Page 1
Trane
Liqui-Flo Adden du m
Instruction Manual
D2-3415
Page 2
The information in this manual is subject to change without notice.
Trademarks not belonging to Rockwell Automation
are property of their respective companies.
Throughout this manual, the following notes are used to alert you to safety considerations:
ATTENTION:Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.
!
Important: Identifies information that is critical for successful application and understanding of the product.
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: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.
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.
Flexibar is a trademark of Erico.
Trane and CenTraVac are trademarks of American Standard, Inc.
Liqui-Flo and Reliance are trademarks of Rockwell Automation.
©1998 Rockwell International Corporation
Page 3
C
ONTENTS
Chapter 1 Introduction
1.1 Intended Audience........................................................................................... 1-1
1.2 Other Required Manuals .................................................................................1-1
Chapter 2 About the Drive and Cabinet
2.1 Identifying the Trane Model Number ...............................................................2-1
2.2 Enclosure Rating ............................................................................................. 2-2
2.3 Identifying Trane Cabinet Components...........................................................2-2
2.4 Trane Options..................................................................................................2-6
Chapter 3 Cabinet Mounting, Wire Routing, and Liquid-Cooling Connections
3.1 Planning the Cabinet Installation.....................................................................3-1
3.2 Mounting the Cabinet ......................................................................................3-1
3.3 Cabinet Wire Routing ......................................................................................3-4
3.4 Grounding the Cabinet ....................................................................................3-4
3.5 Liquid-Cooling Connections............................................................................. 3-6
Chapter 4 Connecting Cabinet Power Wiring
4.1 Cabinet Input Disconnect ................................................................................4-1
4.2 Installing Input Power Wiring (6-Pulse Rectifier Cabinet)................................4-1
4.3 Installing Input Power Wiring (12-Pulse Rectifier Cabinet)..............................4-3
4.4 Installing Output Power Wiring ........................................................................ 4-5
4.5 Regulator Board Wiring ................................................................................... 4-5
Chapter 5 Cabinet Servicing
5.1 Removing the Liqui-Flo Drive from the Cabinet...............................................5-1
5.1.1 Removing the Drive from a 6-Pulse Rectifier Cabinet...........................5-1
5.1.2 Removing the Drive from a 12-Pulse Rectifier Cabinet.........................5-3
5.2 Replacement Parts.................................................. ...... ...... ....... ...... ....... ...... .. 5-6
Appendix A Trane Liqui-Flo Wiring Diagrams..............................................................................A-1
Index ........................................................................................................................... Index-1
Contents
I
Page 4
II
Trane Liqui-Flo Addendum
Page 5
List of Figures
Figure 2.1 – Identifying the Trane Model Number ....................................................2-1
Figure 2.2 – Trane Cabinet Component Locations (6-Pulse Rectifier)..................... 2-3
Figure 2.3 – Trane Cabinet Component Locations (12-Pulse Rectifier)................... 2-5
Figure 3.1 – Cabinet Dimensions .............................................................................3-2
Figure 3.2 – Cabinet Mounting Holes....................................................................... 3-3
Figure 3.3 – Cabinet Wire Routing Locations (6-Pulse Rectifier).............................3-5
Figure 3.4 – Cabinet Wire Routing Locations (12-Pulse Rectifier) ...........................3-6
Figure 3.5 – Liquid Cooling Bulkhead Fittings .......................................................... 3-7
Figure 3.6 – Liquid-Cooling Connections..................................................................3-8
Figure 4.1 – Trane Cabinet Electrical Connections (6-Pulse Rectifier) ....................4-2
Figure 4.2 – Trane Cabinet Electrical Connections (12-Pulse Rectifier) ..................4-4
Contents
III
Page 6
IV
Trane Liqui-Flo Addendum
Page 7
List of Tables
Table 2.1 – Power and Enclosure Ratings ...............................................................2-2
Table 3.1 – Cabinet Dimensions...............................................................................3-1
Table 3.2 – Cabinet Mounting Hole Dimensions ......................................................3-1
Table 5.1 – Hardware Tightening Torques...............................................................5-3
Table 5.2 – C-Frame Liqui-Flo Drive Replacement Parts......................................... 5-6
Contents
V
Page 8
VI
Trane Liqui-Flo Addendum
Page 9
This addendum covers the features and specifications that are unique to the
AC Liqui-Flo drives being produced for the Trane Company. Only product
information that differs from that presented in the standard Liqui-Flo instruction
manuals is covered here. This addendum must be used with the Liqui-Flo software
and hardware instruction manuals listed below.
1.1 Intended Audience
This addendum is intended for the following qualified electrical personnel: Trane
manufacturing, Trane service, and Rockwell Automation Global Technical Service
personnel who are familiar with the custom liquid-cooling features described.
