Hardware Reference, Installation, and Troubleshooting Manual D2-3411-8 LiquiFlo AC Power Modules Version 6.
Important User Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices.
CONTENTS Chapter 1 Introduction 1.1 Related Publications ........................................................................................ 1-1 1.2 Getting Assistance from Reliance Electric....................................................... 1-1 Chapter 2 About the Drive 2.1 Identifying the Drive by Model Number ........................................................... 2-1 2.2 Enclosure Ratings ........................................................................................... 2-2 2.
Chapter 4 Mounting the Drive, Grounding, and Finding Wire Routing Locations 4.1 Lifting and Mounting the Drive .........................................................................4-1 4.1.1 Verifying the Drive’s Watts Loss Rating.................................................4-2 4.2 Determining Input, Motor Output, Ground, and Control Wire Routing for the Drive ........................................................................................4-2 4.
Appendix D C-Frame LiquiFlo Drive Wiring Diagrams .................................................................D-1 Appendix E D-Frame LiquiFlo Drive Wiring Diagrams .................................................................
IV LiquiFlo AC Power Modules, Hardware Reference Version 6.
List of Figures Figure 2.1 – Identifying the Drive Model Number ..................................................... 2-1 Figure 2.2 – B-Frame LiquiFlo Drive Component Locations..................................... 2-3 Figure 2.3 – C-Frame LiquiFlo Drive Component Locations .................................... 2-5 Figure 2.4 – D-Frame LiquiFlo Drive Component Locations .................................... 2-7 Figure 2.5 – LiquiFlo Regulator Board Component Locations..................................
VI LiquiFlo 2.
List of Tables Table 2.1 – Power and Enclosure Ratings ............................................................... 2-2 Table 2.2 – Available Kits and Options................................................................... 2-17 Table 3.1 – Environmental Conditions...................................................................... 3-2 Table 3.2 – Drive Dimensions and Weights.............................................................. 3-2 Table 3.3 – Recommended Power Wire Sizes for B-Frame Drives.
VIII LiquiFlo 2.
CHAPTER 1 Introduction This instruction manual describes the LiquiFlo™ drive’s Power Module and regulator hardware. It does not cover the LiquiFlo software. For software information, refer to the LiquiFlo AC General Purpose (V/Hz) and Vector Duty Drive Software Start-Up and Reference Manual (D2-3410). This manual is intended for qualified electrical and plumbing personnel. LiquiFlo drives will typically be referenced by frame size. If additional clarity is required, drive model numbers wil also be included.
1-2 LiquiFlo AC Power Modules, Hardware Reference Version 6.
CHAPTER 2 About the Drive This chapter describes how to identify the drive using the model number matrix and shows the major drive components. The LiquiFlo AC drive is a PWM (pulse-width-modulated) liquid-cooled drive that provides vector and general purpose regulation for a wide range of applications. Using vector regulation, the drive can provide high dynamic response, maintain full rated motor torque to zero speed, and precisely control motor speed in both directions.
Table 2.
1 2 3 12 9b 4 11 5 10 9a 8 7 6 Figure 2.
2.4 C-Frame LiquiFlo Drive Component Locations The C-Frame LiquiFlo drives have the following main components. The numbered items listed below provided correspond to the numbers used in figure 2.3. Replacement parts are listed in chapter 9. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
16 1 2 3 17 4 5 18 6 7 19 8 20 9 21 22 10 23 11 12 13 14 15 24 Figure 2.
2.5 D-Frame LiquiFlo Drive Component Locations The D-Frame LiquiFlo drives have the following main components. The numbered items listed below provided correspond to the numbers used in figure 2.4. Replacement parts are listed in chapter 9. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
1 2 3 4 14 5 6 7 8 9 10 11 12 13 Figure 2.
2.6 Regulator Board Description LiquiFlo drive regulation is performed by a microprocessor on the Regulator board. See figure 2.5. Drive operation is adjusted by the parameters entered through the keypad. The Regulator board accepts power circuit feedback signals and an external speed reference signal, as well as data from an encoder that is attached to the motor when set up for FVC regulation.
