Rockwell-automation Liqui-Flo AC Power Modules User Manual

LiquiFlo AC Power ModulesVersion 6.4Hardware Reference, Installation, and Troubleshooting Manual D2-3411-8

VIIILiquiFlo 2.0 AC Drive User Manual

D-2LiquiFlo 2.0 AC Drive User Manual

D-Frame LiquiFlo Drive Wiring DiagramsE-1APPENDIX ED-Frame LiquiFlo Drive WiringDiagramsReplace with file E.fm (17 x 11, z-fold).

E-2LiquiFlo 1.5 AC Power Modules, Hardware Reference Version 1.2

Index Index-1INDEXAAC inputdiodes, checking, 9-5 to 9-6disconnect, installing, 5-2 to 5-4isolation, transformer, 5-1line branch circuit fuses, 3-8, 5-

Index-2LiquiFlo AC Power Modules, Hardware Reference Version 6.4EEmergency stop, 7-6Enclosures, NEMA, 2-2, 3-1Encoderspecifications, A-3wiring, 2-12 t

IndexIndex-3 NetworkAutoMax Network Option board, 2-17communication, 2-13, 3-7OOpen loop, see Volts/Hertz RegulationOption kits, see KitsOutputanalog,

Index-4LiquiFlo AC Power Modules, Hardware Reference Version 6.4Transients, AC line voltage, 5-1VVector regulation, 2-1Ventilation, see Air FlowVolts/

Publication D2-3411-8 – May 2013 PN-223512Supersedes Publication D2-3411-7 – April 2005 Copyright © 2013 Rockwell Automation, Inc. All rights reser

Introduction1-1CHAPTER 1 IntroductionThis instruction manual describes the LiquiFlo drive’s Power Module and regulator hardware. It does not cover th

1-2LiquiFlo AC Power Modules, Hardware Reference Version 6.4

About the Drive2-1CHAPTER 2 About the DriveThis chapter describes how to identify the drive using the model number matrix and shows the major drive co

2-2LiquiFlo AC Power Modules, Hardware Reference Version 6.4Table 2.1 – Power and Enclosure Ratings* With V/Hz regulation, 110% continuous output curr

About the Drive2-3Figure 2.2 – B-Frame LiquiFlo Drive Component Locations1234109a8765129b11

2-4LiquiFlo AC Power Modules, Hardware Reference Version 6.42.4 C-Frame LiquiFlo Drive Component LocationsThe C-Frame LiquiFlo drives have the followi

About the Drive2-5Figure 2.3 – C-Frame LiquiFlo Drive Component Locations135782122239151113201712102461418191624

2-6LiquiFlo AC Power Modules, Hardware Reference Version 6.42.5 D-Frame LiquiFlo Drive Component LocationsThe D-Frame LiquiFlo drives have the followi

About the Drive2-7Figure 2.4 – D-Frame LiquiFlo Drive Component Locations8976543211310 11 1214

Important User InformationSolid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines

2-8LiquiFlo AC Power Modules, Hardware Reference Version 6.42.6 Regulator Board Description LiquiFlo drive regulation is performed by a microprocessor

About the Drive2-9Figure 2.5 – LiquiFlo Regulator Board Component LocationsUSER I/O TERMINAL STRIP34-Pin Ribbon CableJ8J17J460-Pin Ribbon CableJ16J9J3

2-10LiquiFlo AC Power Modules, Hardware Reference Version 6.42.6.1 Jumper Locations and SettingsJumpers J4 and J17 on the Regulator board are factory-

About the Drive2-11Step 8. Verify that Terminal Strip Analog Input Offset (P.009), Terminal Strip Analog Input Gain (P.010), and Terminal Strip Analog

2-12LiquiFlo AC Power Modules, Hardware Reference Version 6.4Step 7. Reapply input power.Step 8. Verify that parameter P.012 is set correctly for eith

About the Drive2-13Figure 2.8 – Typical Regulator Board Terminal Strip Connections2.6.3 RS-232 Communication PortThe Regulator board contains a 9-pin

