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LiquiFlo AC Power Modules Hardware Reference

1. 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 4 aj ET 4 ule H A Piin E Left Side View Front View Figure 3 3 D Frame Drive Dimensions Planning the Installation 3 5 3 2 3 2 1 3 2 2 3 2 2 1 3 2 2 2 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 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 Be sure input power to the drive corresponds to the drive nameplate voltage and frequency Wiring Requirements for the Drive Certain drive requirements should be checked before continuing with the drive installation Wire sizes branch circuit protection encoder feedback for FVC regulation and E stop wiring see chapter 7 are all areas that need to be evaluated Meeting Terminal Strip Input and Output Specificat
2. Drive Output j Wiring d E To Motor 3 Places op O i ser wee Connections 1 Coolant EM m Connections Figure 4 2 Wire Routing Locations for C Frame LiquiFlo Drives 4 4 LiquiFlo AC Power Modules Hardware Reference Version 6 4 Drive Input 6 Places Drive Output To Motor e VW m Tm aL Te o Front View Left Side View User Control Li Connections User Control Wire Openings d 4 e Bottom View Figure 4 3 Wire Routing Locations for D Frame LiquiFlo Drives Mounting the Drive Grounding and Finding Wire Routing Locations 4 5 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
3. t DANGER TP6 T HIGH VOLTAGE T TPS 2030000 DO0000 000000000000 0000UO I e OOCOOOOOOODOOOOOOOOOOOOOOOU Figure 9 2 DC Bus Voltage Terminals C Frame Drives Troubleshooting the Drive 9 3 Initial DC Bus Measurement Points Figure 9 3 DC Bus Voltage Terminals D Frame Drives 9 4 LiquiFlo AC Power Modules Hardware Reference Version 6 4 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 Failure to observe this precaution could result in severe bodily injury or loss of life Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Turn off and lock out input power Wait five minutes Verify that there is
4. Planning the Installation 3 7 3 2 2 5 3 2 3 Table 3 6 Recommended Terminal Strip Wire Sizes 1 to 31 Regulator 20 to 14 AWG 2 to 0 5 mm 41 to 69 RMI 3 2 2 4 Recommended Motor Lead Lengths Motor lead lengths can total up to 76 meters 250 feet 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 Two RS 232 cables are available from Reliance Electric A3 meter 10 feet D shell 9 pin to 9 pin cable M N 2CA3000 A 0 3 meter 1 foot D shell 9 pin to 25 pin adaptor cable M N 2CA3001 User constructed cables can be up to 15 meters 50 feet in length Note that for communication between a LiquiFlo drive and a personal computer the Control and Configuration Software must also be used Refer to instruction manual 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 Selecting Input Line Branch Circuit Fuses ATTENTION Most codes require that upstream branch circuit protection be provided to protect input power wiring Install the fuses recommended in table 3 6
5. 50LW4060 50LR4060 64LW4060 64LR4060 120L4060 3 2 LiquiFlo AC Power Modules Hardware Reference Version 6 4 563 Thru 4 Places I o o o ot d c 2 E q Wu q q q O lj q L Le F Typ 4 PI Le A G Typ 4 PI C Front View Right Side View Figure 3 1 B Frame Drive Dimensions Planning the Installation 3 3 563 Thru 4 Places i Le F Typ 4 PI G G Typ 4 PI a A C
6. Default Remote Local parameter P 007 ATTENTION If a maintained start contact is used when the control source rE switching from local to remote from the terminal strip will cause power to be applied to the motor if the remote start contact is closed Stay 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 e P 006 Second Menu Password e P 007 Terminal Strip Digital Inputs Configure Selects and assigns a control function to digital inputs 6 to 8 e P 008 Terminal Strip Speed Reference Source Analog Motor Operated Potentiometer MOP or Preset Speeds 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 8 P 023 MOP Accel Decel Time P 024 MOP Reset Configuration P 031 to P 038 Preset Speeds 1 8 Refer to the LiquiFlo Software Start Up and Reference manual for additional information Terminal 17 On Local Control Diagram shows factory setting Wiring the Regulator Board and RMI Board Terminal Strips 7 13 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 Digital Input 7 Digital input 7 is control function programmable t
7. Do not exceed the fuse ratings Failure to observe this precaution could result in damage to or destruction of the equipment Input line branch circuit protection fuses must be used to protect the input power lines See figures 5 1 and 5 2 Recommended fuse values are shown in table 3 7 The input fuse ratings listed in table 3 7 are applicable for one drive per branch circuit No other load may be applied to that fused circuit LiquiFlo AC Power Modules Hardware Reference Version 6 4 Table 3 7 AC Input Line Fuse and Circuit Breaker Selection Values Input Voltage Motor Circuit Protector Model Number 10 Fuse Rating or Circuit Breaker 41L4060 380 480 VAC 41LR4060 50LW4060 380 480 VAC 50LR4060 64LW4060 380 480 VAC 64LR4060 120L4060 380 480 VAC 1Recommended fuse type UL Class J 600 V time delay or equivalent Recommended fuse type UL Class L 600 V time delay or equivalent 3 2 4 Meeting Encoder Specifications FVC Regulation Only LiquiFlo drives set up for FVC regulation require an encoder for closed loop operation Refer to table A 6 for specifications Drives set up for V Hz or SVC regulation do not require an encoder for feedback because they operate in the open loop mode 3 2 4 4 Encoder Wiring Guidelines Encoder connections are considered signal level wiring and therefore must be run separate from control and power wiring Reliance Electric recommends 18 AWG unshield
8. Encoder Cable kit 2 17 lead lengths 3 8 overload protection mechanical 6 1 speed setting maximum 7 7 wiring 6 1 to 6 2 Mounting dimensions 3 2 to 3 5 N NEMA enclosures 2 2 3 1 Index 2 LiquiFlo AC Power Modules Hardware Reference Version 6 4 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 P Parts location see Component Locations replacement 9 7 9 8 9 9 PC control see Control Source Planning drive clearances 3 6 location 3 1 to 3 2 Power output wiring 3 6 to 3 8 4 2 to 4 5 6 1 to 6 2 input wiring 3 6 to 3 8 4 2 to 4 5 5 1 to 5 4 Power Module checking 9 5 to 9 6 verifying output current rating 3 6 Power terminals torque specifications 5 5 wiring 3 6 to 3 8 4 2 to 4 5 5 1 to 5 4 6 1 to 6 2 Protection mechanical motor overload 6 1 Publications related 1 2 R Ramp1 ramp2 digital input 7 2 10 to 2 12 7 3 to 7 5 7 13 Ratings AC input 2 2 to 2 7 fuse 3 8 NEMA 2 2 output 2 2 power loss 2 2 Reactor 2 2 to 2 5 Regulator board 2 2 to 2 7 9 7 9 8 9 9 Relays output status see Status Relays 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 disch
9. r 004 10 to 10 VDC Offset r 005 Gain r 006 67 Analog Output No 3 Configuration r 007 V OUT 0 to 10 VDC Offset r 008 C OUT 0 to 20 mA Gain r 009 68 Analog Common Common for all analog outputs Terminals 57 and 61 are not used Wiring the Regulator Board and RMI Board Terminal Strips 7 21 7 22 LiquiFlo AC Power Modules Hardware Reference Version 6 4 8 1 Completing the Installation This chapter provides instructions on how to perform a final check of the installation before power is applied to the drive 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 Checking the Installation Use the following procedure to verify the condition of the installation 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 injury or loss of life Step 1 Turn off lock out and tag the input power to the drive Wait fi
10. through holes are provided in the sheet metal chassis 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 attached clevis clamps and secure them with a clevis clamp Using an overhead or portable hoist minimum 1 2 ton rated capacity attach a free fall chain to the chain secured to the drive Take up any vertical slack in the chain Using the hoist lift the drive from the horizontal shipping pallet Position the drive in the enclosure For M N 41L4060 41LR4060 M N 50LW4060 50LR4060 64LW4060 and 64LR4060 attach the drive to the vertical surface selected using the four 4 mounting holes provided For M N 120L4060 attach the drive to the vertical surface using the six 6 mounting holes provided Mounting the Drive Grounding and Finding Wire Routing Locations 4 1 4 2 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 18 UN UNC 2A Grade 2 Step 7 For M N 50LW4060 50LR4060 64LW4060 and 64LR4060 remove the eyebolts and the chain between them
11. 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 6 2 LiquiFlo AC Power Modules Hardware Reference Version 6 4 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 000 is set to remote rE the drive will be controlled by 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 Transmit Tx Receive Rx Regulator Common Notes The RS 232 terminals should only be used when the RS 232 communication port J8 or an Operator Interface Module OIM is not being used as all three devices use the same transmit receive lines Table 7 2 Encoder Connections Terminals 4 9 Terminal 15 VDC Phase A Phase A Not Phase B Phase B Not Regulator Common Notes An encoder feedback device must be ins
12. 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 Description 350 HP Power Module Control PMC Printed Circuit Board Part Number 179170 Quantity M N 41L4060 M N 41LR4060 Gate Driver PCB 179168 Membrane Switch Keypad Bracket 410483 15B Regulator PCB 179116 Remote Meter Interface RMI PCB 814 56 00 Current Feedback Devices 25503 012 03 LEM Harness 179215 Laminate Harness 179216 Chillplate Harness 342435 C01 SCR Gate Harness 179218 Internal Fan 179196 Troubleshooting the Drive 9 7 Table 9 3 C Frame LiquiFlo Drive Replacement Parts Description 450 HP Power Module Adapter PMA Printed Circuit Board PCB Part Number 179134 Quantity M N 50LW4060 M N 50LR4060 M N 64LW4060 M N 64LR4060 600 HP Power Module Adapter PMA Printed Circuit Board PCB 179067 DC Bus Control PCB 179069 Gate Driver PCB 179065 Membrane Switch Keypad Bracket 410483 15B Regulator PCB 179116 Remote Meter Interface RMI PCB 814 56 00 Current Feedback Devices 25503 011 01 SCR Module 22501 025 04 Bus Gate Driver Interface Harness 179055 Gate Driver Jumper Harness 179056 Bus PMA Interface Harness 179057 Power Interface Harness 179058 SCR S1 S2 S3 Gate Interfa