60-Pin Ribbon Cable J16 USER DISPLAY 34-Pin Ribbon Cable J3 J9 J7 J17 J4 J8 USER I/O TERMINAL STRIP J3 J4 J7 J8 - Option Board Connector J9 - Keypad/Display Connector J16 - Power Module Feedback Cable Analog Input Jumper OIM (Optional) Connector J17 - Analog Output Jumper RS-232C Port Figure 2.
2.6.1 Jumper Locations and Settings Jumpers J4 and J17 on the Regulator board are factory-set for voltage in and voltage out signals. Refer to figure 2.5 for their locations on the Regulator board. If you need to change the jumpers’ settings, use the following procedures. ! ATTENTION: Do not alter the setting of any jumper not described in this instruction manual. Failure to observe this precaution could result in damage to, or destruction of, the equipment. 2.6.1.
Step 8. Verify that Terminal Strip Analog Input Offset (P.009), Terminal Strip Analog Input Gain (P.010), and Terminal Strip Analog Input Configure (P.011) are correctly set. Note that the jumper settings must match the software settings; otherwise, the reference value may differ from what is expected. Refer to the LiquiFlo Software Start-Up and Reference manual for more information. Voltage Input Option Pins 2-3 Current Input Option Pins 1-2 +10 VDC 0-20 mA J4 (default) J4 Figure 2.
Step 7. Reapply input power. Step 8. Verify that parameter P.012 is set correctly for either speed or current. Voltage Output Option Pins 2-3 Current Output Option Pins 1-2 +10 VDC 4-20 mA J17 (default) J17 Figure 2.7 – Jumper J17 Settings for Analog Outputs 2.6.2 Wiring the Regulator Board Terminal Strip The terminal strip on the Regulator board provides terminals for connecting customer I/O devices. See figures 2.5 and 2.8.
18 19 RS-232 Connections Encoder Connections Analog Analog Speed Output Reference N.O. Relay Common 17 16 N.O. Relay Contact Isolated Reference Gnd 15 N.C. Relay Common Ma Speed Reference 14 N.C.
Refer to the appropriate board instruction manual for more information. Refer to section 2.8 of this manual for more information on optional drive kits. 2.6.5 Operator Interface Module Connector Flat-ribbon connector J7 provides a means of attaching the optional Operator Interface Module (OIM). The OIM is available for use as a remote keypad for the LiquiFlo drive. Refer to the OIM instruction manual (D2-3342) for more information. 2.6.
2.7 RMI Board Description The following signals are available at the RMI board terminal strip. Refer to figure 2.10 for terminal identification. For a detailed description of the RMI board signals, refer to section 7.4. 2.7.1 Digital Inputs Four 24 volt DC digital inputs provide additional speed reference options. The inputs are active high. A 24 VDC supply is provided by the RMI board for use with the digital inputs. The supply is short circuit- and overvoltage-protected. 2.7.
2.7.7 Wiring the RMI Board Terminal Strip ATTENTION: You are 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.
2.8 Optional Equipment Table 2.2 lists standard available LiquiFlo kits and options. Table 2.
2-18 LiquiFlo AC Power Modules, Hardware Reference Version 6.
CHAPTER 3 Planning the Installation This chapter provides how to plan a LiquiFlo drive installation. ! 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.
• Do not install the drive above 1000 meters (3300 feet) without derating output power. For every 91.4 meters (300 feet) above 1000 meters (3300 feet), derate the output current 1%. • Verify that the drive location will meet the environmental conditions specified in table 3.1. Table 3.
.563" Thru 4 Places B E F (Typ. 4 Pl.) A D C G (Typ. 4 Pl.) Front View Right Side View Figure 3.
.563" Thru 4 Places B E F (Typ. 4 Pl.) D G (Typ. 4 Pl.) A C Front View (Control Panel Assembly and Bus Laminate Removed) Right Side View Figure 3.2 – C-Frame Drive Dimensions 3-4 LiquiFlo AC Power Modules, Hardware Reference Version 6.
A C 13.93 F 16.50 16.50 D 0.56 6 Pl. B E Left Side View G Front View Figure 3.
