How it Works
Rockwell Automation
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20N Pwr
User Manual
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Rockwell Automation 20N Pwr User Manual

LPM15 Liquid-Cooled Adjustable Frequency AC Drive
FRN 2.xxx
User Manual
Important User Information
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
!
environment, which may lead to personal injury or death, property damage, or economic loss.
Important: Identifies information that is critical for successful application and
understanding of the product.
ATT E NT I ON : Identifies information about practices or circumstances that can lead to personal injury or death, property
!
damage, or economic loss. Attentions help you identify a hazard, avoid the hazard, and recognize the consequences.
Shock Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures.
Allen-Bradley, PLC, DriveExplorer, DriveExecutive, and SCANport are either registered trademarks or trademarks of
Rockwell Automation, Inc.

Summary of Changes

The information below summarizes the changes made to this manual since its last release (September 2005):
Description of Changes Page
Since the LPM15 drive has no encoder feedback option, removed all encoder information and references.
Changed Table 4.F columns and information, and deleted Table 4.G and Table 4.H. 4-16
The information below summarizes the changes made to this manual since its last release (January 2005):
Description of Changes Page
Added CE Low Voltage Directive instructions in the new “CE Conformity” section. 1-30
Throughout Manual
soc-ii
Preface Overview
Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Chapter 1 Installation/Wiring
Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Enclosure Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
B-Frame LPM15 Drive Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
C-Frame LPM15 Drive Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
D-Frame LPM15 Drive Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Mounting the Drive, Determining Wire Routing, and Grounding . . . . . . . . . . . . . . . . . 1-13
Coolant Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Installing Input Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Installing Output Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Using Input/Output Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Auto/Manual Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

Table of Contents

Chapter 2 Start Up
Prepare For Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Start-Up Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Running S.M.A.R.T. Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Running an Assisted Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Chapter 3 Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
How Parameters are Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Monitor File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Motor Control File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Speed Command File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Dynamic Control File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Utility File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Communication File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Inputs & Outputs File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Parameter Cross Reference – by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Parameter Cross Reference – by Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
ii Table of Contents
Chapter 4 Troubleshooting
Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Clearing Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Alarm Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Testpoint Codes and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Test Equipment Needed To Troubleshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Verifying That DC Bus Capacitors Are Discharged . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Checking the Power Modules with Input Power Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Appendix A Supplemental Drive Information
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Communication Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Appendix B Technical Specifications
Appendix C HIM Overview
Remote HIM Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
LCD Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
ALT Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Removing/Installing the HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Appendix D Application Notes
Minimum Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Motor Control Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Motor Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Power Loss Ride Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Process PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
Reverse Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8
Skip Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9
Sleep Wake Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
Start At PowerUp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11
Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12
Voltage Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14
Appendix E B-Frame LPM15 Drive Wiring Diagram
Appendix F C-Frame LPM15 Drive Wiring Diagram
Appendix G D-Frame LPM15 Drive Wiring Diagram
Index
Table of Contents iii
iv Table of Contents

Preface

Overview

The purpose of this manual is to provide you with the basic information needed to install, start-up, and troubleshoot the LPM15 Liquid-Cooled Adjustable Frequency AC Drive.
For information on… See page…

Who Should Use this Manual?

Reference Materials P-1
Manual Conventions P-2
General Precautions P-2
Catalog Number Explanation P-4
P-1
Who Should Use this Manual?

Reference Materials

This manual is intended for qualified personnel. You must be able to program and operate Adjustable Frequency AC Drive devices. In addition, you must have an understanding of the parameter settings and functions. The User Manual is designed to provide only basic start-up information.
The following manuals are recommended for general drive information:
Title Publication
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001… Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001…
Safety Guidelines for the Application, Installation and Maintenance of Solid State Control
A Global Reference Guide for Reading Schematic Diagrams 0100-2.10
Guarding Against Electrostatic Damage 8000-4.5.2
Publications can be obtained at
http://www.rockwellautomation.com/literature
.
SGI-1.1
P-2 Overview

