Rockwell Automation LiquiFlo 1.0 User Manual

External Bus Resistor Kit

for LiquiFlo AC Drives

Drive M/N’s 41L4060, 41LR4060, LF150414W4

Instruction Manual D2-3535

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: Do not install or remove modification kits with power applied to the drive. Disconnect
and lock out incoming power before attempting such installation or removal. Failure to observe this

!

precaution could result in severe bodily injury or loss of life.

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 that the DC bus capacitors are discharged before touching
any internal components. Failure to observe this precaution could result in severe bodily injury or loss of
life.

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

!

equipment.

ATTENTION: The drive contains ESD- (Electrostatic Discharge) sensitive parts and assemblies. Static
control precautions are required when installing, testing, servicing or repairing the drive. Erratic machine

!

operation and damage to, or destruction of, equipment can result if this procedure is not followed.
Failure to observe this precaution could result in severe bodily injury or loss of life.

What the Kit
Contains

External Resistor Kit M/N 180788-A02 can be used only with B-frame (414A)
LiquiFlo AC drives, model numbers: 41L4060, 41LR4060 and LF150414W4. Verify
that you have the correct resistor assembly by verifying that the harness is labeled,
“414AMP EXT BUS RESIS KIT.”

Quantity: Description

1 Resistor Assembly
6 M4 x 16 Mounting Screws with captive locking hardware
1Protective Cover
1 Drilling Template / Cabinet Guard

This kit is for field upgrade only. You should not use it if you are replacing the drive. If
you replace the drive in the future, you should remove the resistor kit from the drive
system.

©2004 Rockwell Automation. All rights reserved.

2 Instruction Manual D2-3535

What You Need to Do

Step 1: Verifying the DC Bus
Capacitors are Discharged

To install the external bus resistor kit you need to:

❐ Step 1: Verify that the DC Bus Capacitors are discharged

❐ Step 2: Identify a mounting location for the resistor assembly

❐ Step 3: Drill mounting holes for the resistor assembly, using the

template

❐ Step 4: Mount the resistor assembly

❐ Step 5: Unplug connectors P1 and P2, and route harness

❐ Step 6: Connect the ground wire

❐ Step 7: Connect the harness

❐ Step 8: Verify installation

❐ Step 9: Register installation

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
that the DC bus capacitors are discharged before touching any
internal components. Failure to observe this precaution could
result in severe bodily injury or loss of life.

Task Description

Turn off and lock out input power. Wait five minutes

A

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

B

Remove front cover

C

Measure the DC bus potential with a voltmeter while standing on a non-conductive surface

D

and wearing insulated gloves (1000V)

Test Points for initial

DC Bus Voltage

Measurement

Pos

(+)

D

J3

J4

TP1 TP2

D13

D34

U16

U22

R8 R9 R10

U32

U3

D31U8D30

D35

D61

U37

R11 R12 R13 R6

C6

D14

D15

U4

D25

U7

D32

U9

U17

U23

U24

D58

DS2

D62

U33

D63

J8

J5

R5

R7

RV2

RV6

RV7

RV8

J7

C12

C10

C11

D21

R25C17

D23

D22

C18 R26

C19

R27

U5

C21

T6

T7 T8

R34

R32

R33

C26

U11

U12

U10

D37

C28

D41

D42

D39

D40

C30

U18

U19

U20

D46

D45

D48

D47

U25

U26

D53

D54

D55

U27

U28

DS3

DS4

D59

C48

U34

J1

J6

RV1

R1

C1

C4

C2 C3

C5

Neg

(-)

TP2TP1

Q2Q1

D10

T1

D11

U1 C13

R19

D12

Q4

D16

T2

D24

L1

C20

U6

D26

C22

R36

R35

T10

Q5

D52

D49

D50

D51

U21

R37

Q6

T11

1

D56

D60

C39

C41

U36

C49

D65

D64

D66

C50

FUSE1

R14

R15

R16 R17

R2

R3J2R4

RV4

RV3

C8

C7

D18

R23

D17 R22

C15

C14

T3

T4 T5

C23

R29 R30

D27

T9

D29

DS1

U14

U15

D44

D43

C33

C32

C31

C38

C37

C36

C35

L2

FUSE2

C40

U29

U30

U35

C42

C44

C43

C45

R18

D3

D4

D2

D5

D1

D7

D8 D9

D6

RV5

Q3

C9

R20

C16 R24

D19

U2

R21

D20

R28

R31

D28

C24

C25

D33

C27

U13

D36

C29

D38

C34

Made in USA

BARCODE

ASSY

R38

R39 D57

R41

R40

R43

R42

U31

C47

C46

TP4TP5TP6 TP3

Instruction Manual D2-3535 3

Step 2: Identifying the
Mounting Location

Consider the following factors when choosing the location for the resistor
assembly:

• the resistor assembly must be mounted inside the drive cabinet

• the resistor assembly must be mounted vertically, with the closed part of

the protective cover pointing towards the front of the enclosure

• the wiring harness must be able to reach connectors P1 and P2 inside the
drive

• the wiring harness must not pass over unprotected sharp edges or hot
surfaces

• the resistor assembly must not be mounted on the enclosure door

Resistor assembly shown without
harness for clarity

Towards

Enclosure

Door

Protective
Cover

4 Instruction Manual D2-3535

Step 3: Drilling the Mounting
Holes

ATTENTION: Metal debris or other foreign matter must be
kept from falling into the drive. Metal debris or other foreign

!

matter may become lodged in the drive circuitry resulting in
component damage. Failure to observe this precaution could
result in severe bodily injury or loss of life and/or damage to, or
destruction of, equipment.

Task Description

Protect internal components from drilling debris

A

Using the template, mark locations for six mounting holes

B

Drill six 5mm (3/16 inch) mounting holes

C

B

B

Drilling Template /

A

Cabinet Guard

TIP: The template is symmetrical, so you have the options of drilling from
the outside or inside of the enclosure. Drilling outside reduces the risk of
debris falling into the drive.

B

B

B

B