ACE20 and ACE30 Variable Frequency Drive System

Installation & Maintenance Information

SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE

shroud blower cooling Intake

Data nameplate, including torque Information control Pad

Manifold blower baffle terminal block transformer temperature controller

WIM fan communication

Module

VfD explosionproof filter

(pre-filters removed for clarity) control Pad

Viewing Window blower fuse block

(not shown) external

Ground

Internal Ground Disconnect switch

IF 1660

Warning nameplate

Product nameplate with critical

Markings

Disconnect operating Handle

Pushbutton start/stop

(not shown)

Potentiometer

Hand-off-auto selector switch

(not shown)

Warning Plate

table of contents

1. safety Instructions

1.1 Application

1.2 Electrical Safety

1.3 Blower Safety

1.4 Hot Surfaces

1.5 Enclosure Safety

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

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

4. General operation

4.1 Control Pad Viewing Window

4.2 Disconnect and Lockout/Tagout

4.3 Communication Modules

4.4 POT, RR3 (HOA), and PB23 (Pushbutton Start/Stop)

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Page 12

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Pre-filters

5. Maintenance

5.1 Drive Maintenance

5.2 Cooling System Maintenance

5.3 Periodic Mechanical Maintenance (Torque Verification)

5.4 Status Indication

5.5 Explosive Event Required Maintenance

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

8. Replacement Parts

8.1 Pre-filter Kit

8.1.1 Pre-filter Installation Instructions

8.2 Sintered Filter Kit

8.2.1 Sintered Filter Installation Instructions

8.3 Blower Kit

8.3.1 Blower Installation Instructions

8.4 Temperature Controller Kit

8.4.1 Temperature Controller Installation Instructions

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IF 1660 • 01/14 Copyright © 2014, Eaton’s Crouse-Hinds Business Page 1

1. safety InstRuctIons

The ACE Explosionproof VFD should be installed, inspected, and maintained by qualified and competent personnel.

1.1 aPPlIcatIon

The ACE Explosionproof VFD is rated 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 / wastewater

• Pharmaceutical

• Food and beverage manufacturing wARNINg

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.

1.2 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.

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 1660 • 01/14 Copyright © 2014, Eaton’s Crouse-Hinds Business Page 2

1.5 enclosuRe safety

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.

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.

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.

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.

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.

Wireless Interface Module (WIM) offered with ACE20 (Rockwell VFD) must be used with precaution. If the device communicating to the WIM is exposed to the hazardous environment during operation, it must be rated and certified for the area of intended use. For the device used to communicate to the WIM, refer to the manufacturer’s instructions on acceptable use.

2. MecHanIcal InstallatIon

2.1 aIRfloW PRoVIsIons - InstallatIon DRaWInG

"X"

"X"

3 first eight (8) cover screws sequentially per Figure 1 before torquing the remaining screws.

1

3

7

7

1

5 6

5 6

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).

2.2 WeIGHts

enclosure

1-5 HP

7-50 HP

Weight

390 lbs.

600 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.

4

2 8

2 8 figure 1 wARNINg

To avoid personnel injury and property damage, DO NOT remove or modify the control pad viewing window.

4

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 1660 • 01/14 Copyright © 2014, Eaton’s Crouse-Hinds Business Page 3

2.4 DIMensIonal DRaWInGs

632

24.88

128

5.04

487.7

19.20

106.4

4.19

248.7

9.79

812.2

31.98

398.4

15.69

555.6

21.88

438.2

17.25

156.6

6.17

101.5

4.00

1" NPT

1-1/2" NPT

(2 PLACES)

5/8" BOLT

(4 PLACES)

171.5

6.75

12.7

.50

106.6

4.20

215.8

8.50

ace size 1

638.8

25.15

125.7

4.95

555.6

21.88

1176.3

46.31

717.6

28.25

532.1

20.95

281.5

11.08

414.1

16.30

148.7

5.85

398.4

15.69

5/8" BOLT

(4 PLACES)

203.2

8.00

12.7

.50

88.8

3.50

93.9

3.70

228.5

9.00

1" NPT ace size 2

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.

