.
1.3 blower safety
warning
To avoid cooling system malfunction, cooling system failure, and personnel injury,
close and seal the enclosure before energizing.
Filter Shrouds
Blower Intake
warning: high speed
To avoid personnel injury, DO NOT handle the blower or service the enclosure
while energized.
IF 1619 • 01/14
Copyright© 2014, Eaton’s Crouse-Hinds Business
Page 2
D
1.5 enclosure safety
warning
To avoid cooling system malfunction and personnel injury, be sure to torque the
first eight (8) cover screws sequentially per Figure 1 before torquing the remaining
screws.
WARNING
To avoid personnel injury and property damage, clean dirt and debris from flat
ground joint surfaces before the cover is closed. NEVER energize this equipment if
the flat ground joint has been scratched or damaged.
7
3
1
All pipe threaded connections into the enclosure require a minimum of five (5) full
threads of engagement. All straight threaded connections into the enclosure require
a minimum of eight (8) full threads of engagement. Personnel injury or equipment
damage can result from threaded joints containing less than the minimum thread
engagement required.
7
3
1
C
All unused conduit openings must be plugged. UL Listed plug must engage a minimum
of five (5) full threads and be a minimum of 1/8” thick.
5
6
Conduit sealing fittings MUST be installed in each attached conduit run (within eighteen
(18) inches of the enclosure) to comply with the latest edition of the National Electrical
Code® (NEC) plus any other applicable code.
5
The cover must be properly fastened to the body with all cover bolts torqued to 40-45
ft.-lbs. (19.2-21.5 N-m). Personnel injury or equipment damage can result if the flat
joint flame path is not properly fastened.
6
4
2
2
8
4
8
Figure 1
B
warning
To avoid personnel injury and property damage, DO NOT remove or modify the
control pad viewing window.
SW_REV 06/2009
2. mechanical installation
2.1 airflow provisions - installation drawing
A
CCHSY-Template-D
"X"
"X"
8
7
5
6
4
"X"
"X"
It is imperative that the enclosure be well ventilated to ensure reliable performance. Adequate space around the intake and exhaust of the enclosure MUST be accommodated.
Crouse-Hinds recommends ‘x’ be a minimum of 12 inches (0.3 meters).
IF 1619 • 01/14
Copyright© 2014, Eaton’s Crouse-Hinds Business
Page 3
2.2 weights
Enclosure
Weight
1.5-10 HP
352 lbs.
15-60 HP
552 lbs.
2.3 lifting
1. Remove top and sides from shipping crate.
2. Remove lag bolts from enclosure mounting feet.
caution
Do not attach shrouds or pre-filters until after enclosure is mounted.
caution: unbalanced load
To avoid personnel injury, utilize the dedicated lifting eye and handle appropriately
to ensure safe installation.
3. Use the dedicated lifting eye to mount enclosure on suitable mounting surface.
Select a mounting location that will provide suitable strength and rigidity for
supporting the enclosure and all components.
IF 1619 • 01/14
Copyright© 2014, Eaton’s Crouse-Hinds Business
Page 4
2.4 dimensional drawings
25.08
[637.0]
15.08
[383.0]
21.83
[554.5]
31.98
[812.2]
9.38
[238.2]
17.25
[438.2]
9.22
[234.2]
4.40 [111.7]
6.16 [156.6]
5/8" BOLT
(4 PLACES)
5.00 [127.0]
6.75 [171.3]
.50 [12.7]
3.50 [88.9]
3.70 [94.0]
8.00
[203.2]
1" NPT
1-1/2" NPT
(2 PLACES)
632
24.88
399.8
15.74
555.6
21.88
856.1
33.71
238.2
9.38
438.2
17.25
234.2
9.22
111.7
4.40
387.4
15.25
5/8" BOLT
(4 PLACES)
230.9
9.09
127.1
5.00
171.5
6.75
106.6
4.20
12.7
.50
101.5
4.00
215.8
8.50
1" NPT
1-1/2" NPT
(2 PLACES)
638.8
25.15
399.8
15.74
555.6
21.88
1176.3
46.31
559.4
22.02
432.9
17.04
717.6
28.25
281.5
11.08
414.1
16.30
5/8" BOLT
(4 PLACES)
240.8
9.48
112.2
4.42
148.7
5.85
203.2
8.00
88.8
3.50
12.7
.50
93.9
3.70
228.5
9.00
1" NPT
2" NPT
(2 PLACES)
IF 1619 • 01/14
Copyright© 2014, Eaton’s Crouse-Hinds Business.
