External Bus Resistor Kit for LiquiFlo AC Drives Drive M/N s 120L4060, LF151200W4

Size: px

Start display at page:

Download "External Bus Resistor Kit for LiquiFlo AC Drives Drive M/N s 120L4060, LF151200W4"

Erin Alice Curtis
6 years ago
Views:

1 External us Resistor Kit for LiquiFlo Drives Drive M/N s 120L4060, LF151200W4 Instruction Manual D2-3537!!!!! TTENTION: 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. TTENTION: 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. TTENTION: D us capacitors retain hazardous voltages after input power has been disconnected. fter disconnecting input power, wait five (5) minutes for the D bus capacitors to discharge and then check the voltage with a voltmeter to ensure that the D bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life. TTENTION: 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. TTENTION: 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 could result in severe bodily injury or loss of life. What the Kit ontains External Resistor Kit M/N can be used only with D-frame (1200) LiquiFlo drives, model numbers: 120L4060 and LF151200W4. Verify that you have the correct resistor assembly by verifying that the harness is labeled, 1200MP EXT US RESIS KIT. Quantity: Description 1 Resistor ssembly 6 M4 x 16 Mounting Screws with captive locking hardware 1 Protective over 1 Drilling Template / abinet Guard This kit is for field upgrade only. You should not use it if you are replacing the drive. If you replace the drive in the future, you should remove the resistor kit from the drive system Rockwell utomation. ll rights reserved.

2 J1 J2 J3 J4 J5 R14 R15 R16 R17 R18 RV2 J9 J6 RV1 R2 R3 R4 R8 R11 R12 R13 R5 R6 R7 R1 R9 R10 1 RV8 RV3 RV4 4 RV6 RV Q1 Q2 D1 D2 D3 D4 D9 D6 D7 D8 D5 D10 RV5 Q3 T1 D U1 R R19 D17 14 R22 D18 15 R23 D19 16 R24 D21 17 R25 D22 18 R26 D23 19 R27 D12 U2 R21 D13 D14 D15 Q4 D16 T2 D20 D24 L1 U3 U4 U5 20 U6 D25 DNGER 21 HIGH VOLTGE T3 T4 T5 R28 T6 T7 T8 D TP1 TP2 R31 U7 R34 R29 R30 D27 D28 R32 R33 24 D29 T9 25 D30 D31 D32 26 D33 R35 R36 27 U8 U9 U10 U11 U12 T10 28 Q5 D37 DS1 U14 D36 U13 29 D34 D35 D38 30 D39 D41 D40 D42 D43 D U16 U17 U18 U19 U20 D52 D49 D50 D51 31 Rockwell utomation U Made in US D46 R37 RODE Q6 D45 D47 D48 35 SSY T11 U22 U23 U25 1 U26 D53 L2 FUSE2 D54 D56 D55 40 U24 U29 U30 D60 39 U27 U28 R41 R43 D57 D58 DS2 DS3 U32 DS4 D59 R38 R39 D61 41 D62 48 U33 U34 U36 R40 R42 U U D63 U37 49 TP5 TP3 TP6 TP4 J8 D64 D65 IU IV IW OM D66 50 FUSE1 DIP16 DIP8 2 Instruction Manual D What You Need to Do To install the external bus resistor kit you need to: Step 1: Verify that the D us apacitors are discharged Step 2: Identify a mounting location for the resistor assemblies Step 3: Drill mounting holes for the resistor assemblies, using the template Step 4: Mount the resistor assemblies Step 5: Locate the connection points, and route harness Step 6: onnect the ground wires Step 7: onnect the J4, J4 and J4 Step 8: onnect the harness to the capacitor bank Step 9: Verify installation Step 10: Register installation Step 1: Verifying the D us apacitors are Discharged! TTENTION: D us capacitors retain hazardous voltages after input power has been disconnected. fter disconnecting input power, wait five (5) minutes for the D bus capacitors to discharge and then check the voltage with a voltmeter to ensure that the D bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life. Task D Description Turn off and lock out input power. Wait five minutes Verify that there is no voltage at the drive s input power terminals Remove front cover Measure the D bus potential with a voltmeter while standing on a non-conductive surface and wearing insulated gloves (1000V) Test Points for initial D us Voltage Measurement Pos (+) D Neg (-) + TP1 - TP2