1.2 Other Re qui red Manuals
This addendum must be used with the following publications:
•
D2-3410 Liqui-Flo AC Drive Software Startup and Reference Manual
C
HAPTER
Introduction
1
•
D2-3411 Liqui-Flo AC Power Modules Hardware Reference, Installation,
and Troubleshooting
•
D2-3341 Remote Meter Interface (RMI) Board
Introduction
1-1
Page 10
1-2
Trane Liqui-Flo Addendum
Page 11
C
About the Drive and Cabinet
This chapter describes how to identify the Trane cabinet and the Liqui-Flo drive using
the Trane model number matrix. Liqui-Flo drive power ratings are listed as well as
available Trane options. Cabinet component drawings are also provided. Note that in
this manual references to the “cabinet” refer to both the 6-pulse and 12-pulse rectifier
cabinets, unless otherwise indicated.
2.1 Identif ying the Tran e Model Number
Each Trane cabinet can be identified by its model number. See figure 2.1. A typical
cabinet model number is shown in table 2.1 as are the Liqui-Flo drive power ratings.
HAPTER
2
Adaptive Frequency Drive
Liquid-Cooled
Running Load Amps
Voltage
F = 460 V, 60 Hz, 3-Phase
G = 480 V, 60 Hz, 3-Phase
First Design
Mounting Location
A = Unit Mounted
B = Remote Mounted
Agency Listing
1 = UL/CUL Listed
2 = California Code (includes UL)
Rectifier
0 = 6-Pulse Rectifier
A = 12-Pulse Rectifier
Special Options
0 = None
S = Special
AFD B NA0NNNN
NNNN
About the Drive and Cabinet
Figure 2.1 – Identifying the Trane Model Number
2-1
Page 12
Table 2.1 – Power and Enclosure Ratings
Output
Trane Cabinet M/N
Reliance
Liqui-Flo
Drive M/N
Frame
Size
Cabinet
Enclosure
Rating
Input
Power
(KVA)
Input
Current
(Amps)
Current
at 2 kHz
(Amps)
Full Load
Power
Loss Watts
AFDB0643GA0A10 64L4060 C NEMA 1 555 667 643 9500
2.2 Enclosure Rating
The Trane cabinet has a NEMA 1 enclosure rating:
•
NEMA 1: Vented. Intended for general-purpose indoor applications.
NEMA 1 enclosures are to be located in a clean and dry environment that is away
from oil, coolant, or other airborne contaminants.
2.3 Identifying Trane Cabinet Components
The 6-pulse rectifier Trane cabinets have the following main components. The
identification numbers provided correspond to the numbers used in figure 2.2.
t
Cabine
1.
Control Panel Assembly
2.
C-Frame Liqui-Flo Drive
3.
Liqui-Flo Power Module Adapter Board
4.
electronics and power structure
Liqui-Flo Bus Control Board
5.
Liqui-Flo Regulator Board
6.
Super Remote Meter Interface (RMI) Board
7.
under the Regulator board)
Coolant Lines -
8.
Motor Connection Studs (6) P/O CTV
9.
AC Input Bus Bars
10.
Current Transformers (3)
11.
current
1200 A Circuit Breaker
12.
4 KVA Transformer
13.
(3) Type RK-5 Fuses
14.
(2 fuses: 15 amp)
(2) Type K5Fuses
15.
module’s 115 VAC line (1 fuse: 30 amp)
Terminal Block
16.
Potential Transformers (3)
17.
480 VAC input voltage
Trane Starter Module
18.
Relay 2K1
19.
Relay 2K2
20.
Relay 2K3
21.
50 VA Transformer 460VAC / 115VAC/ 24 VAC
22.
Module
- Provides cooling for the DC bus reactor
Fan
23.
Removab le Plate
24.
Surge Suppressor
25.
(a) Outlet, (b) Inlet
(6-Pulse Rectifier)
- Steps down the 480 VAC input voltage to 115 VAC
- Protect the primary of the 4 KVA transformer - (1 fuse: 2 amp)
- Protect the coolant pump’s reactor (1 fuse: 10 amp) and the Starter
- Provides termination points for cabinet I/O wiring
- Interfaces the Liqui-Flo drive to the Trane UCP2 Control Panel
- Circulating coolant pump motor interposing relay
- Oil pump interposing relay
- Run/stop function interposing relay
- Provides chain hoist access
- Controls the drive’s power supplies and SCRs
- Controls overall drive operation
- Used by the Trane UCP2 Control Panel to monitor output
- Used by the Trane UCP2 Control Panel to measure the
- Provides the interface between the drive’s
- Provides additional analog I/O (located
- Supplies power to the Trane Starter
2-2
Trane Liqui-Flo Addendum
Page 13
24
1
25
9
T1
T2
T3
10
11
12
13
14
15
16
15A
15A
2A
30A 10A
T4
T5T6
2
3
4
5
6
7
8a
17
About the Drive and Cabinet
18
19
20 21
23
Front View
Figure 2.2 – Trane Cabinet Component Locations (6-Pulse Rectifier)
8b
22
2-3
Page 14
The 12-pulse rectifier Trane cabinets have the following main components. The
identification numbers provided correspond to the numbers used in figure 2.3.
