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LPM20
User Manual
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Rockwell Automation LPM20 User Manual

LPM20 Liquid-Cooled Adjustable Frequency AC Drive
With High Performance Drive Control
Installation Manual
Important User Information
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
!
environment, which may lead to personal injury or death, property damage, or economic loss.
Important: Identifies information that is critical for successful application and
understanding of the product.
ATT E NT I ON : Identifies information about practices or circumstances that can lead to personal injury or death, property
!
damage, or economic loss. Attentions help you identify a hazard, avoid the hazard, and recognize the consequences.
Shock Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures.
Allen-Bradley, PLC, DriveExplorer, DriveExecutive, DriveLogix, SCANport, and SynchLink are either registered
trademarks or trademarks of Rockwell Automation, Inc.

Summary of Changes

The information below summarizes the changes to this manual since the last release (July 2005):
Description of Changes Page
In Table 1.A, changed column heading from “Output Current at 2 kHz (Amps)” to “Output Current at 4 kHz (Amps).” Changed the last sentence in footnote 2 from “…also capable of running at 3 kHz or 4 kHz…” to “…also capable of running at 2 kHz or 3 kHz.”
Changed Table 3.A columns and information. 3-7
Deleted Table 3.B, and added replacement fuses subheading and reference to the drive wiring diagram.
In the“Control” category specifications section for the “Carrier Frequency,” changed the statement “Drive rating based on 2 kHz” to “Drive rating based on 4 kHz.”
The information below summarizes the changes to this manual since the last release (January 2005):
Description of Changes Page
Deleted Chapter 3 - Programming and Parameters. The active converter information formerly contained in Chapter 3 is now contained in the PowerFlex 700 Active Converter Power Module User Manual (Publication No. PFLEX-UM002…), which is referenced in the Preface.
Changed the following catalog string information:
• In Digits 4 through 7 (Input Voltage & Output Current Rating), deleted Cat. Code D405.
Also removed all “405A” drive information from Table 1.A, Table 1.B, Table 1.C, Table 3A, Table 3B, and the VFD Power Module Table on page C-11.
• In Digit 12 (Input Filter Items), deleted Cat. Code C.
Added a reference to the PowerFlex 700 Active Converter Power Module User Manual (Publication No. PFLEX-UM002…) for more information about active converter communication.
Added a reference to the PowerFlex 700 Active Converter Power Module User Manual (Publication No. PFLEX-UM002…) for more information about wiring the active converter control board I/O terminals.
Re-numbered Chapter 4 - Troubleshooting to be Chapter 3. Chapter 3
Added a reference to the PowerFlex 700 Active Converter Power Module User Manual (Publication No. PFLEX-UM002…) for active converter fault descriptions and related troubleshooting information.
In Table 3.B, changed replacement Voltage Feedback Resistor Assembly, 460 V kit number from “180924-A03” to “180923-A03.”
1-1
3-7
A-2
P-1
P-5
1-33
1-34
3-3
—
soc-ii Summary of Changes
Preface Overview
Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
What Is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Chapter 1 Installation/Wiring
Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Enclosure Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Drive Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Mounting the Drive, Determining Wire Routing, and Grounding . . . . . . . . . . . . . . . . . 1-12
Coolant Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Installing Input Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Installing Output Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Using Input/Output Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Main Control Board I/O and Encoder Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Connecting SynchLink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Active Converter Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Auto Tune Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Pre-charge Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Wiring the Active Converter Control Board I/O Terminals . . . . . . . . . . . . . . . . . . . . . . 1-34
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
C-Tick Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

Table of Contents

Chapter 2 Start Up
Prepare For Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Assisted Start Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Chapter 3 Troubleshooting
Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Drive Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Manually Clearing Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Drive Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Active Converter Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Clearing Drive Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Test Equipment Needed To Troubleshoot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Verifying That DC Bus Capacitors Are Discharged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Appendix A Supplemental Drive Information
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
ii Table of Contents
Appendix B HIM Overview
Remote HIM Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
LCD Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
ALT Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Removing/Installing the HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Appendix C Wiring Diagrams
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Power Module – Overall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Power Module – Active Converter Control and Rectifier Power Interface . . . . . . . . . . . C-6
Power Module – High Voltage Interconnect and Inverter Power Interface . . . . . . . . . . . C-8
Power Module – Rectifier IGBT and Inverter IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
Index

Preface

Overview

The purpose of this manual is to provide you with the basic information needed to install and troubleshoot the LPM20 Liquid-Cooled AC Drive with High Performance Drive Control.
For information on ... See page ...