13. For M N 41L4060 41LR4060 and 120L4060 remove the clevis clamps and chain between them Verifying the Drive s Watts Loss Rating When mounting the drive inside of an enclosure you should determine the watts loss rating of the drive from table 2 1 This table lists the typical full load power loss watts value at 2 kHz rated carrier frequency Ensure that the enclosure is adequately ventilated with 0 to 40 C ambient air based on the drive s watts loss rating Determining Input Motor Output Ground and Control Wire Routing for the Drive All wiring should be installed in conformance with the applicable local national 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 ATTENTION Do not route signal and control wiring with power wiring in the same conduit This can cause interference with drive operation Failure to observe this precaution could result in damage to or destruction of the equipment Do not route more than three sets of motor leads through a single conduit This will minimize cross talk that could reduce the effectiveness of noise reduction methods more than three drive
14. Line Voltage Variation 10 to 10 Line Dip Ride Through FVC Maximum 500 milliseconds V Hz SVC Adjustable up to 999 9 seconds See P 042 Motor Lead Lengths 76 meters 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 nameplate rating Service Factor 1 0 Speed Adjustable Range From 0 RPM to maximum speed vector Speed Regulation Vector 0 01 FVC 0 5 SVC steady state V Hz Motor slip dependent Speed Reference Resolution 1 RPM with local keypad 4095 to 4095 counts with a network or serial reference Torque Control Response 180 to 220 Hz Torque Linearity 3 with optimal parameter setting typical see parameter U 005 Technical Specifications A 1 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 ade
15. So 6 SS Connection to the negative side of the power supply is only required when an external 15V power supply is used Wiring the Regulator Board and RMI Board Terminal Strips 7 11 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 Related parameters 10VDC P 000 Control Source Analog Speed Torque x Reference Input Voltage 4 P 009 Terminal Strip Analog Input Offset 10VDC P 010 Terminal Strip Analog Input Gain Analog Speed Torque P 011 Terminal Strip Analog Input Configure Reference Input Current 0 20mA Refer to the LiquiFlo Software Start Up and Reference manual for additional parameter information Isolated Speed Torque Reference Common Jumper J4 must also be set See figure 2 4 Voltage Current 10V OV 20mA OV Hee 1B 42 slo le 13 A006 O 20 SK 10V DC SPEE 7 12 LiquiFlo AC Power Modules Hardware Reference Version 6 4 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 24 VDC Power Supply Current limited for remote input logic use only Digital Input 8 Digital input 8 is control function programmable through
16. damage to or destruction of equipment can result if this procedure is not followed Failure to observe this precaution can result in bodily injury Trademarks not belonging to Rockwell Automation are property of their respective companies Copyright 2005 Rockwell Automation All rights reserved Introduction 1 1 1 2 Related Publications 1 1 Getting Assistance from Reliance Electric 1 1 About the Drive 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 Identifying the Drive by Model Number ecccceeeeeeteeeeeeeneeeeeeeeetaeeeeeteaaees 2 1 Enclosure Ratings sn nc ette ios e ee e e I a pe ERR Poe Red 2 2 B Frame LiquiFlo Drive Component Locations 2 2 C Frame LiquiFlo Drive Component Locations sseeeees 2 4 D Frame LiquiFlo Drive Component Locations 2 6 Regulator Board Description essennm enn 2 8 2 6 1 Jumper Locations and Settings 2 10 2 6 1 1 Setting the Analog Input Speed Reference Jumper J4 2 10 2 6 1 2 Setting the Analog Output Jumper J17 2 11 2 6 2 Wiring the Regulator Board Terminal Strip 2 12 2 6 3 RS 232 Communication Port ss 2 13 2 6 4 RMI Board Connector ii 2 13 2 6 5 Operator Interface Module Connector 2 14 2 6 6 Keypad Display us 2 14 RMI Board Description is 2 15 2 1 Digital Inp ts ci eene nn eee ERROR mes 2 15 2 17 2 Digital Outputs 2 rite ree
17. do not require the use of an encoder feedback device The encoder connects to terminals 4 to 9 of the regulator s terminal strip Terminal Encoder Connection Supply 15 VDC 250 mA capacity Phase A Differential Input Phase A Not Differential Input Phase B Differential Input Phase B Not Differential Input Encoder Regulator Common Use the following procedure to connect an encoder to the terminal strip Step 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 and Reference manual for more information 7 8 LiquiFlo AC Power Modules Hardware Reference Version 6 4 Tamagawa Style 16 Pin MS Connector M N 2TC4025 and 2TC4075 Regulator Terminal Strip Terminal 6 WHITE ORANGE Pin 1 Terminal 5 once Pin2 Terminal 4 RED Pin 6 Terminal 9 wnt szo Pin 12 Terminal 7 mow Pin 8 Terminal 8 wite srown Pin 9 View of Encoder Cable MS Connector Female Connector Cable End Phase A Phase A Not 0 VDC 15 VDC Phase B Phase B Not Dynapar Style 10 Pin MS Connector M N 2TC3025 and 2T
18. 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 This will minimize cross talk that could reduce the effectiveness of noise reduction methods If more than three drive motor connections per conduit are required shielded cable must be used If possible each conduit should contain only one set of motor leads ATTENTION Do not route signal and control wiring with power wiring in the same conduit This can cause interference with drive operation Failure to observe these precautions could result in damage to or destruction of the equipment ATTENTION Unused wires in conduit must be grounded at both ends to avoid a possible shock hazard caused by induced voltages Also if a drive sharing a conduit is being serviced or installed all drives using this conduit should be disabled to eliminate the possible shock hazard from cross coupled motor leads Failure to observe these precautions could result in bodily injury Step 2 Connect the three phase AC power motor leads to the appropriate output terminals Figures 4 1
19. motor connections per conduit are required shielded cable must be used If possible each conduit should contain only one set of motor leads ATTENTION Unused wires in conduit must be grounded at both ends to avoid a possible shock hazard caused by induced voltages Also if a drive sharing a conduit is being serviced or installed all drives using this conduit should be disabled to eliminate the possible shock hazard from cross coupled motor leads Failure to observe these precautions could result in bodily injury LiquiFlo AC Power Modules Hardware Reference Version 6 4 Drive Input WiEes Riputpui 3 Places Coolant Connections Top View MARR gonnection Cfections Front View Bottom View Figure 4 1 Wire Routing Locations for B Frame LiquiFlo Drives Mounting the Drive Grounding and Finding Wire Routing Locations 4 3 J pns O00 Dun Sr tit 1 0000 00 c5 00 I tod tod ERR tod Dod TJ SH g ifo
20. to 7 5 7 15 Fuse AC input 3 7 5 2 to 5 3 G Gate Driver board 2 4 to 2 5 9 5 Grounding 4 2 to 4 6 5 3 to 5 4 H Humidity 3 2 A 2 IGBT power devices 2 8 testing resistance checks 9 5 to 9 6 Input specifications terminal strip A 2 Input AC see AC Input Input digital see Digital Input Wiring Installation AC input disconnect 5 2 to 5 4 checking 8 1 to 8 2 completing 8 1 to 8 2 fuses AC input line branch circuit 3 8 5 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 Control and Configuration Software 2 15 DeviceNet Option Board 2 15 Motor Encoder Cable 2 15 Operator Interface Module 2 15 Remote Meter Interface 2 15 L Lead lengths motor 3 8 LEDs 2 8 2 14 Line branch circuit fuses AC input 3 8 5 2 to 5 4 Line frequency A 1 Line noise avoiding 5 1 Local digital input 8 2 10 to 2 11 7 3 to 7 5 7 12 Loss function see Function Loss M Mechanical motor overload protection 6 1 Meter output 2 12 to 2 13 7 2 7 10 Model numbers 2 1 to 2 2 MOP motor operated potentiometer 7 12 to 7 14 Motor
21. 0 C 60 F to 104 F See note 15 C to 40 C 60 F to 104 F See note 15 C to 40 C 60 F to 104 F Minimum Coolant Flow Rate at Full Load 7 0 gpm See note 5 0 gpm See note 8 0 gpm Differential Coolant Pressure at Minimum Flow Rate 3 0 psi See note 34 0 psi See note 5 0 psi Maximum Inlet Pressure 450 psi See note 300 psi See note 50 psi Maximum Heat Load 16 000 BTU hour 16 000 BTU Hour 25 000 BTU hour 25 000 BTU Hour 40 000 BTU hour Approved corrosion inhibitor Chemtool Inc Crystal Lake IL part number CT787 C Concentration is 2 by volume 2Coolant temperature should be greater than the dew point of the surrounding air to prevent condensation on the tubing and heatsink Contact Reliance Electric for coolant circuit requirements Cooling System Specifications B 1 LiquiFlo AC Power Modules Hardware Reference Version 6 4 B Frame LiquiFlo Drive Wiring Diagrams Replace with file C fm 17 x 11 z fold B Frame LiquiFlo Drive Wiring Diagrams C 1 LiquiFlo 2 0 AC Drive User Manual C Frame LiquiFlo Drive Wiring Diagrams Replace with file D fm 17 x 11 z fold C Frame LiquiFlo Drive Wiring Diagrams D 1 LiquiFlo 2 0 AC Drive User Manual D Frame LiquiFlo Drive Wiring Diagrams Replace with file E fm 17 x 11 z fold D Frame LiquiFlo Drive Wiring Diagram