Cabinet
1.
AC Input to Drive
2.
Control Panel Assembly
3.
C-Frame Liqui-Flo Drive
4.
Liqui-Flo Power Module Adapter Board
5.
electronics and power structure
Liqui-Flo Bus Control Board
6.
Liqui-Flo Regulator Board
7.
Super Remote Meter Interface (RMI) Board
8.
under the Regulator board)
Coolant Lines -
9.
Motor Connection Studs (6) P/O CTV
10.
AC Output from Load Side of Circuit Breaker
11.
AC Input Connections
12.
Current Transformers (3)
13.
current
1200 A Circuit Breaker
14.
4 KVA Transformer
15.
(3) Type RK-5 Fuses
16.
(2 fuses: 15 amp)
(2) Type K5 Fuses
17.
module’s 115 VAC line (1 fuse: 30 amp)
Terminal Block
18.
Potential Transformers (3)
19.
480 VAC input voltage
Trane Starter Module
20.
Relay 2K1
21.
Relay 2K2
22.
Relay 2K3
23.
50 VA Transformer 460 VAC/ 115 VAC / 24 VAC
24.
Module
Fan
25.
Removab le Plate
26.
Surge Suppressor
27.
- Circulating coolant pump motor interposing relay
- Oil pump interposing relay
- Run/stop function interposing relay
- Provides cooling for the DC bus reactor
(from Secondary of Delta-Wye Transformer)
- Provides the interface between the drive’s
- Controls the drive’s power supplies and SCRs
- Controls overall drive operation
- Provides additional analog I/O (located
(a) Outlet, (b) Inlet
(located behind item 12)
(to Line Side of Circuit Breaker)
- Used by the Trane UCP2 Control Panel to monitor output
- Steps down the 480 VAC input voltage to 115 VAC
- Protect the primary of the 4 KVA transformer - (1 fuse: 2 amp)
- Protect the coolant pump’s reactor (1 fuse: 10 amp) and the Starter
- Provides termination points for cabinet I/O wiring
- Used by the Trane UCP2 Control Panel to measure the
- Interfaces the Liqui-Flo drive to the Trane UCP2 Control Panel
- Supplies power to the Trane Starter
- Provides chain hoist access
2-4
Trane Liqui-Flo Addendum
Page 15
10
11
12
13
T6
T1
T2 T3
T4 T5
26
1
27
2
3
4
5
14
15
16
17
18
19
30A 10A
20
15A
15A
2A
22
Front View
6
7
8
9a
9b
2321
25
24
About the Drive and Cabinet
Figure 2.3 – Trane Cabinet Component Locations (12-Pulse Rectifier)
2-5
Page 16
2.4 Trane Options
There is one available Trane option, the 12-pulse rectifier cabinet, which is described
in this addendum. Note that all Trane Liqui-Flo drives have a factory-installed Remote
Meter Interface (RMI) board and meet California code regulations.
2-6
Trane Liqui-Flo Addendum
Page 17
Cabinet Mounting, Wire Routing,
and Liquid-Cooling Connections
This chapter provides cabinet dimension information that must be considered when
installing a Trane cabinet. It describes how to mount the Trane cabinet and shows
where the wire entry areas and liquid-cooling connection points are located.
3.1 Planning the Cabinet Installation
Cabinet dimensions and weights are listed in table 3.1. Overall cabinet dimensions are
illustrated in figure 3.1. Cabinet mounting holes are shown in figure 3.2.
Table 3.1 – Cabinet Dimensions
Dim. A Dim. B Dim. C Dim. D Dim. E Dim. F Weight
C
HAPTER
3
965 mm
38.0"
Be sure there is adequate clearance for air ventilation around the cabinet. Allow a
minimum clearance of 1 foot per side. Allow 4 feet of clearance for the door to open.
1524 mm
60.0"
379 mm
15.1"
3.2 Mounting the Cabinet
Attach the cabinet to the CenTraVac chiller using the 8 mounting holes provided. In
order to maintain a flat mounting surface and to ensure that screw tightness is
maintained, use a washer and lock washer under the screw heads. Refer to figure 3.1
and table 3.1 for cabinet mounting dimensions. Use 3/8” (upper) and 1/2” (lower)
mounting screws and washers to attach the cabinet to the chiller. See figure 3.2 and
table 3.2 for mounting hole locations and dimensions.
Table 3.2 – Cabinet Mounting Hole Dimensions
Dim. A Dim. B Dim. C Dim. D Dim. E Dim. F Dim. G
1268.4mm
49.94"
85.7mm
3.38"
114.3mm
4.5"
1608 mm
63.3"
314.3mm
12.38"
60 mm
2.4"
127.0mm
5.0"
23 mm
0.91"
254.0mm
10.0"
440 kg
970 lbs
660.4mm
26.0"
Cabinet Mounting, Wire Routing, and Liquid-Cooling Connections
3-1
Page 18
CA
E
D
F
Figure 3.1 – Cabinet Dimensions
B
3-2
Trane Liqui-Flo Addendum
Page 19
D
A
3/8" Screws, 4 Pl. (Inside Cabinet)
E
F
(3 Pl.)
