Rockwell Automation Liqui-Flo User Manual

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Hardware Reference, Installation, and Troubleshooting Manual D2-3411-8

LiquiFlo AC Power Modules

Version 6.4

Important User Information

IMPORTANT

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/ important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

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.

available from

) describes some

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.

ATTENTION: 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 a hazard, and recognize the consequence.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Identifies information that is critical for successful application and understanding of the product.

Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Chapter 1

Chapter 2

ONTENTS

Introduction

1.1 Related Publications ........................................................................................ 1-1

1.2 Getting Assistance from Reliance Electric....................................................... 1-1

About the Drive

2.1 Identifying the Drive by Model Number ........................................................... 2-1

2.2 Enclosure Ratings ........................................................................................... 2-2

2.3 B-Frame LiquiFlo Drive Component Locations................................................ 2-2

2.4 C-Frame LiquiFlo Drive Component Locations ............................................... 2-4

2.5 D-Frame LiquiFlo Drive Component Locations ............................................... 2-6

2.6 Regulator Board Description ........................................................................... 2-8

2.6.1 Jumper Locations and Settings ........................................................... 2-10

2.6.1.1 Setting the Analog Input Speed Reference Jumper (J4) ...... 2-10

2.6.1.2 Setting the Analog Output Jumper (J17)............................... 2-11

2.6.2 Wiring the Regulator Board Terminal Strip.......................................... 2-12

2.6.3 RS-232 Communication Port............................................................... 2-13

2.6.4 RMI Board Connector ......................................................................... 2-13

2.6.5 Operator Interface Module Connector................................................. 2-14

2.6.6 Keypad/Display ................................................................................... 2-14

2.7 RMI Board Description .................................................................................. 2-15

2.7.1 Digital Inputs ....................................................................................... 2-15

2.7.2 Digital Outputs..................................................................................... 2-15

2.7.3 Relay Outputs ..................................................................................... 2-15

2.7.4 Analog Input ........................................................................................ 2-15

2.7.5 Analog Outputs ................................................................................... 2-15

2.7.6 Frequency Input .................................................................................. 2-15

2.7.7 Wiring the RMI Board Terminal Strip................................................... 2-16

2.8 Optional Equipment ....................................................................................... 2-17

Contents

Chapter 3

Planning the Installation

3.1 General Requirements for the Installation Site ................................................ 3-1

3.1.1 Making Sure Environmental Conditions are Met ................................... 3-1

3.1.2 Determining Total Area Required Based on Drive Dimensions ............ 3-2

3.1.3 Verifying the Site Provides for Recommended Air Flow Clearances .... 3-6

3.1.4 Verifying Power Module Input Ratings Match Supplied Power ............. 3-6

3.2 Wiring Requirements for the Drive .................................................................. 3-6

3.2.1 Meeting Terminal Strip Input and Output Specifications ....................... 3-6

3.2.2 Determining Wire Size Requirements ................................................... 3-6

3.2.2.1 Conduit Entry Opening Sizes .................................................. 3-6

3.2.2.2 Recommended Power Wire Sizes .......................................... 3-6

3.2.2.3 Recommended Control and Signal Wire Sizes ....................... 3-7

3.2.2.4 Recommended Motor Lead Lengths....................................... 3-8

3.2.2.5 Recommended Serial Communication Cable Lengths ........... 3-8

3.2.3 Selecting Input Line Branch Circuit Fuses ............................................ 3-8

3.2.4 Meeting Encoder Specifications (FVC Regulation Only)....................... 3-9

3.2.4.1 Encoder Wiring Guidelines ..................................................... 3-9

3.2.5 Verifying Power Module Output Current Rating Is

Greater Than Motor Full Load Amps..................................................... 3-9

Chapter 4

Chapter 5

Chapter 6

Mounting the Drive, Grounding, and Finding Wire Routing Locations

4.1 Lifting and Mounting the Drive .........................................................................4-1

4.1.1 Verifying the Drive’s Watts Loss Rating.................................................4-2

4.2 Determining Input, Motor Output, Ground, and Control Wire

Routing for the Drive ........................................................................................4-2

4.3 Installing the DC Bus Reactor Fan (C-Frame Drives Only)..............................4-6

4.4 Grounding the Drive .........................................................................................4-7

4.5 Connecting Coolant Lines ................................................................................4-7

4.5.1 B-Frame Coolant Connections ..............................................................4-7

4.5.2 C-Frame Coolant Connections ..............................................................4-7

4.5.3 D-Frame Coolant Connections ..............................................................4-8

Installing Input Power Wiring

5.1 Installing Transformers and Reactors (Optional) .............................................5-1

5.2 Installing Fuses for Branch Circuit Protection ..................................................5-1

5.3 Installing a Required External/Separate Input Disconnect...............................5-4

5.4 Installing Power Wiring from the AC Input Line to the

Drive’s Power Terminals ..................................................................................5-4

Installing Output Power Wiring

6.1 Installing Output Contactors (Optional) ............................................................6-1

6.2 Installing Mechanical Motor Overload Protection (Optional) ............................6-1

6.3 Installing Output Wiring from the Drive Output Terminals to the Motor............6-2

Chapter 7

Chapter 8

Chapter 9

Appendix A

Appendix B

Wiring the Regulator Board and RMI Board Terminal Strips

7.1 Stopping the Drive............................................................................................7-7

7.2 Wiring the Encoder Feedback Device (FVC Regulation Only)8

7.3 Wiring the Signal and Control I/O...................................................................7-10

7.4 Wiring the RMI Board Terminal Strip .............................................................7-19

Completing the Installation

8.1 Checking the Installation ..................................................................................8-1

8.2 Powering Up After Installation Is Complete......................................................8-2

Troubleshooting the Drive

9.1 Test Equipment Needed To Troubleshoot .......................................................9-1

9.2 Drive Alarms and Faults...................................................................................9-1

9.3 Verifying That DC Bus Capacitors Are Discharged..........................................9-1

9.4 Checking the Power Modules with Input Power Off .........................................9-5

9.5 Replacement Parts...........................................................................................9-7

Technical Specifications........................................................................................... A-1

Cooling System Specifications................................................................................. B-1

Appendix C

B-Frame LiquiFlo Drive Wiring Diagrams................................................................. C-1

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Appendix D

Appendix E

C-Frame LiquiFlo Drive Wiring Diagrams .................................................................D-1

D-Frame LiquiFlo Drive Wiring Diagrams .................................................................E-1

Contents

III

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

List of Figures

Figure 2.1 – Identifying the Drive Model Number ..................................................... 2-1

Figure 2.2 – B-Frame LiquiFlo Drive Component Locations..................................... 2-3

Figure 2.3 – C-Frame LiquiFlo Drive Component Locations .................................... 2-5

Figure 2.4 – D-Frame LiquiFlo Drive Component Locations .................................... 2-7

Figure 2.5 – LiquiFlo Regulator Board Component Locations.................................. 2-9

Figure 2.6 – Jumper J4 Settings for Analog Input Speed Reference ..................... 2-11

Figure 2.7 – Jumper J17 Settings for Analog Outputs............................................ 2-12

Figure 2.8 – Typical Regulator Board Terminal Strip Connections......................... 2-13

Figure 2.9 – Keypad/Display................................................................................... 2-14

Figure 2.10 – Terminal Connections on the RMI Board ......................................... 2-16

Figure 3.1 – B-Frame Drive Dimensions .................................................................. 3-3

Figure 3.2 – C-Frame Drive Dimensions .................................................................. 3-4

Figure 3.3 – D-Frame Drive Dimensions .................................................................. 3-5

Figure 4.1 – Wire Routing Locations for B-Frame LiquiFlo Drives ........................... 4-3

Figure 4.2 – Wire Routing Locations for C-Frame LiquiFlo Drives ........................... 4-4

Figure 4.3 – Wire Routing Locations for D-Frame LiquiFlo Drives ........................... 4-5

Figure 4.4 – DC Bus Reactor Cooling Fan Mounting Location ................................. 4-6

Figure 4.5 – Coolant Connector Locations for B-Frame LiquiFlo Drives .................. 4-8

Figure 4.6 – Coolant Connector Locations for C-Frame LiquiFlo Drives .................. 4-9

Figure 4.7 – Coolant Connector Locations for D-Frame LiquiFlo Drives .................. 4-9

Figure 5.1 – Typical AC Input/Output Electrical Connections

(6-Pulse Rectifier, All Frames)................................................................ 5-2

Figure 5.2 – Typical AC Input/Output Electrical Connections

(12-Pulse Rectifier, B- and C-Frames Only) ........................................... 5-3

Figure 7.1 – Two-Wire Start/Stop Sample Control Wiring ........................................ 7-5

Figure 7.2 – Three-Wire Start/Stop Sample Control Wiring...................................... 7-6

Figure 7.3 – Encoder Wiring Connections ................................................................ 7-9

Figure 7.4 – Terminal Connections on the RMI Board ........................................... 7-19

Figure 9.1 – DC Bus Voltage Terminals (B-Frame Drives)....................................... 9-2

Figure 9.2 – DC Bus Voltage Terminals (C-Frame Drives) ...................................... 9-3

Figure 9.3 – DC Bus Voltage Terminals (D-Frame Drives) ...................................... 9-4

Contents

LiquiFlo 2.0 AC Drive User Manual

List of Tables

Table 2.1 – Power and Enclosure Ratings ............................................................... 2-2

Table 2.2 – Available Kits and Options................................................................... 2-17

Table 3.1 – Environmental Conditions...................................................................... 3-2

Table 3.2 – Drive Dimensions and Weights.............................................................. 3-2

Table 3.3 – Recommended Power Wire Sizes for B-Frame Drives.......................... 3-7

Table 3.4 – Recommended Power Wire Sizes for C-Frame Drives ......................... 3-7

Table 3.5 – Recommended Power Wire Sizes for D-Frame Drives ......................... 3-7

Table 3.6 – Recommended Terminal Strip Wire Sizes............................................. 3-8

Table 3.7 – AC Input Line Fuse and Circuit Breaker Selection Values .................... 3-9

Table 5.1 – Terminal Tightening Torques................................................................. 5-4

Table 7.1 – RS-232 Connections (Terminals 1-3) .................................................... 5-1

Table 7.2 – Encoder Connections (Terminals 4-9) ................................................... 7-1

Table 7.3 – Analog Output Connections (Terminals 10 and 11)............................... 7-2

Table 7.4 – Analog Speed/Torque Reference Connections (Terminals 12-15)........ 7-2

Table 7.5 – Digital Input Connections (Terminals 16-25) ......................................... 7-3

Table 7.6 – Reserved Connections (Terminals 26 and 27) ...................................... 7-3

Table 7.7 – Status Relay Connections (Terminals 28-31) ........................................ 7-4

Table 7.8 – Wiring Signal and Control I/O to the Regulator Board Terminal Strip.. 7-10

Table 7.9 – Wiring Signal and Control I/O to the RMI Board Terminal Strip........... 7-20

Table 9.1 – Resistance Checks ................................................................................ 9-6

Table 9.2 – B-Frame LiquiFlo Drive Replacement Parts .......................................... 9-7

Table 9.3 – C-Frame LiquiFlo Drive Replacement Parts .......................................... 9-8

Table 9.4 – D-Frame LiquiFlo Drive Replacement Parts .......................................... 9-9

Contents

VII

VIII

LiquiFlo 2.0 AC Drive User Manual

This instruction manual describes the LiquiFlo™ drive’s Power Module and regulator hardware. It does not cover the LiquiFlo software. For software information, refer to the LiquiFlo AC General Purpose (V/Hz) and Vector Duty Drive Software Start-Up and Reference Manual (D2-3410).

This manual is intended for qualified electrical and plumbing personnel.

LiquiFlo drives will typically be referenced by frame size. If additional clarity is required, drive model numbers wil also be included.