Page 5
2.5 mounting
1. Select a mounting location that will provide suitable strength, rigidity, and space
(per Section 2.1) for supporting the ACE Series system and all contained wiring.
caution
To avoid cooling system malfunction, cooling system failure, and personnel injury,
be sure to mount the enclosure as depicted in Section 2.4.
caution
To avoid cooling system malfunction, cooling system failure, and personnel injury,
be sure to mount the enclosure in a shaded area to avoid direct sunlight.
2. Refer to Section 2.2 for approximate weights and Section 2.4 for dimensions.
6. Be sure to stretch pre-filter elastic band completely around the explosionproof filter
and seat the elastic band on the filter’s threads. This will ensure all air flow to the
bottom filters passes through the pre-filters.
3. Install two (2) 5/8” bolts on left side.
4. Tap each of the four (4) mounting feet with a mallet to ensure tight assembly.
Explosionproof Filter
5. Align enclosure with the two left side mounting feet engaged with the mounting
bolts on selected mounting surface.
3. electrical installation
6. Tighten two (2) bolts on left side.
7. Install two (2) 5/8” bolts on right side and tighten.
8. After enclosure is positioned and secured in its permanent location, pull wires
into the ACE Series system, making sure that they are long enough to make the
required connections.
2.6 Shroud installation
1. Remove rubber caps from explosionproof filters.
2. Insert threaded rods into the explosionproof filters. Leave 3-5⁄8 of threaded rod
exposed.
3. Place shroud over explosionproof filters and threaded rod, with shroud opening
facing back of enclosure. See Figure 2.
4. Insert washer and nuts onto end of threaded rod and tighten securely until shroud
is firmly contacting the top wall of the enclosure. See Figure 3.
3.1 enclosure grounding - internal/external
Grounding and bonding of the conduit and equipment is required by the National
Electrical Code®. A grounding conductor must be connected to the grounding lug(s)
furnished.
Determine the type of distribution systems to be used that will comply with NEC
requirements and ensure grounding continuity.
All conductive equipment that enclose the electrical conductors or attached equipment
or forming part of such equipment must be grounded. A permanent connection must
be made between all such equipment and the earth. Refer to Section 5.3 for the torque
requirements of all terminations within this device.
3.2 line feed
ACORN NUT
LOCKING NUT
WASHER
THREADED STUD
VFD Terminal Shroud VFD Ground
Figure 2
Figure 3
2.7 pre-filter installation
1. Remove rubber caps from explosionproof filters.
2. Install wire guard using the bracket, screw, and lock washer provided to the bottom
filter(s).
3. Align guard with notches within the bracket as shown.
Disconnect Terminal Shrouds
This equipment is designed for line connection directly to the integral disconnect switch.
Factory wiring transmits power to the variable frequency drive.
1. Remove disconnect terminal shrouds (only required on 40-60 HP units).
2. Attach line conductors with phase A on the left, B center, and C to the right (see
Torque Table on page 10).
3. Re-install terminal shrouds (only required on 40-60 HP units).
Notch
Detail View
Bracket
Guard
4. Tighten screw.
5. Slip pre-filter mesh over guard.
IF 1619 • 01/14 3.3 load feed and shield grounding to drive
This equipment is designed for load connection directly from the variable frequency
drive, although, in the case of an oversized VFD for the given motor, use the VFD and
motor manufacturer’s recommendations for proper motor overload protection. In certain
cases, it is required to include additional motor overload protection between the VFD
and the motor for proper motor overload protection. Always be sure to shield load wiring
from line and control wiring to reduce noise. Refer to the drive manufacturer’s manual
for further details.
Copyright© 2014, Eaton’s Crouse-Hinds Business
Page 6
1.
Remove VFD terminal shroud.
2.
Attach load conductors with phase A to U2, B to V2, and C to W2 (see Torque
Table on page 8).
3.
Attach motor cable shielding to VFD ground (see recommendations by drive
manufacturer).
4.