3.1.3 Verifying the Site Provides for Recommended Air Flow Clearances Be sure there is adequate clearance for air circulation around the user-supplied enclosure. A 6-inch minimum clearance is required wherever vents are located in the cabinet. 3.1.4 Verifying Power Module Input Ratings Match Supplied Power It is important to verify that plant power will meet the input power requirements of the LiquiFlo drive’s Power Module circuitry. Refer to table 2.1 for input power rating specifications.
Table 3.3 – Recommended Power Wire Sizes for B-Frame Drives Type of Power Wiring Drive M/N 41L4060, 41LR4060 with kit M/N 41L4060PM AC Input Power (R/L1, S/L2, T/L3) Output Power (U/T1, V/T2, W/T3) Delta-Wye Transformer (S1 to S6) Lug1 accepts two (2) 300 MCM to 6 AWG conductors Ground (PE) 1Lugs not provided with standard drive. They are available as part of kit M/N 41L4060PM. Table 3.
Table 3.6 – Recommended Terminal Strip Wire Sizes Terminals Wire Size 1 to 31 (Regulator) 41 to 69 (RMI) 20 to 14 AWG, 2 to 0.5 (mm2) 3.2.2.4 Recommended Motor Lead Lengths Motor lead lengths can total up to 76 meters (250 feet). 3.2.2.5 Recommended Serial Communication Cable Lengths Connector J8 on the Regulator boards is an RS-232 serial communication port. This connector allows the LiquiFlo drive to communicate with external devices such as a personal computer using RS-232 protocol. See table A.5.
Table 3.7 – AC Input Line Fuse and Circuit Breaker Selection Values Model Number 41L4060 41LR4060 50LW4060 50LR4060 64LW4060 64LR4060 120L4060 Input Voltage (+/-10%) 380-480 VAC Fuse Rating 600 A1 Motor Circuit Protector or Circuit Breaker 600 A 380-480 VAC 750 A2 800 A 380-480 VAC 1000 A2 1000 A 380-480 VAC 1600 A2 1500 A 1 Recommended fuse type: UL Class J, 600 V, time-delay, or equivalent. 2 Recommended fuse type: UL Class L, 600 V, time-delay, or equivalent. 3.2.
3-10 LiquiFlo AC Power Modules, Hardware Reference Version 6.
CHAPTER 4 Mounting the Drive, Grounding, and Finding Wire Routing Locations This chapter shows how to mount the drive and properly ground it. Also shown are the entry areas where wiring is to be routed in and out of the drive. 4.1 Lifting and Mounting the Drive Use the following procedure to lift the LiquiFlo drive and mount it in the required enclosure: Step 1. For M/N 50LW4060, 50LR4060, 64LW4060, and 64LR4060, install two eyebolts into the drive to serve as lifting points.
In order to maintain a flat mounting surface and to ensure that bolt tightness is maintained, use flat washers and split-ring lock washers under the bolt heads. Refer to table 3.2 and figures 3.1 to 3.3 for drive mounting dimensions. Use the following user-supplied mounting bolts and washers on C-frame drives: 1/2”-13, UN/UNC-2A, Grade 2. Step 7. For M/N 50LW4060, 50LR4060, 64LW4060, and 64LR4060, remove the eyebolts and the chain between them.
Drive Input Wiring (6 Places) Drive Output Wiring (3 Places) Coolant Connections Top View User Connection Wiring User Connections Front View Bottom View Figure 4.
Drive Input Wiring Drive Output Wiring To Motor (3 Places) User Connections Coolant Connections Figure 4.2 – Wire Routing Locations for C-Frame LiquiFlo Drives 4-4 LiquiFlo AC Power Modules, Hardware Reference Version 6.
Drive Input 6 Places L1 U L4 Drive Output To Motor L2 V L5 L3 W L6 Left Side View User Control Connections Front View User Control Wire Openings Bottom View Figure 4.
4.3 Installing the DC Bus Reactor Fan (C-Frame Drives Only) A fan must be installed in the LiquiFlo drive enclosure to keep the DC bus reactor at the proper operating temperature. The fan should be a Comair Rotron M/N PT2B3 rated at 0.26 amps, 31 watts, 235 CFM (115 VAC, 60 Hz), or equivalent. Use the following procedure to install the DC bus reactor fan: Step 1. Open the door of the enclosure. Step 2. Mount the fan beneath the drive in the enclosure as shown in figure 4.