1/2" Screws, 4 Pl.
C
Figure 3.2 – Cabinet Mounting Holes
Cabinet Mounting, Wire Routing, and Liquid-Cooling Connections
GB
3-3
Page 20
3.3 Cabin et Wire Routing
All wiring should be installed in conformance with the applicable local, national, and
internation al co des (for example, NEC/CEC). Figures 3.3 and 3.4 show the wire
routing, grounding terminal, and power terminal strips of the cabinet. Control wiring
enters the cabinet through the three holes on the left side and terminates at the
control panel’s terminal block. Tighten the control wire connections from 7.1 to 8.9
in-lb.
3.4 Grounding the Cabinet
ATTENTION:
local, national, and international codes. Failure to observe this precaution
!
Use the following steps to ground the cabinet:
Step 1. Open the cabinet’s door. The grounding stud is located on the left side of the
Step 2. Run a suitable grounding conductor unbroken from the cabinet’s ground stud
Step 3. Connect a suitable grounding conductor to the motor frame and the
could result in damage to, or destruction of, the equipment.
cabinet.
to the motor’s ground terminal and then to earth ground. See figures 3.3 and
3.4. The cabinet’s ground stud connection point has two 5/16" socket-head
screws. Tighten the ground connections to 23 ft lbs (+
delta-wye transformer (if used). Run each conductor unbroken to earth
ground.
The user is responsible for conforming with all applicable
10%).
3-4
Trane Liqui-Flo Addendum
Page 21
3-Phase AC
Voltage Enters
Cabinet Here
Top View
3-Phase
AC Volts
Input to
Line Side
of Circuit
Breaker
Ground Stud
Connections
(Left Side Wall)
127.0 mm (5.0")
Recommended, 3 Pl.
T1
T6
T2
T4
T3
T5
3-Phase
AC Volts
Output to
Motor
28.58 mm
(1.125")
22.23 mm
(0.875")
Coolant
Bulkhead
Fittings
2 Pl.
15A
Signal Control
Wiring Enters
15A
2A
30A 10A
Cabinet Here
Signal
Control
Wiring
Front ViewSide View
Figure 3.3 – Cabinet Wire Routing Locations (6-Pulse Rectifier)
Cabinet Mounting, Wire Routing, and Liquid-Cooling Connections
3-5
Page 22
Top View
111.1 mm (4.38")
Recommended, 8 Pl.
28.58 mm
(1.125")
22.23 mm
(0.875")
Coolant
Bulkhead
Fittings
2 Pl.
Side View
3-Phase AC
Volt Output
from Load Side
of Circuit Breaker
to Primary of
Delta-Wye
Transformer
Ground Stud
Connections
(Left Side Wall)
3-Phase AC
Volt Input to
Line Side
of Circuit
Breaker
Signal Control
Wiring Enters
Cabinet Here
Signal
Control
Wiring
15A
15A
2A
30A 10A
T1
T2
T6
T4
Front View
127.0 mm (5.0")
Recommended, 3 Pl.
T3
T5
3-Phase AC Volt
Input to C-Frame
Liqui-Flo Drive
from Secondary of
Delta-Wye Transformer
(6 Places)
3-Phase
AC Volts
Output to
Motor
3-6
Figure 3.4 – Cabinet Wire Routing Locations (12-Pulse Rectifier)
3.5 Liquid-Cooling Connections
External coolant lines connect to the cabinet through two bulkhead fittings. The
bulkhead fittings are located on the rear panel of the cabinet as shown in figure 3.5.
Use the following steps to connect the coolant lines to the cabinet:
Step 1. Be sure the threads of the bulkhead fittings and the CenTraVac chiller’s
tubing connectors are free of dirt, burrs, and excessive nicks.
Step 2. Apply liquid sealer to the pipe thread end of the chiller’s tubing connectors.
Screw the connectors into the cabinet’s bulkhead fittings until they are
finger-tight. See figure 3.6.
Trane Liqui-Flo Addendum
Page 23
Step 3. Use a wrench to further tighten the connectors 1.5 to 2.5 turns. Do not hold
the bulkhead fitting with a pipe wrench when tightening the connectors as the
fitting may be damaged. Note that the bulkhead fitting has a built-in
anti-rotation feature and will not turn as the connector is screwed in.
ATTENTION: The cabinet’s bulkhead fittings may be damaged if they are
held with a pipewrench. Do not hold the bulkhead fitting with a pipe
!
wrench when tightening the connectors. The bulkhead fitting has a built-in
anti-rotation feature and will not turn as the connector is screwed in.
Failure to observe this precaution could result in damage to, or
destruction of, the equipment
Step 4. Visually inspect the connections for leaks.