22. 2 9 1 8 LiquiFlo AC Power Modules Hardware Reference Version 6 4 1 gt gt dieset d Fwd Rev Function Loss olo O 1 6 Run Jog 1 1 Figure 7 2 Three Wire Start Stop Sample Control Wiring ON and P 026 Function Loss Response Remote 4 20 mA Speed Torque Reference Important A maintained function loss switch should be used if P 054 Level Sense Start Enable 7 6 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 ATTENTION The user must provide an external hardwired emergency stop circuit outside of the drive circuitry This circuit must disable the system in case of improper operation Uncontrolled machine operation may result if this procedure is not followed Failure to observe this precaution could result in bodily injury Depending upon the requirements of the application the LiquiFlo drive can be programmed to provide either a coa
23. 232 Signal Regulator These terminals should only be used when the RS 232 port Common J8 or an Operator Interface Module OIM are not being used as all three devices use the same transmit receive lines PERSONAL COMPUTER TERMINAL STRIP 25 PIN D SHELL MALE OR 9 PIN D SHELL PLUG 1 1 doa OEEO OR oeeo TXD DATA OUT TERMINAL 1 PIN 2 RXD DATA IN RXD DATA IN TERMINAL 2 PIN 3 TXD DATA OUT COMMON COMMON TERMINAL 3 PIN 7 25 PIN D SHELL PIN 5 9 PIN D SHELL WIRE LENGTH 50 FEET MAX iring Encoder Inputs Encoder Wiring See section 7 2 7 10 LiquiFlo AC Power Modules Hardware Reference Version 6 4 Table 7 8 Wiring Signal and Control I O to the Terminal Strip Continued Terminal Number Description Parameters Wiring Connections Wiring Analog Outputs 0 10 VDC or 4 20 mA The setting of parameter P 012 selects the terminal strip Analog Output Reference analog output source either speed or torque Jumper J17 must also be set See figure 2 5 Regulator Common 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 Terminal Strip Load Meter or Analog Input
24. 4 1 Encoder Wiring Guidelines seeeeeese 3 9 3 2 5 Verifying Power Module Output Current Rating Is Greater Than Motor Full Load Amps 3 9 Contents Mounting the Drive Grounding and Finding Wire Routing Locations 4 1 Lifting and Mounting the Drive sseesseeeennm m 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 sisi 4 2 4 3 Installing the DC Bus Reactor Fan C Frame Drives Only 4 6 4 4 Grounding the Drive nennen enne rennen nnns 4 7 4 5 Connecting Coolant Lines 4 7 4 5 1 B Frame Coolant Connections sssssesseeeeeeeeenne 4 7 4 5 2 C Frame Coolant Connections sesssseeeeeneenes 4 7 4 5 3 D Frame Coolant Connections ssssseeeeennenes 4 8 Installing Input Power Wiring 5 1 Installing Transformers and Reactors Optional ssseseeessss 5 1 5 2 Installing Fuses for Branch Circuit Protection 5 1 5 3 Installing a Required External Separate Input Disconnect 5 4 5 4 Installing Power Wiring from the AC Input Line to the Drive s Power Terminals eeessseeeeeenn emen 5 4 Installing Output Power Wiring 6 1 Installing Output Contactors Optional esseeeseeeseeessreeeressreeerrsennerrneerrserens 6 1 6 2 Instal
25. 4060PM or can be user supplied M Coolant Outlet Connection Coolant Inlet Connection Figure 4 5 Coolant Connector Locations for B Frame LiquiFlo Drives 4 8 LiquiFlo AC Power Modules Hardware Reference Version 6 4 Hose assemblies are provided with Coolant Outlet the drive Hose Connection assemblies of longer length are provided with kit M N 64L4060PM or can be user supplied Tube assemblies gaskets and hardware are provided with kit M N 120L4060PM or can be user supplied Coolant Inlet Connection Coolant Outlet Front View Connection Figure 4 7 Coolant Connector Locations for D Frame LiquiFlo Drives Mounting the Drive Grounding and Finding Wire Routing Locations 4 9 4 10 LiquiFlo AC Power Modules Hardware Reference Version 6 4 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 red
26. 5900 so 0 Og EGE EE R CREC LL Elcg En E SOE 0 00 Co SESS 5 LES CTS onos Eo E 9 9 x x9 9 205909 9 9 3739 9 0002222 FETO sect ogty PED 0208888 mnm D 0 D L L EG 0 AA A A S osogo Qe mre Dm OcOmrmercc 9 0 D 5 D 0 6 2 Q LS 3 a lt 505 EN d Ge E E MS E E QE On NE ooo9S8s2382060o08sod492999o955o9s845o30000 Eq i un0ulnrgtct mr 52s57 00notcltmrioow ztzzzz SOOO SO S 6 6 6 6 PG 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 amp GE 6 2 1 22 3 4 5 6 7 8 9 10 11 12 13 14 15 18 21 22 23 24 25 26 27 28 29 30 31 je ie tilt na Factory RS 232 Encoder Analog Analog Speed Configurapie InStall d Status Relays Jumper Connections Connections Output Reference p Digital Inputs Isolated 24 VDC 2 6 3 2 6 4 Figure 2 8 Typical Regulator Board Terminal Strip Connections RS 232 Communication Port The Regulator board contains a 9 pin D shell RS 232 communication port J8 This port provides RS 232 communication between the LiquiFlo drive and a personal computer running the Control and Configuration CS3000 software See figure 2 5 Refer to instruction manual D2 3348 for more information about the CS3000 software RMI Board Connector The flat ribbon cable connector J3 on the left side of the Regulator board is a parallel bus connection port that is used on LiquiFlo drives for the Remote Meter Interface RMI board The RMI board provides an extended set of term
27. AC Power Modules Hardware Reference Version 6 4 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 2 Installing Mechanical Motor Overload Protection Optional To provide the motor with overload protection local national and international codes e g 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 devices integral to the motor are the best way to thermally protect AC motors under all conditions Parameter P 040 must be enabled to provide overload protection Refer to the LiquiFlo Software Start Up and Reference manual for more information In multiple motor applications V Hz regulation only each motor must have its own user supplied overload and branch circuit protection Installing Output Power Wiring 6 1 6 3 Installing Output Wiring
28. C3075 View of Encoder Cable MS Connector Female Regulator Terminal Strip Terminal 6 rome Pin 3 Terminal 5 we 7X Pin 8 Terminal 4 RED Pin 1 Terminal 9 wr seo Pin 6 Terminal 7 BROWN Pin 2 Terminal 8 __ HiTE erown Pin 7 Regulator Terminal Strip Connector Cable End Terminal 6 _WaTE oRNcE Pin A Phase A Terminal 5 oct X Pin H Phase A Not Terminal 4 reo PinF 0 VDC Terminal 9 wean gt lt PinD 15 VDC Terminal 7 erom PinB PhaseB Terminal 8 __wite erowy Pin Phase B Not Lakeshore Style 10 Pin MS Connector T 2 3 4 5 View of Encoder Cable MS Connector Female O O 0 0 0 Lakeshore M N SL56 Slim Tach Encoder O O O O O 6 7 8 9 10 Connector Cable End Phase A Phase A Not 0 VDC 15 VDC Phase B Phase B Not Figure 7 3 Encoder Wiring Connections Wiring the Regulator Board and RMI Board Terminal Strips 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 8 Wiring Signal and Control I O to the Regulator Board Terminal Strip Terminal Number Description Parameters Wiring Connections iring RS 232 Signals RS 232 Transmit Note that RS 232 communication between the LiquiFlo drive and a personal computer requires the use of the RS 232 Receive Control and Configuration CS3000 software Refer to instruction manual D2 3348 for more information RS
29. Conditions are Met Before deciding on an installation site consider the following guidelines Verify that open chassis style drives can be kept clean and dry LiquiFlo drives must be placed in an enclosure The area chosen should allow the space required for proper air flow as defined in section 3 1 3 Be sure that open chassis style drives are installed away from oil coolants or other airborne contaminants Planning the Installation 3 1 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 1 Environmental Conditions Condition Specification Operating Temperature inside a NEMA cabinet C to 55 C 32 to 131 F Storage Temperature Ambient 40 C to 65 C 40 to 149 F Humidity 5 to 95 non condensing With typical heat rise inside a cabinet 40 C ambient outside usually results in 55 C inside 3 1 2 Determining Total Area Required Based on Drive Dimensions Drive dimensions and weights are listed in table 3 2 Overall drive dimensions are illustrated in figures 3 1 3 2 and 3 3 as an aid in calculating the total area required by the LiquiFlo drives Table 3 2 Drive Dimensions and Weights LiquiFlo Drive M N 41L4060 41LR4060
30. 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 1 DC Bus Voltage Terminals B Frame Drives 9 2 LiquiFlo AC Power Modules Hardware Reference Version 6 4 Initial DC Bus Measurement Points
31. DENT ELECTRICS LiquiFlo AC Power Modules Hardware Reference Installation and Troubleshooting Version 6 4 Instruction Manual D2 3411 7 Rockwell The information in this manual is subject to change without notice Throughout this manual the following notes are used to alert you to safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Important Identifies information that is critical for successful application and understanding of the product The thick black bar shown on the outside margin of this page will be used throughout this instruction manual to signify new or revised text or figures 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 ATTENTION Do notinstall or remove modification kits with power applied to the drive Disconnect and lock out incoming power before attempting such installation or removal Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION DC bus capacitors retain hazardous voltages after input power has been d