3 Instruction Manual D Step 2: Identifying the Mounting Location onsider the following factors when choosing the location for the resistor assemblies: both resistor assemblies must be mounted inside the drive cabinet both resistor assemblies must be mounted vertically, with the closed part of the protective cover pointing towards the front of the enclosure the wiring harness must be able to reach the connection points inside the drive the wiring harness must not pass over unprotected sharp edges or hot surfaces the resistor assemblies must not be mounted on the enclosure door Resistor assembly shown without harness for clarity Protective over Towards Enclosure Door

4 4 Instruction Manual D Step 3: Drilling the Mounting Holes! TTENTION: Metal debris or other foreign matter must be kept from falling into the drive. Metal debris or other foreign matter may become lodged in the drive circuitry resulting in component damage. Failure to observe this precaution could result in severe bodily injury or loss of life and/or damage to, or destruction of, equipment. Task Description Protect internal components from drilling debris Using the template, mark locations for six mounting holes for the assembly Drill 5mm (3/16 inch) mounting holes Drilling Template / abinet Guard TIP: The template is symmetrical, so you have the options of drilling from the outside or inside of the enclosure. Drilling outside reduces the risk of debris falling into the drive.

5 Instruction Manual D Step 4: Mounting the Resistor ssemblies! TTENTION: The cabinet can be very hot where the resistor assembly is mounted. HOT surfaces can cause severe burns. You must install the cabinet guard to protect personnel from accidental contact with the hot cabinet surface. Task Description Using a Phillips screw driver, install and tighten the six M4 x 16 mounting screws (torque 12 in-lb) abinet Guard Enclosure Wall Resistor assembly mounted on inside of enclosure Mounting Screws inserted from outside of enclosure Resistor assembly shown without harness for clarity

6 6 Instruction Manual D Step 5: Locating the onnection Points and Routing the Harness Task Description Locate J4 on the PI board on a LiquiFlo 1.0 drive or the PM board on a LiquiFlo 1.5 drive Locate P (-), P MID and P (+) connection points near the top of the capacitor bank Route harness through opening on right side of drive, to the resistor assemblies J4/J4/J4 P (-) and P MID P (+) Important: The harness connections are considered power level wiring. Run them separately from I/O and signal wiring.

7 Instruction Manual D Step 6: onnecting the Ground Wires Typical installations can use the existing ground stud originally intended for grounding the enclosure door. This figure illustrates recommended practices for connecting grounds to an enclosure. Welded Stud Ground Lug Paint Free Star Washer rea olt Ground Lug Nut Star Washer omponent Ground onductor Nut Star Washer omponent Ground onductor Star Washer

8 Harness to Resistor ssembly 8 Instruction Manual D Step 7: onnecting J4, J4 and J4 Task Description Disconnect the J4 plug from its header on the PI board on a LiquiFlo 1.0 drive or the PM board on a LiquiFlo 1.5 drive Plug J4 into J4 Plug J4 into the J4 header on the PM oard Harness to Drive Pin 1 J4 J4 J3 J4 Pin 1 J4 Header on PM oard Important: You must align J4 Pin 1 with J4 Pin 1. J4 has eleven pins and J4 has twelve pins. If you fail to align the connectors, the 120L4060 drive will not run because motor voltage feedback circuits will remain open. The LF151200W4 drive does not use motor voltage feedback, so there is no electrical connection between J4 and J4.

9 Instruction Manual D Step 8: onnecting the New Harness to the apacitor ank Task Description Remove M5 screw to disconnect P(-) ring lug from capacitor bank. Wrap the ring in electrical tape to electrically insulate it and securely mount it. onnect the new P(-) ring lug to the capacitor bank. Install and tighten the M5 screw (torque in-lb). Remove M5 screw to disconnect P MID ring lug from capacitor bank. Wrap the ring in electrical tape to electrically insulate it and securely mount it. onnect the new P MID ring lug to the capacitor bank. Install and tighten the M5 screw (torque in-lb). Remove M5 screw to disconnect P (+) ring lug from capacitor bank. Wrap the ring in electrical tape to electrically insulate it and securely mount it. onnect the new P (+) ring lug to the capacitor bank. Install and tighten the M5 screw (torque in-lb). P (+) P (-) P MID

