Rockwell Automation Reliance Electric LiquiFlo 41L4060 Bedienungsanleitung

Instruction Manual

LiquiFlo AC Power Modules

Hardware Reference, Installation,

and Troubleshooting

Version 6.4

D2-3411-7

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:

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: Identifies information about practices or circumstances that can lead to personal

injury or death, property damage, or economic loss.

DeviceNet is a trademark of Open DeviceNet Vendor Association.

INTERBUS is a trademark of Phoenix Contact.

Metasys is a trademark of Johnson Controls.

Modbus is a trademark of Schneider Automation.

P1 is a trademark of Landis & Staefa.

PROFIBUS is a trademark of PROFIBUS International.

LiquiFlo, AutoMax, and Reliance are trademarks of Rockwell Automation.

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 not install 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

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.

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 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.

Contents

CONTENTS

Chapter 1

Introduction

1.1 Related Publications ........................................................................................ 1-1

1.2 Getting Assistance from Reliance Electric....................................................... 1-1

Chapter 2

About the Drive

2.1 Identifying the Drive by Model Number ........................................................... 2-1

2.2 Enclosure Ratings ........................................................................................... 2-2

2.3 B-Frame LiquiFlo Drive Component Locations................................................ 2-2

2.4 C-Frame LiquiFlo Drive Component Locations ............................................... 2-4

2.5 D-Frame LiquiFlo Drive Component Locations ............................................... 2-6

2.6 Regulator Board Description ........................................................................... 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............................................................... 2-13

2.6.4 RMI Board Connector ......................................................................... 2-13

2.6.5 Operator Interface Module Connector................................................. 2-14

2.6.6 Keypad/Display ................................................................................... 2-14

2.7 RMI Board Description .................................................................................. 2-15

2.7.1 Digital Inputs ....................................................................................... 2-15

2.7.2 Digital Outputs..................................................................................... 2-15

2.7.3 Relay Outputs ..................................................................................... 2-15

2.7.4 Analog Input ........................................................................................ 2-15

2.7.5 Analog Outputs ................................................................................... 2-15

2.7.6 Frequency Input .................................................................................. 2-15

2.7.7 Wiring the RMI Board Terminal Strip................................................... 2-16

2.8 Optional Equipment ....................................................................................... 2-17

Chapter 3

Planning the Installation

3.1 General Requirements for the Installation Site................................................ 3-1

3.1.1 Making Sure Environmental Conditions are Met ................................... 3-1

3.1.2 Determining Total Area Required Based on Drive Dimensions ............ 3-2

3.1.3 Verifying the Site Provides for Recommended Air Flow Clearances .... 3-6

3.1.4 Verifying Power Module Input Ratings Match Supplied Power ............. 3-6

3.2 Wiring Requirements for the Drive .................................................................. 3-6

3.2.1 Meeting Terminal Strip Input and Output Specifications ....................... 3-6

3.2.2 Determining Wire Size Requirements ................................................... 3-6

3.2.2.1 Conduit Entry Opening Sizes.................................................. 3-6

3.2.2.2 Recommended Power Wire Sizes .......................................... 3-6

3.2.2.3 Recommended Control and Signal Wire Sizes ....................... 3-7

3.2.2.4 Recommended Motor Lead Lengths....................................... 3-8

3.2.2.5 Recommended Serial Communication Cable Lengths ........... 3-8

3.2.3 Selecting Input Line Branch Circuit Fuses ............................................ 3-8

3.2.4 Meeting Encoder Specifications (FVC Regulation Only)....................... 3-9

3.2.4.1 Encoder Wiring Guidelines ..................................................... 3-9

3.2.5 Verifying Power Module Output Current Rating Is

Greater Than Motor Full Load Amps..................................................... 3-9

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Chapter 4

Mounting the Drive, Grounding, and Finding Wire Routing Locations

4.1 Lifting and Mounting the Drive .........................................................................4-1

4.1.1 Verifying the Drive’s Watts Loss Rating.................................................4-2

4.2 Determining Input, Motor Output, Ground, and Control Wire

Routing for the Drive ........................................................................................4-2