32. RIP 161718192021 161718 19 2021 OOOGOOQ AANA AFETY INTERI K REMOVE FACTORY FUNCTION FUNCTION E SAFETY INTERLOCKS LOSS JUMPER HERE BUS HBUT TEN Terminal 20 On No Function Loss Important A maintained function loss switch should be used if P 054 Level Sense Start Enable ON and P 026 1 Wiring a Run Jog Input Digital Input 4 The following parameters must be set Rare e P 000 Control Source e P020 Jog Speed Reference e P021 Jog Ramp Accel Time e P022 Jog Ramp Decel Time G Terminal 21 On Jog Operation 7 16 LiquiFlo AC Power Modules Hardware Reference Version 6 4 Table 7 8 Wiring Signal and Control I O to the Terminal Strip Continued Terminal Number Description Digital Input 3 Reset Digital Input 2 Stop Digital Input 1 Start Parameters Wiring Connections iring the Reset Input The following parameter must be set P 000 Control Source 16 Terminal 22 On Reset Wiring the Stop Start Inputs The following parameter must be set P 000 Control Source P 025 Stop Type 16 La Terminal 23 Off 2 Stop Terminal 24 On Transition Start 24 VDC Isolated Common Reserved Teminals No Connection 24 VDC Isolated Common Terminal 26 has no connection and is not used in LiquiFlo applications Terminal 27 can be used as a 24V DC common Wiring the Regulat
33. a maximum operating temperature of 40 C 104 F Actual operating flow rate through the drive is 8 gpm at 10 psi It is recommended that a flow switch be installed after the coolant outlet to shut off the drive if coolant flow drops below 4 gpm It is also recommended that the water pump 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 2 C Frame Coolant Connections C frame LiquiFlo drives have inlet and outlet coolant connections as shown in figure 4 6 The inlet and outlet connectors are size 10 SAE 37 flare female fittings Use the appropriate male fittings attached to hoses or for the coolant supply and return lines These fittings should be torqued to 80 Nm 60 ft lb Supply and return lines should be sized for 5 gpm 120 psi service with a maximum operating temperature of 40 C 104 F Actual operating flow rate through the drive is 5 gpm at 30 psi It is recommended that a flow switch be installed after the coolant outlet to shut off the drive if coolant flow drops below 4 gpm It is also recommended that the water pump Mounting the Drive Grounding and Finding Wire Routing Locations 4 7 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 fra
34. al 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 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 D2 3449 LiquiFlo AC Drive Panel Mount Kit 1 2 Getting Assistance from Reliance Electric If you have any questions or problems with the products described in this instruction manual contact your local Reliance Electric sales office For technical assistance call 1 864 284 5444 Introduction 1 1 LiquiFlo AC Power Modules Hardware Reference Version 6 4 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 liqui
35. are Reference Version 6 4 U S 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 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication D2 3411 7 April 2005 Copyright 2005 Rockwell Automation Inc All Rights Reserved Printed in USA
36. arge 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 Selecting operation see Control Source Sensorless vector regulation 2 1 Serial communication see RS 232 Site requirements 3 1 Specifications conduit 4 2 dimensions 3 2 to 3 5 encoder feedback A 3 environmental 3 2 inputs terminal strip A 2 outputs terminal strip A 2 terminal torque ratings 5 4 wire sizes 3 7 to 3 8 Speed maximum setting 7 7 Start digital input 1 2 10 to 2 11 7 3 to 7 5 7 16 Status relays Form A B 2 4 7 3 to 7 5 7 17 Stop digital input 2 2 10 to 2 11 7 3 to 7 5 7 16 Stopping the drive 7 6 Switch membrane see Keypad Display T Tachometer pulse see Encoder Terminal strip wiring 2 12 to 2 13 3 8 7 1 to 7 17 input specifications A 2 output specifications A 2 RS 232 specifications A 3 torque specifications 3 7 wire sizes 3 7 3 8 Testing IGBT 9 5 to 9 6 Transformer isolation input installing 5 1 Index Index 3 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 Hardw
37. bers used in figure 2 4 Replacement parts are listed in chapter 9 CONDAARWON Chillplate Harness Bus Bars AC Input Bus Bars AC Output Power Module Control PCB Membrane Switch Keypad Regulator PCB RMI Option PCB Current Feedback Devices Gate Driver PCB Coolant Connection Outlet IGBT Module Capacitors Coolant Connection Inlet Output Laminate 2 6 LiquiFlo AC Power Modules Hardware Reference Version 6 4 1 ea Lu M 2 OO g Figure 2 4 D Frame LiquiFlo Drive Component Locations About the Drive 2 7 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 The Regulator board provides PWM gating signals to the IGBT power devices Based on the output of the control loop the regulator sends PWM gating signals to isolated drivers on the Gate Driver board These drivers switch the Insulated Gate Bi polar Transistors IGBTs producing a waveform that c
38. button 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 and Reference manual for more information Table 7 6 Reserved Connections Terminals 26 and 27 RE PE No Connection 24 VDC Common Notes Terminal 26 has no connection and is not used in LiquiFlo applications Terminal 27 can be used as a 24 VDC common Wiring the Regulator Board and RMI Board Terminal Strips 7 3 Table 7 7 Status Relay Connections Terminals 28 31 Terminal N C Relay Contact N C Relay Common N O Relay Contact 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 4 uOoWWOD ejeH O N 19e31u02 e ed O N UOWWOD e eu O N 1eju09 eleu O N UOWWOD OCA ver uonoeuuo2 ON UOWWOD OCA ver uelis dois jeseH Bor uny sso7 uonounJ es1e eu pyew04 9 Indy jex6iq gdwey dwey Z indy jevbig je901 e1ouieu 8 ndul jeu6iq OGA vet PUD eoueJojeH peijeljos aouelajay peeds v
39. ce Harness 179059 SCR S4 S5 S6 Gate Interface Harness 179060 LEM Interface Harness 179061 Laminate PMA Interface Harness 179062 Chillplate Interface Harness 342410 C01 Internal Fan Assembly user supplied Comair Rotron M N P2TB3 or equivalent 9 8 LiquiFlo AC Power Modules Hardware Reference Version 6 4 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 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 Troubleshooting the Drive 9 9 9 10 LiquiFlo AC Power Modules Hardware Reference Version 6 4 AC Line Distribution System Capacity maximum for 460 VAC Units Technical Specifications Table A 1 Service Conditions 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 96 Line Frequency 50 60Hz 2 Hz
40. ct before starting the drive Refer to the LiquiFlo Software Start Up and Reference manual for more information Use the following procedure to set jumper J4 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 injury or loss of life 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 desired setting as shown in figure 2 6 Step 6 Close the door of the enclosure Step 7 Reapply input power LiquiFlo AC Power Modules Hardware Reference Version 6 4 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 mor
41. d 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 The drive can provide this functionality either with encoder feedback flux vector control or FVC or without Sensorless vector control or SVC 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 regulator version Drive power ratings are provided in table 2 1 NNN AA N N NN Continuous Ampere Rating x10 41 414 amps 50 2 500 amps 64 643 amps 120 2 1200 amps LW water cooled LR refrigerant cooled Voltage 2 200 to 230 VAC 3 270 to 310 VAC 4 380 to 480 VAC Enclosure 0 Open Chassis 1 NEMA 1 2 NEMA 12 Only 4 NEMA 4x Indoor Only or NEMA 12 Regulator Version 60 Version 6 x Firmware Figure 2 1 Identifying the Drive Model Number About the Drive 2 1 Model Number 41L4060 41LR4060 Frame Size and Selected Regulation B Frame V Hz or Vect
42. dia e de Dex ee eek etae Aa 2 15 2 7 9 Relay Outputs iacere c E DH ROREM eed 2 15 2 4 4 Analog Input 5 uctus ertet ber eren sere un 2 15 2 7 5 Analog Outputs iii 2 15 2 7 6 Frequency Input ss 2 15 2 7 7 Wiring the RMI Board Terminal Strip 2 16 Optional Equipment sine 2 17 Planning the Installation 3 1 3 2 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 3 6 3 1 4 Verifying Power Module Input Ratings Match Supplied Power 3 6 Wiring Requirements for the Drive sseessseennne 3 6 3 2 1 Meeting Terminal Strip Input and Output Specifications 3 6 3 2 2 Determining Wire Size Requirements ssseeeeee 3 6 3 2 2 1 Conduit Entry Opening Sizes 3 6 3 2 2 2 Recommended Power Wire Sizes ssessssssss 3 6 3 2 2 3 Recommended Control and Signal Wire Sizes 3 7 3 2 2 4 Recommended Motor Lead Lenglths 3 8 3 2 2 5 Recommended Serial Communication Cable Lengths 3 8 3 2 3 Selecting Input Line Branch Circuit Fuses sseseesees 3 8 3 2 4 Meeting Encoder Specifications FVC Regulation Only 3 9 3 2
43. drive requirements and is connected properly 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 Visually inspect the liquid cooling connections for leaks Uncouple the motor from any driven machinery to initially start the drive Powering Up After Installation Is Complete Use the following procedure to verify that the drive is installed correctly and is receiving the proper line voltage Step 1 Step 2 Step 3 Step 4 Turn the drive s input power disconnect to the On position Turn coolant on Apply power to the drive Follow the start up procedure in the LiquiFlo Software Start Up and Reference manual 8 2 LiquiFlo AC Power Modules Hardware Reference Version 6 4 9 1 9 2 9 3 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 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 Drive Alarms and Faults The drive will display alarm and fault codes to assist in troubleshooting when a problem develops during self tuning or drive operation If an a
44. e information Voltage Input Option Current Input Option Pins 2 3 Pins 1 2 10 VDC 0 20 mA O O O O O O J4 J4 default Figure 2 6 Jumper J4 Settings for Analog Input Speed Reference 2 6 1 2 Setting the Analog Output Jumper J17 Jumper J17 is the analog output jumper This jumper selects either a 0 10 VDC or 4 20 mA scaled signal output that is programmable to be proportional to either speed or torque using parameter P 012 Refer to the LiquiFlo Software Reference manual for more information about this parameter The jumper only selects a 0 10 VDC source voltage or 4 20 mA sink current to represent speed or torque Note that the 4 20 mA current selection requires a power supply for operation as shown in table 7 8 terminals 10 and 11 Use the following procedure to set jumper J17 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 injury or loss of life Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Turn off input power to the drive and wait five minutes Open the door of the enclosure Verify that the DC bus voltage is zero by following th