1.1 Related Publications

Refer to the following related publications as necessary for more information:

• D2-3410 - LiquiFlo AC General Purpose (V/Hz) and Vector Duty Drive Software Start-Up and Reference Manual

• D2-3305 - Motor Encoder Cable Kit

HAPTER

Introduction

• D2-3348 - Control and Configuration Software (CS3000)

• D2-3341 - Remote Meter Interface Board

• D2-3342 - Operator Interface Module

• D2-3449 - LiquiFlo AC Drive Panel Mount Kit

1.2 Getting Assistance from Reliance Electric

If you have any questions or problems with the products described in this instruction manual, contact your local Reliance Electric sales office. For technical assistance, call 1-864-284-5444.

Introduction

1-1

1-2

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

HAPTER

About the Drive

This chapter describes how to identify the drive using the model number matrix and shows the major drive components.

The LiquiFlo AC drive is a PWM (pulse-width-modulated) liquid-cooled drive that provides vector and general purpose regulation for a wide range of applications.

Using vector regulation, the drive can provide high dynamic response, maintain full rated motor torque to zero speed, and precisely control motor speed in both directions. The drive can provide this functionality either with encoder feedback (flux vector control or FVC) or without (sensorless vector control or SVC).

Using general purpose (volts/hertz or V/Hz) regulation, the drive is suited for a broad range of applications requiring adjustable speed control of motors.

2.1 Identifying the Drive by Model Number

Each LiquiFlo AC drive can be identified by its model number. See figure 2.1. This number appears on the shipping label and on the drive’s nameplate. The drive’s model number includes the Power Module and the regulator version. Drive power ratings are provided in table 2.1.

Continuous Ampere Rating (x10) 41 = 414 amps 50 = 500 amps 64 = 643 amps 120 = 1200 amps

LW= water-cooled LR = refrigerant-cooled

Voltage 2 = 200 to 230 VAC 3 = 270 to 310 VAC 4 = 380 to 480 VAC

Enclosure 0 = Open Chassis 1 = NEMA 1 2 = NEMA 12 Only 4 = NEMA 4x (Indoor Only) or NEMA 12

Regulator V e rsio n 60 = Version 6.x Firmware

Figure 2.1 – Identifying the Drive Model Number

NNN AA N N NN

About the Drive

2-1

Table 2.1 – Power and Enclosure Ratings

Frame Size and

Model

Number

41L4060

41LR4060

50LW4060

50LR4060

64LW4060

64LR4060

120L4060 D-Frame

* With V/Hz regulation, 110% continuous output current capability. With vector regulation, 150% output current capability for 5 sec.

**Note that LiquiFlo 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. The LiquiFlo drive is also capable of running at 4 kHz or 8 kHz. Contact Reliance Electric for ratings.

Selected

Regulation*

B-Frame

V/Hz or Vector

C-Frame

V/Hz or Vector

C-Frame

V/Hz or Vector

Enclosure

Rating

Open-Chassis

Style

Open-Chassis

Style

Open-Chassis

Style

Open-Chassis

Style

Input

Power

(KVA)

344 414 414 4600 / 1100

398 500 500 5500 / 1500

512 643 643 7000 / 2000

956 1200 1200 11700/4000

Input

Current

(Amps)

Output Current

at 2 kHz**

(Amps)

Full Load

Power Loss Watts

Fluid / Air

2.2 Enclosure Ratings

LiquiFlo drives have the following enclosure rating:

• Open-Chassis Style: Intended to be installed in an enclosure.

LiquiFlo drives must be placed in an enclosure.

2.3 B-Frame LiquiFlo Drive Component Locations

The B-Frame LiquiFlo drives have the following main components. The numbered items listed below provided correspond to the numbers used in figure 2.2. Replacement parts are listed in chapter 9.

1. Bus Bars (3) (AC Output)

2. Bus Bars (6) (AC Input)

3. IGBT Modules

4. Output Laminate

5. Capacitors

6. RMI Board

7. Casting

8. Membrane Switch Keypad

9. Coolant Lines - (a) Inlet, (b) Outlet

10. Regulator Board

11. Power Module Control (PCB)

12. Current Feedback Devices (3)

2-2

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

About the Drive

Figure 2.2 – B-Frame LiquiFlo Drive Component Locations

2-3

2.4 C-Frame LiquiFlo Drive Component Locations

The C-Frame LiquiFlo drives have the following main components. The numbered items listed below provided correspond to the numbers used in figure 2.3. Replacement parts are listed in chapter 9.

1. Bus Bars (AC Input)

2. SCR Bridge (AC to DC Converter)

3. Power Module Adapter Printed Circuit Board (PCB)

4. Power Interface Harness

5. Bus Bars (AC Output)

6. LEM InterfaceHarness

7. DC Bus Control PCB

8. Gate Driver PCB -Low Side

9. DC Bus Laminate Assembly

10. Output Current Feedback Devices

11. IGBT Modules

12. Chillplate (Heatsink)

13. Capacitors

14. Drive Baseplate

15. Reactor (Not Shown)

16. Discharge Resistors (Not Shown)

17. Control Panel Assembly

18. Bus Control - PMA Harness

19. Bus Control - Gate Drive Harness

20. Gate Driver PCB- High Side (Not Shown)

21. Membrane Switch Keyboard/Bracket

22. Regulator PCB

23. Option Board (Optional)

24. Coolant Lines - (Not Shown)

2-4

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

About the Drive

Figure 2.3 – C-Frame LiquiFlo Drive Component Locations

2-5

2.5 D-Frame LiquiFlo Drive Component Locations

The D-Frame LiquiFlo drives have the following main components. The numbered items listed below provided correspond to the numbers used in figure 2.4. Replacement parts are listed in chapter 9.

1. Chillplate Harness

2. Bus Bars (AC Input)

3. Bus Bars (AC Output)

4. Power Module Control PCB

5. Membrane Switch Keypad

6. Regulator PCB

7. RMI Option PCB

8. Current Feedback Devices

9. Gate Driver PCB

10. Coolant Connection (Outlet)

11. IGBT Module

12. Capacitors

13. Coolant Connection (Inlet)

14. Output Laminate

2-6

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Figure 2.4 – D-Frame LiquiFlo Drive Component Locations

1310 11 12

About the Drive

2-7

2.6 Regulator Board Description

LiquiFlo drive regulation is performed by a microprocessor on the Regulator board. See figure 2.5. Drive operation is adjusted by the parameters entered through the keypad. The Regulator board accepts power circuit feedback signals and an external speed reference signal, as well as data from an encoder that is attached to the motor when set up for FVC regulation. The Regulator board provides:

• PWM gating signals to the IGBT power devices

Based on the output of the control loop, the regulator sends PWM gating signals to isolated drivers on the Gate Driver board. These drivers switch the Insulated Gate Bi-polar Transistors (IGBTs), producing a waveform that corresponds to the voltage and frequency outputs of the inner V/Hz, FVC, or SVC regulators. The IGBTs can be switched at either a 2, 4, or 8 kHz carrier frequency.

• Form A and B contacts for drive status indicators

The Form A and B contacts are under control of the user via programmable parameters. A Form A or B transition can indicate drive status. The contacts are rated for 5 amps resistive load at 250 VAC/30 VDC and are made available through the terminal strip.

• Display data for a four-character display and fourteen indicator LEDs

For a description of the keypad/display refer to section 2.6.6. For operational instructions, see the LiquiFlo Software Reference manual (D2-3410).

• An analog output

The analog output is a scaled voltage (0-10 VDC) or current (4-20 mA) signal proportional to either motor speed (RPM), motor torque, or current (%TORQUE). The current signal selection (via jumper J17) requires a power supply for operation. The power can be sourced from the encoder terminals (4 and 9) or from an external 15 V power supply. See table 7.1, terminals 10 and 11, for more information. The analog output signal is available through the terminal strip.

2-8

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

J16

60-Pin Ribbon Cable

USER DISPLAY

J17

34-Pin Ribbon Cable

USER I/O TERMINAL STRIP

J3 - Option Board Connector J4 - Analog Input Jumper J7 - OIM (Optional) Connector

J9 - Keypad/Display Connector J16 - Power Module Feedback Cable J17 - Analog Output Jumper

J8 - RS-232C Port

Figure 2.5 – LiquiFlo Regulator Board Component Locations

About the Drive

2-9

2.6.1 Jumper Locations and Settings

Jumpers J4 and J17 on the Regulator board are factory-set for voltage in and voltage out signals. Refer to figure 2.5 for their locations on the Regulator board. If you need to change the jumpers’ settings, use the following procedures.

ATTENTION:Do not alter the setting of any jumper not described in this instruction manual. Failure to observe this precaution could result in

2.6.1.1 Setting the Analog Input Speed Reference Jumper (J4)

Jumper J4 is the analog speed/torque (U.000) reference jumper. This jumper selects either +/- 10 VDC or 0-20 mA input. Parameters P.009, P.010, and P.011 are used in conjunction with the jumper.

Note that if the position of jumper J4 is changed after the parameters are programmed, the software will not recognize that the input reference or polarity has been changed. Be sure to verify that parameters P.009, P.010, and P.011 are correct before starting the drive. Refer to the LiquiFlo Software Start-Up and Reference manual for more information.

Use the following procedure to set jumper J4:

damage to, or destruction of, the equipment.

ATTENTION:DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five

Step 1. Turn off input power to the drive and wait five minutes.

Step 2. Open the door of the enclosure.

Step 3. Verify that the DC bus voltage is zero by following the procedure in section

Step 4. Locate jumper J4 on the Regulator board. Refer to figure 2.5.

Step 5. Locate pin 1 on jumper J4. Move the jumper to the desired setting as shown

Step 6. Close the door of the enclosure.

Step 7. Reapply input power.

(5) minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure 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.

9.3.

in figure 2.6.

2-10

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Step 8. Verify that Terminal Strip Analog Input Offset (P.009), Terminal Strip Analog

Input Gain (P.010), and Terminal Strip Analog Input Configure (P.011) are correctly set. Note that the jumper settings must match the software settings; otherwise, the reference value may differ from what is expected. Refer to the LiquiFlo Software Start-Up and Reference manual for more information.

Voltage Input Option Current Input Option

Pins 2-3 Pins 1-2

+10 VDC

J4 J4

(default)

Figure 2.6 – Jumper J4 Settings for Analog Input Speed Reference

2.6.1.2 Setting the Analog Output Jumper (J17)

Jumper J17 is the analog output jumper. This jumper selects either a 0-10 VDC or 4-20 mA scaled signal output that is programmable to be proportional to either speed or torque using parameter P.012. Refer to the LiquiFlo Software Reference manual for more information about this parameter.

The jumper only selects a 0-10 VDC source voltage or 4-20 mA sink current to represent speed or torque. Note that the 4-20 mA current selection requires a power supply for operation as shown in table 7.8, terminals 10 and 11.

Use the following procedure to set jumper J17:

0-20 mA

About the Drive

ATTENTION:DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five

Step 1. Turn off input power to the drive and wait five minutes.

Step 2. Open the door of the enclosure.

Step 3. Verify that the DC bus voltage is zero by following the procedure in section

Step 4. Locate jumper J17 on the Regulator board. Refer to figure 2.5.

Step 5. Locate pin 1 on jumper J17. Move the jumper to the desired setting as shown

Step 6. Close the door of the enclosure.

9.3.

in figure 2.7.

2-11

Step 7. Reapply input power.

Step 8. Verify that parameter P.012 is set correctly for either speed or current.

Voltage Output Option

Pins 2-3

+10 VDC

J17 J17

(default)

Figure 2.7 – Jumper J17 Settings for Analog Outputs

Current Output Option

Pins 1-2

4-20 mA

2.6.2 Wiring the Regulator Board Terminal Strip

The terminal strip on the Regulator board provides terminals for connecting customer I/O devices. See figures 2.5 and 2.8. The following terminals are provided:

• Terminals 1-3: RS-232 connections

• Terminals 4-9: encoder connections

• Terminals 10-11: analog output connections

• Terminals 12-15: analog speed/torque reference connections

• Terminals 16-25: 24 VDC digital input connections

• Terminal 26: no connection

• Terminal 27: 24 VDC common

• Terminals 28-31: status relay connections

See chapter 7 for a complete description of, and how to wire, all of the signals available through the Regulator board terminal strip.

