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

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1 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 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: DC us capacitors retain hazardous voltages after input power has been disconnected. fter disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure that 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. 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 Contains External Resistor Kit M/N can be used only with C-frame (500/643) LiquiFlo C drives, model numbers: 50L4060, 50LW4060, 50LR4060, 64L4060, 64LW4060, 64LR4060, LF150500W4 and LF150643W4. Verify that you have the correct resistor assembly by verifying that the harness is labeled, 500/643MP EXT US RESIS KIT. Quantity: Description 1 Resistor ssembly 6 M4 x 16 Mounting Screws with captive locking hardware 1 Protective Cover 1 Drilling Template / Cabinet Guard 2004 Rockwell utomation. ll rights reserved.

2 2 Instruction Manual D 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. What You Need to Do To install the external bus resistor kit you need to: Step 1: Verify that the DC us Capacitors are discharged Step 2: Identify a mounting location for the resistor assembly Step 3: Drill mounting holes for the resistor assembly, using the template Step 4: Mount the resistor assembly Step 5: Unplug connectors P1 and P2, and route harness Step 6: Connect the ground wire Step 7: Connect the harness Step 8: Verify installation Step 9: Register installation

3 Instruction Manual D Step 1: Verifying the DC us Capacitors are Discharged! TTENTION: DC us capacitors retain hazardous voltages after input power has been disconnected. fter disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure that 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. Task C 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 DC bus potential with a voltmeter while standing on a non-conductive surface and wearing insulated gloves (1000V) Checking DC us Voltage on LiquiFlo 1.0 Drives (M/N s 50LXXX, 64LXXXX) Pos (+) Neg (-) Test Points for initial DC us Voltage Measurement D Checking DC us Voltage on LiquiFlo 1.5 Drives (M/N s LF150XXXX) Pos (+) Test Points for initial DC us Voltage Measurement D Neg (-)

4 4 Instruction Manual D Step 2: Identifying the Mounting Location Consider the following factors when choosing the location for the resistor assembly: the resistor assembly must be mounted inside the drive cabinet the resistor assembly 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 connectors P1 and P2 inside the drive the wiring harness must not pass over unprotected sharp edges or hot surfaces the resistor assembly must not be mounted on the enclosure door Resistor assembly shown without harness for clarity Protective Cover Towards Enclosure Door

5 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 C Description Protect internal components from drilling debris Using the template, mark locations for six mounting holes Drill six 5mm (3/16 inch) mounting holes Drilling Template / Cabinet 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.

6 6 Instruction Manual D Step 4: Mounting the Resistor ssembly! 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) Cabinet Guard Enclosure Wall Resistor assembly mounted on inside of enclosure Mounting Screws inserted from outside of enclosure Resistor assembly shown without harness for clarity

7 Instruction Manual D Step 5: Unplugging Connectors P1 and P2 and Routing the Wiring Harness Locate the P1 and P2 Connectors near the upper part of the power structure and unplug them. Route the harness from the resistor assembly to P1 and P2. P1 and P2 Push Here to Release Connector Important: The harness connections are considered power level wiring. Run them separately from I/O and signal wiring.

8 8 Instruction Manual D Step 6: Connecting the Ground Wire 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. Star Washer Ground Lug Welded Stud Paint Free rea olt Ground Lug Nut Star Washer Component Ground Conductor Nut Star Washer Component Ground Conductor Star Washer

9 Instruction Manual D Step 7: Connecting the Harness Task Description Plug P1 into P1 Plug P2 into P2 Harness to Resistor ssembly P2 P2 Wires to Drive P1 P1 Wires from Drive

10 10 Instruction Manual D Step 8: Verifying the Installation Task C Description Disconnect connector (J3 on PM board for LiquiFlo 1.0 drives or J4 on PMC board for LiquiFlo 1.5 drives) Confirm continuity between the points specified in either Table or Table Reconnect connector (J3 on PM board for LiquiFlo 1.0 drives or J4 on PMC board for LiquiFlo 1.5 drives) Continuity Checks on LiquiFlo 1.0 Drives (M/N s 50LXXX, 64LXXXX) C Pin 1 J3 Table J3 Continuity Tests Test Points (1) J3 End of Cable Resistor ssembly End of Cable (2) Meter Reading J3:Pin 1 US (+) Continuity or J3:Pin 3 US MID approximately zero ohms J3:Pin 5 US (-) (1) If you are unfamiliar with continuity tests, refer to Performing Continuity Tests on page 11. (2) See Wiring Diagram for Reference on page 13. Continuity Checks on LiquiFlo 1.5 Drives (M/N s LF150XXXX) J4 Table J4 Continuity Tests Test Points (1) J4 End of Cable Resistor ssembly End of Cable (2) Meter Reading J4:Pin 1 US (+) Continuity or J4:Pin 3 US MID approximately zero ohms J4:Pin 5 US (-) (1) If you are unfamiliar with continuity tests, refer to Performing Continuity Tests on page 11. (2) See Wiring Diagram for Reference on page 13. C Pin 1

11 Instruction Manual D 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 C General Purpose (Volts/Hertz) and Vector Duty Drive Software Start-up D2-3411, LiquiFlo C Power Modules Hardware Reference, Installation and Troubleshooting LiquiFlo 1.5 drive D2-3494, LiquiFlo 1.5 C Power Modules Hardware Reference, Installation, and Troubleshooting D2-3495, LiquiFlo 1.5 C General Purpose (Volts/Hertz) and Vector Duty Drive Software Start-Up and Reference Manual Performing Continuity 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.

12 Instruction Manual D2-3536 Step 9: Registering the Installation Register the installation of the External us

12 12 Instruction Manual D Step 9: Registering the Installation Register the installation of the External us Resistor kit on the Rockwell utomation Warranty nd Returns Processing (WRP) website ( Click on Field Retrofits C Click on Continue Select External us Resistor Upgrade from the drop-down D Click on Register Retrofit E Enter all the required and pertinent information. F Click on Create Registration

13 Instruction Manual D Wiring Diagram for Reference DC+ US LEEDER (+) LEEDER (-) TEMPSW1 TEMPSW2 P P CHILLPLTE DC MIDPT TEMP SWITCH RECTOR 1 DC- US US (+) US (-) 2600 Ohm 2600 Ohm US MID R1 R2 R3 DISCHRGE RESISTOR 10K Ohms DISCHRGE RESISTOR 10K Ohms P P EXTERNL US RESISTOR SSEMLY RESISTOR TEMP SWITCH SFY OR SFY OR Note: The old resistors and their connecting wires remain in the drive.

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. PublicationD July 2004 Copyright 2004 Rockwell utomation, Inc. ll Rights Reserved. Printed in US.

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

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