45. e procedure in section 9 3 Locate jumper J17 on the Regulator board Refer to figure 2 5 Locate pin 1 on jumper J17 Move the jumper to the desired setting as shown in figure 2 7 Close the door of the enclosure About the Drive Step 7 Reapply input power Step 8 Verify that parameter P 012 is set correctly for either speed or current Voltage Output Option Current Output Option Pins 2 3 Pins 1 2 10 VDC 4 20 mA O O O O O J17 J17 default 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 The following terminals are provided Terminals 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 through the Regulator board terminal strip LiquiFlo AC Power Modules Hardware Reference Version 6 4 m ANE g 2 c o 3 o D O Sr E amp D JESS E op oE Jr e S205 va c z E E E g EES c ce 54 5 5 9290
46. ed twisted pair wires with 2 3 twists per inch for applications to a maximum distance 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 Planning the Installation 3 9 LiquiFlo AC Power Modules Hardware Reference Version 6 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 Step 2 Step 3 Step 4 Step 5 Step 6 For M N 50LW4060 50LR4060 64LW4060 and 64LR4060 install two eyebolts into the drive to serve as lifting points Two 3 4 nuts are welded to the drive s baseplate Screw two eyebolts 2 eye I D 6 long shank into the nuts For M N 41L4060 or 41LR4060 install two clevis clamps into the drive to serve as lifting points Two 9 16 through holes are machined into the casting protrusions For M N 120L4060 install two clevis pins into the drive to serve as lifting points Two 1 00
47. en to earth ground For B and C frame drives use one of the bolts that pass through the drive baseplate and are used to fasten the drive to the wall or cabinet For D frame drives use the ground stud provided See figures 4 1 4 2 4 3 5 1 and 5 2 Tighten these grounding connections to the proper torque as shown in table 5 1 Step 3 Connect a suitable grounding conductor to the motor frame and the remote control station if used Run each conductor unbroken to earth ground When adding more than one grounding conductor wire to a single chassis ground twist the conductors together Tighten these grounding connections to the proper torque as shown in table 5 1 Step 4 Close the door of the enclosure 4 5 Connecting Coolant Lines LiquiFlo drives are rated for use with clean potable water as the coolant Coolant must be properly filtered to ensure it is free from contamination Some coolant fluids may allow an increased output rating while others may require a derating For LiquiFlo drive M N 41LR4060 contact Reliance Electric for additional information 4 5 1 B Frame Coolant Connections B frame LiquiFlo drives have inlet and outlet coolant connections 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
48. fications A 3 Table A 7 Input Signal Response Times Maximum Signal Type and Source Volts Hertz Regulation Vector Regulation Keypad START 150 milliseconds 130 milliseconds Terminal Strip 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 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 Speed Trim Reference 5 milliseconds network transport time 5 milliseconds network transport time Torque Reference N A 0 5 milliseconds network transport time These are the maximum times from transitioning the input to the drive reacting to the input A 4 LiquiFlo AC Power Modules Hardware Reference Version 6 4 M N 41L4060 Cooling System Specifications M N 41LR4060 M N 50LW4060 M N 64LW4060 M N 50LR4060 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 inhibitor Inlet Coolant Temperature Range 15 C to 4
49. hrough Default Ramp1 Ramp2 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 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 parameters can affect digital input 7 P 023 MOP Accel Decel Time P 024 MOP Reset Configuration P 031 to P 038 Preset Speeds 1 8 Refer to the LiquiFlo Software Start Up and Reference manual for additional information Terminal 18 On Ramp 2 Diagram shows factory setting 7 14 LiquiFlo AC Power Modules Hardware Reference Version 6 4 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 Digital Input 6 Default Forward Reverse Digital input 6 is control function programmable through parameter P 007 The following parameters must be set e P 000 Control Source e P 006 Second Menu Password e P 007 Terminal Strip Digital Inputs Configure Selects and assigns a control function to digital in
50. inal strip inputs and outputs for the LiquiFlo drive When the drive control source is the terminal strip P 000 rE the RMI board can be used to provide additional speed reference selections The RMI board also provides an outer PI regulator that is used to adjust trim An optional adjustable torque vector or current V Hz limit is available using the RMI 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 drive Note that you must first remove the RMI board before a communication board can be added to the LiquiFlo drive About the Drive 2 13 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 d
51. 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 lt sEpest 00 00 ooo oo 000000 co 0 0 C 000000 0 O 0100000 OT m 2 008 006 il gt oo oma Om RR 0 0 LA Clearance Allowable B T Coolant eae f onnections ibl ins 2 Enclosure loor A NI M 4 0 Min i Figure 4 4 DC Bus Reactor Cooling Fan Mounting Location 4 6 LiquiFlo AC Power Modules Hardware Reference Version 6 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 th
52. ions The terminal strip on the 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 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 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 Conduit Entry Opening Sizes It is important to determine the size of the conduit openings in the cabinet that the drive is mounted in so that the wire planned for a specific entry point will fit through the opening Recommended Power Wire Sizes Input power wiring should be copper and should be sized according to applicable codes to handle the drive s continuous rated input current Output wiring should be copper and should be sized according to applicable codes to handle the drive s continuous rated output current See tables 3 3 3 4 and 3 5 for recommended power wire sizes See figures 5 1 and 5 2 for input and output wiring connections 3 6 LiquiFlo AC Power Modules Hardware Reference Version 6 4 Table 3 3 Recommended Power Wire Sizes for B Frame Drives Type of Power Wiring AC Input Power R L1 S L2 T L3 Output P
53. isconnected 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 injury or loss of life ATTENTION The drive is capable of operating at and maintaining zero speed The user is responsible for assuring safe conditions for operating personnel by providing suitable guards audible or visual alarms or other devices to indicate that the drive is operating or may operate at or near zero speed Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION The user must provide an external hardwired emergency stop circuit outside of the drive circuitry This circuit must disable the system in case of improper operation Uncontrolled machine operation may result if this procedure is not followed Failure to observe this precaution could result in bodily injury 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 ATTENTION The drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing the drive Erratic machine operation and
54. larm condition occurs the drive will continue to run and a 2 or 3 digit alarm code will flash on the display If a fault occurs the drive 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 Verifying That DC Bus Capacitors Are Discharged 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 injury or loss of life The LiquiFlo drive s DC bus capacitors retain hazardous voltages after input power has been disconnected Perform the following steps before touching any internal components Step 1 Turn off and lock out input power Wait five minutes Step 2 Verify that there is no voltage at the drive s input power terminals Troubleshooting the Drive 9 1 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
55. ling Mechanical Motor Overload Protection Optional 6 1 6 3 Installing Output Wiring from the Drive Output Terminals to the Motor 6 2 Wiring the Regulator Board and RMI Board Terminal Strips TA Stopping the Drive cr tta rer ee pe rei oo dele EP irn 7 7 7 2 Wiring the Encoder Feedback Device FVC Regulation Only 8 7 3 Wiring the Signal and Control 1 0 7 10 7 4 Wiring the RMI Board Terminal Strip 7 19 Completing the Installation 8 1 Checking the Installation 8 1 8 2 Powering Up After Installation Is Complete 8 2 Troubleshooting the Drive 9 1 Test Equipment Needed To Troubleshoot seeee 9 1 9 2 Drive Alarms and Faults nutritive dg 9 1 9 3 Verifying That DC Bus Capacitors Are Discharged esssse 9 1 9 4 Checking the Power Modules with Input Power Off 9 5 9 5 Replacement Parts is 9 7 Technical Specifications x eer eee serere et edie Taek re ee tenets A 1 Cooling System Specifications B 1 B Frame LiquiFlo Drive Wiring Diagrams C 1 LiquiFlo AC Power Modules Hardware Reference Version 6 4 C Frame LiquiFlo Drive Wiring Diagrams D Frame LiquiFlo Drive Wiring Diagrams Contents LiquiFlo AC Power Modules Hardware Reference Version 6 4 Figure 2 1 Identifying the Drive Model Number esee 2 1 Figure 2 2 B Frame LiquiFlo Drive Compone