2-14LiquiFlo AC Power Modules, Hardware Reference Version 6.4Refer to the appropriate board instruction manual for more information. Refer to section

About the Drive2-152.7 RMI Board DescriptionThe following signals are available at the RMI board terminal strip. Refer to figure 2.10 for terminal ide

2-16LiquiFlo AC Power Modules, Hardware Reference Version 6.42.7.7 Wiring the RMI Board Terminal StripRefer to figure 2.10 for the signal and control

About the Drive2-172.8 Optional EquipmentTable 2.2 lists standard available LiquiFlo kits and options.Table 2.2 – Available Kits and OptionsDescriptio

ContentsICONTENTSChapter 1 Introduction1.1 Related Publications ...

2-18LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Planning the Installation3-1CHAPTER 3 Planning the Installation This chapter provides how to plan a LiquiFlo drive installation. 3.1 General Requireme

3-2LiquiFlo AC Power Modules, Hardware Reference Version 6.4• Do not install the drive above 1000 meters (3300 feet) without derating output power. Fo

Planning the Installation3-3Figure 3.1 – B-Frame Drive DimensionsE B C Right Side ViewFront ViewF (Typ. 4 Pl.)G (Typ. 4 Pl.) A D4 Places.563" Th

3-4LiquiFlo AC Power Modules, Hardware Reference Version 6.4Figure 3.2 – C-Frame Drive DimensionsG (Typ. 4 Pl.)F (Typ. 4 Pl.) A DE B CFront View (Con

Planning the Installation3-5Figure 3.3 – D-Frame Drive Dimensions6 Pl.FAGEBC13.9316.5016.50 0.56DLeft Side ViewFront View

3-6LiquiFlo AC Power Modules, Hardware Reference Version 6.43.1.3 Verifying the Site Provides for Recommended Air Flow ClearancesBe sure there is adeq

Planning the Installation3-73.2.2.3 Recommended Control and Signal Wire Sizes The recommended wire sizes to connect I/O signals to the terminal strip

3-8LiquiFlo AC Power Modules, Hardware Reference Version 6.43.2.2.4 Recommended Motor Lead Lengths Motor lead lengths can total up to 76 meters (250 f

Planning the Installation3-9 3.2.4 Meeting Encoder Specifications (FVC Regulation Only) LiquiFlo drives set up for FVC regulation require an encoder f

IILiquiFlo AC Power Modules, Hardware Reference Version 6.4Chapter 4 Mounting the Drive, Grounding, and Finding Wire Routing Locations4.1 Lifting and

3-10LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Mounting the Drive, Grounding, and Finding Wire Routing Locations4-1CHAPTER 4 Mounting the Drive, Grounding, and Finding Wire Routing Locations This c

4-2LiquiFlo AC Power Modules, Hardware Reference Version 6.4In order to maintain a flat mounting surface and to ensure that bolt tightness is maintain

Mounting the Drive, Grounding, and Finding Wire Routing Locations4-3Figure 4.1 – Wire Routing Locations for B-Frame LiquiFlo DrivesFront ViewTop ViewB

4-4LiquiFlo AC Power Modules, Hardware Reference Version 6.4Figure 4.2 – Wire Routing Locations for C-Frame LiquiFlo DrivesUserConnectionsCoolantConne

Mounting the Drive, Grounding, and Finding Wire Routing Locations4-5Figure 4.3 – Wire Routing Locations for D-Frame LiquiFlo DrivesUser ControlConnect

4-6LiquiFlo AC Power Modules, Hardware Reference Version 6.44.3 Installing the DC Bus Reactor Fan (C-Frame Drives Only)A fan must be installed in the

Mounting the Drive, Grounding, and Finding Wire Routing Locations4-74.4 Grounding the Drive Use the following steps to ground the drive:Step 1. Open t

4-8LiquiFlo AC Power Modules, Hardware Reference Version 6.4not be powered unless the drive is also powered. Failure to do this may result in condensa

Mounting the Drive, Grounding, and Finding Wire Routing Locations4-9Figure 4.6 – Coolant Connector Locations for C-Frame LiquiFlo DrivesFigure 4.7 – C

