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Rockwell Automation 41LR4060, Instruction Manual

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Rockwell Automation 41LR4060 Instruction Manual Download Page 18

2-6

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

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.

Chillplate Harness

2.

Bus Bars (AC Input)

3.

Bus Bars (AC Output)

4.

Power Module Control PCB

5.

Membrane Switch Keypad

6.

Regulator PCB

7.

RMI Option PCB

8.

Current Feedback Devices

9.

Gate Driver PCB

10.

Coolant Connection (Outlet)

11.

IGBT Module

12.

Capacitors

13.

Coolant Connection (Inlet)

14.

Output Laminate

Summary of Contents for 41LR4060

Page 1: ...Instruction Manual LiquiFlo AC Power Modules Hardware Reference Installation and Troubleshooting Version 6 4 D2 3411 7 ...

Page 2: ... or loss of life ATTENTION DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power wait five 5 minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components Failure to observe this precaution could result in severe bodily in...

Page 3: ...g Outputs 2 15 2 7 6 Frequency Input 2 15 2 7 7 Wiring the RMI Board Terminal Strip 2 16 2 8 Optional Equipment 2 17 Chapter 3 Planning the Installation 3 1 General Requirements for the Installation Site 3 1 3 1 1 Making Sure Environmental Conditions are Met 3 1 3 1 2 Determining Total Area Required Based on Drive Dimensions 3 2 3 1 3 Verifying the Site Provides for Recommended Air Flow Clearances...

Page 4: ...e Drive s Power Terminals 5 4 Chapter 6 Installing Output Power Wiring 6 1 Installing Output Contactors Optional 6 1 6 2 Installing Mechanical Motor Overload Protection Optional 6 1 6 3 Installing Output Wiring from the Drive Output Terminals to the Motor 6 2 Chapter 7 Wiring the Regulator Board and RMI Board Terminal Strips 7 1 Stopping the Drive 7 7 7 2 Wiring the Encoder Feedback Device FVC Reg...

Page 5: ...Contents III Appendix D C Frame LiquiFlo Drive Wiring Diagrams D 1 Appendix E D Frame LiquiFlo Drive Wiring Diagrams E 1 ...

Page 6: ...IV LiquiFlo AC Power Modules Hardware Reference Version 6 4 ...

Page 7: ... Figure 4 2 Wire Routing Locations for C Frame LiquiFlo Drives 4 4 Figure 4 3 Wire Routing Locations for D Frame LiquiFlo Drives 4 5 Figure 4 4 DC Bus Reactor Cooling Fan Mounting Location 4 6 Figure 4 5 Coolant Connector Locations for B Frame LiquiFlo Drives 4 8 Figure 4 6 Coolant Connector Locations for C Frame LiquiFlo Drives 4 9 Figure 4 7 Coolant Connector Locations for D Frame LiquiFlo Drive...

Page 8: ...VI LiquiFlo 2 0 AC Drive User Manual ...

Page 9: ...ble 7 1 RS 232 Connections Terminals 1 3 5 1 Table 7 2 Encoder Connections Terminals 4 9 7 1 Table 7 3 Analog Output Connections Terminals 10 and 11 7 2 Table 7 4 Analog Speed Torque Reference Connections Terminals 12 15 7 2 Table 7 5 Digital Input Connections Terminals 16 25 7 3 Table 7 6 Reserved Connections Terminals 26 and 27 7 3 Table 7 7 Status Relay Connections Terminals 28 31 7 4 Table 7 8...

Page 10: ...VIII LiquiFlo 2 0 AC Drive User Manual ...

Page 11: ...d drive model numbers wil also be included 1 1 Related Publications Refer to the following related publications as necessary for more information D2 3410 LiquiFlo AC General Purpose V Hz and Vector Duty Drive Software Start Up and Reference Manual D2 3305 Motor Encoder Cable Kit D2 3348 Control and Configuration Software CS3000 D2 3341 Remote Meter Interface Board D2 3342 Operator Interface Module...

Page 12: ...1 2 LiquiFlo AC Power Modules Hardware Reference Version 6 4 ...

Page 13: ... Using general purpose volts hertz or V Hz regulation the drive is suited for a broad range of applications requiring adjustable speed control of motors 2 1 Identifying the Drive by Model Number Each LiquiFlo AC drive can be identified by its model number See figure 2 1 This number appears on the shipping label and on the drive s nameplate The drive s model number includes the Power Module and the...