56. me 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 The center to center hole dimension is 1 625 Use the appropriate sweat fittings to connect the two bolt hole flanges to hoses or copper tube For adequate sealing a compressed fiber gasket is required between each flange and the drive For bolted joint strength use a 5 16 split ring lockwasher between each 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 the drive is 8 gpm at 10 psi It is recommended that a flow switch be installed after the coolant outlet to shut off the drive if the coolant flow drops below 4 gpm It is also recommended that the water pump not be powered unless the drive is also powered A corrosion inhibitor is required An approved source is Chemtool Inc part number CT787 C The recommended concentration of the inhibitor is 2 by volume Tube assemblies for water cooling are provided with kit M N 41L
57. ment ATTENTION You are responsible for conforming with all applicable local the RMI Board Terminal Str iring Refer to figure 2 10 for the signal and control I O terminal connections on the RMI board terminal strip connections and related parameters Refer to section 7 4 for descriptions of and how to wire all RMI board terminal strip connections 2 7 7 W uowuwo9 O Bojeuy punoi 1ndu AouenbeJ4 UOWWOD o Boyeuy YW OZ 0 O A OL 01 0 1ndino Boyeuy A 0L z ndino Bojeuy A OL 010 L 1ndino Bojeuy UOWWOD O 1 8ojeuy vu Oz 0 p 0 anduj Boyeuy AOL 0 0 nduj Bopeuy pesn JON uedo AjeuuoN Aejoy uowwog Ajay peso Ajeuuow Aejoy pesn iON uedo Aj euuowN g Aejoy uowwop g Aejay peso 2 Aj euuoN z Aejoy uedo Aj euuowN L Aejoy uowwog ejed uouJulo do jeu iq y ndo eysa indino peysa e 1ndino eysa L nding eysa sindino lela 40 Induy A pz leuIexz Ajuo sindur eu6ip 104 A v2 y ndul eysa Indu jeubiq e ndul reya 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 SELLCsLCcescesesTceTc eT PSPSPS PSPSVSVS9sgsgsgsgss L indy jey6iq LiquiFlo AC Power Modules Hardware Reference Version 6 4 Figure 2 10 Terminal Connections on the RMI Board 2 16 2 8 Optional Equipment Table 2 2 lists standard available LiquiFlo kits and options Table 2 2 Available Kits and Options Descrip
58. meter descriptions 7 4 W UOWWOD O Boyeuy punoi 1ndu Aouenbas4 UOWWOD C Hoyeuy VW OZ 0 O A OL O10 1ndino Boyeuy A 01 2 1ndino Bojeuy A OL 010 E 1ndino Bojeuy UOWWOD O I Bojeuy vu Oz 0 v 0 anduj Boyeuy A OL 010 nduj Boreuy pesn JON uedo Aj euJoN Aejoy UOuJUJO2 e oH pesol9 Aj euuoN e gy pesn JON uedo Aj euJoN z Aejoy uouwuwuo z Aejay pesol9 Aj euuoN z Aejey uedo Aj euuoN Aejoy uOWWUOD e oH uouJulo 1ndino epa 1ndino eu iq 1ndino jeubiq e 1ndino jeubiq 1ndino erba sindino eysa 10 1ndu A pz jeuJe1x3 Ajuo sindui jey6ip 104 A pet y ndul jeubig du esia z du resia 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 SSES L indy 2161 7 19 Figure 7 4 Terminal Connections on the RMI Board Wiring the Regulator Board and RMI Board Terminal Strips Terminal Table 7 9 Wiring Signal and Control I O to the RMI Board Terminal Strip Description Related Parameters Specifications and Jumpers Digital Inputs Control Voltage Output Digital Input 1 Digital Input 2 Digital Input 3 Digital Input 4 The four digital inputs are configured using parameter r 030 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 24 VDC Supply Cont
59. n severe bodily injury or loss of life ATTENTION When the level sense start feature is enabled P 054 ON the user must ensure that automatic start up of the driven equipment will not cause injury to operating personnel or damage to the driven equipment In addition the user is responsible for providing suitable audible or visual alarms or other devices to indicate that this function is enabled and the drive may start at any moment Refer to the LiquiFlo Software Start Up and Reference manual for additional information Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION Use of power correction capacitors on the output of the drive can result in erratic operation of the motor nuisance tripping and or permanent damage to the drive Remove power correction capacitors before proceeding Failure to observe this precaution could result in damage to or destruction of the equipment 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 General Requirements for the Installation Site It is important to properly plan before installing a LiquiFlo drive to ensure that the drive s environment and operating conditions are satisfactory Read the following recommendations before continuing with drive installation Making Sure Environmental
60. no voltage at the drive s input power terminals Check the DC bus potential with a voltmeter as described in section 9 3 to ensure that the DC bus capacitors are discharged Disconnect the motor from the drive Check all AC line and DC bus fuses If a fuse is open use a multimeter to check the input diodes and output IGBTs See table 9 1 Reconnect the motor to the drive Reapply input power Troubleshooting the Drive 9 5 Table 9 1 Resistance Checks Meter Connection Component is OK if resistance R is Component is defective if L1 10 R 1 megohm Continuity short circuit or open when the meter is Le connected with reversed L3 polarity L4 L5 L6 TOE L2 kk 2 3 4 5 6 7 8 9 L3 o La Es nd 12 L6 5 DC Bus Volts power terminal DC Bus Volts power terminal Table 9 1 Resistance Checks Continued Meter Connection Component is OK if resistance R is Component is defective if 10 R 1 megohm Continuity short circuit or open when the meter is connected with reversed polarity DC Bus Volts power terminal DC Bus Volts power terminal LiquiFlo AC Power Modules Hardware Reference Version 6 4 9 5 Replacement Parts Tables 9 2 9 3 and 9 4 list the replacement parts that are available from Reliance
61. nt Locations 2 3 Figure 2 3 C Frame LiquiFlo Drive Component Locations susss 2 5 Figure 2 4 D Frame LiquiFlo Drive Component Locations sssss 2 7 Figure 2 5 LiquiFlo Regulator Board Component Locations 2 9 Figure 2 6 Jumper J4 Settings for Analog Input Speed Reference 2 11 Figure 2 7 Jumper J17 Settings for Analog Outputs 2 12 Figure 2 8 Typical Regulator Board Terminal Strip Connections 2 13 Figure 2 9 Keypad Display us 2 14 Figure 2 10 Terminal Connections on the RMI Board seeeees 2 16 Figure 3 1 B Frame Drive Dimensions essssseseeee 3 3 Figure 3 2 C Frame Drive Dimensions 3 4 Figure 3 3 D Frame Drive Dimensions esssseseeene 3 5 Figure 4 1 Wire Routing Locations for B Frame LiquiFlo Drives 4 3 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 LiquiFl
62. nterconnecting bus bar provided with M N 41L4060PM 64L4060PM or 120L4060PM kit or can be user supplied bH LiquiFlo Power Module User Supplied Figure 5 1 Typical AC Input Output Electrical Connections 6 Pulse Rectifier All Frames 5 2 LiquiFlo AC Power Modules Hardware Reference Version 6 4 3 Phase AC Input Voltage 380 480 V 181 182 183 GND n Manual Disconnect User Supplied Transformer L2 L3 L6 L5 LiquiFlo Power Module User Supplied Figure 5 2 Typical AC Input Output Electrical Connections 12 Pulse Rectifier B and C Frames Only Installing Input Power Wiring 5 3 5 3 5 4 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 Refer to section 5 1 for additional information Installing Power Wiring from the AC Input Line to the Drive s Power Terminals Use the following steps to connect AC inpu
63. o Drives 4 9 Figure 4 7 Coolant Connector Locations for D Frame LiquiFlo Drives 4 9 Figure 5 1 Typical AC Input Output Electrical Connections 6 Pulse Rectifier All Frames 5 2 Figure 5 2 Typical AC Input Output Electrical Connections 12 Pulse Rectifier B and C Frames Only 5 3 Figure 7 1 Two Wire Start Stop Sample Control Wiring usssse 7 5 Figure 7 2 Three Wire Start Stop Sample Control Wiring 7 6 Figure 7 3 Encoder Wiring Connections 7 9 Figure 7 4 Terminal Connections on the RMI Board 7 19 Figure 9 1 DC Bus Voltage Terminals B Frame Drives ssssse 9 2 Figure 9 2 DC Bus Voltage Terminals C Frame Drives sussssss 9 3 Figure 9 3 DC Bus Voltage Terminals D Frame Drives ssesssss 9 4 Contents V VI LiquiFlo 2 0 AC Drive User Manual Table 2 1 Power and Enclosure Ratings c cccceeessseeeeeeeeneeeeeeeeneeeeeeesaeeeeeeeaas 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 3 7 Table 3 4 Recommended Power Wi
64. o o USER I O TERMINAL STRIP SS SS SORS 6 6 6 6 6 6 6 6 6 SS 6 6 6 SS SS SS SGSGSGSG 1 2 3 4 5 6 7 B 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Option Board Connector J9 Keypad Display Connector Analog Input Jumper J16 Power Module Feedback Cable J7 OIM Optional Connector J17 Analog Output Jumper RS 232C Port Figure 2 5 LiquiFlo Regulator Board Component Locations About the Drive 2 9 2 6 1 2 6 1 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 Setting the Analog Input Speed Reference Jumper J4 Jumper J4 is the analog speed torque U 000 reference jumper This jumper selects either 10 VDC or 0 20 mA input Parameters P 009 P 010 and P 011 are used in conjunction with the jumper Note that if the position of jumper J4 is changed after the parameters are programmed the software will not recognize that the input reference or polarity has been changed Be sure to verify that parameters P 009 P 010 and P 011 are corre
65. or Table 2 1 Power and Enclosure Ratings Input Current Amps Enclosure Rating Open Chassis Style Output Current at 2 kHz Amps Full Load Power Loss Watts Fluid Air 4600 1100 50LW4060 50LR4060 C Frame V Hz or Vector Open Chassis Style 5500 1500 64LW4060 64LR4060 120L4060 C Frame V Hz or Vector D Frame V Hz or Vector Open Chassis Style Open Chassis Style 7000 2000 11700 4000 With V Hz regulation 110 continuous output current capability With vector regulation 150 output current capability for 5 sec Note that LiquiFlo drives are rated for use with water at specified temperatures and pressures as the coolant Some coolant fluids may allow an increased output rating while others may require the output to be derated The LiquiFlo drive is also capable of running at 4 kHz or 8 kHz Contact Reliance Electric for ratings 2 2 2 3 LiquiFlo drives have the following enclosure rating Enclosure Ratings Open Chassis Style Intended to be installed in an enclosure LiquiFlo drives must be placed in an enclosure B Frame LiquiFlo Drive 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 NO 0 amp D Bus Bars 3 AC Output Bus Bars 6 AC Input IGBT Modules O