Who Should Use this Manual?

What Is Not in this Manual P-1
Reference Materials P-2
Manual Conventions P-3
General Precautions P-4
Catalog Number Explanation P-5
P-1
Who Should Use this Manual?

What Is Not in this Manual

This manual is intended for qualified personnel. You must be able to mount and wire Adjustable Frequency AC Drive devices.
This manual is designed to provide only installation, wiring, and troubleshooting information.
PowerFlex 700 Active Converter Power Module Information
LPM20 Liquid-Cooled Adjustable Frequency AC Drives are equipped with a PowerFlex 700 Active Converter Power Module. For details on active converter I/O wiring, start-up, programming, and other related information, please refer to the PowerFlex 700 Active Converter Power Module User Manual (Publication No. PFLEX-UM002…).
PowerFlex 700S Phase II Control Information
LPM20 Liquid-Cooled Adjustable Frequency AC Drives are equipped with a PowerFlex 700S Phase II control cassette. Please refer to the Power Fl ex
700S High Performance AC Drive — Phase II Control User Manual
(Publication No. 20D-UM006…) in the locations shown in parenthesis below for information on:
• Start-up (Chapter 2).
• Drive programming and parameters (Chapter 3).
• Application notes (Appendix C).
P-2 Overview

Reference Materials

Publications can be obtained online at
http://www.rockwellautomation.com/literature
The following manuals are recommended for general drive information :
Title Publication
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001… Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001…
Safety Guidelines for the Application, Installation and Maintenance of Solid State Control
A Global Reference Guide for Reading Schematic Diagrams 0100-2.10
Guarding Against Electrostatic Damage 8000-4.5.2
The following publications provide specific feedback card information:
Title Publication
Hi-Resolution (Stegmann) Feedback Option Card Installation Instructions for PowerFlex 700S Drives (also LPM20 with High Performance Drive Control)
Resolver Feedback Option Card Installation Instructions for PowerFlex 700S Drives (also LPM20 with High Performance Drive Control)
Multi-Device Interface Option Card Installation Instructions for PowerFlex 700S Drives (also LPM20 with High Performance Drive Control)
The following publication provides information that is necessary when applying the 700S Phase II Control DriveLogix5730 Controller:
.
SGI-1.1
20D-IN001 …
20D-IN002 …
20D-IN004 …
Title Publication
DriveLogix5730 Controller User Manual 20D-UM003 …
The following publications provide information that is useful when planning and installing communication networks:
Title Publication
ControlNet Coax Tap Installation Instructions 1786-5.7
ControlNet Cable System Planning and Installation Manual 1786-6.2.1 ControlNet Fiber Media Planning and Installation Guide CNET-IN001 … SynchLink Design Guide 1756-TD008 …
For Allen-Bradley Drives Technical Support:
E-mail: support@drives.ra.rockwell.com Tel: (1) 262.512.8176 Fax (1) 262.512.2222 Online: www.ab.com/support/abdrives
Overview P-3

Manual Conventions

• In this manual we refer to the LPM20 Liquid-Cooled AC Drive as; drive, LPM20 or LPM20 Drive.
• To help differentiate parameter names and LCD display text from other text, the following conventions will be used:
– Parameter Names will appear in [brackets].
For example: [DC Bus Voltage].
– Display Text will appear in “quotes.” For example: “Enabled.”
• The following words are used throughout the manual to describe an action:
Word Me aning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Must Unavoidable, you must do this
Shall Required and necessary
Should Recommended
Should Not Not recommended
P-4 Overview