10 10 Instruction Manual D Step 9: Verifying the Installation Task Description Disconnect J4 from the PI board on a LiquiFlo 1.0 drive or the PM board on a LiquiFlo 1.5 drive onfirm continuity between the points specified in Table Reconnect J4 onfirm continuity between the points specified in Table J4/J4/J4 Pin 1 P (-) and P MID P (+) Table J4 ontinuity Tests Test Points (1) Resistor ssembly End of J4 End of able able (2) Meter Reading J4:Pin 1 US (+) ontinuity or J4:Pin 3 US MID approximately zero J4:Pin 5 US (-) ohms Table apacitor ank ontinuity Tests Test Points (1) Resistor apacitor ank ssembly End of End of able able (2) Meter Reading P (+) US (+) ontinuity or P MID US MID approximately zero P (-) US (-) ohms (1) If you are unfamiliar with continuity tests, refer to Performing ontinuity Tests on page 10. (2) See Wiring Diagram for Reference on page 12. Follow the normal steps for verifying drive installation and operation. Refer to the drive Hardware Reference and Software Start-up manuals. If you have a refer to these publications: LiquiFlo 1.0 drive D2-3410, LiquiFlo General Purpose (Volts/Hertz) and Vector Duty Drive Software Start-up D2-3411, LiquiFlo Power Modules Hardware Reference, Installation and Troubleshooting LiquiFlo 1.5 drive D2-3494, LiquiFlo 1.5 Power Modules Hardware Reference, Installation, and Troubleshooting D2-3495, LiquiFlo 1.5 General Purpose (Volts/Hertz) and Vector Duty Drive Software Start-Up and Reference Manual Performing ontinuity Tests In these tests you are verifying continuity, a short circuit, between the two test points. The continuity mode on a digital multi-meter provides the easiest method for performing this test. Place one meter lead on the first test point and the meter should beep when you place the other lead on the second test point. If your meter does not have a continuity mode, you can use a resistance mode. Place one meter lead on the first test point and the meter should indicate a short circuit (read approximately zero ohms) when you place the other lead on the second test point.

Instruction Manual D2-3537 11 Step 10: Registering the Installation Register the installation of the External

11 Instruction Manual D Step 10: Registering the Installation Register the installation of the External us Resistor kit on the Rockwell utomation Warranty nd Returns Processing (WRP) website ( lick on Field Retrofits lick on ontinue Select External us Resistor Upgrade from the drop-down D lick on Register Retrofit E Enter all the required and pertinent information. F lick on reate Registration

12 12 Instruction Manual D Wiring Diagram for Reference 120L4060 ONLY MV W MV V 9 8 MV U 7 6 D- US 5 4 D MIDPT 3 2 D+ US 1 J J4 MV W MV V MV U D- US D MIDPT D+ US 12 MV W MV V 9 8 MV U J4 P (+) P MID P (-) J4 11 MV W 10 9 MV V 8 7 MV U 6 5 D- US 4 3 D MIDPT 2 1 D+ US MOTOR W MOTOR V MOTOR U US (-) 2600 Ohm US MID EXTERNL US RESISTOR SSEMLY RESISTOR L4060 ONLY P (-) P MID P (+) US (+) 2600 Ohm SFY 10K Ohm DISHRGE RESISTORS EXISTING US R1 R Note: The old resistors and their connecting wires remain in the drive.

13 Notes: Instruction Manual D

14 14 Instruction Manual D Notes:

15 Notes: Instruction Manual D

16 U.S. Drives Technical Support Tel: (1) , Fax: (1) , Online: Trademarks not belonging to Rockwell utomation are property of their respective companies. Publication D July 2004 opyright 2004 Rockwell utomation, Inc. ll Rights Reserved. Printed in US.

External Bus Resistor Kit for LiquiFlo AC Drives Drive M/N s 50L4060, 50LW4060, 50LR4060, 64L4060, 64LW4060, 64LR4060, LF150500W4, LF150643W4

External Bus Resistor Kit for LiquiFlo AC Drives Drive M/N s 50L4060, 50LW4060, 50LR4060, 64L4060, 64LW4060, 64LR4060, LF150500W4, LF150643W4 External us Resistor Kit for LiquiFlo C Drives Drive M/N s 50L4060, 50LW4060, 50LR4060, 64L4060, 64LW4060, 64LR4060, LF150500W4, LF150643W4 Instruction Manual D2-3536!!!!! TTENTION: Only qualified electrical