4.4 Grounding the Drive ! 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. Use the following steps to ground the drive: Step 1. Open the door of the enclosure. Step 2. Run a suitable equipment grounding conductor unbroken from the drive to the motor’s ground terminal and then to earth ground.
not be powered unless the drive is also powered. Failure to do this may result in condensation accumulating on the casting and/or circuit boards, which could damage the drive. 4.5.3 D-Frame Coolant Connections D-frame LiquiFlo drives have inlet and outlet coolant connections as shown in figure 4.7. The inlet and outlet connections are tapped holes suitable for two bolt-hole flanges. The internal threads of the tapped holes are 5/16-18 UNC-2B. The depth of thread is 3/4".
Hose assemblies are provided with the drive. Hose assemblies of longer length are provided with kit M/N 64L4060PM, or can be usersupplied. Coolant Outlet Connection Coolant Inlet Connection Figure 4.6 – Coolant Connector Locations for C-Frame LiquiFlo Drives Tube assemblies, gaskets, and hardware are provided with kit M/N 120L4060PM, or can be user-supplied. Coolant Inlet Connection Front View Coolant Outlet Connection Figure 4.
4-10 LiquiFlo AC Power Modules, Hardware Reference Version 6.
CHAPTER 5 Installing Input Power Wiring This chapter describes incoming line components and how to install them. 5.1 Installing Transformers and Reactors (Optional) The LiquiFlo AC drive may be used on distribution systems with 85,000 amps or less symmetrical fault current capacity. Line reactors are not needed for safe operation of the drive but may be required to reduce line harmonics.
3-Phase AC Input Voltage 380/480 V L2 L1 L3 GND Manual Disconnect User-Supplied Fuse Interconnecting bus bar provided with M/N 41L4060PM, 64L4060PM, or 120L4060PM kit, or can be user-supplied. GND (PE) L1 L2 L3 L6 L5 L4 LiquiFlo Power Module U W V User-Supplied M GND Figure 5.1 – Typical AC Input/Output Electrical Connections (6-Pulse Rectifier, All Frames) 5-2 LiquiFlo AC Power Modules, Hardware Reference Version 6.
3-Phase AC Input Voltage 380/480 V 181 182 183 GND Manual Disconnect User-Supplied Fuse Transformer L1 L2 L3 L6 L5 L4 GND (PE) LiquiFlo Power Module U V W User-Supplied M GND Figure 5.
5.3 Installing a Required External/Separate Input Disconnect An input disconnect must be installed in the line before the drive input terminals in accordance with local, national, and international codes (e.g., NEC/CEC). The disconnect should be sized according to the in-rush current as well as any additional loads the disconnect might supply. The trip rating for the inrush current (10-12 times full load current) should be coordinated with that of the input isolation transformer, if used.
CHAPTER 6 Installing Output Power Wiring This chapter provides instructions on wiring output contactors, motor overload protection, and output wiring to the motor. 6.1 Installing Output Contactors (Optional) Output contactors provide a positive means of disconnecting the motor from the drive. If the application requires the use of output contactors, contact Reliance Electric for assistance. 6.
6.3 Installing Output Wiring from the Drive Output Terminals to the Motor Important: The total motor lead length must not exceed 76 meters (250 feet). Use the following steps to connect the AC output power wiring from the drive to the motor: Step 1. Wire the three-phase AC output power motor leads by routing them as shown in figures 4.1, 4.2, or 4.3. Tables 3.3, 3.4, and 3.5 contain the recommended power wiring sizes. Do not route more than three sets of motor leads through a single conduit.
CHAPTER 7 Wiring the Regulator Board and RMI Board Terminal Strips This chapter describes how to wire the Regulator board and RMI board terminal strips for stop, encoder feedback, and remote control signals. The signals available through the Regulator board terminal strip are shown in tables 7.1 to 7.7 and figures 7.1 and 7.2. Table 7.8 provides additional information. Note that when the Control Source parameter (P.