2" NPT

(2 PLACES)

2.6 sHRouD InstallatIon

1. Remove rubber caps from explosionproof filters.

2. Insert threaded rods into the explosionproof filters. Leave 35 ⁄

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.

THREADED STUD

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.

5. Align enclosure with the two left side mounting feet engaged with the mounting bolts on selected mounting surface.

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.

figure 2

IF 1660 • 01/14 Copyright © 2014, Eaton’s Crouse-Hinds Business Page 4

ACORN NUT

LOCKING NUT

WASHER

3. electRIcal InstallatIon

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.

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 lugs 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

notch bracket

Guard

Detail View

4. Tighten screw.

5. Slip pre-filter mesh over guard.

Disconnect terminal shrouds

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.

explosionproof filter

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 40-50 HP units).

2. Attach line conductors with phase A on the left, B center, and C to the right (see torque table in Section 5.3).

3. Re-install terminal shrouds (only required on 40-50 HP units).

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.

1. Attach load conductors with phase A to W/T1, B to V/T2, and C to W/T3 (see torque table in Section 5.3).

2. Attach motor cable shielding to VFD ground (see recommendations by drive manufacturer).

3. 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

To avoid the transmission of noise to/from the blower, control system, and/or the variable frequency drive load conductors, be sure to bundle all field control wiring and shield as necessary.

IF 1660 • 01/14 Copyright © 2014, Eaton’s Crouse-Hinds Business Page 5

3.5 bloWeR anD sIGnal scHeMatIc

RED PIL

GREEN PIL

WHIT WHIT

TERMINAL BL

.6A FUSE

DIN RAIL MOUNTE TERMINAL BL

OCKS 1-6

TERMINAL BL

OCKS FACING BLOWER

TERMINAL BL

DIN RAIL MOUNTE TERMINAL BL

OCKS 7-12

TERMINAL BL

TERMINAL BL

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DIN RAIL MOUNTED TERMINAL BL

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DIN RAIL MOUNTED TERMINAL BL

TERMINAL BL

IF 1660 • 01/14 Copyright © 2014, Eaton’s Crouse-Hinds Business Page 8

RED PIL

GREEN PIL

WHIT WHIT

TERMINAL BL

.6A FUSE

DIN RAIL MOUNTE TERMINAL BL

OCKS 1-6

TERMINAL BL

DIN RAIL MOUNTE TERMINAL BL

OCKS 7-12

TERMINAL BL

TERMINAL BL

IF 1660 • 01/14 Copyright © 2014, Eaton’s Crouse-Hinds Business Page 9

DIN RAIL MOUNTED TERMINAL BL

TERMINAL BL

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TERMINAL BL

IF 1660 • 01/14 Copyright © 2014, Eaton’s Crouse-Hinds Business Page 11

4. GeneRal oPeRatIon

4.1 contRol PaD VIeWInG WInDoW

The control pad viewing window shows the control pad display containing such information as drive status and operating data. Refer to the drive manufacturer’s manual for information regarding the control pad display.

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.

2. Depress lockout tab at the end of the handle.

3. Install OSHA approved lock or tag.

4. Release lockout tab.

wARNINg

To avoid ignition of explosive atmospheres, all circuits must be de-energized before opening cover.

lockout tab

4.3 coMMunIcatIon MoDules

Available Options:

Protocol

Profibus

Devicenet

CAN Open

Modbus

Ethernet

Wireless cat. # suffix cP cD cc • ACE20 Only cM ce

Wl • ACE20 Only

Refer to the drive manufacturer’s manual for information regarding communication module and WIM installation and use.

4.4 Pot, RR3 (Hoa) anD Pb23 (PusHbutton staRt/ stoP)

Potentiometer, RR3, and PB23 options, when ordered, get wired to the drive for additional user control. Parameters for these options are set up at the factory.

Refer to drive manufacturer’s manual for further information as well as parameters in Section 7.1.

5. MaIntenance

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.