Manual Conventions

General Precautions

• In this manual we refer to the LPM15 Adjustable Frequency AC Drive
as; drive, LPM15 or LPM15 Drive.
• To help differentiate parameter names and LCD display text from other
text, the following conventions will be used:
– Parameter Names will appear in [brackets].
For example: [DC Bus Voltage].
– Display Text will appear in “quotes.” For example: “Enabled.”
• The following words are used throughout the manual to describe an
action:
Word Me aning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Must Unavoidable, you must do this
Shall Required and necessary
Should Recommended
Should Not Not recommended
ATTENTION: This drive contains ESD (Electrostatic
!
Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, refer to Allen-Bradley publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can
!
!
!
result in component damage or a reduction in product life. Wiring or application errors, such as, undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system.
ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive. After removing power to the drive, wait 5 minutes for the bus capacitors to discharge. Measure the DC bus voltage at the locations shown in
Figure 4.2
, Figure 4.3 or Figure 4.4. The voltage must be zero.
Overview P-3
ATTENTION: Risk of injury or equipment damage exists.
!
!
DPI or SCANport host products must not be directly connected together via 1202 cables. Unpredictable behavior can result if two or more devices are connected in this manner.
ATTENTION: The “adjust freq” portion of the bus regulator function is extremely useful for preventing nuisance overvoltage faults resulting from aggressive decelerations, overhauling loads, and eccentric loads. It forces the output frequency to be greater than commanded frequency while the drive's bus voltage is increasing towards levels that would otherwise cause a fault. However, it can also cause either of the following two conditions to occur.
1. Fast positive changes in input voltage (more than a 10%
increase within 6 minutes) can cause uncommanded positive speed changes. However an “OverSpeed Limit” fault will occur if the speed reaches [Max Speed] + [Overspeed Limit]. If this condition is unacceptable, action should be taken to 1) limit supply voltages within the specification of the drive and, 2) limit fast positive input voltage changes to less than 10%. Without taking such actions, if this operation is unacceptable, the “adjust freq” portion of the bus regulator function must be disabled (see parameters 161 and 162).
2. Actual deceleration times can be longer than commanded
deceleration times. However, a “Decel Inhibit” fault is generated if the drive stops decelerating altogether. If this condition is unacceptable, the “adjust freq” portion of the bus regulator must be disabled (see parameters 161 and 162). In addition, installing a properly sized dynamic brake resistor will provide equal or better performance in most cases.
Important: These faults are not instantaneous. Test results
have shown that they can take between 2-12 seconds to occur.
P-4 Overview

Catalog Number Explanation

The LPM15 catalog numbering scheme is shown below.
I / O Cat. Code
24V DC A
120V AC B
I / O & FEEDBACK
RATING Cat. Code
Not Filtered N
EMISSION CLASS
NO I / O N
C NET-COAX C
DeviceNET D
RIO R
VERSION Cat. Code
COM SLOT 1
RS485, DF-1 S
C NET-FIBER Q
RS485 HVAC H
PROFIBUS DPV1 P
BRAKING DEVICE Cat. Code
BRAKING DEVICE
INTERBUS I
LONWORKS L
ETHERNET E
N/A N
TYPE Cat. Code
DOCUMENTATION
User Man. A
N
NEMA IP Type Cat.Code
ENCLOSURE AND PACKAGING
Open
Chassis
No Manual N
BRAKE IGBT Cat. Code
BRAKE IGBT
No N
No N
LPM15 PRODUCT CATALOG NUMBER EXPLANATION
Voltage + Current selects PWR Parts,
Cat.
Code
Version
SA / CB
sets frame size w/ emission type
RATING
414 414 350
500 500 450
643 643 600
AMPS Cat. Code HP (REF.)
OUTPUT CURRENT @ 480 VAC IN
1200 1K2 1000
12345678910111213141516
20MD NNA NNN 0
Product Cat. Code
PRODUCT
LPM15 20M
CONTROL/FLASH PARTS-
1. Drawing, SW Build
2. SW Build & Flash
3. Control Board Ass'y
VERSION & VOLTAGE RATING
Voltage Phase
480 VAC 3 PH. SA D
Stand Alone ONLY (SA)

Chapter 1

Installation/Wiring

This chapter provides information on mounting and wiring the LPM15 Drive.
For information on… See page…