Table 7.3 – Analog Output Connections (Terminals 10 and 11) Terminal # Signal 10 Analog Meter Output 11 Regulator Common Notes: The output of this terminal is either 0-10 VDC or 4-20 mA as determined by the setting of jumper J17 on the Regulator board. The analog output must also be programmed via parameter P.012 for an indication of speed and direction or percent of torque. Table 7.
. Table 7.
Table 7.7 – Status Relay Connections (Terminals 28-31) Terminal # Signal 28 N.C Relay Contact 29 N.C. Relay Common 30 N.O. Relay Contact 31 N.O. Relay Common Notes: Relay contact closure is programmable through parameter P.013. Refer to the LiquiFlo Software Start-Up and Reference manual for more information. 7-4 LiquiFlo AC Power Modules, Hardware Reference Version 6.
RS-232 RX RS-232 Regulator Common +15 VDC Phase A RS-232 TX 2 3 4 12 13 14 Phase A NOT Phase B Phase B NOT Regulator Common Analog Meter Output Regulator Common Isolated Reference Voltage VDC Speed Reference mA Speed Reference Isolated Reference Gnd +24 VDC Digital Input 8 (Remote/Local) Digital Input 7 (Ramp1/Ramp2) Digital Input 6 (Forward/Reverse) Function Loss Run / Jog Reset Stop Start +24 VDC Common No Connection +24 VDC Common N.C. Relay Contact N.C. Relay Common N.O. Relay Contact N.O.
7-6 RS-232 TX RS-232 RX RS-232 Regulator Common +15 VDC Phase A Phase A NOT Phase B Phase B NOT Regulator Common Analog Meter Output Regulator Common Isolated Reference Voltage VDC Speed Reference mA Speed Reference Isolated Reference Gnd +24 VDC Digital Input 8 (Remote/Local) Digital Input 7 (Ramp1/Ramp2) Digital Input 6 (Forward/Reverse) Function Loss Run / Jog Reset Stop Start +24 VDC Common No Connection +24 VDC Common N.C. Relay Contact N.C. Relay Common N.O. Relay Contact N.O.
7.1 Stopping the Drive ! ATTENTION: When P.055 is set to ON, the STOP/RESET key is functional only from the selected control source. As a safety precaution, Reliance recommends that an emergency stop push button be located near the drive in an easily accessible location. As a further safety precaution, the user should post a warning on the drive to alert personnel that the STOP/RESET key is not functional. Failure to observe this precaution could result in severe bodily injury or loss of life.
7.2 Wiring the Encoder Feedback Device (FVC Regulation Only) If the LiquiFlo drive is programmed to provide FVC regulation, an encoder must be installed. Drives using V/Hz or SVC regulation do not require the use of an encoder feedback device.
Tamagawa-Style, 16-Pin MS Connector View of Encoder Cable MS Connector (Female) (M/N 2TC4025 and 2TC4075) Regulator Terminal Strip Terminal 6 Terminal 5 Connector/Cable End Pin 1 Phase A Pin 2 Phase A Not Terminal 4 Pin 6 0 VDC Terminal 9 Pin 12 +15 VDC Terminal 7 Pin 8 Phase B Terminal 8 Pin 9 Phase B Not Dynapar-Style, 10-Pin MS Connector View of Encoder Cable MS Connector (Female) (M/N 2TC3025 and 2TC3075) Regulator Terminal Strip Terminal 6 A H B I G C J F E F Connector/Cabl
7.3 Wiring the Signal and Control I/O Wire the drive’s signal and control I/O to the Regulator board terminal strip as shown in table 7.8. Table 7.
Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring Analog Outputs 10 0-10 VDC or 4-20 mA Analog Output Reference 11 Regulator Common The setting of parameter P.012 selects the terminal strip analog output source (either speed or torque). Jumper J17 must also be set. See figure 2.5. The 4-20 mA current selection requires a power supply for operation.
Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring Analog Speed Reference Inputs Isolated Reference Voltage (+10VDC) 13 Analog Speed/Torque Reference Input Voltage (+/10VDC) • P.009: Terminal Strip Analog Input Offset Analog Speed/Torque Reference Input Current (0-20mA) • P.
Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring a Remote/Local Input 16 +24 VDC Power Supply Current limited for remote input logic use only. 17 Digital Input 8 (Default - Remote/Local) Digital input 8 is control function programmable through parameter P.007.
Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring an Additional Ramp Input 18 Digital Input 7 (Default - Ramp1/Ramp2) Digital input 7 is control function programmable through parameter P.007. The following parameters must be set: • P.000:Control Source • P.001:Accel Time 1 (Ramp 1) • P.002:Decel Time 1 (Ramp 1) • P.006:Second Menu Password • P.
Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring a Forward/Reverse Input 19 Digital Input 6 (Default - Forward/Reverse) Digital input 6 is control function programmable through parameter P.007. The following parameters must be set: • P.000:Control Source • P.006:Second Menu Password • P.007:Terminal Strip Digital Inputs Configure (Selects and assigns a control function to digital inputs 6 to 8) • P.
Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring a Function Loss Input 20 Digital Input 5 (Function Loss) The following parameters must be set: • P.026:Function Loss Response A signal must be present at terminal 20 for the drive to be able to start. See figures 7.1 and 7.2. The drive is shipped from the factory with a jumper between terminals 16 and 20 which provides the signal.
Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring the Reset Input 22 Digital Input 3 (Reset) The following parameter must be set: • P.000: Control Source Terminal 22 On = Reset Wiring the Stop/Start Inputs 23 24 Digital Input 2 (Stop) The following parameter must be set: Digital Input 1 (Start) • P.025: Stop Type • P.
Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring the Output Status Relays 28 Normally-Closed Contact (Form B) Both Form A and Form B contacts are rated for 250 VAC/ 30 VDC at 5 amps resistive or 2 amps inductive load. 29 Normally-Closed Contact Common (Form B) The following parameter must be set: 30 Normally-Open Contact (Form A) 31 Normally-Open Contact Common (Form A) • P.
7.4 Wiring the RMI Board Terminal Strip ATTENTION: You are 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.
Table 7.9 – Wiring Signal and Control I/O to the RMI Board Terminal Strip Terminal Number Related Parameters, Specifications, and Jumpers Description Digital Inputs, Control Voltage Output 41 42 43 44 Digital Input 1 Digital Input 2 Digital Input 3 Digital Input 4 The four digital inputs are configured using parameter r.030. 45 +24 VDC Supply, Control Voltage Output Current-limited and isolated. This supply should not be used as an external supply for anything other than the four digital inputs.
Table 7.9 – Wiring Signal and Control I/O to the RMI Board Terminal Strip (Continued) Terminal Number Related Parameters, Specifications, and Jumpers Description Analog Outputs 65 Analog Output No. 1 0 to 10 VDC Configuration: r.001 Offset: r.002 Gain: r.003 66 Analog Output No. 2 – 10 to +10 VDC Configuration: r.004 Offset: r.005 Gain: r.006 67 Analog Output No. 3 V OUT: 0 to 10 VDC C OUT: 0 to 20 mA Configuration: r.007 Offset: r.008 Gain: r.
7-22 LiquiFlo AC Power Modules, Hardware Reference Version 6.
CHAPTER 8 Completing the Installation This chapter provides instructions on how to perform a final check of the installation before power is applied to the drive. ! 8.1 ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should start and adjust it. Read and understand this manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
Step 10. Check the motor installation and length of motor leads. Step 11. Disconnect any power correction capacitors connected between the drive and the motor. Step 12. Check that the rating of the transformer (if used) matches the drive requirements and is connected properly. Step 13. Verify that a properly-sized ground wire is installed and a suitable earth ground is used. Check for and eliminate any grounds between the motor frame and the motor power leads. Verify that all ground leads are unbroken.
CHAPTER 9 Troubleshooting the Drive This chapter describes how to troubleshoot the drive and the equipment that is needed to do so. Also provided are replacement part lists and information on clearing faults. 9.1 Test Equipment Needed To Troubleshoot An isolated multimeter will be needed to measure DC bus voltage and to make resistance checks. Note that dedicated troubleshooting test points are not provided. 9.