Rear View
Figure 3.5 – Liquid Cooling Bulkhead Fittings
Cabinet Mounting, Wire Routing, and Liquid-Cooling Connections
Coolant Input
Fitting
Coolant Output
Fitting
3-7
Page 24
Drive
Side
SAE 37× Swivel Nut, Thread Size 7/8-14
Hex Nut
Lock Washer
Flat Washer
Double-D Anti-Rotation Feature Between
the Bulkhead Fitting and Main Panel Assembly
Main Panel Assembly
Bulkhead Fitting @ Rear of Cabinet
1-11 1/2 NPTF - Dryseal American Standard Taper
Pipe Thread (SAE J476)
Chiller
Side
Tubing Connection from Trane-Supplied
Heat Exchanger / Pump Assembly
Figure 3.6 – Liquid-Cooling Connections
3-8
Trane Liqui-Flo Addendum
Page 25
Connecting Cabinet Power Wiring
This chapter describes how to connect input and output power to the cabinet.
4.1 Cabin et Input Disconnect
C
HAPTER
4
ATTENTION:
local, national, and international codes. Failure to observe this precaution
!
An input disconnect circuit breaker is factory-installed in the cabinet. Verify that the
available fault current is less than the interrupting rating on the circuit breaker
nameplate, which is 65,000 amps at 480 VAC.
could result in damage to, or destruction of, the equipment.
The user is responsible for conforming with all applicable
4.2 Installing Input Power Wiring (6-Pulse Rectifier
Cabinet)
ATTENTION:
local, national, and international codes. Failure to observe this precaution
!
Use the following steps to connect AC input power to the cabinet:
Step 1. Remove the top panel of the cabinet.
Important:
could result in damage to, or destruction of, the equipment.
Care must be taken to prevent debris from falling into the cabinet while
performing this installation.
The user is responsible for conforming with all applicable
Step 2. Drill the wire routing holes in the panel. Note that the wire routing hole
Step 3. Install the appropriate conduit hubs.
Step 4. Reinstall the cabinet’s top panel.
Step 5. Connect the three-phase 480 VAC input power leads to circuit breaker
Connecting Cabinet Power Wiring
patterns shown in figure 3.3 are recommendations only. These wire routing
holes are the only entry points for input power wiring into the cabinet.
terminals L1, L2, and L3. See figure 4.1 and Appendix A. Tighten these
connections to 23 ft-lb (+
power leads.
10%). Use only copper conductors for the input
4-1
Page 26
AC Input
3-Phase 380/480 V
L1 L2 L3
RST
Liqui-Flo
AC Drive
On-Site Connections
Will Accept Four 3/0
To 400 MCM/Phase
(Copper Conductors Only)
Circuit
Breaker
On-Site Ground
Connection
Will Accept Two
4/0 to 350 MCM
(Copper Conductors Only)
UW
V
Flexibar
8x40x1
T3T1 T2
T5T6 T4
Motor
Figure 4.1 – Trane Cabinet Electrical Connections (6-Pulse Rectifier)
Inside
Cabinet
Trane-Supplied
Connections
4-2
Trane Liqui-Flo Addendum
Page 27
4.3 Installing Input Power Wiring (12-Pulse Rectifier
Cabinet)
ATTENTION:
local, national, and international codes. Failure to observe this precaution
!
Use the following steps to connect AC input power to the cabinet:
Step 1. Remove the top panel of the cabinet.
Important:
Step 2. Drill the wire routing holes in the panel. Note that the wire routing hole
Step 3. Install the appropriate conduit hubs.
Step 4. Reinstall the cabinet’s top panel.
Step 5. Connect the three-phase 480 VAC input power leads to circuit breaker
Step 6. Twelve-pulse cabinets require a delta-wye transformer be installed external
could result in damage to, or destruction of, the equipment.
Care must be taken to prevent debris from falling into the cabinet while
performing this installation.
patterns shown in figure 3.4 are recommendations only. These wire routing
holes are the only entry points for input power wiring into the cabinet.
terminals L1, L2, and L3. See figure 4.2 and Appendix A. Tighten these
connections to 23 ft-lb (+
power leads.
to the cabinet. Install the Trane-specified transformer by following the
installation instructions supplied with it.
The user is responsible for conforming with all applicable
10%). Use only copper conductors for the input
Step 7. Connect the load side of the circuit breaker to the R, S, and T teminals on the
delta-wye transformer. Tighten these connections to 23 ft-lb (+
Step 8. Connect the load side of the delta-wye transformer to the S1 through S6
terminals on the Liqui-Flo drive. Tighten these connections to 23 ft-lb
10%).
(+
10%).