Powe r R at in gs

Enclosure Ratings 1-2
B-Frame LPM15 Drive Component Locations 1-2
C-Frame LPM15 Drive Component Locations 1-4
D-Frame LPM15 Drive Component Locations 1-6
AC Supply Source Considerations 1-12
Fuses and Circuit Breakers 1-13
Mounting the Drive, Determining Wire Routing, and Grounding 1-13
Coolant Considerations 1-16
Installing Input Power Wiring 1-19
Installing Output Power Wiring 1-22
Powe r W ir ing 1-23
Using Input/Output Contactors 1-24
I/O Wiring 1-24
Reference Control 1-28
Auto/Manual Examples 1-29
CE Compliance 1-30
1-1
Most start-up difficulties are the result of incorrect wiring. Every precaution must be taken to assure that the wiring is done as instructed. All items must be read and understood before the actual installation begins.
ATTENTION: The following information is merely a guide
!
for proper installation. The Allen-Bradley Company cannot assume responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.
Power Ratings
Catalog Number (positions 1-7 only)
20MD414 B-Frame 344 414 414 350 4600/1100
20MD500 C-Frame 398 500 500 450 5500/1500
20MD643 C-Frame 512 643 643 600 7000/2000
20MD1K2 D-Frame 956 1200 1200 1000 11700/4000
(1)
110% output current capability for one minute, 150% output current capability for 5 seconds.
(2)
Note that LPM15 drives are rated for use with water at specified temperatures and pressures as the coolant. Some coolant fluids may allow an increased output rating
while others may require the output to be derated. LPM15 drives are also capable of running at 3 kHz or 4 kHz at reduced output.
Frame Size
LPM15 Drives have power ratings as described in Tabl e 1.A below:
Table 1.A Power Ratings
Input Power (KVA)
Input Current (Amps)
(1)
Output Current at 2 kHz
(2)
(Amps)
HP Ratings
Full Load Power Loss Watts Fluid/Air
1-2 Installation/Wiring

Enclosure Ratings

B-Frame LPM15 Drive Component Locations

LPM15 drives have the following enclosure rating:
• Open-Chassis Style: Intended to be installed in an enclosure.
LPM15 drives must be placed in an enclosure.
The B-Frame LPM15 drives have the following main components. The numbered items listed below correspond to the numbers used in Figure 1.1 Replacement parts are listed in Chapter
1. AC Input Bus Bars (6)
2. AC Output Bus Bars (6)
3. IGBT Modules
4. Output Laminated Bus
5. Capacitors
6. Chassis (Heatsink)
7. Inlet Coolant Connection
8. Outlet Coolant Connection
9. Power Interface Control (PIC) PCB
10. Inverter Control PCB
11. Communication Interface PCB
12. Standard I/O PCB (Optional)
13. Communication Board (Optional)
14. Current Feedback Devices (3)
4.
.
Installation/Wiring 1-3
Figure 1.1 B-Frame LPM15 Drive Component, Wiring, Mounting and
Coolant Locations
Ø9.5
[Ø0.37]
(3) Pl.
50.4
[1.98]
4
3
5
DPI Comm. Port
123.1 [4.85]
22.2
[0.88]
(3) Pl.
76.2
[3.00]
UV
76.2
[3.00]
Drive Output Wiring (3) Pl.
W
Drive Input Wiring (6) Pl.
Ø7.1
[Ø0.28]
(6) Pl.
17.4
[0.69]
(6) Pl.
14
8
9
11
10
12
6.4 [0.25] (3) Pl.
2
6.4
[0.25]
(6) Pl.
275.5
[10.85]
165.0 [6.50]
1
13
6
User Connections
326.6 [12.8
300.8
[11.84]
Air Flow
Ø19.1
[Ø0.75]
Typ.
User Control Wiring Openings
39.7
[1.56]
Dimensions in millimeters and [inches]
7
52.3 [2.06] (2) Pl.
128.3
[5.05]
L1 L4 L2 L5 L3 L6
19.1 [0.75] (6) Pl.
38.1
[1.50]
(3) Pl.
TOP VIEW
1-4 Installation/Wiring