2-12

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

RS-232 Tx

12 435197698

RS-232

Connections Connections

Phase A Not

Encoder

Phase B

Figure 2.8 – Typical Regulator Board Terminal Strip Connections

Phase A

+15 VDC

RS-232 Regulator Common

RS-232 Rx

2.6.3 RS-232 Communication Port

The Regulator board contains a 9-pin D-shell RS-232 communication port (J8). This port provides RS-232 communication between the LiquiFlo drive and a personal computer running the Control and Configuration (CS3000) software. See Refer to instruction manual D2-3348 for more information about the CS3000 software.

2.6.4 RMI Board Connector

The flat-ribbon cable connector (J3) on the left side of the Regulator board is a parallel bus connection port that is used on LiquiFlo drives for the Remote Meter Interface (RMI) board.

Isolated Reference Voltage

VDC Speed Reference

Ma Speed Reference

Isolated Reference Gnd

+24 VDC

Digital Input 8 (Remote/Local)

Analog Meter Output

Regulator Common

Phase B Not

Regulator Common

10 1211 1413 15 171618 22

Analog Output

Analog Speed

Reference

Digital Input 7 (Ramp1/Ramp2)

Configurable

(Isolated 24 VDC)

Digital Input 6 (Forward/Reverse)

Function Loss

Run / Jog

Digital Inputs

Stop

Reset

Factory Installed Jumper

Start

2423 25

+24 VDC Common

No Connection

+24 VDC Common

Status Relays

N.O. Relay Contact

N.C. Relay Common

N.C. Relay Contact

292726 28 30

figure 2.5.

N.O. Relay Common

About the Drive

The RMI board provides an extended set of terminal strip inputs and outputs for the LiquiFlo drive. When the drive control source is the terminal strip (P.000 = rE), the RMI board can be used to provide additional speed reference selections. The RMI board also provides an outer PI regulator that is used to adjust trim. An optional adjustable torque (vector) or current (V/Hz) limit is available using the RMI board's analog or frequency input. See section 2.7 for a more detailed description of the RMI board. Refer to section 7.4 for a detailed description of the RMI terminal strip signals, and how to wire the RMI board.

The J3 connector can also be used to provide a means of attaching optional boards such as the DeviceNet

™

Option board, the AutoMax™ Network Option board, or similar boards to the LiquiFlo drive. Note that you must first remove the RMI board before a communication board can be added to the LiquiFlo drive.

2-13

Refer to the appropriate board instruction manual for more information. Refer to section 2.8 of this manual for more information on optional drive kits.

2.6.5 Operator Interface Module Connector

Flat-ribbon connector J7 provides a means of attaching the optional Operator Interface Module (OIM). The OIM is available for use as a remote keypad for the LiquiFlo drive. Refer to the OIM instruction manual (D2-3342) for more information.

2.6.6 Keypad/Display

The front panel keypad/display is used to program and operate the LiquiFlo drive. See figure 2.9. The four-character display is used to indicate drive parameters, parameter values, and fault codes. The fourteen single LEDs indicate drive status and mode, as well as identifying drive outputs whose values are displayed on the four-character display.

Refer to the LiquiFlo Software Start-Up and Reference manual for more information.

Drive Status LEDs

Monitor Mode LEDs

Password LED

Display

Stop/Reset

Key

Keypad

Start Key

2-14

Figure 2.9 – Keypad/Display

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

2.7 RMI Board Description

The following signals are available at the RMI board terminal strip. Refer to figure 2.10 for terminal identification. For a detailed description of the RMI board signals, refer to section 7.4.

2.7.1 Digital Inputs

Four 24 volt DC digital inputs provide additional speed reference options. The inputs are active high. A 24 VDC supply is provided by the RMI board for use with the digital inputs. The supply is short circuit- and overvoltage-protected.

2.7.2 Digital Outputs

Four 24 volt digital outputs are turned on and off as a result of data comparisons in the drive. All digital outputs are source-driven (active high with common ground) and short circuit-protected. Each output has an adjustable time delay that can be programmed as an on-delay or an off-delay. An option to select an external 24 volt supply for increased current capability at the outputs is jumper-selectable.

2.7.3 Relay Outputs

Three relay outputs can be turned on and off as a result of data comparisons in the drive. Each output has an adjustable time delay that can be programmed as an on-delay or an off-delay. All contacts are rated at 2

A, 24 VDC or 250 VA, 120 VAC.

2.7.4 Analog Input

The analog input is based on a 10-bit analog-to-digital (A/D) converter and is jumper-selected between 0 to 10 volts or 0 to 20 mA. Separate connection terminals are provided for voltage input and current input. The inputs are overvoltage-protected. Offset and gain are computed by software.

2.7.5 Analog Outputs

Three analog output channels can be configured. The outputs are short circuit protected. The output value is modulated over four 1 msec scans to provide 10-bit data resolution.

2.7.6 Frequency Input

The frequency input operates from 0 to 200 kHz, 15 VDC. The input is single-ended and uses the same common as the analog input.

About the Drive

2-15

2.7.7 Wiring the RMI Board Terminal Strip

ATTENTION:You are responsible for conforming with all applicable local,

national, and inter national codes. Failure to obser ve this precaution could

Refer to figure 2.10 for the signal and control I/O terminal connections on the RMI board. terminal strip connections and related parameters. Refer to section 7.4 for descriptions of, and how to wire, all RMI board terminal strip connections.

result in damage to, or destruction of, the equipment.

Digital Input 1

Digital Input 2

Digital Input 3

Digital Input 4

+24 V (for digital inputs only)

External +24 V Input for Digital Outputs

Digital Output 1

Digital Output 2

Digital Output 3

Digital Output 4

Digital Output Common

Relay 1 Common

Relay 1 Normally Open

Relay 2 Normally Closed

Relay 2 Common

Relay 2 Normally Open

Not Used

Relay 3 Normally Closed

Relay 3 Common

Relay 3 Normally Open

Not Used

Analog Input: 0 to 10 V

Analog Input: 0 (4) to 20 mA

Analog I/O Common

Analog Output 1: 0 to 10 V

Analog Output 2: +/-10 V

Analog Output 3: 0 to 10 V/0 to 20 mA

Analog I/O Common

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69

Figure 2.10 – Terminal Connections on the RMI Board

Frequency Input (Ground = Analog I/O Common)

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LiquiFlo AC Power Modules, Hardware Reference Version 6.4

2.8 Optional Equipment

Table 2.2 lists standard available LiquiFlo kits and options.

Table 2.2 – Available Kits and Options

Description Model Number

Instruction

Manual

2TC3025 2TC3075

Motor Encoder Cable

DeviceNet Network Option Board 2DV3000 MAN0096-03

ControlNet Network Option Board 2CN3000 D2-3390

InterBus-S Network Option Board 2NB3000 49’1333

AutoMax Network Option Board with 762mm (30”) of Cable

Johnson Metasys N2 Option Board 2MT3000 HE-HGV3MT

Landis and Staefa P1 Option Board

Modbus Option Board 2MB3000 MAN0183-02

PROFIBUS Option Board 2PB3000 49’1355

AutoMax RS-232 Adapter Cable 2CA3001 D2-3348

2TC4025 2TC4075 2TC4100 2TC4300

2AX3000 D2-3308

2LS3000 Horner Electric

D2-3305

Application 2710

Manual

About the Drive

Operator Interface Module (OIM) 2RK3000 D2-3342

CS3000 Control and Configuration Software

CS3000 RS-232 Computer Cable 2CA3000 D2-3348

115 VAC Interface Option Board 2LB3000 D2-3376

2CS3000 D2-3348

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LiquiFlo AC Power Modules, Hardware Reference Version 6.4

HAPTER

Planning the Installation

This chapter provides how to plan a LiquiFlo drive installation.

ATTENTION: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.

ATTENTION:When the level-sense start feature is enabled (P.054 = ON), the user must ensure that automatic start up of the driven equipment will not cause injury to operating personnel or damage to the driven equipment. In addition, the user is responsible for providing suitable audible or visual alarms or other devices to indicate that this function is enabled and the drive may start at any moment. Refer to the LiquiFlo Software Start-Up and Reference manual for additional information. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:Use of power correction capacitors on the output of the drive can result in erratic operation of the motor, nuisance tripping, and/or permanent damage to the drive. Remove power correction capacitors before proceeding. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION:The user is responsible for conforming with all applicable local, national, and international codes. Failure to obser ve this precaution could result in damage to, or destruction of, the equipment.

3.1 General Requirements for the Installation Site

3.1.1 Making Sure Environmental Conditions are Met

Planning the Installation

It is important to properly plan before installing a LiquiFlo drive to ensure that the drive’s environment and operating conditions are satisfactory. Read the following recommendations before continuing with drive installation.

Before deciding on an installation site, consider the following guidelines:

• Verify that open-chassis style drives can be kept clean and dry. LiquiFlo drives must

be placed in an enclosure.

• The area chosen should allow the space required for proper air flow as defined in

section 3.1.3.

• Be sure that open-chassis style drives are installed away from oil, coolants, or other

airborne contaminants.

3-1

• Do not install the drive above 1000 meters (3300 feet) without derating output

power. For every 91.4 meters (300 feet) above 1000 meters (3300 feet), derate the output current 1%.

• Verify that the drive location will meet the environmental conditions specified in table

3.1.

Table 3.1 – Environmental Conditions

Condition Specification

LiquiFlo

Drive M/N

41L4060

41LR4060

50LW4060

50LR4060

64LW4060

64LR4060

Operating Temperature (inside a NEMA cabinet)

0°C to +55°C

(32° to 131°F)

Storage Temperature (Ambient) -40°C to 65°C (−40° to 149°F)

Humidity 5% to 95% (non-condensing)

With typical heat rise inside a cabinet, 40°C ambient outside usually results in 55°C inside.

3.1.2 Determining Total Area Required Based on Drive Dimensions

Drive dimensions and weights are listed in table 3.2. Overall drive dimensions are illustrated in figures 3.1, 3.2, and 3.3 as an aid in calculating the total area required by the LiquiFlo drives.

Table 3.2 – Drive Dimensions and Weights

Frame Dim. A Dim. B Dim. C Dim. D Dim. E Dim. F Dim. G Weight

B 475 mm

18.69”

C 583 mm

22.96”

C 583 mm

22.96”

800 mm

31.52”

971 mm

38.23”

971 mm

38.23”

357 mm

14.06”

347 mm

13.66”

347 mm

13.66”

397 mm

15.63”

464 mm

18.25”

464 mm

18.25”

711mm

28.00”

787 mm

31.00”

787 mm

31.00”

39 mm

1.53”

28 mm

1.09”

28 mm

1.09”

20 mm

0.79”

25 mm

1.00”

25 mm

1.00”

125 kg

275 lb

168 kg

370 lb

170 kg

375 lb

120L4060 D 1010 mm

3-2

39.75”

1245 mm

49.00”

360 mm

14.16”

838 mm

33.00”

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

1200 mm

47.25”

29 mm

1.12”

25 mm

1.00”

386 kg

850 lb

.563" Thru

4 Places

F (Typ. 4 Pl.)

G (Typ. 4 Pl.)

Right Side ViewFront View

Figure 3.1 – B-Frame Drive Dimensions

Planning the Installation

3-3

.563" Thru

4 Places

F (Typ. 4 Pl.)

G (Typ. 4 Pl.)

Front View (Control Panel Assembly and Bus Laminate Removed) Right Side View

Figure 3.2 – C-Frame Drive Dimensions

3-4

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

13.93

16.5016.50

0.56 6 Pl.

Left Side View

Planning the Installation

Figure 3.3 – D-Frame Drive Dimensions

Front View

3-5

3.1.3 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.

3.1.4 Verifying Power Module Input Ratings Match Supplied Power

It is important to verify that plant power will meet the input power requirements of the LiquiFlo drive’s Power Module circuitry. Refer to table 2.1 for input power rating specifications. Be sure input power to the drive corresponds to the drive nameplate voltage and frequency.

3.2 Wiring Requirements for the Drive

Certain drive requirements should be checked before continuing with the drive installation. Wire sizes, branch circuit protection, encoder feedback (for FVC regulation), and E-stop wiring (see chapter 7) are all areas that need to be evaluated.