Page 14: ...ive Component Locations The B Frame LiquiFlo drives have the following main components The numbered items listed below provided correspond to the numbers used in figure 2 2 Replacement parts are listed in chapter 9 Model Number Frame Size and Selected Regulation Enclosure Rating Input Power KVA Input Current Amps Output Current at 2 kHz Amps Full Load Power Loss Watts Fluid Air 41L4060 41LR4060 B ...

Page 15: ...About the Drive 2 3 Figure 2 2 B Frame LiquiFlo Drive Component Locations 1 2 3 4 10 9a 8 7 6 5 12 9b 11 ...

Page 16: ...dapter Printed Circuit Board PCB 4 Power Interface Harness 5 Bus Bars AC Output 6 LEM InterfaceHarness 7 DC Bus Control PCB 8 Gate Driver PCB Low Side 9 DC Bus Laminate Assembly 10 Output Current Feedback Devices 11 IGBT Modules 12 Chillplate Heatsink 13 Capacitors 14 Drive Baseplate 15 Reactor Not Shown 16 Discharge Resistors Not Shown 17 Control Panel Assembly 18 Bus Control PMA Harness 19 Bus C...

Page 17: ...About the Drive 2 5 Figure 2 3 C Frame LiquiFlo Drive Component Locations 1 3 5 7 8 21 22 23 9 15 11 13 20 17 12 10 2 4 6 14 18 19 16 24 ...

Page 18: ...below provided correspond to the numbers used in figure 2 4 Replacement parts are listed in chapter 9 1 Chillplate Harness 2 Bus Bars AC Input 3 Bus Bars AC Output 4 Power Module Control PCB 5 Membrane Switch Keypad 6 Regulator PCB 7 RMI Option PCB 8 Current Feedback Devices 9 Gate Driver PCB 10 Coolant Connection Outlet 11 IGBT Module 12 Capacitors 13 Coolant Connection Inlet 14 Output Laminate ...

Page 19: ...About the Drive 2 7 Figure 2 4 D Frame LiquiFlo Drive Component Locations 8 9 7 6 5 4 3 2 1 13 10 11 12 14 ...

Page 20: ...IGBTs can be switched at either a 2 4 or 8 kHz carrier frequency Form A and B contacts for drive status indicators The Form A and B contacts are under control of the user via programmable parameters A Form A or B transition can indicate drive status The contacts are rated for 5 amps resistive load at 250 VAC 30 VDC and are made available through the terminal strip Display data for a four character...

Page 21: ... USER I O TERMINAL STRIP 34 Pin Ribbon Cable J8 J17 J4 60 Pin Ribbon Cable J16 J9 J3 J3 Option Board Connector J4 Analog Input Jumper J7 OIM Optional Connector J8 RS 232C Port J9 Keypad Display Connector J16 Power Module Feedback Cable J17 Analog Output Jumper USER DISPLAY J7 ...

Page 22: ...eference manual for more information Use the following procedure to set jumper J4 Step 1 Turn off input power to the drive and wait five minutes Step 2 Open the door of the enclosure Step 3 Verify that the DC bus voltage is zero by following the procedure in section 9 3 Step 4 Locate jumper J4 on the Regulator board Refer to figure 2 5 Step 5 Locate pin 1 on jumper J4 Move the jumper to the desire...

Page 23: ...equires a power supply for operation as shown in table 7 8 terminals 10 and 11 Use the following procedure to set jumper J17 Step 1 Turn off input power to the drive and wait five minutes Step 2 Open the door of the enclosure Step 3 Verify that the DC bus voltage is zero by following the procedure in section 9 3 Step 4 Locate jumper J17 on the Regulator board Refer to figure 2 5 Step 5 Locate pin ...

Page 24: ...minals 1 3 RS 232 connections Terminals 4 9 encoder connections Terminals 10 11 analog output connections Terminals 12 15 analog speed torque reference connections Terminals 16 25 24 VDC digital input connections Terminal 26 no connection Terminal 27 24 VDC common Terminals 28 31 status relay connections See chapter 7 for a complete description of and how to wire all of the signals available throu...

Page 25: ...MI board s analog or frequency input See section 2 7 for a more detailed description of the RMI board Refer to section 7 4 for a detailed description of the RMI terminal strip signals and how to wire the RMI board The J3 connector can also be used to provide a means of attaching optional boards such as the DeviceNet Option board the AutoMax Network Option board or similar boards to the LiquiFlo dr...

Page 26: ...Refer to the OIM instruction manual D2 3342 for more information 2 6 6 Keypad Display The front panel keypad display is used to program and operate the LiquiFlo drive See figure 2 9 The four character display is used to indicate drive parameters parameter values and fault codes The fourteen single LEDs indicate drive status and mode as well as identifying drive outputs whose values are displayed o...