C-Frame LPM15 Drive Component Locations

The C-Frame LPM15 drives have the following main components. The numbered items listed below correspond to the numbers used in Figure 1.2 Replacement parts are listed in Chapter
1. AC Input Bus Bars (6)
2. AC Output Bus Bars (3)
3. SCR Bridge (AC to DC Converter)
4. Laminated Assembly
5. Capacitors
6. Heatsink
7. Inlet Coolant Connection
8. Outlet Coolant Connection
9. Power Interface Control (PIC) PCB
10. Inverter Control PCB
11. Communication Interface PCB
12. Standard I/O PCB (Optional)
13. Communication Board (Optional)
14. Current Feedback Devices (3)
4.
.
Installation/Wiring 1-5
Figure 1.2 C-Frame LPM15 Drive Component, Wiring, Mounting and
Coolant Locations
85.3
[3.36]
220.3 [8.67]
40.7
[1.60]
[1.38]
34.9
[0.25]
34.9
[1.38]
6.4
Dimensions in millimeters and [inches]
42.4
[1.67]
1/2-13 Nut
(6) Pl.
Drive Input Wiring (6) Pl.
2
Drive Output Wiring (3) Pl.
Ø11.1 Ø0.44]
[
(3) Pl.
DPI Comm. Port
1
U
13
V
125.4 [4.94]
69.4
[2.73]
68.3
[2.69]
54.0
[2.13]
L1
L2 L3 L6 L5
68.3
[2.69]
54.0
[2.13]
38.1
[1.50]
L4
9
11
10
12
220.1 [8.67]
342.7
[13.49]
193.1 [7.60]
9.5
[0.37]
Connections
38.1
[1.50]
User Control Wiring Opening
User
14
6
W
3
5
8
7
Air Flow
4
1-6 Installation/Wiring