3.2.1 Meeting Terminal Strip Input and Output Specifications

The terminal strip on the Regulator board provides terminals for 24 VDC power for the eight remote control inputs. Refer to tables A.3 and A.4 for control input and output specifications.

3.2.2 Determining Wire Size Requirements

Wire size should be determined based on the size of conduit openings, and applicable local, national, and international codes (e.g., NEC/CEC regulations).

ATTENTION:The user is responsible for conforming with all applicable local, national, and international codes. Failure to obser ve this precaution

3.2.2.1 Conduit Entry Opening Sizes

It is important to determine the size of the conduit openings in the cabinet that the drive is mounted in so that the wire planned for a specific entry point will fit through the opening.

3.2.2.2 Recommended Power Wire Sizes

Input power wiring should be copper and should be sized according to applicable codes to handle the drive’s continuous-rated input current. Output wiring should be copper and should be sized according to applicable codes to handle the drive’s continuous-rated output current. See tables 3.3, 3.4, and 3.5 for recommended power wire sizes. See figures 5.1 and 5.2 for input and output wiring connections.

could result in damage to, or destruction of, the equipment.

3-6

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Table 3.3 – Recommended Power Wire Sizes for B-Frame Drives

Type of Power Wiring

AC Input Power (R/L1, S/L2, T/L3)

Drive M/N 41L4060, 41LR4060

with kit M/N 41L4060PM

Output Power (U/T1, V/T2, W/T3)

Delta-Wye Transformer (S1 to S6)

accepts two (2) 300 MCM to 6 AWG

Lug conductors

Ground (PE)

Lugs not provided with standard drive. They are available as part of kit M/N 41L4060PM.

Table 3.4 – Recommended Power Wire Sizes for C-Frame Drives

Drive M/N 50LW4060, 50LR4060,

64LW4060, 64LR4060

Type of Power Wiring

with kit M/N 64L4060PM

AC Input Power (R/L1, S/L2, T/L3)

Output Power (U/T1, V/T2, W/T3)

Delta-Wye Transformer (S1 to S6)

accepts two (2) 350 MCM to 4 AWG

Lug conductors

Ground (PE)

Lugs not provided with standard drive. They are available as part of kit M/N 64L4060PM.

Table 3.5 – Recommended Power Wire Sizes for D-Frame Drives

3.2.2.3 Recommended Control and Signal Wire Sizes

Planning the Installation

Drive M/N 120L4060

Type of Power Wiring

with kit M/N 120L4060PM

AC Input Power (R/L1, S/L2, T/L3)

Output Power (U/T1, V/T2, W/T3)

Delta-Wye Transformer (S1 to S6)

accepts two (2) 800 MCM to

Lug 300 MCM conductors

Ground (PE)

Lugs not provided with standard drive. They are available as part of kit M/N 120L4060PM.

The recommended wire sizes to connect I/O signals to the terminal strip on the Regulator board and RMI board are shown in table 3.6. Recommended terminal tightening torque is 0.5 Newton-meters (4.5 in-lbs). Operator controls can be up to 303 meters (1000 feet) from the LiquiFlo drive.

3-7

Table 3.6 – Recommended Terminal Strip Wire Sizes

Ter minals Wi re Size

1 to 31 (Regulator)

41 to 69 (RMI)

3.2.2.4 Recommended Motor Lead Lengths

Motor lead lengths can total up to 76 meters (250 feet).

3.2.2.5 Recommended Serial Communication Cable Lengths

Connector J8 on the Regulator boards is an RS-232 serial communication port. This connector allows the LiquiFlo drive to communicate with external devices such as a personal computer using RS-232 protocol. See table A.5.

Two RS-232 cables are available from Reliance Electric:

20 to 14 AWG, 2 to 0.5 (mm

• A 3 meter (10 feet) D-shell 9-pin to 9-pin cable (M/N 2CA3000)

• A 0.3 meter (1 foot) D-shell 9-pin to 25-pin adaptor cable (M/N 2CA3001).

User-constructed cables can be up to 15 meters (50 feet) in length.

Note that for communication between a LiquiFlo drive and a personal computer, the Control and Configuration Software must also be used. Refer to instruction manual D2-3348 for more information about the CS3000 software.

)

The Regulator boards have one set of RS-232 transmit/receive lines. These lines can be accessed by only one on the terminal strip, or an Operator Interface Module (OIM).

device at a time: connector J8, the RS-232 terminals (1-3)

3.2.3 Selecting Input Line Branch Circuit Fuses

ATTENTION:Most codes require that upstream branch circuit protection

be provided to protect input power wiring. Install the fuses recommended

Input line branch circuit protection fuses must be used to protect the input power lines. See figures 5.1 and 5.2. Recommended fuse values are shown in table 3.7. The input fuse ratings listed in table 3.7 are applicable for one drive per branch circuit. No other load may be applied to that fused circuit.

in table 3.6. Do not exceed the fuse ratings. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

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LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Table 3.7 – AC Input Line Fuse and Circuit Breaker Selection Values

Model Number

41L4060

Input Voltage

(+/-10%) Fuse Rating

380-480 VAC

600 A

Motor Circuit Protector

or Circuit Breaker

600 A

41LR4060

50LW4060

380-480 VAC

750 A

800 A

50LR4060

64LW4060

380-480 VAC

1000 A

64LR4060

120L4060 380-480 VAC

Recommended fuse type: UL Class J, 600 V, time-delay, or equivalent.

Recommended fuse type: UL Class L, 600 V, time-delay, or equivalent.

1600 A

1500 A

3.2.4 Meeting Encoder Specifications (FVC Regulation Only)

LiquiFlo drives set up for FVC regulation require an encoder for closed-loop operation. Refer to table A.6 for specifications. Drives set up for V/Hz or SVC regulation do not require an encoder for feedback because they operate in the open loop mode.

3.2.4.1 Encoder Wiring Guidelines

Encoder connections are considered signal level wiring and, therefore, must be run separate from control and power wiring. Reliance Electric recommends 18 AWG unshielded twisted pair wires with 2-3 twists per inch for applications to a maximum distance of 303 meters (1000 feet). The recommended Reliance Electric part number is 417900-207CG, 18 AWG, 6 conductor (3 twisted pairs).

3.2.5 Verifying Power Module Output Current Rating Is Greater Than Motor Full Load Amps

Verify that the LiquiFlo output current rating is equal to or greater than the motor’s full load current (amps). Table 2.1 lists the output current values.

Planning the Installation

3-9

3-10

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Mounting the Drive, Grounding, and

Finding Wire Routing Locations

This chapter shows how to mount the drive and properly ground it. Also shown are the entry areas where wiring is to be routed in and out of the drive.

4.1 Lifting and Mounting the Drive

Use the following procedure to lift the LiquiFlo drive and mount it in the required enclosure:

Step 1. For M/N 50LW4060, 50LR4060, 64LW4060, and 64LR4060, install two

eyebolts into the drive to serve as lifting points. Two 3/4” nuts are welded to the drive’s baseplate. Screw two eyebolts (2” eye I.D., 6” long shank) into the nuts.

For M/N 41L4060 or 41LR4060, install two clevis clamps into the drive to serve as lifting points. Two 9/16” through holes are machined into the casting protrusions.

For M/N 120L4060, install two clevis pins into the drive to serve as lifting points. Two 1.00" through holes are provided in the sheet metal chassis.

HAPTER

Step 2. For M/N 41L4060, 41LR4060, M/N 50LW4060, 50LR4060, 64LW4060, and

64LR4060, connect 18” (nominal) of chain between the eyebolts or attached clevis clamps and secure them with a clevis clamp.

For M/N 120L4060, connect 50" (nominal) of chain between the eyebolts or attached clevis clamps and secure them with a clevis clamp.

Step 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.

Step 4. Using the hoist, lift the drive from the horizontal shipping pallet.

Step 5. Position the drive in the enclosure.

Step 6. For M/N 41L4060, 41LR4060, M/N 50LW4060, 50LR4060, 64LW4060, and

64LR4060, attach the drive to the vertical surface selected using the four (4) mounting holes provided.

For M/N 120L4060, attach the drive to the vertical surface using the six (6) mounting holes provided.

Mounting the Drive, Grounding, and Finding Wire Routing Locations

4-1

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 table 3.2 and figures 3.1 to 3.3 for drive mounting dimensions. Use the following user-supplied mounting bolts and washers on C-frame drives: 1/2”-13, UN/UNC-2A, Grade 2.

Step 7. For M/N 50LW4060, 50LR4060, 64LW4060, and 64LR4060, remove the

eyebolts and the chain between them.

For M/N 41L4060, 41LR4060, and 120L4060, remove the clevis clamps and chain between them.

4.1.1 Verifying the Drive’s Watts Loss Rating

When mounting the drive inside of an enclosure, you should determine the watts loss rating of the drive from table 2.1. This table lists the typical full load power loss watts value at 2 kHz (rated carrier frequency). Ensure that the enclosure is adequately

ventilated with 0

° to 40°C ambient air based on the drive’s watts loss rating.

4.2 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. Figures 4.1,

4.2, and 4.3 show the wire routing, grounding terminal, and power terminal strips of the B-frame, C-frame, and D-frame LiquiFlo drives.

ATTENTION:Do not route signal and control wiring with power wiring in the same conduit. This can cause interference with drive operation.

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.

Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: Unused wires in conduit must be grounded at 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.

4-2

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Drive Input Wiring

(6 Places)

Drive Output Wiring

(3 Places)

Front View

Coolant Connections

User Connection Wiring

User

Connections

Figure 4.1 – Wire Routing Locations for B-Frame LiquiFlo Drives

Top View

Bottom View

Mounting the Drive, Grounding, and Finding Wire Routing Locations

4-3

Drive Input

Wiring

Drive Output Wiring To Motor (3 Places)

User Connections

Coolant Connections

Figure 4.2 – Wire Routing Locations for C-Frame LiquiFlo Drives

4-4

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Drive

Input

6 Places

Left Side View

Drive

Output

To Motor

User Control

Front View

Connections

User Control

Wire Openings

Figure 4.3 – Wire Routing Locations for D-Frame LiquiFlo Drives

Mounting the Drive, Grounding, and Finding Wire Routing Locations

Bottom View

4-5

4.3 Installing the DC Bus Reactor Fan (C-Frame Drives Only)

A fan must be installed in the LiquiFlo drive enclosure to keep the DC bus reactor at the proper operating temperature. The fan should be a Comair Rotron M/N PT2B3 rated at 0.26 amps, 31 watts, 235 CFM (115 VAC, 60 Hz), or equivalent.

Use the following procedure to install the DC bus reactor fan:

Step 1. Open the door of the enclosure.

Step 2. Mount the fan beneath the drive in the enclosure as shown in figure 4.4 such

that the air flow is directed up through the drive.

Step 3. Connect the fan to a 115 VAC, 60 Hz power source inside of the enclosure.

Step 4. Close the door of the enclosure.

4-6

FAN

Coolant

Connections

Enclosure

Floor

Figure 4.4 – DC Bus Reactor Cooling Fan Mounting Location

Airflow

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

FAN

0.0” Clearance Allowable

4.0" Max.

1.0" Min.

4.4 Grounding the Drive

ATTENTION:The user is responsible for conforming with all applicable

local, national, and international codes. Failure to obser ve this precaution

Use the following steps to ground the drive:

Step 1. Open the door of the enclosure.

Step 2. Run a suitable equipment grounding conductor unbroken from the drive to

Step 3. Connect a suitable grounding conductor to the motor frame and the remote

Step 4. Close the door of the enclosure.

could result in damage to, or destruction of, the equipment.

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 figures 4.1, 4.2, 4.3, 5.1, and 5.2. Tighten these grounding connections to the proper torque as shown in table 5.1.

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 5.1.

4.5 Connecting Coolant Lines

LiquiFlo drives are rated for use with clean, potable water as the coolant. Coolant must be properly filtered to ensure it is free from contamination. Some coolant fluids may allow an increased output rating while others may require a derating. For LiquiFlo drive M/N 41LR4060, contact Reliance Electric for additional information.