Remove terminal knock-outs and re-install VFD terminal shroud. Refer to the
drive manufacturer’s manual for further information regarding drive installation.
caution
Failure to add additional motor overload protection between the VFD and motor
when required can cause motor failure and equipment damage.
3.4 control wire routing
caution
To avoid the transmission of noise to/from the blower and/or the variable frequency
drive load conductors, be sure to bundle all field control wiring and shield as
necessary.
1
2
3.5 blower and signal schematic
IF 1619 • 01/14 Copyright© 2014, Eaton’s Crouse-Hinds Business
Page 7
3.6 communication modules
4. general operation
Available Options:
4.1 keypad interface
ProtocolCat. # Suffix
Profibus
CP
Devicenet
CD
CAN Open
CC
Modbus
CM
Ethernet
CE
Variable
Selection
Button*
Toggle Up
Variable
Selection
Button*
Help
Local /
Remote
Control
Drive Stop
All communication modules will be installed in ‘Slot 3’ on the VFD. Plug in and fasten
using the integral screw provided.
IF 1619 • 01/14 Toggle Down
Drive Start
*To review selection criteria, observe the control pad screen through the viewing window. Criteria
is identified in the lower corners of the control pad corresponding to the buttons (as shown). Refer
to the drive manufacturer’s manual for additional instruction on the proper use and capability of the
keypad interface.
Copyright© 2014, Eaton’s Crouse-Hinds Business
Page 8
5. MAINTENANCE
4.2 disconnect and lockout/tagout
The disconnect handle is furnished with three (3) holes for lockout/tagout purposes.
1. Turn handle to the ‘off’ position.
caution
To avoid cooling system malfunction and cooling system failure, be sure to
vacuum debris from the enclosure before energizing. NEVER use forced air
for the removal of debris from this enclosure.
2. Depress lockout tab at the end of the handle.
3. Install OSHA approved lock or tag.
5.1 DRIVE MAINTENANCE
4. Release lockout tab.
Periodic cleaning of the drive fan and heat sink is recommended. Removal of
the drive from the enclosure is recommended to ensure debris does not obstruct
the cooling system. Refer to the drive manufacturer’s manual for additional
maintenance recommendations and specific instructions.
warning
To avoid ignition of explosive atmospheres, all circuits must be de-energized
before opening cover.
5.2 cooling system maintenance
1. Clean pre-filter periodically (recommended when parameters 0115 (inverter)
or 0116 (brake chopper) are above 80%). Remove pre-filter and rinse with
water as needed.
2. Clean sintered filter as needed. Use of abrasives on the explosionproof filters
may compromise the integrity of the cooling system.
Lockout Tab
3. Clean/inspect blower intake.
caution
To avoid damage to the integral disconnect operating mechanism, be sure the disconnect coupling is in the off position before closing cover.
Blower Intake
4. Perform visual, electrical, and mechanical checks on all components on
a regular maintenance schedule. NFPA 70B recommends maintenance
intervals not exceeding 2 months.
Disconnect
Coupling ‘OFF’
Position
5. Visually check for any damage to the filter assemblies, flat joints, threaded
joints, journal joints, and window.
6. Visually check for evidence of excessive heating within the enclosure.
7. Mechanically check that all parts are properly assembled and operating
mechanisms are in proper working condition.
Disconnect
Shaft
8. Verify airflow provisions are maintained per Section 2.1.
4.3 POTENTIOMETER SETTINGS
Rotate potentiometer counterclockwise to reduce speed. Refer to Table 1 for
approximate speed de-rating with respect to angle of rotation.
Table 1
Po wer De-ra t i ng wi th Re s pe ct to Rotation for Rheos tat Applic ati o n
Percent R o t a t i o n
Multiply ing Wattage Rati n g B y
100
1.00
90
.99
80
.98
70
.96
60
.93
50
.89
40
.84
30
.68
20
.49
10
.23
0
.11
IF 1619 • 01/14
Copyright© 2014, Eaton’s Crouse-Hinds Business
Page 9
5.3 periodic mechanical maintenance (torque
verification, pushbutton lubrication, window
cleaning)
ITEM DESCRIPTION
FRAME A DRIVE (1.5-5 HP):
LINE/LOAD
GROUND
FRAME B DRIVE (7.5-10 HP):
LINE/LOAD
GROUND
FRAME C DRIVE (15-30 HP):
LINE/LOAD
LINE/LOAD LUGS
GROUND
FRAME D DRIVE (40-60 HP):
LINE/LOAD
LINE/LOAD LUGS
GROUND
DRIVE CONTROL:
XPOW, XRO1, XRO2, XRO3, XD24
XDI, XDIO, XAI, XAO, XD20, XSTO
DISCONNECT:
30 AMP
60 AMP
100 AMP
TIMER RELAY
RELAY
INTERNAL GROUND LUG
EXTERNAL GROUND LUG
BLOWER MANIFOLD
HOSE CLAMPS
COVER BOLTS
TORQUE REQUIREMENTS
WIRE RANGE
TORQUE REQ.