Page 27: ...n to select an external 24 volt supply for increased current capability at the outputs is jumper selectable 2 7 3 Relay Outputs Three relay outputs can be turned on and off as a result of data comparisons in the drive Each output has an adjustable time delay that can be programmed as an on delay or an off delay All contacts are rated at 2A 24VDC or 250VA 120VAC 2 7 4 Analog Input The analog input ...

Page 28: ... 10 Terminal Connections on the RMI Board 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 Digital Input 1 Digital Input 2 Digital Input 3 Digital Input 4 24 V for digital inputs only External 24 V Input for Digital Outputs Digital Output 1 Digital Output 2 Digital Output 3 Digital Output 4 Digital Output Common Relay 1 Common Relay 1 Normally Open Relay 2 Nor...

Page 29: ...terBus S Network Option Board 2NB3000 49 1333 AutoMax Network Option Board with 762mm 30 of Cable 2AX3000 D2 3308 Johnson Metasys N2 Option Board 2MT3000 HE HGV3MT Landis and Staefa P1 Option Board 2LS3000 Horner Electric Application 2710 Manual Modbus Option Board 2MB3000 MAN0183 02 PROFIBUS Option Board 2PB3000 49 1355 AutoMax RS 232 Adapter Cable 2CA3001 D2 3348 Operator Interface Module OIM 2R...

Page 30: ...2 18 LiquiFlo AC Power Modules Hardware Reference Version 6 4 ...

Page 31: ...and this manual and other applicable manuals in their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION When the level sense start feature is enabled P 054 ON the usermustensurethat automatic start up of the driven equipment will not cause injury to operating personnel or damage to the driven equipment In addition the user ...

Page 32: ...on Operating Temperature inside a NEMA cabinet 0 C to 55 C1 32 to 131 F 1With typical heat rise inside a cabinet 40 C ambient outside usually results in 55 C inside Storage Temperature Ambient 40 C to 65 C 40 to 149 F Humidity 5 to 95 non condensing Table 3 2 Drive Dimensions and Weights LiquiFlo Drive M N Frame Dim A Dim B Dim C Dim D Dim E Dim F Dim G Weight 41L4060 41LR4060 B 475 mm 18 69 800 m...

Page 33: ...Planning the Installation 3 3 Figure 3 1 B Frame Drive Dimensions E B C Right Side View Front View F Typ 4 Pl G Typ 4 Pl A D 4 Places 563 Thru ...

Page 34: ...lo AC Power Modules Hardware Reference Version 6 4 Figure 3 2 C Frame Drive Dimensions G Typ 4 Pl F Typ 4 Pl A D E B C Front View Control Panel Assembly and Bus Laminate Removed Right Side View 563 Thru 4 Places ...

Page 35: ...Planning the Installation 3 5 Figure 3 3 D Frame Drive Dimensions 6 Pl F A G E B C 13 93 16 50 16 50 0 56 D Left Side View Front View ...

Page 36: ...Regulator board provides terminals for 24 VDC power for the eight remote control inputs Refer to tables A 3 and A 4 for control input and output specifications 3 2 2 Determining Wire Size Requirements Wire size should be determined based on the size of conduit openings and applicable local national and international codes e g NEC CEC regulations 3 2 2 1 Conduit Entry Opening Sizes It is important ...

Page 37: ...t of kit M N 41L4060PM Output Power U T1 V T2 W T3 Delta Wye Transformer S1 to S6 Ground PE Table 3 4 Recommended Power Wire Sizes for C Frame Drives Type of Power Wiring Drive M N 50LW4060 50LR4060 64LW4060 64LR4060 with kit M N 64L4060PM AC Input Power R L1 S L2 T L3 Lug1 accepts two 2 350 MCM to 4 AWG conductors 1 Lugs not provided with standard drive They are available as part of kit M N 64L40...

Page 38: ...anual D2 3348 for more information about the CS3000 software The Regulator boards have one set of RS 232 transmit receive lines These lines can be accessed by only one device at a time connector J8 the RS 232 terminals 1 3 on the terminal strip or an Operator Interface Module OIM 3 2 3 Selecting Input Line Branch Circuit Fuses Input line branch circuit protection fuses must be used to protect the ...

Page 39: ...tance of 303 meters 1000 feet The recommended Reliance Electric part number is 417900 207CG 18 AWG 6 conductor 3 twisted pairs 3 2 5 Verifying Power Module Output Current Rating Is Greater Than Motor Full Load Amps Verify that the LiquiFlo output current rating is equal to or greater than the motor s full load current amps Table 2 1 lists the output current values Table 3 7 AC Input Line Fuse and ...