66. or Board and RMI Board Terminal Strips Terminal Number Table 7 8 Wiring Signal and Control I O to the Terminal Strip Continued Description Parameters Wiring Connections Wiring the Output Status Relays Normally Closed Contact Both Form A and Form B contacts are rated for 250 VAC Form B 30 VDC at 5 amps resistive or 2 amps inductive load Normally Closed Contact The following parameter must be set Common Form B P013 Output Relay Configuration Normally Open Contact Form A Note that depending on the setting of parameter P 013 the relay coil will energize the normally open contact will close Normally Open Contact and the normally closed contact will open Refer to the Common Form A LiquiFlo Software Start Up and Reference manual for more information SER SUPPLIED DEVICE AMETER P 013 SELECTS OUTPUT CATION 7 18 LiquiFlo AC Power Modules Hardware Reference Version 6 4 ip national andinternational codes Failure to observe this precaution could ATTENTION You are responsible for conforming with all applicable local result in damage to or destruction of the equipment the RMI Board Terminal Str iring Refer to figure 7 4 for the signal and control I O terminal connections on the RMI board Table 7 9 describes terminal strip connections and related parameters Refer to the RMI board instruction manual D2 3341 for para
67. orresponds to the voltage and frequency outputs of the inner V Hz FVC or SVC regulators The 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 display and fourteen indicator LEDs For a description of the keypad display refer to section 2 6 6 For operational instructions see the LiquiFlo Software Reference manual D2 3410 An analog output The analog output is a scaled voltage 0 10 VDC or current 4 20 mA signal proportional to either motor speed RPM motor torque or current Jc TORQUE The current signal selection via jumper J17 requires a power supply for operation The power can be sourced from the encoder terminals 4 and 9 or from an external 15 V power supply See table 7 1 terminals 10 and 11 for more information The analog output signal is available through the terminal strip 2 8 LiquiFlo AC Power Modules Hardware Reference Version 6 4 c Co 34 Pin Ribbon Cable J16 60 Pin Ribbon Cable USER DISPLAY e e e e J9 J7 Oooooooooo J17 J4 J8 o o CES 0 el Le
68. ovided correspond to the numbers used in figure 2 3 Replacement parts are listed in chapter 9 NO 0 8 amp D Bus Bars AC Input SCR Bridge AC to DC Converter Power Module Adapter Printed Circuit Board PCB Power Interface Harness Bus Bars AC Output LEM InterfaceHarness DC Bus Control PCB Gate Driver PCB Low Side DC Bus Laminate Assembly Output Current Feedback Devices IGBT Modules Chillplate Heatsink Capacitors Drive Baseplate Reactor Not Shown Discharge Resistors Not Shown Control Panel Assembly Bus Control PMA Harness Bus Control Gate Drive Harness Gate Driver PCB High Side Not Shown Membrane Switch Keyboard Bracket Regulator PCB Option Board Optional Coolant Lines Not Shown 2 4 LiquiFlo AC Power Modules Hardware Reference Version 6 4 T Pi MSS gee Jane pe ry 3 0 oO Figure 2 3 C Frame LiquiFlo Drive Component Locations About the Drive 2 5 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 num
69. ower U T1 V T2 W T3 Delta Wye Transformer S1 to S6 Ground PE Drive M N 41L4060 41LR4060 with kit M N 41L4060PM Lug accepts two 2 300 MCM to 6 AWG conductors Lugs not provided with standard drive They are available as part of kit M N 41L4060PM Table 3 4 Recommended Power Wire Sizes for C Frame Drives Type of Power Wiring AC Input Power R L1 S L2 T L3 Output Power U T1 V T2 W T3 Delta Wye Transformer S1 to S6 Ground PE Drive M N 50LW4060 50LR4060 64LW4060 64LR4060 with kit M N 64L4060PM Lug accepts two 2 350 MCM to 4 AWG conductors Lugs not provided with standard drive They are available as part of kit M N 64L4060PM Table 3 5 Recommended Power Wire Sizes for D Frame Drives Type of Power Wiring AC Input Power R L1 S L2 T L3 Output Power U T1 V T2 W T3 Delta Wye Transformer S1 to S6 Ground PE Drive M N 120L4060 with kit M N 120L4060PM Lug accepts two 2 800 MCM to 300 MCM conductors Lugs not provided with standard drive They are available as part of kit M N 120L4060PM 3 2 2 3 Recommended Control and Signal Wire Sizes The recommended wire sizes to connect I O signals to the terminal strip on the Regulator board and RMI board are shown in table 3 6 Recommended terminal tightening torque is 0 5 Newton meters 4 5 in Ibs Operator controls can be up to 303 meters 1000 feet from the LiquiFlo drive
70. puts 6 to 8 e 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 038 Preset Speeds 1 8 Refer to the LiquiFlo Software Start Up and Reference manual for additional information 16 19 FOR REV IF P 027 1 FORWARD DIRECTION ONLY Terminal 19 On Reverse Direction Diagram shows factory setting From the encoder end of the motor clockwise rotation indicates forward motor movement Wiring the Regulator Board and RMI Board Terminal Strips 7 15 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 Digital Input 5 The following parameters must be set Function Loss 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 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 ST
71. quate heat dissipation to maintain an internal temperature not to exceed 55 C Refer to table 2 1 for drive air watts loss Table A 3 Terminal Strip Input Specifications Signal Type Terminal s Specification Speed Reference Input 10 V 50 K ohm input impedance or 20 mA Digital Inputs 1 8 24 VDC Isolated Supply Remote Local Default Ramp1 Ramp2 Default Forward Reverse Default Function Loss Run Jog Reset Stop Start Table A 4 Terminal Strip Output Specifications Signal Type Terminal s Specification Analog Output 10 11 0 10 VDC or 4 20 mA scaled signal No Connection 26 There is no connection to terminal 26 Common 27 424 VDC common A 2 LiquiFlo AC Power Modules Hardware Reference Version 6 4 Table A 5 Terminal Strip RS 232 Specifications Signal Type Terminal s Specification RS 232 Communications 1 XMIT 2 RECV 3 COMMON Table A 6 Encoder Feedback 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 Technical Speci
72. re Sizes for C Frame Drives 3 7 Table 3 5 Recommended Power Wire Sizes for D Frame Drives 3 7 Table 3 6 Recommended Terminal Strip Wire Sizes 3 8 Table 3 7 AC Input Line Fuse and Circuit Breaker Selection Values 3 9 Table 5 1 Terminal Tightening Torques 5 4 Table 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 Wiring Signal and Control I O to the Regulator Board Terminal Strip 7 10 Table 7 9 Wiring Signal and Control I O to the RMI Board Terminal Strip 7 20 Table 9 1 Resistance Checks eene nennen 9 6 Table 9 2 B Frame LiquiFlo Drive Replacement Parts sssessss 9 7 Table 9 3 C Frame LiquiFlo Drive Replacement Parts 9 8 Table 9 4 D Frame LiquiFlo Drive Replacement Parts 9 9 Contents VII VIII LiquiFlo 2 0 AC Drive User Manu
73. rive 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 on the four character display Refer to the LiquiFlo Software Start Up and Reference manual for more information Drive Status LEDs Display Keypad AUIO Forward E seep ane MAN Reverse VOLTS MOI 1 P JOG Monitor Mode LEDs E i AUTO PROCRAM a Kw BR FORWARD ae TORQUE REVERSE NEN Password LED Password PROGRAM N mM SIARI RELIANCE RESET b ELECTRIC S gt Stop Reset Start Key Key Figure 2 9 Keypad Display LiquiFlo AC Power Modules Hardware Reference Version 6 4 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 Digital Outputs Four 24 volt digital outputs are t
74. rol Voltage Input 100 mA per output with an external power supply Jumper 24 V EXT Digital Output 1 Digital Output 2 Digital Output 3 Digital Output 4 r 031 Timer r 040 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 Configuration Configuration Common Digital 1 O common Relay Outp uts Common Normally Open Contact Configuration r 035 Timer r 044 Normally Closed Contact Common Normally Open Contact Configuration r 036 Timer r 045 Normally Closed Contact Common Normally Open Contact Configuration r 037 Timer r 046 Analog Inputs Freq uency Input Voltage Signal Input 10 VDC supply isolated stabilized max 2 7 mA jumper setting V IN default Current Signal Input Oto 20mA Analog current speed reference input jumper setting C IN Frequency Input 0 to 200 kHz Analog I O Common Isolated common for voltage current or frequency input 7 20 LiquiFlo AC Power Modules Hardware Reference Version 6 4 Table 7 9 Wiring Signal and Control I O to the RMI Board Terminal Strip Continued Terminal Related Parameters Specifications and Number Description Jumpers Analog Outputs 65 Analog Output No 1 Configuration r 001 0 to 10 VDC Offset r 002 Gain r 003 66 Analog Output No 2 Configuration
75. s 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 wiring 7 4 to 7 5 Control wiring 2 13 7 1 to 7 17 Coolant connections 4 7 to 4 8 pressure 4 8 B 1 temperature range 4 8 B 1 type 4 8 B 1 D DC bus Control Board 2 4 to 2 5 9 8 reactor fan 4 6 terminals 9 2 9 3 9 4 verifying capacitor voltage 9 1 to 9 4 Digital input wiring 2 12 to 2 13 7 3 to 7 5 7 12 to 7 16 1 start 7 3 7 4 7 5 7 16 2 stop 7 3 7 4 7 5 7 16 3 reset 7 3 7 4 7 5 7 16 4 run jog 7 3 7 4 7 5 7 15 5 function loss 7 3 7 4 7 5 7 15 6 forward reverse 7 3 7 4 7 5 7 14 7 ramp1 ramp2 7 3 7 4 7 5 7 13 8 remote local 7 3 7 4 7 5 7 12 Digital output wiring see Status Relays Dimensions 3 2 to 3 5 Discharge resistors 2 4 to 2 5 Disconnect installing input 5 2 to 5 4 Display see Keypad Display Distribution system capacity AC line 5 1 A 1 Drive identifying 2 1 kits 2 17 Index Index 1 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