5.1 DRIVe MaIntenance

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.

5.2 coolInG systeM MaIntenance

1. Clean pre-filter periodically (recommended per parameters and values below). Remove pre-filter and rinse with water as needed.

Parameter number

ace20

234

Parameter type

Parameter

Description

235

236

Utility

Utility

Utility

Testpoint 1 Sel

Testpoint 1 Data

Testpoint 2 Sel

237 ace30

Utility Testpoint 2 Data

U4-08 Maintenance Monitors Heat Sink Temperature testpoint code

2 (Heat Sink Temperature)

37 (Control Board Temperature)

Maintenance check Point

105

72

105

2. Clean sintered filter as needed. Use of abrasives on the explosionproof filters may compromise the integrity of the cooling system.

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.

Disconnect shaft

Disconnect coupling ‘off’

Position blower

Intake

4. For ACE20 (Rockwell VFD), clean/inspect muffin fan.

5. Clean/inspect temperature controller.

6. Perform visual, electrical, and mechanical checks on all components on a regular maintenance schedule. NFPA 70B recommends maintenance intervals not exceeding 2 months.

7. Visually check for any damage to the filter assemblies, flat joints, threaded joints, journal joints, and window.

8. Visually check for evidence of excessive heating within the enclosure.

9. Mechanically check that all parts are properly assembled and operating mechanisms are in proper working condition.

10. Verify airflow provisions are maintained per Section 2.1.

IF 1660 • 01/14 Copyright © 2014, Eaton’s Crouse-Hinds Business Page 12

5.3 PeRIoDIc MecHanIcal MaIntenance (toRque

VeRIfIcatIon)

Item Description ace20 Drive (0.5-5 HP)

Line/Load & Ground ace20 Drive (7.5-20 HP)

Line/Load & Ground ace20 Drive (25-50 HP)

Line/Load & Ground ace30 Drive (0.75-5 HP)

Line/Load ace30 Drive (7.5-20 HP)

Line

Load

Ground ace30 Drive (25-30 HP)

Line/Load

Ground

Drive control (I/o)

ACE20 Drive

ACE30 Drive

Disconnect

30 Amp

60 Amp torque Requirements

Wire Range

18-6 AWG (0.9-13.2 mm 2 )

18-6 AWG (0.9-13.2 mm

2

)

14-3 AWG (2.1-26.6 mm 2 )

14-10 AWG (2.1-5.2 mm 2 )

8-6 AWG (8.4-13.2 mm

2

)

10-6 AWG (5.3-13.2 mm 2 )

10-8 AWG (5.3-8.3 mm 2 )

6-4 AWG (13.3-21.1 mm 2 )

8-6 AWG (8.4-13.2 mm 2 )

22-14 AWG (0.4-2.0 mm 2 )

24-16 AWG (0.2-1.3 mm 2 )

18-8 AWG (0.9-8.3 mm

2

)

14-4 AWG (2.1-21.1 mm 2 )

100 Amp blower fuse block terminal blocks temperature controller transformer

Internal Ground lug external Ground lug blower Manifold

Hose clamps cover bolts

14-2/0 AWG (2.1-67.4 mm 2 )

18-10 AWG (0.9-5.2mm

2

)

24-8 AWG (0.2-8.3 mm 2 )

24-12 AWG (0.2-3.3 mm 2 )

18-16 AWG (0.9-1.3 mm

2

)

16-2/0 AWG (1.4-67.4 mm 2 )

6-1/0 AWG (13.3-53.4 mm 2 )

N/A

N/A

N/A

5.4 status InDIcatIon

torque Required

12 in.-lbs. (1.4 N-m)

12 in.-lbs. (1.4 N-m)

16 in.-lbs. (1.8 N-m)

12 in.-lbs. (1.4 N-m)

25 in.-lbs. (2.8 N-m)

25 in.-lbs. (2.8 N-m)

45 in.-lbs. (5.1 N-m)

50 in.-lbs. (5.7 N-m)

45 in.-lbs. (5.1 N-m)

