Product Advisories: FlexPak3000 and Bulletin 1397 - 400 to 600 Horsepower products shipped since September 2000.

Ref: CPAG 2001-09-002

Problem Description

In certain applications a fire hazard is created because two of the four output bus bars of 400-600 HP FlexPak3000 and A-B Bulletin 1397 DC drives were incorrectly labeled during the period from September 2000 through May 2001. The busbar labels, located at the top of the drive, should read from left to right; A1, S2, DBR, A2/S1. Drives produced during this period were incorrectly labeled; A1, A2/S1, DBR, S2. The labels "S1" and "A2/S2" are the labels of concern because their positions are swapped on the affected drives.

In drive applications utilizing a stabilized shunt motor with Dynamic Braking or Inverting Fault Circuit Breaker kits, the incorrect labeling results in drive power wire connections, which would be incorrect. In these situations, an internal link jumper (A2/S1 - S2) is removed per the drive instruction manuals. This could result in a condition where the motor armature circuit is not protected by the Inverting Fault Circuit Breaker and/or wiring properly sized for dynamic braking duty current will, instead, be subject to the motor armature full load current continuously carrying approximately three (3) times its rated ampacity. Either one of these conditions creates a fire hazard.

Reliance Brand Kit M/N's:

• Dynamic Braking Kits: 913FK4000, 913FK5000, 913FK6000 ( I/M D2-3374 )
• Inverting Fault Breaker Kit: 906FK3101 ( I/M D2-3421 )

Allen Bradley Brand Kit M/N's:

• Dynamic Braking Kits: 1397-DB-B400L, 1397-DB-B500L, 1397-DB-B600L (Pub. 1397-5.15)
• Inverting Fault Breaker Kit: 1397-IFB600 (Pub. 1397-5.29)

See Fig. 2.21 of FlexPak3000 Hardware manual (D2-3404) for proper bus bar label locations.

Drive applications wired for use with a straight shunt motor and no other options wired into the armature circuit (i.e. Dynamic Braking or Inverting Fault Circuit Breaker kits), allows for motor terminal A2 to be wired to either A2/S1 or S2 of the drive (see FlexPak3000 Installation Instruction Manual D2-3404 or Bulletin 1397 Publication 1397-5.0). In this situation, the mis-labeled condition of the A2/S1 and S2 busbars would be electrically correct and the drive would operate properly.

Product Identification

This Safety Alert affects all FlexPak3000 and Bulletin 1397 DC drives shipped since September 2000. This product may have been supplied through Drive Systems, Regional Drive Centers or through Distribution and is shipped as standard with the following product model numbers:

Requested Customer Action

We request that customers perform the following actions:

• Make note of the information provided in this letter and ensure that their application will not be adversely affected by this product's operation.
• It is requested that the customer contact the Rockwell Automation Technical Support at (440) 646-5800 so that appropriate corrective action can be determined. This action at a minimum will require the re-labeling of the affected Bus Bars. If the affected drive is wired to a series field motor and/or the drive includes dynamic braking or inverting fault circuit breaker option kits, drive re-wiring may be required. Refer to drive and associated option kit manuals.
  

We require and appreciate your immediate cooperation in this matter. If you have any questions regarding this Safety Alert, please contact us.