76. s E 1 LiquiFlo 1 5 AC Power Modules Hardware Reference Version 1 2 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 2 11 to 2 12 A 2 wiring 2 13 7 2 7 4 to 7 5 7 10 Analog input speed reference input current wiring 2 10 to 2 11 2 12 7 2 7 4 to 7 5 7 11 A 2 0 10 VDC J4 2 10 to 2 11 2 13 7 2 4 20 mA J4 2 10 to 2 11 2 13 7 2 Area required 3 2 3 6 Audience intended 1 1 Board DC Bus Control 2 2 to 2 7 9 8 Gate Driver 2 2 to 2 7 9 5 Power Module Adapter PMA 2 2 to 2 7 9 8 Option 2 2 to 2 7 Regulator 2 2 to 2 7 9 7 9 8 9 9 RMI 2 13 to 2 14 7 19 to 7 21 C Capacitors DC bus 9 1 to 9 4 Carrier frequency 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 Contact
77. st to rest or a ramp to rest operational stop without physical separation of the power source from the motor A coast to rest stop turns off the transistor power device drivers A ramp to rest stop fires the transistor power device drivers until the motor comes to a stop and then turns off the power devices The user can also program zero speed with power maintained to the motor but in this condition the drive is not actually stopped See the description of terminals 23 and 24 or Stop Type P 025 for more information on how to program the operational stop In addition to the operational stop the user must provide a hardwired emergency stop external to the drive The emergency stop circuit must contain only hardwired electromechanical components Operation of the emergency stop must 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 Wiring the Regulator Board and RMI Board Terminal Strips 7 7 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
78. t power to the drive Step 1 Wire the AC input power leads by routing them as shown in figure 4 1 Tables 3 3 3 4 and 3 5 contains the recommended power wiring sizes ATTENTION Do not route signal and control wiring with power wiring in the same conduit This can cause interference with drive operation Failure to observe this precaution could result in damage to or destruction of the equipment Step 2 Connect the three phase AC input power 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 Table 5 1 Terminal Tightening Torques Maximum Tightening Torque Drive Type Terminals Hardware Type 410 L1 to LG 1 4 20 Gr 5 13 Newton meters 10 ft lb U V W 5 16 18 Gr 5 24 Newton meters 18 ft lb GND PE 5 16 Hex 31 Newton meters 23 ft lb L1 to LG 1 2 13 Gr 5 100 Newton meters 75 ft lb U V W 3 8 16 Gr 5 42 Newton meters 31 ft lb GND PE 5 16 Hex 31 Newton meters 23 ft lb L1 to L6 1 2 13 Gr 5 100 Newton meters 75 ft Ib U VW 1 2 13 Gr 5 100 Newton meters 75 ft lb GND PE 1 2 Hex 58 Newton meters 42 ft lb 5 4 LiquiFlo
79. talled if FVC regulation is used Wiring the Regulator Board and RMI Board Terminal Strips 7 1 Table 7 3 Analog Output Connections Terminals 10 and 11 Terminal Analog Meter Output 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 4 Analog Speed Torque Reference Connections Terminals 12 15 Terminal Isolated Reference Voltage VDC Speed Torque Reference mA Speed Torque Reference Isolated Reference Common Notes The analog speed torque P 008 U 000 reference is either 10 VDC or 20 mA as determined by the setting of jumper J4 on the Regulator board The analog reference can be adjusted using parameters P 009 P 010 and P 011 7 2 LiquiFlo AC Power Modules Hardware Reference Version 6 4 Table 7 5 Digital Input Connections Terminals 16 25 Terminal 24 VDC Current Limited For remote control digital inputs only Digital Input 8 Remote Local Programmable Digital Input 7 Ramp1 Ramp2 Programmable Digital Input 6 Forward Reverse Programmable Function Loss Run Jog Reset Stop Start 24 VDC Common Notes When a user installed function loss input a coast to stop push
80. tion Motor Encoder Cable Model Number 2TC3025 2TC3075 2TC4025 2TC4075 2TC4100 2TC4300 Instruction Manual D2 3305 DeviceNet Network Option Board 2DV3000 MANO096 03 ControlNet Network Option Board 2CN3000 D2 3390 InterBus 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 MANO183 02 PROFIBUS Option Board 2PB3000 4971355 AutoMax RS 232 Adapter Cable 2CA3001 D2 3348 Operator Interface Module OIM 2RK3000 D2 3342 CS3000 Control and Configuration Software 2CS3000 D2 3348 CS3000 RS 232 Computer Cable 2CA3000 D2 3348 115 VAC Interface Option Board 2LB3000 D2 3376 2 18 LiquiFlo AC Power Modules Hardware Reference Version 6 4 Planning the Installation 3 1 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 i
81. uce line harmonics Input isolation transformers might be needed to help eliminate the following Damaging line voltage transients from reaching the drive Line noise from the drive back to the incoming power source Damaging currents that could develop if a point inside the drive becomes grounded 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 f 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 Circuit Protection Install the required user supplied branch circuit protection fuses according to the applicable local national and international codes e g NEC CEC The fuses must be installed in the line before the drive input terminals See figures 5 1 and 5 2 Fuse value selections are provided in table 3 7 ATTENTION Most codes require that upstream branch protection be provided to protect input power wiring Failure to observe this precaution could result in severe bodily injury or loss of life Installing Input Power Wiring 5 1 3 Phase AC Input Voltage 380 480 V L1 L2 L3 O O QOcN O 07 0 Manual Disconnect User Supplied I
82. ui aoualajay peeds NGA oDejoA eouoJojeH perelos uouJuJo Joyejnbay indino 1e1ejy Bojeuy UOWWOD Joje n amp eH LON 8 eseug g eseud LON V eseug y eseug OGA SL uoululo5 10jeinBeu zez sH Xu c c SH XL cEc S4 22 23 24 25 26 27 28 29 30 31 19 20 21 o S SS SS Remote 4 20 mA Speed Torque Reference 7 5 Start Stop Fwd Q Rev Function Loss olo Run ES O _ Reset O O Jog Figure 7 1 Two Wire Start Stop Sample Control Wiring ON and vt LA e N s 20 mA Important A maintained function loss switch should be used if P 054 Level P 026 Function Loss Response 1 Sense Start Enable Wiring the Regulator Board and RMI Board Terminal Strips uOWWOD Aejay O N 1Peu09 ej8H O N UOWWOD Aejay N yoe UOD e ed O N UOWWOD OCA vet uonoeuuo ON UOWWOD 230A vet uelis dois yesey Bor uny sso7 uonounJ es1e eu puem04 9 Indy jeyifiq zdwey dureg 7 indui jeu6iq jeo07 e 0W9y 8 1ndu jeu6iq OGA vet pur eoue1eJeH pe ejos a0uelajay peeds vui e2ueJojedH peeds OdA oDejoA e2uoJ9JeH peielos uouluJo JoyejnBay indino 1ejen Bojeuy UOWWOD JojejnDeu LON 8 eseug g eseug LON V eseug y eseug OGA SE UOWWOD JoyejnBey zez sSH XEH c c SH XL vc c SH 22 23 24 25 26 27 28 29 30 31 So o S 6 6 VG 6 21 0
83. urned on and off as a result of data comparisons in the drive All digital outputs are source driven active high with common ground and short circuit protected Each output has an adjustable time delay that can be programmed as an on delay or an off delay An option 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 24 VDC or 250VA 120VAC 2 7 4 Analog Input The analog input is based on a 10 bit analog to digital A D converter and is jumper selected between 0 to 10 volts or 0 to 20 mA Separate connection terminals are provided for voltage input and current input The inputs are overvoltage protected Offset and gain are computed by software 2 7 5 Analog Outputs Three analog output channels can be configured The outputs are short circuit protected The output value is modulated over four 1 msec scans to provide 10 bit data resolution 2 7 6 Frequency Input The frequency input operates from 0 to 200 kHz 15 VDC The input is single ended and uses the same common as the analog input About the Drive 2 15 ip national andinternational codes Failure to observe this precaution could result in damage to or destruction of the equip
84. utput Laminate Capacitors RMI Board Casting Membrane Switch Keypad Coolant Lines a Inlet b Outlet 10 Regulator Board 11 Power Module Control PCB 12 Current Feedback Devices 3 LiquiFlo AC Power Modules Hardware Reference Version 6 4 11 10 7 eo Go o e OIL O ISA 4 pe BED she o B i mp is O L E OE E uc 1 oT Trae eel M e o o CG m C 0 mg LT Ct EF UC 2 3 Figure 2 2 B Frame LiquiFlo Drive Component Locations About the Drive 2 4 C Frame LiquiFlo Drive Component Locations The C Frame LiquiFlo drives have the following main components The numbered items listed below pr
85. ve minutes Step 2 Verify that the DC bus voltage is zero Refer to section 9 3 Step 3 If a function loss coast stop pushbutton has been installed verify that it has been wired correctly Be sure the factory installed jumper at terminals 16 and 20 has been removed so that the coast stop pushbutton will work ATTENTION The user must provide an external hardwired emergency stop circuit outside of the drive circuitry This circuit must disable the system in case of improper operation Uncontrolled machine operation may result if this procedure is not followed Failure to observe this precaution could result in bodily injury Step 4 Remove any debris such as metal shavings from around the drive Step 5 Check that there is adequate clearance around the drive Step 6 Verify that the wiring to the terminal strip and the power terminals is correct Step 7 Check that the wire size is within terminal specifications and that the wires are tightened 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 Completing the Installation 8 1 8 2 Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 Check the motor installation and length of motor leads Disconnect any power correction capacitors connected between the drive and the motor Check that the rating of the transformer if used matches the

LiquiFlo AC Power Modules Hardware Reference

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