Page 40: ...3 10 LiquiFlo AC Power Modules Hardware Reference Version 6 4 ...

Page 41: ... N 120L4060 install two clevis pins into the drive to serve as lifting points Two 1 00 through holes are provided in the sheet metal chassis Step 2 For M N 41L4060 41LR4060 M N 50LW4060 50LR4060 64LW4060 and 64LR4060 connect 18 nominal of chain between the eyebolts or attached clevis clamps and secure them with a clevis clamp For M N 120L4060 connect 50 nominal of chain between the eyebolts or att...

Page 42: ...ional and international codes e g NEC CEC Signal wiring control wiring and power wiring must be routed in separate conduits to prevent interference with drive operation Use grommets when hubs are not provided to guard against wire chafing Figures 4 1 4 2 and 4 3 show the wire routing grounding terminal and power terminal strips of the B frame C frame and D frame LiquiFlo drives Do not route more t...

Page 43: ...ng Wire Routing Locations 4 3 Figure 4 1 Wire Routing Locations for B Frame LiquiFlo Drives Front View Top View Bottom View User Connections Drive Input Drive Output Wiring 6 Places 3 Places User Connection Wiring Wiring Coolant Connections ...

Page 44: ...uiFlo AC Power Modules Hardware Reference Version 6 4 Figure 4 2 Wire Routing Locations for C Frame LiquiFlo Drives User Connections Coolant Connections Drive Input Wiring Drive Output Wiring To Motor 3 Places ...

Page 45: ...ire Routing Locations 4 5 Figure 4 3 Wire Routing Locations for D Frame LiquiFlo Drives User Control Connections User Control L6 L3 W L5 L2 L1 L4 V U Output To Motor Drive Drive Input 6 Places Wire Openings Front View Bottom View Left Side View ...

Page 46: ...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 such that the air flow is directed up through the drive Step 3 Connect the fan to a 115 VAC 60 Hz power source inside of the enclosure Step 4 Close the door of the enclosure Figure 4 4 DC Bus React...

Page 47: ...ns as shown in figure 4 5 The inlet and outlet connectors are 3 4 nominal 7 8 O D copper sweat fittings Use the appropriate sweat fittings attached to hoses or copper tube for the coolant supply and return lines Supply and return lines should be sized for 9 gpm 120 psi service with a maximum operating temperature of 40 C 104 F Actual operating flow rate through the drive is 8 gpm at 10 psi It is r...

Page 48: ...ch 5 16 18 bolt and flange and a nonpermanent thread locking compound on each bolt The flange screws should be torqued to 13 6 Nm 10 ft lb Supply and return lines should be sized for 9 gpm 50 psi service with a maximum operating temperature of 40 C 104 F A pressure regulator or pressure relief device to control the drive inlet pressure below 50 psi is recommended Actual operating flow rate through...

Page 49: ...for D Frame LiquiFlo Drives Hose assemblies are provided with the drive Hose assemblies of longer length are provided with kit M N 64L4060PM or can be user supplied Coolant Outlet Connection Coolant Inlet Connection Coolant Outlet Coolant Inlet Connection Connection Front View Tube assemblies gaskets and hardware are provided with kit M N 120L4060PM or can be user supplied ...

Page 50: ...4 10 LiquiFlo AC Power Modules Hardware Reference Version 6 4 ...

Page 51: ... Observe the following guidelines when installing an isolation transformer A power disconnecting device must be installed between the power line and the primary of the transformer If the power disconnecting device is a circuit breaker the circuit breaker trip rating must be coordinated with the in rush current 10 to 12 times full load current of the transformer 5 2 Installing Fuses for Branch Circ...

Page 52: ...al Connections 6 Pulse Rectifier All Frames Manual LiquiFlo Power V U W Disconnect GND 3 Phase AC Input Voltage 380 480 V Module Fuse GND PE M User Supplied User Supplied GND L1 L2 L3 L1 L2 L3 L6 L5 L4 Interconnecting bus bar provided with M N 41L4060PM 64L4060PM or or can be user supplied 120L4060PM kit ...

Page 53: ...l AC Input Output Electrical Connections 12 Pulse Rectifier B and C Frames Only Manual LiquiFlo Power V U W Disconnect 181 182 183 GND Module Fuse GND PE M L1 L2 L3 L6 L5 L4 Transformer User Supplied User Supplied 3 Phase AC Input Voltage 380 480 V GND ...