Connecting Cabinet Power Wiring
4-3
Page 28
AC Input
3-Phase 380/480 V
Circuit
Breaker
L1 L3L2
R
S2S1
ST
S4S3 S5 S6
On-Site Connections
Will Accept Four 3/0
To 400 MCM/Phase
(Copper Conductors Only)
Inside
Cabinet
On-Site Connections
Will Accept Four 3/0
To 400 MCM/Phase
(Copper Conductors Only)
Transformer
On-Site Connections
Will Accept Two 6 AWG
To 250 MCM/Phase
(Copper Conductors Only)
On-Site Ground
Connection
Will Accept Two
4/0 To 350 MCM
(Copper Conductors Only)
4-4
U
Liqui-Flo
AC Drive
WV
Flexibar
Inside
Cabinet
8x40x1
T1
T2
T3
Trane-Supplied
Connections
T6
T4
Figure 4.2 – Trane Cabinet Electrical Connections (12-Pulse Rectifier)
T5
Motor
Trane Liqui-Flo Addendum
Page 29
4.4 Installing Output Power Wiring
ATTENTION:
local, national, and international codes. Failure to observe this precaution
!
Use the following steps to connect the cabinet’s output power wiring from the Liqui-Flo
drive to the chiller motor:
Step 1. Connect the Trane-supplied Flexibar (8x40x1) conductors to the Liqui-Flo
Step 2. Tighten these connections to Trane specifications.
Step 3. Connect the Flexibar conductors to the T1, T2, and T3 motor connection
Step 4. Tighten these connections to Trane specifications.
could result in damage to, or destruction of, the equipment.
drive’s U, V, W output terminals using the Trane-supplied hardware. See
figures 3.3, 3.4, 4.1, and 4.2.
studs using the Trane-supplied hardware. See figures 3.3, 3.4, 4.1, and 4.2.
The user is responsible for conforming with all applicable
4.5 Regulat or Board Wiring
The cabinet’s start/stop wiring on the Regulator board’s terminal strip is factory-wired
as shown in Appendix A.
Connecting Cabinet Power Wiring
4-5
Page 30
4-6
Trane Liqui-Flo Addendum
Page 31
C
HAPTER
Cabinet Servicing
This chapter describes how to remove the Liqui-Flo drive from the cabinet and
provides a list of replacement parts.
5.1 Removing the Liqui-Flo Drive from the Cabinet
Follow the procedure in section 5.1.1 if you are removing a Liqui-Flo drive from a
6-pulse rectifier cabinet. Follow the procedure in section 5.1.2 if you are removing a
Liqui-Flo drive from a 12-pulse rectifier cabinet.
5.1.1 Removing the Drive from a 6-Pulse Rectifier Cabinet
Use the following procedure to remove a Liqui-Flo drive from a 6-pulse rectifier
cabinet:
5
ATTENTION:
power has been disconnected. After disconnecting input power, wait five
!
Step 1. Turn off and lock out AC input power to the cabinet.
Step 2. Place the circuit breaker in the Off position. Wait five minutes.
Step 3. Verify that there is no voltage at the drive’s input power terminals.
Step 4. Check the DC bus potential with a voltmeter to ensure that the DC bus
Step 5. Drain the drive’s coolant and disconnect the coolant lines.
(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.
capacitors are discharged.
a. Use a ball valv e at the inlet connection to drain the coolant while running
the pump for 1 to 2 minutes.
b. Connect one end of a drain hose to the accumulator on the closed loop
coolant system. Connect the other end of the hose to a drain.
c. Connect a shop air line to the closed loop coolant system at the quick
disconnect fitting. Pressurize the line to 60-90 psi for 1 to 2 minutes to
flush all of the cool ant out of the drive.
d. Remove the basket from the Y-strainer and check for any contaminants.
DC bus capacitors retain hazardous voltages after input
Cabinet Servicing
e. F rom inside the cabinet, disconnect the coolant lines from the panel using
a 1-1/16” wrench on the swivel nut connected to the bulkhead fitting. A
crow’s-foot wrench is recommended. Verify that no residual coolant
remains in the drive.
5-1
Page 32
Step 6. Disconnect the Flexibar conductors at the drive’s U, V, and W output
terminals.
a. Remove the two 3/8”-16-UNC-2B nuts from the clamp holding the
Flexibar to the AC output busbar at output terminals U, V, and W.
b. Remove the load plate and the clamps.
c. Save this hardware for reassembly.
Step 7. Remove the rigid buswork that connects the load side of the circuit breaker to
the drive.
a. Remove the 1/12”-13 bolts and washers from each of the drive’s AC input
terminals (L1 through L6).
b. Remove the two 3/8”-16 bolts, washers, and nuts from each of the six
circuit breaker input busbar connections.
c. Save this hardware for reassembly.
Step 8. Disconnect the 12-position terminal connection located on the lower left side
of the drive. Cut the wire tie on the wire mounting base leading to the panel.
Step 9. Disconnect the leads from each of the three current transformers (CTs).
Wrap the CT leads around the AC output busbar to keep them from being
damaged. Cut the wire ties on the wire mounting bases.
Step 10. Disconnect the AC busbar support from the AC input busbar.
a. Remove the six M5 pan head screws that connect the AC input busbar
(L1 through L6) to the busbar support.
b. Save this hardware for reassembly.