4.3 Installing the DC Bus Reactor Fan (C-Frame Drives Only)..............................4-6

4.4 Grounding the Drive .........................................................................................4-7

4.5 Connecting Coolant Lines ................................................................................4-7

4.5.1 B-Frame Coolant Connections ..............................................................4-7

4.5.2 C-Frame Coolant Connections ..............................................................4-7

4.5.3 D-Frame Coolant Connections ..............................................................4-8

Chapter 5

Installing Input Power Wiring

5.1 Installing Transformers and Reactors (Optional) .............................................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 ..................................................................................5-4

Chapter 6

Installing Output Power Wiring

6.1 Installing Output Contactors (Optional) ............................................................6-1

6.2 Installing Mechanical Motor Overload Protection (Optional) ............................6-1

6.3 Installing Output Wiring from the Drive Output Terminals to the Motor............6-2

Chapter 7

Wiring the Regulator Board and RMI Board Terminal Strips

7.1 Stopping the Drive............................................................................................7-7

7.2 Wiring the Encoder Feedback Device

(FVC Regulation Only)8

7.3 Wiring the Signal and Control I/O...................................................................7-10

7.4 Wiring the RMI Board Terminal Strip .............................................................7-19

Chapter 8

Completing the Installation

8.1 Checking the Installation ..................................................................................8-1

8.2 Powering Up After Installation Is Complete......................................................8-2

Chapter 9

Troubleshooting the Drive

9.1 Test Equipment Needed To Troubleshoot .......................................................9-1

9.2 Drive Alarms and Faults...................................................................................9-1

9.3 Verifying That DC Bus Capacitors Are Discharged..........................................9-1

9.4 Checking the Power Modules with Input Power Off .........................................9-5

9.5 Replacement Parts...........................................................................................9-7

Appendix A

Technical Specifications........................................................................................... A-1

Appendix B

Cooling System Specifications................................................................................. B-1

Appendix C

B-Frame LiquiFlo Drive Wiring Diagrams................................................................. C-1

Contents

III

Appendix D

C-Frame LiquiFlo Drive Wiring Diagrams .................................................................D-1

Appendix E

D-Frame LiquiFlo Drive Wiring Diagrams .................................................................E-1

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Contents

List of Figures

Figure 2.1 – Identifying the Drive Model Number ..................................................... 2-1

Figure 2.2 – B-Frame LiquiFlo Drive Component Locations..................................... 2-3

Figure 2.3 – C-Frame LiquiFlo Drive Component Locations .................................... 2-5

Figure 2.4 – D-Frame LiquiFlo Drive Component Locations .................................... 2-7

Figure 2.5 – LiquiFlo Regulator Board Component Locations.................................. 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................................................................................... 2-14

Figure 2.10 – Terminal Connections on the RMI Board ......................................... 2-16

Figure 3.1 – B-Frame Drive Dimensions .................................................................. 3-3

Figure 3.2 – C-Frame Drive Dimensions .................................................................. 3-4

Figure 3.3 – D-Frame Drive Dimensions .................................................................. 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 LiquiFlo 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 ........................................ 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)....................................... 9-2

Figure 9.2 – DC Bus Voltage Terminals (C-Frame Drives) ...................................... 9-3

Figure 9.3 – DC Bus Voltage Terminals (D-Frame Drives) ...................................... 9-4

LiquiFlo 2.0 AC Drive User Manual

Contents

VII

List of Tables

Table 2.1 – Power and Enclosure Ratings ............................................................... 2-2

Table 2.2 – Available Kits and Options................................................................... 2-17

Table 3.1 – Environmental Conditions...................................................................... 3-2

Table 3.2 – Drive Dimensions and Weights.............................................................. 3-2

Table 3.3 – Recommended Power Wire Sizes for B-Frame Drives.......................... 3-7

Table 3.4 – Recommended Power Wire 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 ................................................................................ 9-6

Table 9.2 – B-Frame LiquiFlo Drive Replacement Parts .......................................... 9-7

Table 9.3 – C-Frame LiquiFlo Drive Replacement Parts .......................................... 9-8

Table 9.4 – D-Frame LiquiFlo Drive Replacement Parts .......................................... 9-9

VIII

LiquiFlo 2.0 AC Drive User Manual

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