Page 54: ...r leads three wire 380 480 VAC to the appropriate terminals On 6 pulse rectifier drives connect the AC input power leads to the L1 L2 and L3 terminals See figure 5 1 On 12 pulse rectifier drives connect the AC input power leads to the L1 L2 L3 L4 L5 and L6 terminals See figure 5 2 Step 3 Tighten the AC input power terminals to the proper torque as shown in table 5 1 ATTENTION Do not route signal a...

Page 55: ... NEC CEC may require one of the following a motor thermostat be installed internal to the motor a mechanical thermal motor overload relay sized to protect the motor be installed between the motor and the drive s output terminals The Motor Overload Enable parameter P 040 can be used in place of thermal motor overload relays in single motor applications Note however that temperature measuring device...

Page 56: ... If possible each conduit should contain only one set of motor leads Step 2 Connect the three phase AC power motor leads to the appropriate output terminals Figures 4 1 4 2 and 4 3 show the locations of the output power terminals Step 3 Tighten the three phase AC output power terminals to the proper torque as shown in table 5 1 ATTENTION Do not route signal and control wiring with power wiring in ...

Page 57: ...the signals connected to the Regulator board terminal strip Refer to the LiquiFlo Software Start Up and Reference manual for more information on how parameter P 000 is used to specify where the drive is controlled from Table 7 1 RS 232 Connections Terminals 1 3 Terminal Signal 1 Transmit Tx 2 Receive Rx 3 Regulator Common Notes The RS 232 terminals should only be used when the RS 232 communication...

Page 58: ...must also be programmed via parameter P 012 for an indication of speed and direction or percent of torque Table 7 4 Analog Speed Torque Reference Connections Terminals 12 15 Terminal Signal 12 Isolated Reference Voltage 13 VDC Speed Torque Reference 14 mA Speed Torque Reference 15 Isolated Reference Common Notes The analog speed torque P 008 U 000 reference is either 10 VDC or 20 mA as determined ...

Page 59: ...stop pushbutton or another external interlock is installed the factory installed jumper connecting terminals 16 and 20 must be removed so that a contact when open will stop the drive Terminals 17 18 and 19 remote control inputs 8 7 and 6 are programmed using parameters P 007 P 008 and P 031 through P 038 Factory default settings are shown here in parentheses Refer to the LiquiFlo Software Start Up...

Page 60: ...elay 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 ...

Page 61: ...N C Relay Contact 24 VDC Common No Connection 24 VDC Common Start Stop Reset 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 Phase A 15 VDC RS 232 Regulator Common RS 232 RX RS 232 TX Analog Meter Output Regulator Common Phase B NOT Phase B ...

Page 62: ...ed if P 054 Level Sense Start Enable ON and P 026 Function Loss Response 1 N O Relay Common N C Relay Common N C Relay Contact 24 VDC Common No Connection 24 VDC Common Start Stop Reset 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 Phase A...

Page 63: ...t not depend on electronic logic hardware or software or on the communication of commands over an electronic network or link Parameter P 055 STOP RESET Key Disable can be used to change the operation of the STOP RESET key See the parameter P 055 description in the software manual for more information Note that the user installed hardwired emergency stop may be used at any time to stop the drive AT...

Page 64: ...p 1 Connect the encoder s wires to terminals 4 through 9 of the terminal strip See figure 7 3 See table A 6 for additional encoder specifications Step 2 Set the following parameters to establish the maximum motor speed P 004 Maximum Speed U 001 Encoder PPR U 002 Motor Poles U 003 Motor Nameplate Base Frequency U 005 Motor Nameplate RPM U 017 Motor Top Speed Refer to the LiquiFlo Software Start Up ...

Page 65: ...Encoder Regulator Terminal Strip Pin 1 Phase A Pin 2 Phase A Not Pin 6 0 VDC Pin 12 15 VDC Pin 8 Phase B Pin 9 Phase B Not Terminal 6 Terminal 5 Terminal 4 Terminal 9 Terminal 7 Terminal 8 Connector Cable End Tamagawa Style 16 Pin MS Connector View of Encoder Cable MS Connector Female M N 2TC4025 and 2TC4075 Regulator Terminal Strip Pin A Phase A Pin H Phase A Not Pin F 0 VDC Pin D 15 VDC Pin B Ph...

Page 66: ...ctions Wiring RS 232 Signals 1 2 3 RS 232 Transmit RS 232 Receive RS 232 Signal Regulator Common Note that RS 232 communication between the LiquiFlo drive and a personal computer requires the use of the Control and Configuration CS3000 software Refer to instruction manual D2 3348 for more information These terminals should only be used when the RS 232 port J8 or an Operator Interface Module OIM ar...