D-Frame LPM15 Drive Component Locations

The D-Frame LPM15 drives have the following main components. The numbered items listed below correspond to the numbers used in Figure 1.3 Replacement parts are listed in Chapter
1. AC Input Bus Bars (6)
2. AC Output Bus Bars (3)
3. IGBT Modules
4. Laminated Assembly
5. Capacitors
6. Heatsink
7. Inlet Coolant Connection
8. Outlet Coolant Connection
9. Power Interface Control (PIC) PCB
10. Inverter Control PCB
11. Communication Interface PCB
12. Standard I/O PCB (Optional)
13. Communication Board (Optional)
14. Current Feedback Devices (3)
4.
.
Installation/Wiring 1-7
Figure 1.3 D-Frame LPM15 Drive Component, Wiring, Mounting and
Coolant Locations
236.5 [9.31]
152.4 [6.00]
152.4 [6.00]
152.4 [6.00]
152.4 [6.00]
152.4 [6.00]
Drive Input Wiring (6) Pl.
Drive Output Wiring (3) Pl.
Grounding Stud M10 x 1.5 x 27.1 [1.07] Long
Ø14.3 Ø0.56]
[
312.7
[12.31]
304.7
[12.00]
304.7
[12.00]
50.8 [2.00]
(6) Pl.
Ø14.3 Ø0.56]
[
(3) Pl.
DPI
Comm.
Port
User
Connections
50.8 [2.00]
94.6
[3.72]
57.1
[2.25]
L1
U
L4
L2
V
L5
2
L3
W
L6
1
11
9
10
12
4
5
6
102.6 [4.04]
14
9.5 [0.37] (6) Pl.
260.8
[10.27]
Dimensions in millimeters and [inches]
9.5 [0.37] (3) Pl.
13
311.0
[12.24]
8
User Control
Wiring Openings
37
50.8
[2.00]
Air Flow
Ø19.1 Ø0.75]
[
Typ.
1-8 Installation/Wiring
DPI Communication Port
The Communication Interface PCB contains an eight-position, female, locking mini-DIN connector that is used as a DPI communication port. This port (DPI Port 3 shown in Figure 1.4 between the LPM15 drive and another DPI device (for example, a HIM).
Figure 1.4 DPI Communication Interface Board
DPI Port 3
below) provides communication
Rockwell Automation
INV. STATUS
LPM15 Drive Catalog Number (positions 1-7 only)
20MD414 B 573 mm
20MD500 C 648 mm
20MD643 C 648 mm
20MD1K2 D 1010 mm
Frame Dim. A Dim. B Dim. C Dim. D Dim. E Dim. F Dim. G Weight
22.54 in
25.53 in
25.53 in
39.75 in
For more information regarding operating LPM15 drives with a HIM, refer to Appendix
C.
Determining Total Area Required Based on Drive Dimensions
Drive dimensions and weights are listed in Table 1 .B. Overall drive dimensions are illustrated in Figure 1.5 in calculating the total area required by the LPM15 drives.
Table 1.B Drive Dimensions and Weights
800 mm
31.52 in
1078 mm
42.44 in
1078 mm
42.44 in
1245 mm
49.00 in
357 mm
14.06 in
352 mm
13.86 in
352 mm
13.86 in
360 mm
14.16 in
397 mm
15.63 in
464 mm
18.25 in
464 mm
18.25 in
838 mm
33.00 in
, Figure 1.6, and Figure 1.7 as an aid
711 mm
28.00 in
787 mm
31.00 in
787 mm
31.00 in
1200 mm
47.25 in
39 mm
1.53 in
28 mm
1.09 in
28 mm
1.09 in
29 mm
1.12 in
20 mm
0.79 in
160 mm
6.31 in
160 mm
6.31 in
25 mm
1.00 in
125 kg 275 lb
171 kg 378 lb
171 kg 378 lb
386 kg 850 lb
Figure 1.5 B-Frame Drive Dimensions
Installation/Wiring 1-9
C
A
DF
30˚
Outlet
B
E
Inlet
184.0 [7.25]
15.9 [0.62] Thick
362.4
[14.27]
∅
14.3
[
∅
0.56]
(4) Pl.
113.8 [4.48]
Ty p.
Dimensions in millimeters and [inches]
G
30˚
154.8 [6.09]
15.9 [0.62] Thick
179.3 [7.06]
1-10 Installation/Wiring
Figure 1.6 C-Frame Drive Dimensions
A
30.0
[1.18]
DF
∅
14.3
[
∅
0.56] Lifting (2) Pl.
EGB
C
50.8
[2.00]
∅
14.3
[
∅
0.56]
(4) Pl.
83.8
[3.30]
92.5
[3.64]
Dimension in millimeters and [inches]
Outlet
Inlet
64.0
[2.52]
153.4 [6.04]
∅
14.3
[
∅
0.56] Lifting (2) Pl.
50.8
[2.00]
Installation/Wiring 1-11
Figure 1.7 D-Frame Drive Dimensions
A
∅
28.6
[
∅
1.13]
C
Lifting (4) Pl.
B
F
419.1
[16.50]
E
D
∅
14.3
[
∅
0.56]
(6) Pl.
3.0
[0.12]
Thick
Dimensions are in
millimeters and [inches]
Verifying the Site Provides for Recommended Air Flow Clearances
Be sure there is adequate clearance for air circulation around the user-supplied enclosure. A 6-inch minimum clearance is required wherever vents are located in the cabinet.
Verifying Power Module Input Ratings Match Supplied Power
G
329.5
[12.97]
130.8 [5.15]
Outlet
520.6
[20.50]
Inlet
It is important to verify that plant power will meet the input power requirements of the LPM15 drive’s Power Module circuitry. See Ta ble 1 . A for input power rating specifications. Be sure input power to the drive corresponds to the drive nameplate voltage and frequency.
1-12 Installation/Wiring