24-12 AWG (0.25-4 MM2)
N/A
4.4-5.3 IN-LBS (0.5-0.6 N-M)
13 IN-LBS (1.5 N-M)
20-10 AWG (0.5-6 MM2)
N/A
10.6-13.3 IN-LBS (1.2-1.5 N-M)
13 IN-LBS (1.5 N-M)
6. technical data
6.1 technical data chart
Cooper
Max.
Max.
Input
Power
Temp.
Temp.
Crouse-Hinds Disconnect Disconnect Enclosure
Output Nominal
Rating
Loss
Derating
Base
Rating
Fuse Type
Size
Rating Horsepower
Rating
(Amps)
(Watts)
Factor
Cat. #
(Amps)
(Amps)
ACE10 1
2.3
3.0
1.5
106
T6
Figure 1
ACE10 2
3.1
3.6
2.0
112
T6
Figure 1
ACE10 3
4.0
4.8
3.0
132
T6
Figure 1
6.6
8.0
5.0
178
T6
Figure 1
10-2/0 AWG (6-70 MM )
N/A
N/A
11 FT-LBS (15 N-M)
25 IN-LBS (3 N-M)
25 IN-LBS (3 N-M)
10-2/0 AWG (6-70 MM2)
N/A
N/A
11 FT-LBS (15 N-M)
25 IN-LBS (3 N-M)
160 IN-LBS (18 N-M)
ACE10 7
12.0
12.2
7.5
606
T4A
Figure 1
ACE10 10
16.0
15.6
10.0
674
T4A
Figure 1
ACE10 15
20.0
25.0
15.0
737
T4A
Figure 1
24-12 AWG (0.5-2.5 MM2)
28-14 AWG (0.5-1.5 MM2)
5 IN-LBS (0.5 N-M)
3 IN-LBS (0.3 N-M)
ACE10 20
26.0
30.0
20.0
737
T4A
Figure 1
30.0
35.0
25.0
847
T4A
Figure 1
18-8 AWG (0.9-8.3 MM2)
14-4 AWG (2.1-21 MM2)
14-2/0 AWG (2.1 - 67 MM2)
20-14 AWG (0.5-2.5 MM2)
24-12 AWG
16-2/0 AWG
6-1/0 AWG
N/A
N/A
N/A
17 IN-LBS (1.9 N-M)
30 IN-LBS (3.4 N-M)
120 IN-LBS (13.5 N-M)
4.4-7.0 IN-LBS (0.5-0.8 N-M)
3.5-5.3 IN-LBS (0.4-0.6 N-M)
120 IN-LBS (13.5 N-M)
50 IN-LBS (5.6 N-M)
20 IN-LBS (2.3 N-M)
20 IN-LBS (2.3 N-M)
40-45 FT-LBS (54.0-61.0 N-M)
36.0
44.0
30.0
903
T4A
Figure 1
55.0
58.0
40.0
1217
T4A
Figure 1
65.0
72.0
50.0
1397
T4A
Figure 1
82.0
81.0
60.0
1577
T4A
Figure 2
2
ACE10 5
ACE10 25
5.4 status indication - filter maintenance
There are two lights for the status indicator - a GREEN light to signify RUN and a RED
light to signify STOP or ALARM condition.
30
J
1
60
ACE10 30
J
2
ACE10 40
ACE10 50
100
ACE10 60
*Modified product designs may vary in terms of technical information. Contact factory for additional
information.
6.2 power loss (heat dissipation)
When the ACE Series enclosure is not installed in a well ventilated area, provisions must
be made to account for heat generation and ensure proper operation of the device.