Page 67: ... 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 The power can be sourced from the encoder supply terminal 4 15 VDC or from an external 15V power supply Note that the maximum supply current from terminal 4 is 250 mA encoder and current source at 15 V Terminals 9 and 11 are internally connected Termi...

Page 68: ...e 10VDC Analog Speed Torque Reference Input Voltage 10VDC Analog Speed Torque Reference Input Current 0 20mA Isolated Speed Torque Reference Common Voltage Current Related parameters P 000 Control Source P 009 Terminal Strip Analog Input Offset P 010 Terminal Strip Analog Input Gain P 011 Terminal Strip Analog Input Configure Refer to the LiquiFlo Software Start Up and Reference manual for additio...

Page 69: ...tay clear of rotating machinery in this case Failure to observe this precaution could result in bodily injury The following parameters must be set P 000 Control Source Only active when P 000 rE 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 008 Terminal Strip Speed Reference Source Analog Motor Operated Pot...

Page 70: ...d Menu Password P 007 Terminal Strip Digital Inputs Configure Selects and assigns a control function to digital inputs 6 to 8 P 008 Terminal Strip Speed Reference Source Analog Motor Operated Potentiometer MOP or Preset Speeds P 017 Accel Time 2 Ramp 2 P 018 Decel Time 2 Ramp 2 Note that based on the settings of parameters P 000 P 007 P 008 and r 030 if an RMI board is used the following parameter...

Page 71: ... a control function to digital inputs 6 to 8 P 008 Terminal Strip Speed Reference Source Analog Motor Operated Potentiometer MOP or Preset Speeds P 027Forward Reverse Configuration Note that based on the settings of parameters P 000 P 007 P 008 and r 030 if an RMI board is used the following parameters can affect digital input 6 P 023 MOP Accel Decel Time P 024 MOP Reset Configuration P 031 to P 0...

Page 72: ...drive is shipped from the factory with a jumper between terminals 16 and 20 which provides the signal The function loss input should be in series with the drive s external interlocks In this case the jumper must be removed before the connections are made See figure 2 6 Terminal 20 On No Function Loss Important A maintained function loss switch should be used if P 054 Level Sense Start Enable ON an...

Page 73: ...ter must be set P 000 Control Source Terminal 22 On Reset Wiring the Stop Start Inputs 23 24 Digital Input 2 Stop Digital Input 1 Start The following parameter must be set P 000 Control Source P 025 Stop Type Terminal 23 Off Stop Terminal 24 On Transition Start 25 24 VDC Isolated Common Reserved Teminals 26 27 No Connection 24 VDC Isolated Common Terminal 26 has no connection and is not used in Li...

Page 74: ...orm B Normally Open Contact Form A Normally Open Contact Common Form A Both Form A and Form B contacts are rated for 250 VAC 30 VDC at 5 amps resistive or 2 amps inductive load The following parameter must be set P 013 Output Relay Configuration Note that depending on the setting of parameter P 013 the relay coil will energize the normally open contact will close and the normally closed contact wi...

Page 75: ...4 Terminal Connections on the RMI Board 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 Digital Input 1 Digital Input 2 Digital Input 3 Digital Input 4 24 V for digital inputs only External 24 V Input for Digital Outputs Digital Output 1 Digital Output 2 Digital Output 3 Digital Output 4 Digital Output Common Relay 1 Common Relay 1 Normally Open Relay 2 Norma...

Page 76: ...l Output 2 Digital Output 3 Digital Output 4 Configuration r 031 Timer r 040 Configuration r 032 Timer r 041 Configuration r 033 Timer r 042 Configuration r 034 Timer r 043 20 mA per output with jumper set to 24 V INT 51 Common Digital I O common Relay Outputs Relay 1 52 53 Common Normally Open Contact Configuration r 035 Timer r 044 Relay 2 54 55 56 Normally Closed Contact Common Normally Open Co...

Page 77: ...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 009 68 Analog Common Common for all analog outputs Table 7 9 Wiring Signal and Control I O to the RMI Board Terminal Strip Continued Terminal Number Description Related Parameters Specifications and Jumpers ...

Page 78: ...7 22 LiquiFlo AC Power Modules Hardware Reference Version 6 4 ...

Page 79: ... properly Step 8 Check that user supplied branch circuit protection is installed and correctly rated Step 9 Check that the incoming power is rated correctly 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 obser...