AC Supply Source Considerations

LPM15 drives are suitable for use on a circuit capable of delivering up to a maximum of 85,000 rms symmetrical amperes, and a maximum of 480 volts. A circuit breaker with the appropriate KAIC rating needs to be used upstream of the drive.
ATTENTION: To guard against personal injury and/or
!
Unbalanced or Ungrounded Distribution Systems
LPM15 drives should not be used with a supply system that is ungrounded and when the phase-to-phase voltage exceeds 125% of normal line-to-line voltage.
!
equipment damage caused by improper fusing or circuit breaker selection, use only the recommended line fuses/circuit breakers specified in Tab le 1 . C
ATTENTION: LPM15 drives contain protective MOVs on the drive’s printed circuit boards. The MOVs are referenced to ground. The MOVs cannot be disconnected. The LPM15 drives do not contain common mode capacitors.
.
Input Power Conditioning
Certain events on the power system supplying a drive can cause component damage or shortened product life. They are:
• The power system has power factor correction capacitors switched in and
out of the system, either by the user or by the power company.
• The power source has intermittent voltage spikes in excess of 6000 volts.
These spikes could be caused by other equipment on the line or by events such as lightning strikes.
• The power source has frequent interruptions.
Wiring Requirements for the Drive
Certain drive requirements should be checked before continuing with the drive installation. Wire sizes, branch circuit protection, and E-stop wiring are all areas that need to be evaluated.
Installation/Wiring 1-13
Selecting Input Line Branch Circuit Fuses
ATTENTION: Most codes require that upstream branch circuit
!
Input line branch circuit protection fuses must be used to protect the input power lines. See Figure 1.9 connection diagrams. Recommended fuse values are shown in Tab le 1. C The listed input fuse ratings are applicable for one drive per branch circuit. No other load may be applied to that fused circuit.
Table 1.C AC Input Line Fuse and Circuit Breaker Selection Values
protection be provided to protect input power wiring. Install the fuses recommended in Tabl e 1.C ratings. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
and Figure 1.10 for typical AC input/output
. Do not exceed the fuse
.

Fuses and Circuit Breakers

LPM15 Drive Catalog Number (positions 1-7 only)
20MD414 380-480 VAC 600 A
20MD500 380-480 VAC 750 A
20MD643 380-480 VAC 1000 A
20MD1K2 380-480 VAC 1600 A
(1)
Recommended fuse type: UL Class J, 600 V, time-delay, or equivalent.
(2)
Recommended fuse type: UL Class L, 600 V, time-delay, or equivalent.
The LPM15 can be installed with either input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations. Refer to Tabl e 1.C
!
Input Voltage (+/-10%)
for recommended fuses/circuit breakers.
ATTENTION: The LPM15 does not provide branch short circuit protection. Specifications for the recommended fuse or circuit breaker to provide protection against short circuits are provided in Tab le 1.C
Fuse Rating
(1)
(2)
(1)
(2)
.
Motor Circuit Protector or Circuit Breaker
600 A
800 A
1000 A
1500 A