6.3 de-rating factors and curves (ambient
temperature, altitude, switching frequency)
The final drive output rating is a multiplication of all applicable de-rating factors.
Ambient Temperature De-rating
Red
Green
Solid Red = Power On/Drive Stopped/Fault
Solid Green = Drive Running
Blinking Red = Drive Running in Alarm Mode - Maintenance Required
Lights Off = Power Off
Altitude De-rating:
At altitudes from 1,000 to 4,000m (3,280 to 13,123 ft.) above sea level, the de-rating is
1% for every 100m (328 ft.).
NOTE: If the installation site is higher than 2,000m (6,560 ft.) above sea level,
connection of the drive to an ungrounded (IT) or corner-grounded delta network is not
allowed.
Low Motor Noise (Switch Frequency) De-rating:
5.5 explosive event required maintenance
In the event of an explosion within the enclosure, the filter assemblies and pre-filters
must be replaced. Personnel injury or equipment damage may result from failure
to replace the filters with new filters after an explosion occurs within the enclosure.
Inspect all other components and verify that they are in proper operating condition.
Consult Crouse-Hinds for replacement parts as needed.
WARNING: burn hazard
To avoid personnel injury, allow sufficient time for the enclosure to cool prior to
servicing.
IF 1619 • 01/14
Cooper
Crouse-Hinds Base Cat. #
ACE10 1
ACE10 2
ACE10 3
ACE10 5
ACE10 7
ACE10 10
ACE10 15
ACE10 20
ACE10 25
ACE10 30
ACE10 40
ACE10 50
ACE10 60
Copyright© 2014, Eaton’s Crouse-Hinds Business
Enclosure Size
1
2
Input Rating
(Amps)
1.6
2.3
2.8
4.0
9
10
11
15
18
20
31
36
45
Max. Output
Rating (Amps)
2.1
2.6
3.4
4.8
8.7
10.4
14
17
21
25
32
40
45
Nominal
Horsepower
1.0
1.0
2.0
3.0
5.0
8.0
10
10
15
15
25
30
40
Page 10
7. crouse-hinds drive parameters
7.1 parameter table
Parameter
Number
Parameter
Group Name
Parameter
Description
Parameter
Value
1403
Digital I/O
DIO1 out src
Alarm
1442
Digital I/O
RO1 src
Supervision 1 (P.06.13.00)
1444
Digital I/O
RO1 Toff
3000.0 s
1616
System
Menu set active
Long Menu
3301
Supervision
Superv1 func
High
3302
Supervision
Superv1 act
P.01.15
3303
Supervision
Superv1 hi
195.00
3304
Supervision
Superv1 lo
120.00
4001
Motor Control
Motor noise
Default
9503
HW Configuration
Temp inu ambient
55 C
6. Be sure to stretch pre-filter elastic band completely around the explosionproof filter
and seat the elastic band on the filter’s threads. This will ensure all air flow to the
bottom filters passes through the pre-filters.
To ensure cooling system performance, these parameters must be maintained at all
times while observing the appropriate de-rating factors.
Explosionproof Filter
8. replacement parts
ACE Series systems are designed to provide years of reliable service. However,
should the need for replacement parts arise, they are available through your CrouseHinds Distributor. Assistance may also be obtained through your Crouse-Hinds Sales
Representative or the Crouse-Hinds Customer Service Department.
8.2 SINTERED FILTER kit
ACE KIT2: Filter Assembly (1 pc.)
8.1 pre-filter kit
ACE KIT1: Pre-filter and Hardware (1 pc.)
8.2.1 sintered filter installation instructions
8.1.1 pre-filter installation instructions
1. Remove rubber caps from explosionproof filters.
2. Install wire guard using the bracket, screw, and lock washer provided to the bottom
filter(s).
3. Align guard with notches within the bracket as shown.
Filter Shrouds
1. Remove shroud and pre-filters and place all parts in a secure area.
2. Using a 1” socket wrench, remove all filters from the enclosure (top and bottom).
3. Remove rubber caps from explosionproof filters.
Notch
Detail View
Bracket
Guard
4. Tighten screw.
4. Apply thread grease to threads of explosionproof filters.
5. Install new filters (top and bottom) and torque each to 133 ft.-lbs. (180 N-m).
6. Install pre-filters and shrouds; refer to Sections 2.6 and 2.7.
5. Slip pre-filter mesh over guard.
IF 1619 • 01/14
Copyright© 2014, Eaton’s Crouse-Hinds Business
Page 11
8.3 blower kit
11. Align new manifold clamp bracket to threaded studs. Be sure the manifold clamp
bracket flanges point toward the interior of the enclosure.