Page 80: ...nd eliminate any grounds between the motor frame and the motor power leads Verify that all ground leads are unbroken Step 14 Visually inspect the liquid cooling connections for leaks Step 15 Uncouple the motor from any driven machinery to initially start the drive 8 2 Powering Up After Installation Is Complete Use the following procedure to verify that the drive is installed correctly and is recei...

Page 81: ...will coast to rest and a 2 or 3 digit fault code will flash on the display Refer to the LiquiFlo Software Start Up and Reference manual for more information on drive alarms and faults 9 3 Verifying That DC Bus Capacitors Are Discharged The LiquiFlo drive s DC bus capacitors retain hazardous voltages after input power has been disconnected Perform the following steps before touching any internal co...

Page 82: ...C 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 Figure 9 1 DC Bus Voltage Terminals B Frame Drives Initial DC Bus Measurement Points POS TP2 ...

Page 83: ...Troubleshooting the Drive 9 3 Figure 9 2 DC Bus Voltage Terminals C Frame Drives Initial DC Bus Measurement Points ...

Page 84: ...9 4 LiquiFlo AC Power Modules Hardware Reference Version 6 4 Figure 9 3 DC Bus Voltage Terminals D Frame Drives Initial DC Bus Measurement Points POS TP2 TP1 NEG ...

Page 85: ...sconnect the motor from the drive Step 5 Check all AC line and DC bus fuses Step 6 If a fuse is open use a multimeter to check the input diodes and output IGBTs See table 9 1 Step 7 Reconnect the motor to the drive Step 8 Reapply input power ATTENTION DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power wait five 5 minutes for the DC b...

Page 86: ...ted with reversed polarity 2 L2 3 L3 4 L4 5 L5 6 L6 7 L1 8 L2 9 L3 10 L4 11 L5 12 L6 DC Bus Volts power terminal DC Bus Volts power terminal Table 9 1 Resistance Checks Continued IGBT No Meter Connection Component is OK if resistance R is Component is defective if 1 W T3 10 R 1 megohm Continuity short circuit or open when the meter is connected with reversed polarity 2 V T2 3 U T1 4 W T3 5 V T2 6 ...

Page 87: ...placement Parts Description Part Number Quantity M N 41L4060 M N 41LR4060 350 HP Power Module Control PMC Printed Circuit Board 179170 1 Gate Driver PCB 179168 1 Membrane Switch Keypad Bracket 410483 15B 1 Regulator PCB 179116 1 Remote Meter Interface RMI PCB 814 56 00 1 Current Feedback Devices 25503 012 03 3 LEM Harness 179215 1 Laminate Harness 179216 1 Chillplate Harness 342435 C01 1 SCR Gate ...

Page 88: ...r PCB 179065 2 2 Membrane Switch Keypad Bracket 410483 15B 1 1 Regulator PCB 179116 1 1 Remote Meter Interface RMI PCB 814 56 00 1 1 Current Feedback Devices 25503 011 01 3 3 SCR Module 22501 025 04 6 6 Bus Gate Driver Interface Harness 179055 1 1 Gate Driver Jumper Harness 179056 1 1 Bus PMA Interface Harness 179057 1 1 Power Interface Harness 179058 1 1 SCR S1 S2 S3 Gate Interface Harness 179059...

Page 89: ...ol PMC Printed Circuit Board 179452 1 Gate Driver PCB 179355 3 Membrane Switch Keypad Bracket 410483 15B 1 Regulator PCB 179116 1 Remote Meter Interface RMI PCB 814 56 00 1 Current Feedback Devices LEM 179357 3 LEM Harness 179447 1 Gate Drive Control Harness 179448 1 Chillplate Harness 342702 C01 1 Gate Drive Power Harness 179449 1 Internal Fan 179196 2 ...

Page 90: ...9 10 LiquiFlo AC Power Modules Hardware Reference Version 6 4 ...

Page 91: ...rs 250 feet total Remote Operator Control Wire Length Up to 303 meters 1000 feet from the drive Analog Speed Reference Resolution 1 1024 10 bits 0 1 Acceleration Adjustment Range 0 1 to 999 9 seconds within the ability of current Carrier Frequency 2 kHz 4 kHz or 8 kHz software selectable Current Limit Adjustment Vector U 006 to 150 based on motor nameplate rating V Hz 50 to 110 based on drive name...

Page 92: ...0 C to 65 C 40 F to 149 F Humidity 5 to 95 non condensing Table A 3 Terminal Strip Input Specifications Signal Type Terminal s Specification Speed Reference Input 12 15 10 V 50 K ohm input impedance or 20 mA Digital Inputs 1 8 16 24 VDC Isolated Supply 17 Remote Local Default 18 Ramp1 Ramp2 Default 19 Forward Reverse Default 20 Function Loss 21 Run Jog 22 Reset 23 Stop 24 Start Table A 4 Terminal ...