General Precautions

Class 1 LED Product
ATTENTION: Risk of permanent eye damage exists when using optical transmission equipment. This product emits intense light
!
and invisible radiation. Do not look into module ports or fiber optic cable connectors.
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are
!
required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, refer to Allen-Bradley publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring
!
or application errors, such as, undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system.
ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or
!
implement the installation, start-up, and subsequent maintenance of the system. Failure to comply may result in personal injury and/ or equipment damage.
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing
!
any work on the drive. After removing power to the drive, wait 5 minutes for the bus capacitors to discharge. Measure the DC bus voltage at the locations shown in Figure 3.2 zero.
ATTENTION: Risk of injury or equipment damage exists. DPI or SCANport host products must not be directly connected
!
together via 1202 cables. Unpredictable behavior can result if two or more devices are connected in this manner.
ATTENTION: Risk of injury or equipment damage exists. Parameters 365 [Fdbk LsCnfg Pri] - 394 [VoltFdbkLossCnfg] let
!
you determine the action of the drive in response to operating anomalies. Precautions should be taken to ensure that the settings of these parameters do not create hazards of injury or equipment damage.
ATTENTION: Risk of injury or equipment damage exists. Parameters 383 [SL CommLoss Data] - 392 [NetLoss DPI Cnfg]
!
let you determine the action of the drive if communications are disrupted. You can set these parameters so that the drive continues to run. Precautions should be taken to ensure that the settings of these parameters do not create hazards of injury or equipment damage.
. The voltage must be
Overview P-5

Catalog Number Explanation

1817 19 20
The LPM20 with High Performance Drive Control catalog numbering scheme is shown below.
L
ENo
K
Cat.
Code
Comm.
No
Embedded
Options
CONTROL CONFIGURATIONS
Ethernet/IP
700S Phase II Control
700S Phase II Control w/DriveLogix™
700S Phase II Control w/DriveLogix™
1B 1
C 1E
A
Cat. CodeType
FEEDBACK OPTIONS
None N
Resolver
Stegmann Encoder
Multi-Device Interface
Cat.
1
2nd Encoder
Requires Expanded Cassette.
1
Logix
CONTROL OPTIONS
Control
Code
No A
SyncLink
No
Expansion
Cassette
Expanded
Option
700S Phase II
D
2D 2
B
C
YesNoYes
No
Yes
Yes
Expanded
Expanded
Expanded
700S Phase II
700S Phase II
700S Phase II
2
C
Q
Requires DriveLogix™5730 Controller.
42 43 44 45 46 4
1
E
E
N
Q
No
Yes
Yes
Ship CartonDocument(s) Cat. Code
Cat.
Code
DOCUMENTS & SHIPPING CARTON
English Doc Set
No Doc Set
HP
(Ref.)
Cat.
Code
Output
Current
Type
Source
No Doc Set
HIM
Coat
None
LPM20 with High Performance Drive Control
PRODUCT CATALOG NUMBER EXPLANATION
068
Conformal
Rating
Enclosure
Open Chassis / IP00 N
ENCLOSURE TYPE AND CONFORMAL COATING
A
N
Options Cat. Code
INPUT FILTER ITEMS
Replacement Power Module Only
Assembled Input Filter with Power Module
None N
Version Cat. Code
Note: HIM is ordered separately.
DPI Cat. Code
3
None N
DeviceNet
RIO R
ControlNet (Coax)
COMM SLOTS
DriveLogix (NetLinx)
None
N/A
N/A
N/A
NoNo N
EMC Cat. Code
INTERNAL EMC FILTERING
NoneNone N
Brake ResistorBrake IGBT Cat. Code
DYNAMIC BRAKE IGBT & BRAKE RESISTOR
Common Mode
N/A
ControlNet (Fiber)
N/A
N/A
RS485 DF-1 S
Ethernet
N/A
N/A
ControlNet (Coax)
ControlNet Redundant (Coax)
N/A
ControlNet (Fiber)
N/A
N/A
N/A
DeviceNet
ControlNet Redundant (Fiber)
EtherNet/IP (Twisted Pair)
Note that selections are mutually exclusive. For two Comm devices
Requires 700S Phase II Control with Logix Expansion.
(DPI and NetLinx), select the NetLinx Comm option and order the
DPI Comm kit separately.
3
4
12345678910111213141516
20ND NNE NNNNANE
PRODUCT
LPM20 20N
Product Cat. Code
Input
608 A 3 PH. 608 A D608 500
Current
INPUT VOLTAGE & OUTPUT CURRENT RATING
Input
380 - 480 VAC
Voltage Range
P-6 Overview
Notes:

Chapter 1

Installation/Wiring

This chapter provides information on mounting and wiring the LPM20 Drive.
For information on ... See page ...