Step 11. Remove the removable plate and wire entry panels. See figure 2.2.
a. Remove the four 1/4” screws and washers from the upper-right corner of
the cabinet that hold the removable plate in place. Remove the removable
plate which will expose a 2” gap in the lip of the cabinet.
b. Remove the eight 1/4” screws that hold the wire entry panel to the top of
the cabinet.
c. Save the panels and hardware for reassembly.
Step 12. Install two eyebolts into the drive to serve as lifting points.
a. Two 3/4” nuts are welded to the drive’s baseplate. Screw the eyebolts
(recommended: 2” eye I.D., 6” long shank) into the nuts.
b. Connect 18” (nominal) of chain between the eyes, securing them with a
clevis clamp.
Step 13. Using an overhead or portable hoist (minimum 1/2 ton rated capacity), bring
a free-fall chain into the cabinet through the access panel and the wire entry
panel.
Step 14. Attach the free-fall chain to the chain secured to the eye bolts. Take up any
vertical slack in the chain.
5-2
Step 15. Remove the four 1/2” nuts and washers that secure the baseplate of the drive
to the cabinet. Save this hardware for reassembly.
Trane Liqui-Flo Addendum
Page 33
Step 16. Using the hoist, lift the drive slightly to take the load off of the cabinet’s panel
studs. Pull the drive off of the studs and up through the wire entry and access
panels until it is clear of the cabinet enclosure. Note that drive’s center of
gravity is forward of the hoist, which will result in the top of the drive tilting
forward during removal.
Step 17. Move the drive to a horizontal pallet for servicing or shipment. The eyebolts
and the chain between them do not need to be removed.
Step 18. Reinstall the drive by following steps 17 to 1 in reverse order.
a. During reinstallation, tighten the hardware to the torque values (+
shown in table 5.1
b. Visually inspect the insulation of the wiring and buswork to ensure that it
was not damaged.
c. Refill the drive with coolant.
Step 19. Test the drive for proper operation by following the start-up procedures in
instruction manual D2-3410.
Table 5.1 – Hardware Tightening Torques
Maximum Recommended
Hardware
1/4” - 20 UNC Screws 75 in-lb
1/2” - 13 UNC- 2B Nut 45 ft-lb
3/8” - 16 UNC - 2B Nut 19 ft-lb
I/O Terminal Block Screws 4.5 in-lb
Tightening Torque
5.1.2 Removing the Drive from a 12-Pulse Rectifier Cabinet
Use the following procedure to remove a Liqui-Flo drive from a 12-pulse rectifier
cabinet:
10%)
Cabinet Servicing
ATTENTION:
power has been disconnected. After disconnecting input power, wait five
!
Step 1. Turn off and lock out AC input power to the cabinet.
Step 2. Place the circuit breaker in the Off position. Wait five minutes.
Step 3. Verify that there is no voltage at the drive’s input power terminals.
Step 4. Check the DC bus potential with a voltmeter to ensure that the DC bus
Step 5. Drain the drive’s coolant and disconnect the coolant lines.
(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.
capacitors are discharged.
a. Use a ball valv e at the inlet connection to drain the coolant while running
the pump for 1 to 2 minutes.
DC bus capacitors retain hazardous voltages after input
5-3
Page 34
b. Connect one end of a drain hose to the accumulator on the closed loop
coolant system. Connect the other end of the hose to a drain.
c. Connect a shop air line to the closed loop coolant system at the quick
disconnect fitting. Pressurize the line to 60-90 psi for 1 to 2 minutes to
flush all of the cool ant out of the drive.
d. Remove the basket from the Y-strainer and check for any contaminants.
e. F rom inside the cabinet, disconnect the coolant lines from the panel using
a 1-1/16” wrench on the swivel nut connected to the bulkhead fitting. A
crow’s-foot wrench is recommended. Verify that no residual coolant
remains in the drive.
Step 6. Disconnect the Flexibar conductors at the drive’s U, V, and W output
terminals.
a. Remove the two 3/8”-16-UNC-2B bolts and washers from the clamp
holding the Flexibar to the AC output busbar at output terminals U, V,
and W.
b. Remove the load plate and the clamps.
c. Save this hardware for reassembly.
Step 7. Disconnect the AC input wiring at the drive’s AC input terminals (L1 through
L6) and at the circuit breaker’s line and load terminals.
a. Loosen all of the pressure lugs.
b. Bend the individual wires vertically within the cabinet.
Step 8. Disconnect the 12-position terminal connection located on the lower left side
of the drive. Cut the wire tie on the wire mounting base leading to the panel.
Step 9. Disconnect the leads from each of the three current transformers (CTs).
Wrap the CT leads around the AC output busbar to keep them from being
damaged. Cut the wire ties on the wire mounting bases.
Step 10. Remove the removable plate. See figure 2.3.
a. Remove the four 1/4” screws and washers from the upper-right corner of
the cabinet that hold the removable plate in place. Remove the removable
plate which will expose a 2” gap in the lip of the cabinet.
b. Save the panel and hardware for reassembly.