ContentsIIIAppendix D C-Frame LiquiFlo Drive Wiring Diagrams ...D-1Appendix E D-Frame Li

4-10LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Installing Input Power Wiring5-1CHAPTER 5 Installing Input Power Wiring This chapter describes incoming line components and how to install them. 5.1 I

5-2LiquiFlo AC Power Modules, Hardware Reference Version 6.4Figure 5.1 – Typical AC Input/Output Electrical Connections (6-Pulse Rectifier, All Frames

Installing Input Power Wiring5-3Figure 5.2 – Typical AC Input/Output Electrical Connections (12-Pulse Rectifier, B- and C-Frames Only)

5-4LiquiFlo AC Power Modules, Hardware Reference Version 6.45.3 Installing a Required External/Separate Input Disconnect An input disconnect must be i

Installing Output Power Wiring6-1CHAPTER 6 Installing Output Power Wiring This chapter provides instructions on wiring output contactors, motor overlo

6-2LiquiFlo AC Power Modules, Hardware Reference Version 6.46.3 Installing Output Wiring from the Drive Output Terminals to the Motor Important: The t

Wiring the Regulator Board and RMI Board Terminal Strips7-1CHAPTER 7 Wiring the Regulator Board and RMI Board Terminal StripsThis chapter describes ho

7-2LiquiFlo AC Power Modules, Hardware Reference Version 6.4Table 7.3 – Analog Output Connections (Terminals 10 and 11)Terminal # Signal10 Analog Mete

Wiring the Regulator Board and RMI Board Terminal Strips7-3.Table 7.5 – Digital Input Connections (Terminals 16-25)Terminal # Signal16 +24 VDC (Curren

IVLiquiFlo AC Power Modules, Hardware Reference Version 6.4

7-4LiquiFlo AC Power Modules, Hardware Reference Version 6.4Table 7.7 – Status Relay Connections (Terminals 28-31)Terminal # Signal28 N.C Relay Conta

Wiring the Regulator Board and RMI Board Terminal Strips7-5Figure 7.1 – Two-Wire Start/Stop Sample Control Wiring2 435N.O. Relay CommonResetStart/Stop

7-6LiquiFlo AC Power Modules, Hardware Reference Version 6.4Figure 7.2 – Three-Wire Start/Stop Sample Control Wiring12 43519769810 12111413 15 1716 18

Wiring the Regulator Board and RMI Board Terminal Strips7-77.1 Stopping the DriveDepending upon the requirements of the application, the LiquiFlo driv

7-8LiquiFlo AC Power Modules, Hardware Reference Version 6.47.2 Wiring the Encoder Feedback Device (FVC Regulation Only)If the LiquiFlo drive is prog

Wiring the Regulator Board and RMI Board Terminal Strips7-9Figure 7.3 – Encoder Wiring Connections12345678910RegulatorTerminal StripPin 3 Phase APin 8

7-10LiquiFlo AC Power Modules, Hardware Reference Version 6.47.3 Wiring the Signal and Control I/OWire the drive’s signal and control I/O to the Regul

Wiring the Regulator Board and RMI Board Terminal Strips7-11Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)TerminalNumber

7-12LiquiFlo AC Power Modules, Hardware Reference Version 6.4Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)TerminalNumber

Wiring the Regulator Board and RMI Board Terminal Strips7-13Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)TerminalNumber

ContentsVList of FiguresFigure 2.1 – Identifying the Drive Model Number ... 2-1Figure 2.2 – B-Frame

7-14LiquiFlo AC Power Modules, Hardware Reference Version 6.4Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)TerminalNumber

Wiring the Regulator Board and RMI Board Terminal Strips7-15Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)TerminalNumber

7-16LiquiFlo AC Power Modules, Hardware Reference Version 6.4Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)TerminalNumber

Wiring the Regulator Board and RMI Board Terminal Strips7-17Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)TerminalNumber

7-18LiquiFlo AC Power Modules, Hardware Reference Version 6.4Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)TerminalNumber