Powe r R at in gs

Enclosure Ratings 1-2
Drive Component Locations 1-2
AC Supply Source Considerations 1-11
Mounting the Drive, Determining Wire Routing, and Grounding 1-12
Coolant Considerations 1-14
Installing Input Power Wiring 1-17
Installing Output Power Wiring 1-19
Powe r W ir ing 1-20
Using Input/Output Contactors 1-22
I/O Wiring 1-23
Main Control Board I/O and Encoder Settings 1-31
Connecting SynchLink 1-32
Active Converter Communication 1-33
Auto Tune Operation 1-33
Pre-charge Operation 1-34
Wiring the Active Converter Control Board I/O Terminals 1-34
CE Conformity 1-36
C-Tick Conformity 1-37
1-1
Power Ratings
Catalog Number (positions 1-7 only)
20ND608 505 380 to 480 608 608 500 9000/3000
(1)
110% output current capability for one minute, 150% output current capability for 5 seconds.
(2)
Note that LPM20 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. LPM20 drives are also capable of running at 2 kHz or 3 kHz.
Input Power (KVA)
Most start-up difficulties are the result of incorrect wiring. Every precaution must be taken to assure that the wiring is done as instructed. All items must be read and understood before the actual installation begins.
ATTENTION: The following information is merely a guide for proper installation. The Allen-Bradley Company cannot assume
!
responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.
LPM20 Drives with High Performance Drive Control have power ratings as described in Tabl e 1.A
Table 1.A Power Ratings
Input Vol t a g e ( V )
Input Current (Amps)
below:
(1)
Output Current
(2)
at 4 kHz
(Amps)
HP Ratings
Full Load Power Loss Watts Fluid/Air
1-2 Installation/Wiring