Step 11. Place the lifting support bar in the cabinet’s stainless steel C-channel
brackets. The support bar’s pipe supports should face you.
a. Screw two 3/4” screws through the pipe support into the 3/4” nuts which
are welded to the drive’ s baseplate.
b. Hand tighten the screws.
Step 12. Remove the four 1/2” nuts and washers that secure the drive’s baseplate to
the cabinet. Save the hardware for reassembly.
Step 13. Tighten the two 3/4” screws to remove the load on the baseplate. Slide the
support bar along the C-channel brackets until it reaches the cabinet’s front
seal lip.
5-4
Trane Liqui-Flo Addendum
Page 35
Step 14. Using an overhead or portable hoist (minimum 1/2 ton rated capacity), attach
a free-fall chain to the 1.5” hole in the support bar. Take up any vertical slack
in the chain.
Step 15. Vertically lift the support bar and the drive 3” to 4”.
a. Rotate the support bar to the right side, towards you, and slip the support
bar/drive assembly out of the cabinet.
Step 16. Move the drive to a horizontal pallet for servicing or shipment. The support
bar and screws do not need to be removed.
Step 17. Reinstall the drive by following steps 16 to 1 in reverse order.
a. During reinstallation, tighten the hardware to the torque values
(+
10%) shown in table 5.1.
b. Visually inspect the insulation of the wiring and buswork to ensure that it
was not damaged.
c. Refill the drive with coolant.
Step 18. Test the drive for proper operation by following the start-up procedures in
instruction manual D2-3410.
Cabinet Servicing
5-5
Page 36
5.2 Replacement Parts
Table 5.2 lists the replacement parts that are available from Reliance Electric.
Table 5.2 – C-Frame Liqui-Flo Drive Replacement Parts
Quantity
Description Part Number
Power Module Adapter (PMA) Printed Circuit
179067 1
M/N 64L4060
Board (PCB)
DC Bus Control PCB 179069 1
Gate Driver PCB 179065 2
Membrane Switch Keypad/Bracket 410483-15B 1
Regulator PCB 179116 1
Current Feedback Devices 25503-011-01 3
SCR Module 22501-025-04 6
Bus/Gate Driver Interface Harness 179055 1
Gate Driver Jumper Harness 179056 1
Bus/PMA Interface Harness 179057 1
Power Interface Harness 179058 1
SCR (S1, S2, S3) Gate Interface Harness 179059 1
SCR (S4, S5, S6) Gate Interface Harness 179060 1
5-6
LEM Interface Harness 179061 1
Laminate PMA Interface Harness 179062 1
Chill Plate Interface Harness 179063 1
Remote Meter Interface (RMI) PCB 2SI3000 1
Internal Fan Assembly * 1
*Comair - Rotron M/N PT2B3 or equivalent.
Trane Liqui-Flo Addendum
Page 37
I
NDEX
A
Air ventilation, 3-1
Audience, intended, 1-1
B
Board
Bus Control, 2-2 to 2-5
Power Module Adapter (PMA), 2-2 to 2-5
Regulator, 2-2 to 2-5
Remote Meter Interface, 2-2 to 2-5
C
Cabinet
dimensions, 3-1 to 3-2
electrical connections, 4-2, 4-4
grounding, 3-4 to 3-6
mounting, 3-1 to 3-3
weight, 3-1
wire routing, 3-4 to 3-6
Component locations, 2-2 to 2-5
F
Fan, 2-2 to 2-5, 5-6
Fuses, 2-2 to 2-5
G
Grounding, 3-4
H
I
Input current rating, 2-2
Input disconnect, 4-1
Input power rating, 2-2
Installation
input power wiri ng, 4-1 to 4-4
output power wiring, 4-5
planning, 3-1
D
Dimensions, 3-1 to 3-3
Disconnect, input, 4-1
Drive removal, 5-1 to 5-5
E
Enclosures, NEMA, 2-2, 3-1
Index
J
K
L
Liquid-cooling
bulkhead fittings, 3-5 to 3-7
connections, 3-6 to 3-8
Index-1
Page 38
M
Model numbers
Trane, 2-1
Reliance, 2-2
Mounting dimensions, 3-1 to 3-2
T
U
N
NEMA enclosure, 2-2
O
Options, Trane, 2-6
Output current rating, 2-2
P
Planning, cabinet installation, 3-1
Power wiring, 4-1 to 4-5
input, 4-1 to 4-4
output, 4-5
sizes, 4-2, 4-4
Publications, related, 1-1
Q
V
W
Watts loss rating, 2-2
Weight, cabinet, 3-1
Wire
routing, 3-4 to 3-6
sizes, 4-2, 4-4
Wiring diagrams, A-1 to A-2
X
Y
R
Ratings
input, 2-2
output, 2-2
power loss, 2-2
Regulator board, 2-2 to 2-3, 4-5
Replacement parts, 5-6
S
Index-2
Z
Trane Liqui-Flo Addendum
Page 39
Page 40
U.S. Drives Technical Support
Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives
Publication D2-3415-July 1998 Copyright © 1998 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
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