4.5.1 B-Frame Coolant Connections

B-frame LiquiFlo drives have inlet and outlet coolant connections as shown in figure

4.5. The inlet and outlet connectors are 3/4” nominal, 7/8” O.D. copper sweat fittings. Use the appropriate sweat fittings attached to hoses or copper tube for the coolant supply and return lines. 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 at 10 psi. It is recommended that a flow switch be installed after the coolant outlet to shut off the drive if coolant flow drops below 4 gpm. It is also recommended that the water pump not be powered unless the drive is also powered. Failure to do this may result in condensation accumulating on the casting and/or circuit boards, which could damage the drive.

4.5.2 C-Frame Coolant Connections

C-frame LiquiFlo drives have inlet and outlet coolant connections as shown in figure

4.6. The inlet and outlet connectors are size 10, SAE 37° flare female fittings. Use the appropriate male fittings attached to hoses or for the coolant supply and return lines. These fittings should be torqued to 80 Nm (60 ft-lb). 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 at 30 psi. It is recommended that a flow switch be installed after the coolant outlet to shut off the drive if coolant flow drops below 4 gpm. It is also recommended that the water pump

Mounting the Drive, Grounding, and Finding Wire Routing Locations

4-7

not be powered unless the drive is also powered. Failure to do this may result in condensation accumulating on the casting and/or circuit boards, which could damage the drive.

4.5.3 D-Frame Coolant Connections

D-frame LiquiFlo drives have inlet and outlet coolant connections as shown in figure

4.7. The inlet and outlet connections are tapped holes suitable for two bolt-hole flanges. The internal threads of the tapped holes are 5/16-18 UNC-2B. The depth of thread is 3/4". The center-to-center hole dimension is 1.625". Use the appropriate sweat fittings to connect the two bolt-hole flanges to hoses or copper tube. For adequate sealing, a compressed fiber gasket is required between each flange and the drive. For bolted joint strength, use a 5/16" split ring lockwasher between each 5/16-18 bolt and flange and a nonpermanent thread locking compound on each bolt. The flange screws should be torqued to 13.6 Nm (10 ft-lb). Supply and return lines should be sized for 9 gpm/50 psi service with a maximum operating temperature of 40°C (104°F). A pressure regulator or pressure relief device to control the drive inlet pressure below 50 psi is recommended. Actual operating flow rate through the drive is 8 gpm at 10 psi. It is recommended that a flow switch be installed after the coolant outlet to shut off the drive if the coolant flow drops below 4 gpm. It is also recommended that the water pump not be powered unless the drive is also powered.

A corrosion inhibitor is required. An approved source is Chemtool Inc., part number CT787-C. The recommended concentration of the inhibitor is 2% by volume.

Tube assemblies for water cooling are provided with kit M/N 41L4060PM, or can be user-supplied.

Figure 4.5 – Coolant Connector Locations for B-Frame LiquiFlo Drives

Coolant Outlet Connection

Coolant Inlet Connection

Right Side View

4-8

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Coolant Outlet Connection

Coolant Inlet Connection

Hose assemblies are provided with the drive. Hose assemblies of longer length are provided with kit M/N 64L4060PM, or can be usersupplied.

Figure 4.6 – Coolant Connector Locations for C-Frame LiquiFlo Drives

Tube assemblies, gaskets, and hardware are provided with kit M/N 120L4060PM, or can be user-supplied.

Coolant Outlet

Connection

Coolant Inlet Connection

Front View

Figure 4.7 – Coolant Connector Locations for D-Frame LiquiFlo Drives

Mounting the Drive, Grounding, and Finding Wire Routing Locations

4-9

4-10

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

HAPTER

Installing Input Power Wiring

This chapter describes incoming line components and how to install them.

5.1 Installing Transformers and Reactors (Optional)

The LiquiFlo AC drive may be used on distribution systems with 85,000 amps or less symmetrical fault current capacity. Line reactors are not needed for safe operation of the drive but may be required to reduce line harmonics.

Input isolation transformers might be needed to help eliminate the following:

• Damaging line voltage transients from reaching the drive.

• Line noise from the drive back to the incoming power source.

• Damaging currents that could develop if a point inside the drive becomes grounded.

Observe the following guidelines when installing an isolation transformer:

• A power disconnecting device must be installed between the power line and the

primary of the transformer.

• If the power disconnecting device is a circuit breaker, the circuit breaker trip rating

must be coordinated with the in-rush current (10 to 12 times full load current) of the transformer.

5.2 Installing Fuses for Branch Circuit Protection

Install the required, user-supplied branch circuit protection fuses according to the applicable local, national, and international codes (e.g., NEC/CEC). The fuses must be installed in the line before the drive input terminals. See figures 5.1 and 5.2. Fuse

value selections are provided in table 3.7.

ATTENTION:Most codes require that upstream branch protection be provided to protect input power wiring. Failure to observe this precaution

could result in severe bodily injury or loss of life.

Installing Input Power Wiring

5-1

Manual Disconnect

User-Supplied

Interconnecting bus bar provided with M/N 41L4060PM, 64L4060PM, or

or can be user-supplied.120L4060PM kit,

3-Phase AC Input Voltage 380/480 V

Fuse

L1 L2 L3 L6 L5 L4

GND

(PE)

LiquiFlo Power Module

User-Supplied

Figure 5.1 – Typical AC Input/Output Electrical Connections (6-Pulse Rectifier, All Frames)

GND

5-2

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

User-Supplied

Manual Disconnect

Fuse

Transformer

3-Phase AC Input Voltage 380/480 V

181 182 183

L1 L2 L3 L6 L5 L4

GND

LiquiFlo Power Module

GND (PE)

User-Supplied

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

Installing Input Power Wiring

GND

5-3

5.3 Installing a Required External/Separate Input Disconnect

An input disconnect must be installed in the line before the drive input terminals in accordance with local, national, and international codes (e.g., NEC/CEC). The disconnect should be sized according to the in-rush current as well as any additional loads the disconnect might supply. The trip rating for the inrush current (10-12 times full load current) should be coordinated with that of the input isolation transformer, if used. Refer to section 5.1 for additional information.

5.4 Installing Power Wiring from the AC Input Line to the Drive’s Power Terminals

Use the following steps to connect AC input power to the drive:

Step 1. Wire the AC input power leads by routing them as shown in figure 4.1. Tables

3.3. 3.4, and 3.5 contains the recommended power wiring sizes.

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.

Step 2. Connect the three-phase AC input power leads (three-wire 380-480 VAC) to

the appropriate terminals.

On 6-pulse rectifier drives, connect the AC input power leads to the L1, L2, and L3 terminals. See figure 5.1.

On 12-pulse rectifier drives, connect the AC input power leads to the L1, L2, L3, L4, L5, and L6 terminals. See figure 5.2.

Step 3. Tighten the AC input power terminals to the proper torque as shown in table

5.1.

Table 5.1 – Terminal Tightening Torques

Maximum Tightening Torque

Drive Type Terminals Hardware Type

L1 to L6 1/4-20, Gr. 5 13 Newton-meters (10 ft-lb)

B-Frame

C-Frame

D-Frame L1 to L6 1/2-13; Gr. 5 100 Newton-meters (75 ft-lb)

U, V, W 5/16-18, Gr. 5 24 Newton-meters (18 ft-lb)

GND, PE 5/16 Hex 31 Newton-meters (23 ft-lb)

L1 to L6 1/2-13; Gr. 5 100 Newton-meters (75 ft-lb)

U, V, W 3/8-16, Gr. 5 42 Newton-meters (31 ft-lb)

GND, PE 5/16 Hex 31 Newton-meters (23 ft-lb)

U, V, W 1/2-13; Gr. 5 100 Newton-meters (75 ft-lb)

GND, PE 1/2 Hex 58 Newton-meters (42 ft-lb)

(+10%)

5-4

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

HAPTER

Installing Output Power Wiring

This chapter provides instructions on wiring output contactors, motor overload protection, and output wiring to the motor.

6.1 Installing Output Contactors (Optional)

Output contactors provide a positive means of disconnecting the motor from the drive. If the application requires the use of output contactors, contact Reliance Electric for assistance.

6.2 Installing Mechanical Motor Overload Protection (Optional)

To provide the motor with overload protection, local, national, and international codes (e.g., NEC/CEC) may require one of the following:

• a motor thermostat be installed internal to the motor

• a mechanical thermal motor overload relay, sized to protect the motor, be installed

between the motor and the drive’s output terminals.

The Motor Overload Enable parameter (P.040) can be used in place of thermal motor overload relays in single motor applications. Note, however, that temperature measuring devices integral to the motor are the best way to thermally protect AC motors under all conditions. Parameter P.040 must be enabled to provide overload protection. Refer to the LiquiFlo Software Start-Up and Reference manual for more information.

In multiple motor applications (V/Hz regulation only), each motor must have its own user-supplied overload and branch circuit protection.

Installing Output Power Wiring

6-1

6.3 Installing Output Wiring from the Drive Output Terminals to the Motor

Important: The total motor lead length must not exceed 76 meters (250 feet).

Use the following steps to connect the AC output power wiring from the drive to the motor:

Step 1. Wire the three-phase AC output power motor leads by routing them as shown

in figures 4.1, 4.2, or 4.3. Tables 3.3, 3.4, and 3.5 contain the recommended power wiring sizes.

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 these precautions could result in damage to, or destruction of, the equipment

ATTENTION:Unused wires in conduit must be grounded at 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.

Step 2. Connect the three-phase AC power motor leads to the appropriate output

terminals. Figures 4.1, 4.2, and 4.3 show the locations of the output power terminals.

Step 3. Tighten the three-phase AC output power terminals to the proper torque as

shown in table 5.1.

6-2

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

HAPTER

Wiring the Regulator Board and RMI

Board Terminal Strips

This chapter describes how to wire the Regulator board and RMI board terminal strips for stop, encoder feedback, and remote control signals.

The signals available through the Regulator board terminal strip are shown in tables

7.1 to 7.7 and figures 7.1 and 7.2. Table 7.8 provides additional information.

Note that when the Control Source parameter (P.000) is set to remote (rE), the drive will be controlled by the signals connected to the Regulator board terminal strip. Refer to the LiquiFlo Software Start-Up and Reference manual for more information on how parameter P.000 is used to specify where the drive is controlled from.

Table 7.1 – RS-232 Connections (Terminals 1-3)

Terminal # Signal

1 Transmit (Tx)

2 Receive (Rx)

3 Regulator Common

Notes: The RS-232 terminals should only be used when the RS-232 communication port (J8) or an Operator Interface Module (OIM) is not being used, as all three devices use the same transmit/receive lines.

Table 7.2 – Encoder Connections (Terminals 4-9)

Terminal # Signal

4 +15 VDC

5 Phase A

6 Phase A Not

7 Phase B

8 Phase B Not

9 Regulator Common

Notes: An encoder feedback device must be installed if FVC regulation is used.

Wiring the Regulator Board and RMI Board Terminal Strips

7-1

Table 7.3 – Analog Output Connections (Terminals 10 and 11)

Terminal # Signal

10 Analog Meter Output

11 Regulator Common

Notes: The output of this terminal is either 0-10 VDC or 4-20 mA as determined by the setting of jumper J17 on the Regulator board. The analog output must also be programmed via parameter P.012 for an indication of speed and direction or percent of torque.

Table 7.4 – Analog Speed/Torque Reference Connections (Terminals 12-15)

Terminal # Signal

12 Isolated Reference Voltage

13 VDC Speed/Torque Reference

14 mA Speed/Torque Reference

15 Isolated Reference Common

Notes: The analog speed/torque (P.008/U.000) reference is either +/-10 VDC or +/-20 mA, as determined by the setting of jumper J4 on the Regulator board. The analog reference can be adjusted using parameters P.009, P.010, and P.011.