ACE KIT3: Blower, Manifold, and Hardware (1 pc.)
12. Install four (4) lock washers and nuts on threaded studs hand tight before
applying required torque. Tighten to 20 in.-lbs. DO NOT over-tighten.
8.3.1 blower installation instructions
1. Disconnect blower power, ground, and control leads from terminal blocks.
13. Slide new blower/bracket assembly into place until fully seated, aligning to the
threaded studs and the manifold.
caution
To avoid system malfunction and electrical shock, be sure that all wires are
aligned in the baffle’s wire pass through.
14. Tighten nuts wrench tight.
15. Tighten manifold hose clamp, while compressing the manifold to the blower, to
20 in.-lbs.
16. Re-attach blower cooling intake and tighten hose clamp to 20 in-lbs. Be sure to
align bottom of blower cooling intake to the explosionproof filter at the bottom of
the enclosure.
2. Loosen four (4) nuts holding blower bracket to mounting plate. DO NOT remove.
3. Loosen and remove two (2) screws attaching baffle to mounting plate.
Blower
Cooling
Intake
4. Loosen and remove manifold clamp bracket nuts and lock washers. DO NOT remove
jam nuts positioned behind the manifold clamp bracket.
Manifold
Clamp
Bracket
17. Terminate the blower power wires to the appropriate terminal block (black to
black).
18. Perform a continuity check between each blower power terminal and each phase
of the integral disconnect switch.
19. Terminate the blower control wires to the appropriate terminal block (red to red).
Loosen and DO NOT Remove
Nut During Replacement
20. Perform a continuity check between each blower control terminal and the XROI
relay on the variable frequency drive.
21. Terminate the blower ground wire to the appropriate terminal block (with the
blower control wires) (yellow/green to green)
5. Remove blower and brackets.
22. Perform a continuity check between the ground terminal and the ground lug
adjacent to the integral disconnect switch.
6. Remove manifold and manifold clamp bracket.
7. Remove blower cooling intake and hose clamp from old blower assembly and hold
for re-assembly.
8. Loosen and remove three (3) screws holding the baffle to the blower bracket.
Remove baffle and hold for re-assembly.
9. Attach baffle to new blower bracket using the same three (3) screws.
10. Align new manifold to enclosure wall.
IF 1619 • 01/14
Copyright© 2014, Eaton’s Crouse-Hinds Business
Page 12
8.4 pushbutton operator kit
ACE KIT4: Pushbutton Operator, Finger and Hardware (8 pc.)
8.4.1 pushbutton installation instructions
1. Loosen and remove four (4) screws and lock washers from keypad bracket.
Remove keypad and bracket.
Keypad Bracket
Keypad Fingers
Pushbutton
Assembly
2. Loosen and remove eight (8) screws and lock washers from keypad fingers.
Remove fingers.
3. Loosen and remove pushbutton assemblies.
4. Apply Crouse-Hinds STL lubricant lightly to the external threads of the pushbutton
assembly.
5. Install new pushbutton assemblies and tighten wrench tight.
6. Re-install keypad fingers and orient fingers as shown in Detail A.
7. Install lock washers and screws retaining keypad fingers and tighten wrench tight.
8. Re-install keypad bracket and fasten using existing hardware. Tighten screws
wrench tight.
All statements, technical information and recommendations contained herein are based on information and tests we believe to be reliable.The accuracy or completeness thereof are not guaranteed.
In accordance with Crouse-Hinds “Terms and Conditions of Sale,” and since conditions of use are outside our control, the purchaser should determine the suitability of the product for his intended
use and assumes all risk and liability whatsoever in connection therewith.
Eaton’s Crouse-Hinds Business
1201 Wolf Street, Syracuse, New York 13208 • U.S.A.
Copyright© 2014
IF 1619
Revision 3
Revised 01/14
Supercedes 12/13
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