External us Resistor Kit for LiquiFlo Drives Drive M/N s LF200405xxx, LF200460xxx, LF200520xxx, LF200608xxx Instruction Manual D2-3538!!!!! 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 180788-01 can be used only with LiquiFlo 2.0 drives, model numbers: LF200405xxx, LF200460xxx, LF200520xxx and LF200608xxx. Verify that you have the correct resistor assembly by verifying that the harness is labeled, LiquiFlo 2.0 Resistor Kit ssy. Quantity: Description 1 Resistor ssembly 6 M4 x 16 Mounting Screws with captive locking hardware 1 Protective over 1 Drilling Template / abinet Guard 1 Ground Wire for Drive over 2 Ground Washers 2004 Rockwell utomation. ll rights reserved.
2 Instruction Manual D2-3538 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 D bus capacitors are discharged Step 2: Open main drive cover Step 3: Identify a mounting location for the resistor assembly Step 4: Drill mounting holes for the resistor assembly, using the template Step 5: Mount the resistor assembly Step 6: onnect the ground wire attached to the resistor assembly Step 7: Disconnect old resistor wiring Step 8: onnect the new harness to the capacitor bank Step 9: Verify the new wiring Step 10: Replace main drive cover and install cover ground wire Step 11: Register installation
Instruction Manual D2-3538 3 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 top cover Measure the D bus potential with a voltmeter while standing on a non-conductive surface and wearing insulated gloves (1000V) L1 L2 L3 I O D us Measurement Points on Laminated us ssembly (0.25 x 0.32 in. male Faston). ccessible by removal of top cover. D Neg (-) D Pos (+) Front View of Inverter Right Side View of Inverter
4 Instruction Manual D2-3538 Step 2: Opening the Main Drive over Task Description Remove seven (7) M5 x 12 screws which secure door Disconnect four (2) cables Open door
Instruction Manual D2-3538 5 Step 3: Identifying the Mounting Location onsider 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 the connection points 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 over Towards Enclosure Door
6 Instruction Manual D2-3538 Step 4: 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 each 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.
Instruction Manual D2-3538 7 Step 5: 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) 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
8 Instruction Manual D2-3538 Step 6: onnecting 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 omponent Ground onductor Nut Star Washer omponent Ground onductor Star Washer
Instruction Manual D2-3538 9 Step 7: Disconnecting Old Resistor Wiring Task Description ut three (3) wires which connect to old resistors as close to the lugs as possible Wrap the wire ends with electrical tape to insulate them Secure the wire ends so they will not damage drive components or circuits 1 LM-NEG 1 LM-MID 1 LM-POS
10 Instruction Manual D2-3538 Step 8: onnecting the New Harness to the apacitor ank Task Description Install grommet in 1.0 inch diameter hole on side of drive and near the bottom Route wires through the grommet and up to capacitor bank onnect ring lug ends of wiring harness to the capacitor bank as shown US (-) US MID US (+) Important: The harness connections are considered power level wiring. Run them separately from I/O and signal wiring.
Instruction Manual D2-3538 11 Step 9: Verifying New Wiring LM-NEG LM-MID LM-POS heck kit installation prior to restoring power. heck for continuity (0 ohms (1) ) From Power Module D us Terminal To Resistor ssembly LM-NEG US (-) LM-POS US (+) LM-MID US MID (1) n accurate resistance measurement of the bus discharge resistors can NOT be achieved while the resistors are connected to the capacitor bank.
12 Instruction Manual D2-3538 Step 10: Replacing over and Installing Ground Wire for over Task Description Replace the main drive cover and hardware, connect four cables. The procedure for replacing the cover is the reverse of removal (Refer to Step 2: Opening the Main Drive over on page 4). Reserve the appropriate screw from the main drive cover and remove the appropriate screw from the left cover Install the ground wire and ground washers, connecting the main drive cover and the left cover as shown below Important: You must close and fasten the main door and install the ground strap before running the drive. The drive must operate only when the main cover is secured and the ground strap is attached.
Instruction Manual D2-3538 13 Step 11: Registering the Installation Register the installation of the External us Resistor kit on the Rockwell utomation Warranty nd Returns Processing (WRP) website (http://www.automation.rockwell.com/warp/). 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
14 Instruction Manual D2-3538 Wiring Diagram for Reference D Pos (+) Measurement Point Note: Old us Discharge Resistors, 24708-501-13 or 63481-105SFY, and their connecting wires remain in the drive + + 5 KΩ 5 KΩ 5 KΩ 5 KΩ Power Module apacitor ank + + D Neg (-) Measurement Point New us Discharge Resistors 24708-501-12 2600Ω US (+) US (MID) US (-) Resistor ssembly Harness 2600Ω Resistor ssembly
Notes: Instruction Manual D2-3538 15
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