7-2

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Table 7.5 – Digital Input Connections (Terminals 16-25)

Terminal # Signal

16 +24 VDC (Current Limited) (For remote control digital inputs only)

17 Digital Input 8 (Remote/Local) - Programmable

18 Digital Input 7 (Ramp1/Ramp2) - Programmable

19 Digital Input 6 (Forward/Reverse) - Programmable

20 Function Loss

21 Run/Jog

22 Reset

23 Stop

24 Start

25 +24 VDC Common

Notes: When a user-installed function loss input, a coast-to-stop pushbutton, or another external interlock is installed, the factory-installed jumper connecting terminals 16 and 20 must be removed so that a contact, when open, will stop the drive.

Terminals 17, 18, and 19 (remote control inputs 8, 7, and 6) are programmed using parameters P.007, P.008, and P.031 through P.038. Factory default settings are shown here in parentheses. Refer to the LiquiFlo Software Start-Up and Reference manual for more information.

Table 7.6 – Reserved Connections (Terminals 26 and 27)

Teminal # Signal

26 No Connection

27 +24 VDC Common

Notes: Terminal 26 has no connection and is not used in LiquiFlo applications. Terminal 27 can be used as a 24 VDC common.

Wiring the Regulator Board and RMI Board Terminal Strips

7-3

Table 7.7 – Status Relay Connections (Terminals 28-31)

Terminal # Signal

28 N.C Relay Contact

29 N.C. Relay Common

30 N.O. Relay Contact

31 N.O. Relay Common

Notes: Relay contact closure is programmable through parameter P.013. Refer to the LiquiFlo Software Start-Up and Reference manual for more information.

7-4

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

+15 VDC

RS-232 Regulator Common

RS-232 RX

RS-232 TX

2 43

Remote 4-20 mA Speed/Torque Reference

1312 14 15

Phase A

Phase A NOT

Phase B

7698

Phase B NOT

Analog Meter Output

Regulator Common

10 12

Isolated Reference Voltage

Regulator Common

5K ohm

VDC Speed Reference

mA Speed Reference

1413

Isolated Reference Gnd

+24 VDC

151716

Fwd

Digital Input 8 (Remote/Local)

Digital Input 7 (Ramp1/Ramp2)

Digital Input 6 (Forward/Reverse)

Function Loss

Run / Jog

2220

Stop

Reset

Start

2423 25

+24 VDC Common

28 30

N.O. Relay Common

N.O. Relay Contact

N.C. Relay Common

N.C. Relay Contact

+24 VDC Common

No Connection

+20 mA

Important: A maintained function loss switch should be used if P.054 (Level Sense Start Enable) = ON and P.026 (Function Loss Response) = 1.

Figure 7.1 – Two-Wire Start/Stop Sample Control Wiring

Rev

Function Loss

Run

Jog

Reset

Start/Stop

Wiring the Regulator Board and RMI Board Terminal Strips

7-5

RS-232 TX

12 435197698

Phase B

Phase A NOT

Phase B NOT

Analog Meter Output

Regulator Common

10 12

Regulator Common

Phase A

+15 VDC

RS-232 Regulator Common

RS-232 RX

Remote 4-20 mA Speed/Torque Reference

+20 mA

Important: A maintained function loss switch should be used if P.054 (Level Sense Start Enable) = ON and P.026 (Function Loss Response) = 1.

Isolated Reference Voltage

VDC Speed Reference

5K ohm

mA Speed Reference

Isolated Reference Gnd

+24 VDC

Digital Input 8 (Remote/Local)

Digital Input 7 (Ramp1/Ramp2)

Digital Input 6 (Forward/Reverse)

1413 15 1716 18 2220

Fwd

Rev

Function Loss

Run

Jog

Reset

Stop

Function Loss

Run / Jog

Start

Reset

2423 25

292726 28 30

N.O. Relay Contact

N.O. Relay Common

N.C. Relay Common

N.C. Relay Contact

+24 VDC Common

No Connection

+24 VDC Common

Start

Stop

7-6

Figure 7.2 – Three-Wire Start/Stop Sample Control Wiring

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

7.1 Stopping the Drive

ATTENTION: When P.055 is set to ON, the STOP/RESET key is

functional only from the selected control source. As a safety precaution,

Depending upon the requirements of the application, the LiquiFlo drive can be programmed to provide either a coast-to-rest or a ramp-to-rest operational stop without physical separation of the power source from the motor.

A coast-to-rest stop turns off the transistor power device drivers.

A ramp-to-rest stop fires the transistor power device drivers until the motor comes to a stop, and then turns off the power devices.

The user can also program zero speed with power maintained to the motor, but in this condition, the drive is not actually stopped. See the description of terminals 23 and 24 or Stop Type (P.025) for more information on how to program the operational stop.

Reliance recommends that an emergency stop push button be located near the drive in an easily accessible location. As a further safety precaution, the user should post a warning on the drive to alert personnel that the STOP/RESET key is not functional. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:The user must provide an external, hardwired emergency stop circuit outside of the drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled machine operation may result if this procedure is not followed. Failure to observe this precaution could result in bodily injury.

In addition to the operational stop, the user must provide a hardwired emergency stop external to the drive. The emergency stop circuit must contain only hardwired electromechanical components. Operation of the emergency stop must not depend on electronic logic (hardware or software) or on the communication of commands over an electronic network or link.

Parameter P.055 (STOP/RESET Key Disable) can be used to change the operation of the STOP/RESET key. See the parameter P.055 description in the software manual for more information.

Note that the user-installed hardwired emergency stop may be used at any time to stop the drive.

Wiring the Regulator Board and RMI Board Terminal Strips

7-7

7.2 Wiring the Encoder Feedback Device (FVC Regulation Only)

If the LiquiFlo drive is programmed to provide FVC regulation, an encoder must be installed. Drives using V/Hz or SVC regulation do not require the use of an encoder feedback device. The encoder connects to terminals 4 to 9 of the regulator’s terminal strip:

Terminal Encoder Connection

4 Supply +15 VDC (250 mA capacity)

5 Phase A Differential Input

6 Phase A Not Differential Input

7 Phase B Differential Input

8 Phase B Not Differential Input

9 Encoder/Regulator Common

Use the following procedure to connect an encoder to the terminal strip:

Step 1. Connect the encoder’s wires to terminals 4 through 9 of the terminal strip.

See figure 7.3. See table A.6 for additional encoder specifications.

Step 2. Set the following parameters to establish the maximum motor speed:

• P.004: Maximum Speed

• U.001: Encoder PPR

• U.002: Motor Poles

• U.003: Motor Nameplate Base Frequency

• U.005: Motor Nameplate RPM

• U.017: Motor Top Speed

Refer to the LiquiFlo Software Start-Up and Reference manual for more information.

7-8

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Tamagawa-Style, 16-Pin MS Connector

View of Encoder Cable MS Connector (Female)

(M/N 2TC4025 and 2TC4075)

Regulator

Terminal Strip

Terminal 6 Terminal 5

Terminal 4

Terminal 9

Terminal 7

Terminal 8

Connector/Cable End

Pin 1 Phase A

Pin 2 Phase A Not

Pin 6 0 VDC

Pin 12 +15 VDC

Pin 8 Phase B

Pin 9 Phase B Not

Dynapar-Style, 10-Pin MS Connector

View of Encoder Cable MS Connector (Female)

(M/N 2TC3025 and 2TC3075)

Regulator

Terminal Strip

Terminal 6

Terminal 5

Terminal 4

Terminal 9

Terminal 7

Terminal 8

Lakeshore-Style, 10-Pin MS Connector

View of Encoder Cable MS Connector (Female)

(Lakeshore M/N SL56 Slim-Tach Encoder)

Regulator

Terminal Strip

Terminal 6

Terminal 5

Connector/Cable End

Pin A Phase A

Pin H Phase A Not

Pin F 0 VDC

Pin D +15 VDC

Pin B Phase B

Pin I Phase B Not

Connector/Cable End

Pin 3 Phase A

Pin 8 Phase A Not

123

678

Terminal 4

Terminal 9

Terminal 7

Terminal 8

Figure 7.3 – Encoder Wiring Connections

Wiring the Regulator Board and RMI Board Terminal Strips

Pin 1 0 VDC

Pin 6 +15 VDC

Pin 2 Phase B

Pin 7 Phase B Not

7-9

7.3 Wiring the Signal and Control I/O

Wire the drive’s signal and control I/O to the Regulator board terminal strip as shown in table 7.8.

Table 7.8 – Wiring Signal and Control I/O to the Regulator Board Terminal Strip

Terminal

Number Description Parameters/Wiring Connections

Wiring RS-232 Signals

4-9 Encoder Wiring See section 7.2.

RS-232 Transmit

RS-232 Receive

RS-232 Signal/Regulator Common

Note that RS-232 communication between the LiquiFlo drive and a personal computer requires the use of the Control and Configuration (CS3000) software. Refer to instruction manual D2-3348 for more information.

These terminals should only be used when the RS-232 port (J8) or an Operator Interface Module (OIM) are not being used, as all three devices use the same transmit/receive lines.

Wiring Encoder Inputs

7-10

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)

Terminal

Number Description Parameters/Wiring Connections

Wiring Analog Outputs

0-10 VDC or 4-20 mA Analog Output Reference

The setting of parameter P.012 selects the terminal strip analog output source (either speed or torque). Jumper J17 must also be set. See figure 2.5.

Regulator Common

The 4-20 mA current selection requires a power supply for operation. The power can be sourced from the encoder supply, terminal 4 (15 VDC), or from an external 15V power supply. Note that the maximum supply current from terminal 4 is 250 mA (encoder and current source) at 15 V. Terminals 9 and 11 are internally connected.

Terminal Strip

Load (Meter or Analog Input)

Connection to the negative side of the

power supply is only required when an external 15V power supply is used.

Wiring the Regulator Board and RMI Board Terminal Strips

7-11

Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)

Terminal

Number Description Parameters/Wiring Connections

Wiring Analog Speed Reference Inputs

Isolated Reference Voltage (+10VDC)

Analog Speed/Torque Reference Input Voltage (+/10VDC)

Related parameters:

• P.000: Control Source

• P.009: Terminal Strip Analog Input Offset

• P.010: Terminal Strip Analog Input Gain

Analog Speed/Torque Reference Input Current (0-20mA)

Isolated Speed/Torque Reference Common (Voltage/Current)

• P.011: Terminal Strip Analog Input Configure

Refer to the LiquiFlo Software Start-Up and Reference manual for additional parameter information.

Jumper J4 must also be set. See figure 2.4.

7-12

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)

Terminal

Number Description Parameters/Wiring Connections

Wiring a Remote/Local Input

16 +24 VDC Power Supply Current limited for remote input logic use only.

17 Digital Input 8

(Default - Remote/Local)

ATTENTION: If a maintained start contact is used when the control source = rE, switching from local to remote from the terminal strip will cause power to be applied to the motor if

the remote start contact is closed. Stay clear of rotating machinery in this case. Failure to observe this precaution could result in bodily injury.

Digital input 8 is control function programmable through parameter P.007.

The following parameters must be set:

• P.000:Control Source (Only active when P.000 = rE)

• P.006:Second Menu Password

• P.007:Terminal Strip Digital Inputs Configure (Selects and

assigns a control function to digital inputs 6 to 8)

• P.008:Terminal Strip Speed Reference Source

(Analog, Motor Operated Potentiometer (MOP), or Preset Speeds)

Note that based on the settings of parameters P.000, P.007, P.008, and r.030 if an RMI board is used, the following parameters can affect digital input 8:

• P.023:MOP Accel/Decel Time

• P.024:MOP Reset Configuration

• P.031 to P.038: Preset Speeds 1-8

Refer to the LiquiFlo Software Start-Up and Reference manual for additional information.

Terminal 17 On = Local Control Diagram shows factory setting.