Wiring the Regulator Board and RMI Board Terminal Strips7-197.4 Wiring the RMI Board Terminal StripRefer to figure 7.4 for the signal and control I/O

7-20LiquiFlo AC Power Modules, Hardware Reference Version 6.4Table 7.9 – Wiring Signal and Control I/O to the RMI Board Terminal Strip TerminalNumber

Wiring the Regulator Board and RMI Board Terminal Strips7-21Terminals 57 and 61 are not used.Analog Outputs65 Analog Output No. 10 to 10 VDCConfigurat

7-22LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Completing the Installation8-1CHAPTER 8 Completing the InstallationThis chapter provides instructions on how to perform a final check of the installat

VILiquiFlo 2.0 AC Drive User Manual

8-2LiquiFlo AC Power Modules, Hardware Reference Version 6.4Step 10. Check the motor installation and length of motor leads.Step 11. Disconnect any po

Troubleshooting the Drive9-1CHAPTER 9 Troubleshooting the Drive This chapter describes how to troubleshoot the drive and the equipment that is needed

9-2LiquiFlo AC Power Modules, Hardware Reference Version 6.4Step 3. Measure the DC bus potential with a voltmeter while standing on a non-conductive s

Troubleshooting the Drive9-3Figure 9.2 – DC Bus Voltage Terminals (C-Frame Drives)Initial DC BusMeasurementPoints

9-4LiquiFlo AC Power Modules, Hardware Reference Version 6.4Figure 9.3 – DC Bus Voltage Terminals (D-Frame Drives)Initial DC BusMeasurementPointsPOSTP

Troubleshooting the Drive9-59.4 Checking the Power Modules with Input Power OffUse the following procedure to check the drive’s Power Module circuitry

9-6LiquiFlo AC Power Modules, Hardware Reference Version 6.4Table 9.1 – Resistance ChecksInput Diode No.Meter Connection (+) (-)Component is OK

Troubleshooting the Drive9-79.5 Replacement PartsTables 9.2, 9.3, and 9.4 list the replacement parts that are available from Reliance Electric. See fi

9-8LiquiFlo AC Power Modules, Hardware Reference Version 6.4* Comair - Rotron M/N P2TB3 or equivalent.Table 9.3 – C-Frame LiquiFlo Drive Replacement P

Troubleshooting the Drive9-9Table 9.4 – D-Frame LiquiFlo Drive Replacement PartsDescription Part NumberQuantityM/N 120L40601000 HP Power Module Contro

ContentsVIIList of TablesTable 2.1 – Power and Enclosure Ratings ... 2-2Table 2.2 – Availa

9-10LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Technical SpecificationsA-1APPENDIX ATechnical SpecificationsTable A.1 – Service ConditionsAC Line Distribution System Capacity (maximum) for 460 VAC

A-2LiquiFlo AC Power Modules, Hardware Reference Version 6.4Table A.2 – Environmental ConditionsCondition SpecificationOperating Temperature (inside a

Technical SpecificationsA-3Table A.5 – Terminal Strip RS-232 SpecificationsSignal Type Terminal(s) SpecificationRS-232 Communications 1 XMIT2RECV3 COM

A-4LiquiFlo AC Power Modules, Hardware Reference Version 6.4*These are the maximum times from transitioning the input to the drive reacting to the inp

Cooling System SpecificationsB-1APPENDIX B Cooling System SpecificationsM/N 41L4060 M/N 41LR4060M/N 50LW4060M/N 64LW4060M/N 50LR4060M/N 64LR4060 M/N 1

B-2LiquiFlo AC Power Modules, Hardware Reference Version 6.4

B-Frame LiquiFlo Drive Wiring DiagramsC-1APPENDIX CB-Frame LiquiFlo Drive WiringDiagramsReplace with file C.fm (17 x 11, z-fold).

C-2LiquiFlo 2.0 AC Drive User Manual

C-Frame LiquiFlo Drive Wiring DiagramsD-1APPENDIX DC-Frame LiquiFlo Drive WiringDiagramsReplace with file D.fm (17 x 11, z-fold).