Mounting the Drive, Determining Wire Routing, and Grounding

This chapter shows how to mount the drive and properly ground it. Also described is the wiring to be routed in and out of the drive.
Lifting and Mounting the Drive
Use the following procedure to lift the LPM15 drive and mount it in the required enclosure:
1-14 Installation/Wiring
1. For Cat. # 20MD414, install two clevis clamps into the drive to serve as
lifting points. Two 9/16-inch through holes are machined into the casting protrusions.
For Cat. # 20MD500 or 20MD643, install two eyebolts into the drive to serve as lifting points. Two 3/4-inch nuts are welded to the drive’s baseplate. Screw two eyebolts (2-inch eye I.D., 6-inch long shank) into the nuts.
For Cat. # 20MD1K2, install two clevis pins into the drive to serve as lifting points. Two 1-inch through holes are provided in the sheet metal chassis.
2. For Cat. # 20MD414, 20MD500 or 20MD643, connect 18 inches
(nominal) of chain between the eyebolts or attached clevis clamps and secure them with a clevis clamp.
For Cat. # 20MD1K2, connect 50 inches (nominal) of chain between the eyebolts or attached clevis clamps and secure them with a clevis clamp.
3. Using an overhead or portable hoist (minimum 1/2-ton rated capacity),
attach a free-fall chain to the chain secured to the drive. Take up any vertical slack in the chain.
4. Using the hoist, lift the drive from the horizontal shipping pallet.
5. Position the drive in the enclosure.
6. For Cat. # 20MD414, 20MD500 or 20MD643, attach the drive to the
vertical surface selected using the four (4) mounting holes provided.
For Cat. # 20MD1K2, attach the drive to the vertical surface using the six (6) mounting holes provided.
In order to maintain a flat mounting surface and to ensure that bolt tightness is maintained, use flat washers and split-ring lock washers under the bolt heads. Refer to Tabl e 1.B
Figure 1.7
7. For Cat. # 20MD500 or 20MD643, remove the eyebolts and the chain
between them.
For Cat. # 20MD414 or 20MD1K2, remove the clevis clamps and chain between them.
Verifying the Drive’s Watts Loss Rating
for drive mounting dimensions.
and Figure 1.5, Figure 1.6 or
When mounting the drive inside of an enclosure, you should determine the watts loss rating of the drive from Tabl e 1.A load power loss watts value at 2 kHz (rated carrier frequency). Ensure that the enclosure is adequately ventilated with 0 the drive’s watts loss rating.
. This table lists the typical full
° to 40° C ambient air based on
Installation/Wiring 1-15
Determining Input, Motor Output, Ground, and Control Wire Routing for the Drive
All wiring should be installed in conformance with the applicable local, national, and international codes (e.g., NEC/CEC). Signal wiring, control wiring, and power wiring must be routed in separate conduits to prevent interference with drive operation. Use grommets, when hubs are not provided, to guard against wire chafing. Figure 1.1
Figure 1.3
strips of the B-frame, C-frame, and D-frame LPM15 drives.
Do not route more than three sets of motor leads through a single conduit. This will minimize cross-talk that could reduce the effectiveness of noise reduction methods. If more than three drive/motor connections per conduit are required, shielded cable must be used. If possible, each conduit should contain only one set of motor leads.
show the wire routing, grounding terminal, and power terminal
ATTENTION: Do not route signal and control wiring with
!
power wiring in the same conduit. This can cause interference with drive operation. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
, Figure 1.2, and
ATTENTION: Unused wires in conduit must be grounded at
!
Grounding the Drive
!
Use the following steps to ground the drive:
1. Open the door of the enclosure.
2. Run a suitable equipment grounding conductor unbroken from the drive
to the motor’s ground terminal and then to earth ground. For B- and C-frame drives, use one of the bolts that pass through the drive baseplate and are used to fasten the drive to the wall or cabinet. For D-frame drives, use the ground stud provided. See Figure 1.1
Figure 1.3
shown in Tab le 1.E
both ends to avoid a possible shock hazard caused by induced voltages. Also, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled to eliminate the possible shock hazard from cross-coupled motor leads. Failure to observe these precautions 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.
, Figure 1.2 or
. Tighten these grounding connections to the proper torque as
.
1-16 Installation/Wiring
3. Connect a suitable grounding conductor to the motor frame and the
remote control station (if used). Run each conductor unbroken to earth ground. When adding more than one grounding conductor wire to a single chassis ground, twist the conductors together. Tighten these grounding connections to the proper torque as shown in Table 1.E
4. Close the door of the enclosure.
.