Wiring the Regulator Board and RMI Board Terminal Strips

7-13

Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)

Terminal

Number Description Parameters/Wiring Connections

Wiring an Additional Ramp Input

18 Digital Input 7

(Default - Ramp1/Ramp2)

Digital input 7 is control function programmable through parameter P.007. The following parameters must be set:

• P.000:Control Source

• P.001:Accel Time 1 (Ramp 1)

• P.002:Decel Time 1 (Ramp 1)

• P.006:Second Menu Password

• P.007:Terminal Strip Digital Inputs Configure (Selects and

assigns a control function to digital inputs 6 to 8)

• P.008:Terminal Strip Speed Reference Source (Analog

Motor Operated Potentiometer (MOP), or Preset Speeds)

• P.017:Accel Time 2 (Ramp 2)

• P.018:Decel Time 2 (Ramp 2)

Note that based on the settings of parameters P.000, P.007, P.008, and r.030 if an RMI board is used, the following parameters can affect digital input 7:

• P.023:MOP Accel/Decel Time

• P.024:MOP Reset Configuration

• P.031 to P.038: Preset Speeds 1-8

Refer to the LiquiFlo Software Start-Up and Reference manual for additional information.

Terminal 18 On = Ramp 2 Diagram shows factory setting.

7-14

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)

Terminal

Number Description Parameters/Wiring Connections

Wiring a Forward/Reverse Input

19 Digital Input 6

(Default - Forward/Reverse)

Digital input 6 is control function programmable through parameter P.007. The following parameters must be set:

• P.000:Control Source

• P.006:Second Menu Password

• P.007:Terminal Strip Digital Inputs Configure (Selects and

assigns a control function to digital inputs 6 to 8)

• P.008:Terminal Strip Speed Reference Source

(Analog, Motor Operated Potentiometer (MOP), or Preset Speeds)

• P.027Forward/Reverse Configuration

Note that based on the settings of parameters P.000, P.007, P.008, and r.030 if an RMI board is used, the following parameters can affect digital input 6:

• P.023:MOP Accel/Decel Time

• P.024:MOP Reset Configuration

• P.031 to P.038: Preset Speeds 1-8

Refer to the LiquiFlo Software Start-Up and Reference manual for additional information.

IF P.027 = 1 FORWARD DIRECTION ONLY

Terminal 19 On = Reverse Direction Diagram shows factory setting. From the encoder end of the motor, clockwise rotation indicates forward motor movement.

Wiring the Regulator Board and RMI Board Terminal Strips

7-15

Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)

Terminal

Number Description Parameters/Wiring Connections

Wiring a Function Loss Input

20 Digital Input 5

(Function Loss)

The following parameters must be set:

• P.026:Function Loss Response

A signal must be present at terminal 20 for the drive to be able to start. See figures 7.1 and 7.2.

The drive is shipped from the factory with a jumper between terminals 16 and 20 which provides the signal. The function loss input should be in series with the drive’s external interlocks. In this case, the jumper must be removed before the connections are made. See figure 2.6.

21 Digital Input 4

(Run/Jog)

Terminal 20 On = No Function Loss

Important: A maintained function loss switch should be

used if P.054 (Level Sense Start Enable) = ON and P.026 = 1.

Wiring a Run/Jog Input

The following parameters must be set:

• P.000: Control Source

• P.020: Jog Speed Reference

• P.021: Jog Ramp Accel Time

• P.022: Jog Ramp Decel Time

Terminal 21 On = Jog Operation

7-16

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)

Terminal

Number Description Parameters/Wiring Connections

Wiring the Reset Input

22 Digital Input 3

(Reset)

Digital Input 2 (Stop)

Digital Input 1 (Start)

The following parameter must be set:

• P.000: Control Source

Terminal 22 On = Reset

Wiring the Stop/Start Inputs

The following parameter must be set:

• P.000: Control Source

• P.025: Stop Type

25 24 VDC Isolated Common

No Connection

+24 VDC Isolated Common

Terminal 23 Off = Stop Terminal 24 On Transition = Start

Reserved Teminals

Terminal 26 has no connection and is not used in LiquiFlo applications. Terminal 27 can be used as a 24V DC common.

Wiring the Regulator Board and RMI Board Terminal Strips

7-17

Table 7.8 - Wiring Signal and Control I/O to the Terminal Strip (Continued)

Terminal

Number Description Parameters/Wiring Connections

Wiring the Output Status Relays

Normally-Closed Contact (Form B)

Both Form A and Form B contacts are rated for 250 VAC/ 30 VDC at 5 amps resistive or 2 amps inductive load.

Normally-Closed Contact Common (Form B)

Normally-Open Contact (Form A)

Normally-Open Contact Common (Form A)

The following parameter must be set:

• P.013: Output Relay Configuration

Note that depending on the setting of parameter P.013, the relay coil will energize (the normally-open contact will close and the normally-closed contact will open). Refer to the LiquiFlo Software Start-Up and Reference manual for more information.

28 293031

7-18

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

7.4 Wiring the RMI Board Terminal Strip

ATTENTION:You are responsible for conforming with all applicable local,

national, and inter national codes. Failure to obser ve this precaution could

Refer to figure 7.4 for the signal and control I/O terminal connections on the RMI board. Table 7.9 describes terminal strip connections and related parameters. Refer to the RMI board instruction manual (D2-3341) for parameter descriptions.

result in damage to, or destruction of, the equipment.

Digital Input 1

Digital Input 2

Digital Input 3

Digital Input 4

+24 V (for digital inputs only)

External +24 V Input for Digital Outputs

Digital Output 1

Digital Output 2

Digital Output 3

Digital Output 4

Digital Output Common

Relay 1 Common

Relay 1 Normally Open

Relay 2 Normally Closed

Relay 2 Common

Relay 2 Normally Open

Not Used

Relay 3 Normally Closed

Relay 3 Common

Relay 3 Normally Open

Not Used

Analog Input: 0 to 10 V

Analog Input: 0 (4) to 20 mA

Analog I/O Common

Analog Output 1: 0 to 10 V

Analog Output 2: +/-10 V

Analog Output 3: 0 to 10 V/0 to 20 mA

Analog I/O Common

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69

Figure 7.4 – Terminal Connections on the RMI Board

Frequency Input (Ground = Analog I/O Common)

Wiring the Regulator Board and RMI Board Terminal Strips

7-19

Table 7.9 – Wiring Signal and Control I/O to the RMI Board Terminal Strip

Terminal

Number Description

Related Parameters, Specifications, and

Jumpers

Digital Inputs, Control Voltage Output

41 42 43 44

Digital Input 1 Digital Input 2 Digital Input 3 Digital Input 4

The four digital inputs are configured using parameter r.030.

45 +24 VDC Supply, Control Voltage Output Current-limited and isolated. This supply should

not be used as an external supply for anything other than the four digital inputs.

46 24 VDC Supply, Control Voltage Input 100 mA per output with an external power supply.

Jumper 24 V EXT

47 48 49 50

Digital Output 1 Digital Output 2 Digital Output 3 Digital Output 4

Configuration: r.031 Timer: r.040 Configuration: r.032 Timer: r.041 Configuration: r.033 Timer: r.042 Configuration: r.034 Timer: r.043 20 mA per output with jumper set to 24 V INT

51 Common Digital I/O common

Relay Outputs

52 59 6058

57565554

Relay 1

52 53

Common Normally Open Contact

Configuration: r.035 Timer: r.044

Relay 2

54 55 56

Normally Closed Contact Common Normally Open Contact

Configuration: r.036 Timer: r.045

Relay 3

58 59 60

Normally Closed Contact Common Normally Open Contact

Configuration: r.037 Timer: r.046

Analog Inputs, Frequency Input

62 Voltage Signal Input +10 VDC supply, isolated, stabilized, max.

2.7 mA; jumper setting: V IN (default)

63 Current Signal Input 0 to 20 mA Analog current speed reference

input; jumper setting: C IN

69 Frequency Input 0 to 200 kHz

64 Analog I/O Common Isolated common for voltage/current or frequency

input.

7-20

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Table 7.9 – Wiring Signal and Control I/O to the RMI Board Terminal Strip (Continued)

Terminal

Number Description

Related Parameters, Specifications, and

Jumpers

Analog Outputs

65 Analog Output No. 1

0 to 10 VDC

Configuration: r.001 Offset: r.002 Gain: r.003

66 Analog Output No. 2

– 10 to +10 VDC

Configuration: r.004 Offset: r.005 Gain: r.006

67 Analog Output No. 3

V OUT: 0 to 10 VDC C OUT: 0 to 20 mA

Configuration: r.007 Offset: r.008 Gain: r.009

68 Analog Common Common for all analog outputs.

Terminals 57 and 61 are not used.

Wiring the Regulator Board and RMI Board Terminal Strips

7-21

7-22

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Completing the Installation

This chapter provides instructions on how to perform a final check of the installation before power is applied to the drive.

ATTENTION:Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved

8.1 Checking the Installation

Use the following procedure to verify the condition of the installation:

should start and adjust it. Read and understand this manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure 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.

HAPTER

Step 1. Turn off, lock out, and tag the input power to the drive. Wait five minutes.

Step 2. Verify that the DC bus voltage is zero. Refer to section 9.3.

Step 3. If a function loss coast-stop pushbutton has been installed, verify that it has

been wired correctly. Be sure the factory-installed jumper at terminals 16 and 20 has been removed so that the coast-stop pushbutton will work.

ATTENTION:The user must provide an external, hardwired emergency stop circuit outside of the drive circuitry. This circuit must disable the

Step 4. Remove any debris, such as metal shavings, from around the drive.

Step 5. Check that there is adequate clearance around the drive.

Step 6. Verify that the wiring to the terminal strip and the power terminals is correct.

Step 7. Check that the wire size is within terminal specifications and that the wires

Step 8. Check that user-supplied branch circuit protection is installed and correctly

Step 9. Check that the incoming power is rated correctly.

system in case of improper operation. Uncontrolled machine operation may result if this procedure is not followed. Failure to observe this precaution could result in bodily injury.

are tightened properly.

rated.

Completing the Installation

8-1

Step 10. Check the motor installation and length of motor leads.

Step 11. Disconnect any power correction capacitors connected between the drive

and the motor.

Step 12. Check that the rating of the transformer (if used) matches the drive

requirements and is connected properly.

Step 13. Verify that a properly-sized ground wire is installed and a suitable earth

ground is used. Check for and eliminate any grounds between the motor frame and the motor power leads. Verify that all ground leads are unbroken.

Step 14. Visually inspect the liquid-cooling connections for leaks.

Step 15. Uncouple the motor from any driven machinery to initially start the drive.

8.2 Powering Up After Installation Is Complete

Use the following procedure to verify that the drive is installed correctly and is receiving the proper line voltage:

Step 1. Turn the drive’s input power disconnect to the On position.

Step 2. Turn coolant on.

Step 3. Apply power to the drive.

Step 4. Follow the start-up procedure in the LiquiFlo Software Start-Up and

Reference manual.

8-2

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

HAPTER

Troubleshooting the Drive

This chapter describes how to troubleshoot the drive and the equipment that is needed to do so. Also provided are replacement part lists and information on clearing faults.

9.1 Test Equipment Needed To Troubleshoot

An isolated multimeter will be needed to measure DC bus voltage and to make resistance checks. Note that dedicated troubleshooting test points are not provided.

9.2 Drive Alarms and Faults

The drive will display alarm and fault codes to assist in troubleshooting when a problem develops during self-tuning or drive operation.

If an alarm condition occurs, the drive will continue to run and a 2- or 3-digit alarm code will flash on the display.

If a fault occurs, the drive will coast to rest and a 2- or 3-digit fault code will flash on the display.

Refer to the LiquiFlo Software Start-Up and Reference manual for more information on drive alarms and faults.

9.3 Verifying That DC Bus Capacitors Are Discharged

ATTENTION:DC bus capacitors retain hazardous voltages after input

power has been disconnected. After disconnecting input power, wait five

The LiquiFlo drive’s DC bus capacitors retain hazardous voltages after input power has been disconnected. Perform the following steps before touching any internal components:

Step 1. Turn off and lock out input power. Wait five minutes.

Step 2. Verify that there is no voltage at the drive’s input power terminals.

Troubleshooting the Drive

9-1

Step 3. Measure the DC bus potential with a voltmeter while standing on a

Step 4. Once the drive has been serviced, reapply input power.

Initial DC Bus Measurement Points

non-conductive surface and wearing insulated gloves (1000 V).

Measure the DC bus potential at the test points on the Power Module Interface board. See figure 9.1 for B-frame drives, figure 9.2 for C-frame drives, or figure 9.3 for D-frame drives. For additional wiring information, refer to Appendix C, Appendix D, or Appendix E.