Step 3. Measure the DC bus potential with a voltmeter while standing on a non-conductive surface and wearing insulated gloves (1000 V). Measure the DC bus potential at the test points on the Power Module Interface board. See figure 9.1 for B-frame drives, figure 9.2 for C-frame drives, or figure 9.3 for D-frame drives. For additional wiring information, refer to Appendix C, Appendix D, or Appendix E. Step 4. Once the drive has been serviced, reapply input power.
Initial DC Bus Measurement Points Figure 9.
Initial DC Bus Measurement Points POS (+) NEG (-) TP1 TP2 Figure 9.3 – DC Bus Voltage Terminals (D-Frame Drives) 9-4 LiquiFlo AC Power Modules, Hardware Reference Version 6.
9.4 Checking the Power Modules with Input Power Off Use the following procedure to check the drive’s Power Module circuitry with power off: ! 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 the DC bus capacitors are discharged before touching any internal components.
Table 9.1 – Resistance Checks Input Diode No. Meter Connection (+) (-) 1 * L1 2 * L2 3 * L3 4 * L4 5 * L5 6 * L6 7 L1 ** 8 L2 ** 9 L3 ** 10 L4 ** 11 L5 ** 12 L6 ** Component is OK if resistance (R) is: 10 < R < 1 megohm Component is defective if: Continuity (short circuit) or open when the meter is connected with reversed polarity. * (+) DC Bus Volts power terminal ** (-) DC Bus Volts power terminal Table 9.1 - Resistance Checks (Continued) IGBT No.
9.5 Replacement Parts Tables 9.2, 9.3, and 9.4 list the replacement parts that are available from Reliance Electric. See figures 2.2, 2.3, and 2.4 for the location of the parts. Table 9.2 – B-Frame LiquiFlo Drive Replacement Parts Quantity Part Number M/N 41L4060 M/N 41LR4060 350 HP Power Module Control (PMC) Printed Circuit Board 179170 1 Gate Driver PCB 179168 1 410483-15B 1 179116 1 814.56.
Table 9.3 – C-Frame LiquiFlo Drive Replacement Parts Quantity Part Number M/N 50LW4060 M/N 50LR4060 M/N 64LW4060 M/N 64LR4060 450 HP Power Module Adapter (PMA) Printed Circuit Board (PCB) 179134 1 — 600 HP Power Module Adapter (PMA) Printed Circuit Board (PCB) 179067 — 1 DC Bus Control PCB 179069 1 1 Gate Driver PCB 179065 2 2 410483-15B 1 1 179116 1 1 814.56.
Table 9.4 – D-Frame LiquiFlo Drive Replacement Parts Quantity Description Part Number M/N 120L4060 1000 HP Power Module Control (PMC) Printed Circuit Board 179452 1 Gate Driver PCB 179355 3 410483-15B 1 179116 1 814.56.
9-10 LiquiFlo AC Power Modules, Hardware Reference Version 6.
APPENDIX A Technical Specifications Table A.1 – Service Conditions AC Line Distribution System Capacity (maximum) for 460 VAC Units 85,000 amps symmetrical fault current capacity. Short circuit rating may be limited to 65,000 amps if a circuit breaker is used instead of fuses. Control Method All-digital vector, sinusoidal pulse-width-modulated (PWM) Displacement Power Factor 0.
Table A.2 – Environmental Conditions Condition * Specification Operating Temperature (inside an enclosure) 0°C to 55°C* (32°F to 131°F) Storage Temperature (Ambient) -40°C to 65°C (−40°F to 149°F) Humidity 5% to 95% (non-condensing) User-supplied cabinet air cooling system must provide adequate heat dissipation to maintain an internal temperature not to exceed 55°C. Refer to table 2.1 for drive air watts loss. Table A.
Table A.5 – Terminal Strip RS-232 Specifications Signal Type Terminal(s) Specification RS-232 Communications 1 XMIT 2 RECV 3 COMMON Table A.