Coolant Considerations

LPM15 drives use o-ring face seal fittings for connection to the coolant supply. The coolant is typically clean water with a corrosion inhibitor as described in this section.
Considerations Affecting all Frame Sizes
LPM15 drive coolant connections are made with o-ring face seal fittings. The copper tube running from the heatsink to the o-ring fittings is covered with closed cell foam insulation.
The mating connection is shown in Figure 1.8 the following steps:
1. Coat the o-ring with the o-ring lubricant. The goal is a thin film covering
the entire o-ring surface. Avoid excess globs of lubricant.
2. Insert the o-ring into the o-ring groove in the external thread-side fitting
on the user side. Avoid any twisting of the o-ring.
3. Assemble the fittings and tighten to a torque of 37 to 45 N-m (or 27 to 33
lb.-ft.). Use a backup wrench on the user side fitting to avoid twisting the drive side tubing.
. The mating process includes
Figure 1.8 Mating Connection
DRIVE SIDE CONNECTION
ORFS Braze Sleeve
5/8-inch O.D. Copper Tube
(Parker p/n 10-BL-B)
(Parker p/n 2-016-CO873-70)
(Parker p/n 884-2GRAMS-LUBE)
(Parker p/n 10-TL-B)
ORFS Nut
O-Ring, Neoprene
O-Ring Lubricant
USER SIDE CONNECTION
ORFS Braze Adapter (Parker p/n 10-LOHB3-B)
5/8-inch O.D. Copper Tube
Backup Wrench (Use to prevent twisting during nut tightening.)
Installation/Wiring 1-17
Other recommendations include:
1. The allowable coolant temperature range is 4°C to 40°C (40°F to 105°F).
When using coolant at a temperature below the dew point of the surrounding air, condensation could accumulate on the drive heatsink and/or circuit boards and damage the drive. In this situation, install a coolant flow regulating device and tube/hose insulation. A flow regulating device modulates the coolant flow rate to a level that permits the drive heatsink temperature to rise above the dew point. Insulation for customer side tube or hose may be closed-cell foam insulation with minimum 1/2-inch wall thickness.
2. Install a flow switch after the coolant outlet connection to shutoff the
drive if coolant flow drops below 4 gpm.
3. Circulate water through the drive only when the drive is also powered.
Failure to do this may result in condensation accumulating on the drive heatsink and/or circuit boards, which could damage the drive.
4. For applications requiring a closed loop coolant system, ensure the
system is vented to remove air that would otherwise degrade the performance of the drive heatsink.
B-Frame Coolant Connections
B-frame LPM15 drives have inlet and outlet connections as shown in
Figure 1.1
protruding from the heatsink.
Supply and return lines should be sized for 9 gpm/120 psi service with a maximum operating temperature of 40°C (104°F). Actual operating flow rate through the drive is 8 gpm with a pressure drop of 10 psi.
C-Frame Coolant Connections
C-frame LPM15 drives have inlet and outlet connections as shown in
Figure 1.2
protruding from the heatsink.
Supply and return lines should be sized for 5 gpm/120 psi service with a maximum operating temperature of 40°C (104°F). Actual operating flow rate through the drive is 5 gpm with a pressure drop of 30 psi.
D-Frame Coolant Connections
. O-ring fittings and copper tube are brazed to copper tubes
O-ring fittings and copper tube are brazed to copper tubes
D-frame LPM15 drives have inlet and outlet connections as shown in
Figure 1.3
two-bolt-hole flange and compressed fiber gasket.
. O-ring fittings and copper tube are bolted to the heatsink via a
1-18 Installation/Wiring
Supply and return lines should be sized for 8 gpm/120 psi service with a maximum operating temperature of 40°C (104°F). Actual operating flow rate through the drive is 8 gpm with a pressure drop of 10 psi.
The D-frame drive inlet pressure must not exceed 50 psi. A pressure regulator, pressure switch, or pressure relief device is required to limit drive inlet pressure below 50 psi under all normal and abnormal operating conditions.
ATTENTION: Operating the D-Frame drive at a pressure
!
Coolant Requirements
LPM15 drives are rated for use with coolant consisting of clean water with a corrosion inhibitor. Deionized water is prohibited. Use distilled water or water with the following concentrations:
greater than 50 psi will permanently damage the equipment.
• Less than 50 ppm of sulfate and chloride.
• Less than 50 ppm of hard water ions such as Mg++ and Ca++.
Coolant must be properly strained and/or filtered to ensure it is free of contamination.
The coolant must be compatible with the following materials: Copper, brass, aluminum, and neoprene. For the D-frame drive only, the coolant must be compatible with Loctite 587 Ultra Blue
Ultra Blue is a registered trademark of Loctite Corporation.
Corrosion Inhibitor
A corrosion inhibitor is required. The following two options are approved sources:
1. Chemtool, Inc. (www.chemtool.com) Watertool 4435-C. The
recommended concentration of the inhibitor is 8 to 10% by volume.
2. Dow Chemical (www.dow.com) Dowtherm
glycol. The recommended concentration of the inhibitor is 25% by volume.
®
RTC silicone rubber.
®
SR-1 inhibited ethylene
Dowtherm is a registered trademark of the Dow Chemical Company.
ATTENTION: Ethylene glycol must be inhibited and silicate
!
free. Use of common silicate-containing, automotive-type ethylene glycol solutions is prohibited as they may damage the drive and cooling module equipment.
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