5.2 in.-lbs. (0.59 N-m)

4.8 in.-lbs. (0.54 N-m)

17 in.-lbs. (1.9 N-m)

30 in.-lbs. (3.4 N-m)

120 in.-lbs. (13.5 N-m)

20 in.-lbs. (2.3 N-m)

8 in.-lbs. (0.9 N-m)

5 in.-lbs. (0.54 N-m)

12 in.-lbs. (1.4 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)

45 ft.-lbs. (61 N-m)

There are two lights for the status indicator - a GREEN light to signify RUN and a RED light to signify STOP or fault condition. When both lights are off, this indicates the power is off to the drive.

6. tecHnIcal Data

6.1 tecHnIcal Data cHaRt

cc-H base cat. # encl.

size

Max.

Discon.

Rating

(amps)

Discon. fuse type nominal

HP

Input

Rating

(amps)

Max.

output

Rating

(amps)

Power loss

(Watts) temp.

Rating temp.

Derating factor

*ACE20 1

*ACE20 2

*ACE20 3

*ACE20 5

*ACE20 1 600

*ACE20 2 600

*ACE20 3 600

*ACE20 5 600

*ACE20 7

ACE20 10

ACE20 15

ACE20 20

ACE20 25

ACE20 30

ACE20 40

ACE20 50

*ACE30 1

*ACE30 2

ACE30 3

ACE30 5

*ACE30 2 600

ACE30 3 600

ACE30 5 600

*ACE30 7

ACE30 10

ACE30 15

ACE30 20

ACE30 25

ACE30 30

1

2

1

2

30

30

60

100

30

30

60

J

J

J

J

J

J

J

5

7.5

10

5

2

3

15

20

25

30

40

50

0.75

2

3

20

25

30

3

5

7.5

10

15

5

1

2

1

2

3

1.6

2.6

3.9

6.9

1.3

2.1

2.1

3.4

5.0

8.0

1.7

2.7

63

76

93

164 T6

54 T6

65 T6

T6

T6

T6

3.0

5.3

3.9

6.1

83

142

T6

T6

9.5

11.0

594 T4A

12.5

14.0

618 T4A

19.9

22.0

726 T4A

24.8

27.0

794 T4A

31.2

34.0

841 T4A

36.7

40.0

859 T4A

N/A

N/A

N/A

47.7

52.0

1010 T4A N/A

59.6

65.0

1117 T4A Figure 4

2.1

2.1

68 T6 N/A

4.3

8.1

4.1

6.9

81 T6

121 T6

N/A

N/A

9.4

3.6

5.1

8.8

2.7

3.9

126 T6

45 T6

61 T6

8.3

6.1

72 T6

14.0

11.1

562 T4A

20.0

17.5

685 T4A

24.0

23.0

754 T4A

38.0

31.0

855 T4A

44.0

38.0

921 T4A

52.0

44.0

999 T4A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

VfD Mfg. Part #

20BD027A0AYNANC0

20BE022A0AYNANC0

20BD027A0AYNANC0

20BD065A0AYNANC0

CIMR-AU4A0009FUA

CIMR-AU5A0006FUA

CIMR-AU4A0031FUA

CIMR-AU4A0044FUA

*Additional motor overload protection is required between VFD output and motor due to oversized VFD used. For other catalogs and setups refer to section 3.3 of this manual.

**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

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.

altitude and switching frequency De-rating:

Refer to the drive manufacturer’s de-rating guidelines for altitude and switching frequency and ensure compliance.