Table A.7 – Input Signal Response Times (Maximum) Signal Type and Source Volts/Hertz Regulation* Vector Regulation* 150 milliseconds 130 milliseconds START 126 milliseconds 105 milliseconds STOP, RESET, FL 75 milliseconds 75 milliseconds Preset Speeds 75 milliseconds 75 milliseconds Analog Speed/Trim Reference 16 milliseconds 5 milliseconds N/A 0.
APPENDIX B Cooling System Specifications M/N 50LW4060 M/N 50LR4060 M/N 41L4060 M/N 41LR4060 M/N 64LW4060 M/N 64LR4060 M/N 120L4060 Coolant Type Potable water with no additives. Refrigerant Potable water with no additives. Refrigerant Potable water with approved corrosion inhibitor1. Inlet Coolant Temperature Range 15oC to 40oC (60oF to 104oF)2 See note3. 15oC to 40oC (60oF to 104oF)2 See note3. 15oC to 40oC (60oF to 104oF)2 Minimum Coolant Flow 7.0 gpm Rate at Full Load See note3. 5.
B-2 LiquiFlo AC Power Modules, Hardware Reference Version 6.
APPENDIX C B-Frame LiquiFlo Drive Wiring Diagrams Replace with file C.fm (17 x 11, z-fold).
C-2 LiquiFlo 2.
APPENDIX D C-Frame LiquiFlo Drive Wiring Diagrams Replace with file D.fm (17 x 11, z-fold).
D-2 LiquiFlo 2.
APPENDIX E D-Frame LiquiFlo Drive Wiring Diagrams Replace with file E.fm (17 x 11, z-fold).
E-2 LiquiFlo 1.5 AC Power Modules, Hardware Reference Version 1.
INDEX A AC input diodes, checking, 9-5 to 9-6 disconnect, installing, 5-2 to 5-4 isolation, transformer, 5-1 line branch circuit fuses, 3-8, 5-2 to 5-4 ratings, 2-2 wire sizes, 3-7 to 3-8 wiring, 3-7 to 3-8, 4-2 to 4-5, 5-1 to 5-4 voltage transients, avoiding, 5-1 AC line reactors, 5-1 AC output wiring, 3-7 to 3-8, 4-2 to 4-5, 6-1 to 6-2 Air flow, 3-1, 3-6 Alarms, 9-1 Altitude requirements, 3-2 Ambient conditions 3-2, A-2 Analog output, 2-8, 2-9, 2-11 to 2-12 0-10 VDC (J17), 2-11 to 2-12, A-2 4-20 mA (J17),
E Emergency stop, 7-6 Enclosures, NEMA, 2-2, 3-1 Encoder specifications, A-3 wiring, 2-12 to 2-13, 7-8 Environmental conditions, 3-1 to 3-2, A-2 F Fan, DC bus reactor, 4-6 Faults, 9-1 Flux vector regulation, 2-1 Form A contacts, see Status Relays Form B contacts, see Status Relays Forward (digital input 6), 2-12 to 2-12, 7-3 to 7-5, 7-14 Frequency, carrier, 2-8, A-1 Frequency, line, A-1 Function loss (digital input 5), 2-12 to 2-13, 7-3 to 7-5, 7-15 Fuse AC input, 3-7, 5-2 to 5-3 requirements, 3-1 to 3-9
Network AutoMax Network Option board, 2-17 communication, 2-13, 3-7 O Open loop, see Volts/Hertz Regulation Option kits, see Kits Output analog, see analog Output contactors, 6-1 digital, see Status Relays specifications, terminal strip, A-2 Overload, motor, 6-1 Remote (digital input 8), 2-12 to 2-11, 7-3 to 7-5, 7-12 Replacement parts, 9-5 Reset (digital input 3), 2-10 to 2-13, 7-3 to 7-5, 7-16 Resistor, bus discharge, 2-2 to 2-5 Reverse (digital input 6), 2-12 to 2-13, 7-3 to 7-5, 7-14 RMI board, 2-13 t
Transients, AC line voltage, 5-1 V Vector regulation, 2-1 Ventilation, see Air Flow Volts/hertz regulation, 2-1 W Watts loss rating, 2-2, 4-1 Weight, 3-2 Index-4 LiquiFlo AC Power Modules, Hardware Reference Version 6.
U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives www.rockwellautomation.com 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.