Page 93: ...Device Specifications FVC Regulation Only Specification Rating Motor Poles 2 4 6 or 8 poles Overcurrent IET 200 load based on drive nameplate rating Overload Current Rating 150 for 5 seconds Speed Control Range 1 600 with 1024 PPR Speed Control Response 15 Hz typical Encoder Feedback 15 V differential quadrature encoder incremental 512 PPR 1024 PPR 2048 PPR 4096 PPR Service Factor 1 0 ...

Page 94: ...lliseconds STOP RESET FL 75 milliseconds 75 milliseconds Preset Speeds 75 milliseconds 75 milliseconds Analog Speed Trim Reference 16 milliseconds 5 milliseconds Analog Torque Reference N A 0 5 milliseconds Network START 46 milliseconds network transport time 25 milliseconds network transport time STOP RESET FL 26 milliseconds network transport time 25 milliseconds network transport time Analog Sp...

Page 95: ...nge 15o C to 40o C 60oF to 104o F 2 2Coolant temperature should be greater than the dew point of the surrounding air to prevent condensation on the tubing and heatsink See note3 3Contact Reliance Electric for coolant circuit requirements 15o C to 40o C 60oF to 104o F 2 See note3 15o C to 40o C 60oF to 104oF 2 Minimum Coolant Flow Rate at Full Load 7 0 gpm See note3 5 0 gpm See note3 8 0 gpm Differ...

Page 96: ...B 2 LiquiFlo AC Power Modules Hardware Reference Version 6 4 ...

Page 97: ...B Frame LiquiFlo Drive Wiring Diagrams C 1 APPENDIX C B Frame LiquiFlo Drive Wiring Diagrams Replace with file C fm 17 x 11 z fold ...

Page 98: ...C 2 LiquiFlo 2 0 AC Drive User Manual ...

Page 99: ...C Frame LiquiFlo Drive Wiring Diagrams D 1 APPENDIX D C Frame LiquiFlo Drive Wiring Diagrams Replace with file D fm 17 x 11 z fold ...

Page 100: ...D 2 LiquiFlo 2 0 AC Drive User Manual ...

Page 101: ...D Frame LiquiFlo Drive Wiring Diagrams E 1 APPENDIX E D Frame LiquiFlo Drive Wiring Diagrams Replace with file E fm 17 x 11 z fold ...

Page 102: ...E 2 LiquiFlo 1 5 AC Power Modules Hardware Reference Version 1 2 ...

Page 103: ...requency 2 8 A 1 CS3000 see Control and Configuration Software Closed loop see Vector Regulation Communication port J8 2 9 2 13 3 7 7 1 7 9 Communication network 2 1 3 7 Component locations 2 2 to 2 7 Control and Configuration Software 2 1 2 17 3 8 7 9 Contacting Reliance 1 1 Contactors installing output 6 1 Contacts Form A 2 6 7 17 Form B 2 6 7 17 Control source 7 1 7 4 to 7 6 PC 3 7 7 1 7 6 wiri...

Page 104: ... 2 to 5 4 input isolation transformer 5 1 mechanical motor overload protection 6 1 output contactors 6 1 planning 3 1 to 3 9 requirements 3 1 to 3 9 transformers and reactors 5 1 J Jog digital input 4 2 10 to 2 11 7 3 to 7 5 7 15 Jumpers J4 2 10 to 2 13 J17 2 11 to 2 13 location of 2 9 settings for 2 11 to 2 12 K Keypad display 2 2 to 2 7 2 14 9 7 9 8 9 9 Kits AutoMax Network Option Board 2 15 Con...

Page 105: ... 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 to 2 14 7 19 to 7 21 Routing wiring 4 2 to 4 5 RS 232 cable length 3 8 7 9 communication port J8 2 9 2 13 3 7 7 1 7 9 specifications A 3 wiring 2 12 to 2 13 3 6 7 1 7 9 Run digital input 4 2 12 to 2 13 7 3 to 7 5 7 15 S S...

Page 106: ...x 4 LiquiFlo AC Power Modules Hardware Reference Version 6 4 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 ...

Page 107: ......

Page 108: ...upport Tel 1 262 512 8176 Fax 1 262 512 2222 Email support drives ra rockwell com Online www ab com support abdrives Publication D2 3411 7 April 2005 Copyright 2005 Rockwell Automation Inc All Rights Reserved Printed in USA ...

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