IF 1660 • 01/14 Copyright © 2014, Eaton’s Crouse-Hinds Business Page 13

7. cRouse-HInDs DRIVe PaRaMeteRs

7.1 PaRaMeteR table

Parameter number

Parameter type ace20

196

151

Utility

Dynamic Control ace20 RR3 (Hoa)

196

320 ace30

C6-02

Utility

Inputs & Outputs

Tuning ace30 RR3 (Hoa)

A1-03 Initialization

H3-02

H3-06

Terminal Functions

Terminal Functions

Parameter Description

Parameter Access Level

PWM Frequency

Parameter Access Level

Analog Input Configuration

Carrier Frequency

1 (Advanced)

2 (2 kHz)

1 (Advanced)

Bit 0 = 1 (Current)

1 (2 kHz)

Initialize Parameters 2220

Terminal A1 Function Selection 2

Terminal A3 Function Selection F

Parameter

Value ace30 Pb23 (Pushbutton start/stop)

A1-03 Initialization Initialize Parameters 3330

To ensure cooling system performance, these parameters must be maintained at all times while observing the appropriate de-rating factors.

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 Crouse-

Hinds Distributor. Assistance may also be obtained through your Crouse-Hinds Sales

Representative or the Crouse-Hinds Customer Service Department.

8.1 PRe-fIlteR kIt

ACE KIT1: Pre-filter and Hardware (1 pc.)

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.

8.2 sInteReD fIlteR kIt

ACE KIT2: Filter Assembly (1 pc.) explosionproof filter

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.

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.

notch bracket

Guard

Detail View

4. Tighten screw.

5. Slip pre-filter mesh over guard.

IF 1660 • 01/14 Copyright © 2014, Eaton’s Crouse-Hinds Business Page 14

8.3 bloWeR kIt

ACE KIT3: Blower, Manifold, and Hardware (1 pc.)

8.3.1 bloWeR InstallatIon InstRuctIons

1. Disconnect blower power, ground, and control leads from terminal blocks (refer to wiring diagrams in Section 3.5).

10. Align new manifold clamp bracket to threaded studs. Be sure the manifold clamp bracket flanges point toward the interior of the enclosure.

11. 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.

12. 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.

13. Tighten nuts wrench tight.

14. Tighten manifold hose clamp, while compressing the manifold to the blower, to

20 in.-lbs.

15. 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 five (5) nuts holding blower bracket and baffle to mounting plate. DO NOT remove.

3. Loosen and remove manifold clamp bracket nuts and lock washers. DO NOT remove jam nuts positioned behind the manifold clamp bracket.

blower cooling

Intake

Manifold clamp bracket loosen and Do not remove nut during replacement

16. Terminate the blower power wires to the appropriate terminal block connections

(refer to wiring diagrams in Section 3.5).

17. Perform a continuity check between each blower power terminal and each phase of the integral disconnect switch.

18. Terminate the blower control wires to the appropriate terminal block connections

(refer to wiring diagrams in Section 3.5).

19. Perform a continuity check between each blower control terminal and the temperature controller (refer to wiring diagrams in Section 3.5).

4. Remove blower and brackets.

5. Remove manifold and manifold clamp bracket.

6. Remove blower cooling intake and hose clamp from old blower assembly and hold for re-assembly.

7. Loosen and remove three (3) screws and washers holding the baffle and plug plate to the blower bracket. Remove baffle and plug plate and hold for re-assembly.

8. Attach baffle and plug plate to new blower bracket using the same three (3) screws and washers.

9. Align new manifold to enclosure wall.

20. Terminate the blower ground wire to the appropriate terminal block connection

(refer to wiring diagrams in Section 3.5).

21. Perform a continuity check between the ground terminal and the ground lug adjacent to the integral disconnect switch.

IF 1660 • 01/14 Copyright © 2014, Eaton’s Crouse-Hinds Business Page 15

8.4 teMPeRatuRe contRolleR

ACE KIT5: Temperature Controller

8.4.1 teMPeRatuRe contRolleR InstallatIon

InstRuctIons

1. Disconnect wire terminals from temperature controller. Do not remove wires from terminals.

2. Loosen two (2) nuts holding the temperature controller to the mounting plate. Do not remove.

3. Remove temperature controller.

4. Insert new temperature controller into place on mounting plate and tighten two (2) nuts down wrench tight.

5. Reconnect wire terminals to the temperature controller, ensuring terminals are fully inserted.

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 1660

Revision 3

Revised 01/14

Supersedes 12/13