POS

(+)

NEG

(-)

TP2TP1

9-2

Figure 9.1 – DC Bus Voltage Terminals (B-Frame Drives)

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Initial DC Bus Measurement Points

Troubleshooting the Drive

Figure 9.2 – DC Bus Voltage Terminals (C-Frame Drives)

9-3

Initial DC Bus Measurement Points

POS

(+)

NEG

(-)

TP2TP1

9-4

Figure 9.3 – DC Bus Voltage Terminals (D-Frame Drives)

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

9.4 Checking the Power Modules with Input Power Off

Use the following procedure to check the drive’s Power Module circuitry with power off:

ATTENTION:DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five

Step 1. Turn off and lock out input power. Wait five minutes.

Step 2. Verify that there is no voltage at the drive’s input power terminals.

Step 3. Check the DC bus potential with a voltmeter as described in section 9.3 to

Step 4. Disconnect the motor from the drive.

Step 5. Check all AC line and DC bus fuses.

Step 6. If a fuse is open, use a multimeter to check the input diodes and output

Step 7. Reconnect the motor to the drive.

Step 8. Reapply input power.

ensure that the DC bus capacitors are discharged.

IGBTs. See table 9.1.

Troubleshooting the Drive

9-5

Table 9.1 – Resistance Checks

Input

Diode

No.

Meter

Connection

(+) (-)

Component is OK if

resistance (R) is: Component is defective if:

1 * L1 10 < R < 1 megohm Continuity (short circuit) or

open when the meter is

2 * L2

3 * L3

connected with reversed polarity.

4 * L4

5 * L5

6 * L6

7 L1 **

8 L2 **

9 L3 **

10 L4 **

11 L5 **

12 L6 **

* (+) DC Bus Volts power terminal

** (-) DC Bus Volts power terminal

Table 9.1 - Resistance Checks (Continued)

Meter

IGBT

No.

Connection

(+) (-)

Component is OK if

resistance (R) is: Component is defective if:

1 * W/T3 10 < R < 1 megohm Continuity (short circuit) or

2 * V/T2

3 * U/T1

open when the meter is connected with reversed polarity.

4 W/T3 **

5 V/T2 **

6 U/T1 **

* (+) DC Bus Volts power terminal ** (-) DC Bus Volts power terminal

9-6

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

9.5 Replacement Parts

Tables 9.2, 9.3, and 9.4 list the replacement parts that are available from Reliance Electric. See figures 2.2, 2.3, and 2.4 for the location of the parts.

Table 9.2 – B-Frame LiquiFlo Drive Replacement Parts

Quantity

M/N 41L4060

Description Part Number

350 HP Power Module Control (PMC) Printed Circuit Board 179170 1

Gate Driver PCB 179168 1

Membrane Switch Keypad/Bracket 410483-15B 1

Regulator PCB 179116 1

Remote Meter Interface (RMI) PCB 814.56.00 1

Current Feedback Devices 25503-012-03 3

LEM Harness 179215 1

Laminate Harness 179216 1

M/N 41LR4060

Chillplate Harness 342435-C01 1

SCR Gate Harness 179218 1

Internal Fan 179196 1

Troubleshooting the Drive

9-7

Table 9.3 – C-Frame LiquiFlo Drive Replacement Parts

Quantity

Description Part Number

450 HP Power Module Adapter (PMA)

M/N 50LW4060 M/N 50LR4060

179134 1 —

M/N 64LW4060

M/N 64LR4060

Printed Circuit Board (PCB)

600 HP Power Module Adapter (PMA)

179067 — 1

Printed Circuit Board (PCB)

DC Bus Control PCB 179069 1 1

Gate Driver PCB 179065 2 2

Membrane Switch Keypad/Bracket 410483-15B 1 1

Regulator PCB 179116 1 1

Remote Meter Interface (RMI) PCB 814.56.00 1 1

Current Feedback Devices 25503-011-01 3 3

SCR Module 22501-025-04 6 6

Bus/Gate Driver Interface Harness 179055 1 1

Gate Driver Jumper Harness 179056 1 1

Bus/PMA Interface Harness 179057 1 1

Power Interface Harness 179058 1 1

SCR (S1, S2, S3) Gate Interface Harness 179059 1 1

SCR (S4, S5, S6) Gate Interface Harness 179060 1 1

LEM Interface Harness 179061 1 1

Laminate PMA Interface Harness 179062 1 1

Chillplate Interface Harness 342410-C01 1 1

Internal Fan Assembly (user-supplied) * 1 1

* Comair - Rotron M/N P2TB3 or equivalent.

9-8

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Table 9.4 – D-Frame LiquiFlo Drive Replacement Parts

Quantity

Description Part Number

M/N 120L4060

1000 HP Power Module Control (PMC) Printed Circuit Board 179452 1

Gate Driver PCB 179355 3

Membrane Switch Keypad/Bracket 410483-15B 1

Regulator PCB 179116 1

Remote Meter Interface (RMI) PCB 814.56.00 1

Current Feedback Devices (LEM) 179357 3

LEM Harness 179447 1

Gate Drive Control Harness 179448 1

Chillplate Harness 342702-C01 1

Gate Drive Power Harness 179449 1

Internal Fan 179196 2

Troubleshooting the Drive

9-9

9-10

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Technical Specifications

Table A.1 – Service Conditions

PPENDIX

AC Line Distribution System Capacity (maximum) for 460 VAC Units

Control Method All-digital vector, sinusoidal pulse-width-modulated (PWM)

Displacement Power Factor 0.96

Line Frequency

Line Voltage Variation -10% to +10%

Line Dip Ride-Through FVC: Maximum 500 milliseconds

Motor Lead Lengths 76 meters (250 feet) total

Remote Operator Control Wire Length Up to 303 meters (1000 feet) from the drive

Analog Speed Reference Resolution 1/1024 (10 bits) 0.1%

Acceleration Adjustment Range 0.1 to 999.9 seconds (within the ability of current)

Carrier Frequency 2 kHz, 4 kHz. or 8 kHz (software-selectable)

Current Limit Adjustment Vector: U.006 to 150% (based on motor nameplate rating)

Service Factor 1.0

85,000 amps symmetrical fault current capacity. Short circuit rating may be limited to 65,000 amps if a circuit breaker is used instead of fuses.

50/60Hz (

V/Hz, SVC: Adjustable up to 999.9 seconds (See P.042)

V/Hz: 50% to 110% (based on drive nameplate rating)

±2 Hz)

Speed Adjustable Range From 0 RPM to maximum speed (vector)

Speed Regulation Vector: 0.01% FVC, 0.5% SVC (steady state)

V/Hz: Motor slip dependent

Speed Reference Resolution 1 RPM with local keypad, -4095 to +4095 counts with a

network or serial reference

Torque Control Response 180 to 220 Hz

Torque Linearity +3% with optimal parameter setting (typical) (see parameter

U.005)

Technical Specifications

A-1

Table A.2 – Environmental Conditions

Condition Specification

Operating Temperature (inside an enclosure)

0°C to 55°C

(32°F to 131°F)

Storage Temperature (Ambient) -40°C to 65°C (−40°F to 149°F)

Humidity 5% to 95% (non-condensing)

User-supplied cabinet air cooling system must provide adequate heat dissipation to maintain an internal

temperature not to exceed 55°C. Refer to table 2.1 for drive air watts loss.

Table A.3 – Terminal Strip Input Specifications

Signal Type Terminal(s) Specification

Speed Reference Input 12-15 10 V (@ 50 K ohm input

impedance or 20 mA)

Digital Inputs (1 - 8) 16 +24 VDC Isolated Supply

17 Remote/Local (Default)

18 Ramp1/Ramp2 (Default)

19 Forward/Reverse

(Default)

20 Function Loss

21 Run/Jog

22 Reset

23 Stop

24 Start

Table A.4 – Terminal Strip Output Specifications

Signal Type Terminal(s) Specification

Analog Output 10 -11

0-10 VDC or 4-20 mA

scaled signal

No Connection 26 There is no connection to

terminal 26.

Common 27 +24 VDC common

A-2

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Table A.5 – Terminal Strip RS-232 Specifications

Signal Type Terminal(s) Specification

RS-232 Communications 1 XMIT

2RECV

3 COMMON

Table A.6 – Encoder Feedback Device Specifications (FVC Regulation Only)

Specification Rating

Motor Poles 2, 4, 6, or 8 poles

Overcurrent IET 200% load (based on drive nameplate

rating)

Overload Current Rating 150% for 5 seconds

Speed Control Range 1:600 with 1024 PPR

Speed Control Response 15 Hz (typical)

Encoder Feedback 15 V differential quadrature, encoder

incremental (512 PPR, 1024 PPR, 2048 PPR, 4096 PPR)

Service Factor 1.0

Technical Specifications

A-3

Table A.7 – Input Signal Response Times (Maximum)

Signal Type and Source Volts/Hertz Regulation* Vector Regulation*

Keypad START 150 milliseconds 130 milliseconds

Terminal Strip:

START 126 milliseconds 105 milliseconds

STOP, RESET, FL 75 milliseconds 75 milliseconds

Preset Speeds 75 milliseconds 75 milliseconds

Analog Speed/Trim

16 milliseconds 5 milliseconds

Reference

Analog Torque

N/A 0.5 milliseconds

Reference

Network:

START 46 milliseconds +

network transport time

STOP, RESET, FL 26 milliseconds +

network transport time

Analog Speed/Trim Reference

5 milliseconds + network transport time

25 milliseconds + network transport time

5 milliseconds + network transport time

Torque Reference N/A 0.5 milliseconds +

network transport time

*These are the maximum times from transitioning the input to the drive reacting to the input.

Motor Overload Protection

Electronic Motor Overload Protection

Provides class 10 motor overload protection according to NEC article 430. Does not provide speed sensitive overload protection, thermal memory retention, and motor over-temperature sensing according to NEC article 430.126 (A) (2). If such protection is needed in the end-use product, it must be provided by additional means.

A-4

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

PPENDIX

Cooling System Specifications

M/N 50LW4060

M/N 41L4060 M/N 41LR4060

Coolant Type Pot able water

with no additives.

Inlet Coolant Temperature Range

Minimum Coolant Flow Rate at Full Load

Differential Coolant Pressure at Minimum Flow Rate

Maximum Inlet Pressure

Maximum Heat Load 16,000

Approved corrosion inhibitor: Chemtool, Inc., Crystal Lake, IL., part number CT787-C. Concentration is 2% by volume.

Coolant temperature should be greater than the dew point of the surrounding air to prevent condensation on the tubing and heatsink.

Contact Reliance Electric for coolant circuit requirements.

C to 40oC

F to

(60

oF)2

104

7.0 gpm

3.0 psi

450 psi

BTU/hour

Refrigerant Potable water

See note3.

See note

16,000 BTU/Hour

M/N 64LW4060

with no additives.

15oC to 40oC (60 104

5.0 gpm

34.0 psi

300 psi

25,000 BTU/hour

F to

oF)2

M/N 50LR4060 M/N 64LR4060 M/N 120L4060

Refrigerant Potable water

with approved corrosion

inhibitor

See note3.15

(60

See note3.

25,000 BTU/Hour

8.0 gpm

5.0 psi

50 psi

40,000 BTU/hour

C to 40oC

F to 104oF)

Cooling System Specifications

B-1

B-2

LiquiFlo AC Power Modules, Hardware Reference Version 6.4

B-Frame LiquiFlo Drive Wiring

Replace with file C.fm (17 x 11, z-fold).

PPENDIX

Diagrams

B-Frame LiquiFlo Drive Wiring Diagrams

C-1

C-2

LiquiFlo 2.0 AC Drive User Manual

C-Frame LiquiFlo Drive Wiring

Replace with file D.fm (17 x 11, z-fold).

PPENDIX

Diagrams

C-Frame LiquiFlo Drive Wiring Diagrams

D-1

D-2

LiquiFlo 2.0 AC Drive User Manual

Rockwell Automation Liqui-Flo User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

List of Figures

List of Tables