Enclosure Ratings

Drive Component Locations

LPM20 drives have the following enclosure rating:
• Open-Chassis Style: Intended to be installed in an enclosure.
LPM20 drives must be placed in an enclosure.
LPM20 Liquid-Cooled AC drives with High Performance Drive Control are comprised of an input components section and a power module section.
Drive Input Component Locations
The input components section contains the following main components. The numbered items listed below correspond to the numbers used in
Figure 1.1
1. Main Circuit Breaker
2. Circuit Breaker Operating Mechanism
3. Capacitor Bank Filter
4. Fan Tray
5. Precharge AC Contactors (3)
6. Fuses, 15A, Primary Control Transformer (2)
7. Control Transformer, 120 VAC, 1 Phase, 3 KVA
8. Ground Lug, 2-600 MCM
9. Inductor
10. Fuses, Precharge Resistors, 20A, 600V (3)
11. Terminal Block, 4-Position
12. Precharge Resistors (3)
13. 115V Fans (2)
. Replacement parts are listed in Chapter 3.
Figure 1.1 Drive Input Components
Installation/Wiring 1-3
13
1
2
3
8
7
6
10 11 12
SECTION A-A
5
9
A
A
4
See SECTION A-A
1-4 Installation/Wiring
Power Module Component Locations
The power module section contains the following main components. The numbered items listed below correspond to the numbers used in Figure 1.2 and Figure 1.3
1. Cable Assembly, 40-pin, 0.050 in. Pitch, Flex Film (1)
2. Cable Assembly, 30-pin, 0.050 in. Pitch, Flex Film (1)
3. Cable Assembly, 40-pin, 0.050 in. Pitch, Flex Film (1)
4. Wire Harness Assembly, Power Supply, Upper Gate (2)
5. Inverter Power Interface Assembly
6. Wire Harness Assembly, Power Supply, Lower Gate, PF700S (1)
7. 80 W Power Supply Assembly (2)
8. Insulation Sheet (2)
9. Cable Assembly, 40-pin, 0.050 in. Pitch, Flex Film (1)
10. Cable Assembly, 30-pin, 0.050 in. Pitch, Flex Film (1)
11. Wire Harness Assembly, Power Supply, Logic (2)
12. Wire Harness Assembly, Power Supply, Lower Gate (1)
13. Rectifier Power Interface Assembly
14. Current Feedback Device, 1000A (6)
15. Wire Harness Assembly, Gate Driver
16. Wire Harness Assembly, Current Feedback Device
17. Wire Harness Assembly, Input Filter (1)
18. Wire Harness Assembly, DC Bus Bleeder Resistors (1)
19. High Voltage Interconnect Assembly (1)
20. PF700S Voltage Feedback, 400V Class, Assembly (1)
21. Terminal Block, 2-Position (1)
22. Cable Assembly, 10-Position, Ribbon (1)
23. PF700S Control Cassette
24. Active Converter Assembly
25. Connector, Terminal Block, 15-pin
26. Connector, Terminal Block, 7-pin
27. Voltage Feedback Resistor, 460V, Assembly
28. Internal Fan
29. Communications Interface Assembly
30. Cable Assembly, 20-pin, 0.050 in. Pitch, Flex Film (optional)
31. Communications Module (optional)
. Replacement parts are listed in Chapter 3.
Figure 1.2 Power Module Component Locations – Door Open
Installation/Wiring 1-5
19
1
2
3
4
5
6
7
8
9
20
11
10
11
4
12
7
8
13
4
14
15
16
17
18
1-6 Installation/Wiring
Figure 1.3 Power Module Component Locations – Door Closed
29
21
1
22
23
30
31
22
24
25
26
27
28
Installation/Wiring 1-7
DPI Communication Port
The Communication Interface PCB contains an eight-position, female, locking mini-DIN connector that is used as a DPI communication port. This port (DPI Port 4 shown in Figure 1.4 between the LPM20 drive and another DPI device (for example, a HIM).
Figure 1.4 DPI Communication Interface Board
DPI Port 3
below) provides communication
DPI Port 4
DPI Port 5
For more information regarding operating LPM20 drives with a HIM, refer to Appendix
Determining Total Area Required Based on Drive Dimensions
Overall drive dimensions are illustrated in Figure 1.5 and Figure 1.6 as an aid in calculating the total area required by the LPM20 drives.
B.
1-8 Installation/Wiring
Figure 1.5 Power Module Dimensions and Mounting
1.19
0.80
0.88
0.75
1.50
0.25
Ø.472
DETAIL A
Input and Output Wiring Connection SCALE 1:2
Coolant Connections See Notes 2 and 3
OUT
4.76
13.72
IN
8.96
1.25
4.75
Ø.213 Thru For M6 TAPTITE Screw with Enclosure Mounting Bracket
Lifting Ø1.00 Both Sides
W
V
U
L3
A1-P1
L2
Input Filter Harness Connector
L1
9.03
36.04
4.48
20.66
Output
Wiring
to Motor
4.48
4.48
6.66
3.05
Drive
Drive Input
Wiring
21.97
16.00
1.92
1.75
2.65 From Back of
Chassis to ORFS of
Sealing Surfaces
6.84
1.98
SEE DETAIL A
Lifting Ø1.00 Both Sides
LEFT SIDE VIEW
NOTES:
1. Floor Mounting Flange Holes: A. Accept M8 Thread-Rolling Screws per SAE J1237. B. Tightening Torque: 20-24 [N-M], 15-17 [FT-LBF].
2. Inlet and Outlet Coolant Connection Hardware Provided With Unit: A. ORFS Braze Sleeve: a. Material: Brass; for 5/8" O.D. Copper Tube. b. Reference: Parker Hannifin P/N 10 TL-B, or equivalent. B. ORFS Nut: a. Material: Brass; for 5/8" O.D. Copper Tube, 1-14 UN/UNF-2B Thread. b. Tightening Torque: 37-45 [N-M], 27.1-33.3 [FT-LBF]. c. Reference: Parker Hannifin P/N 10 BL-B, or equivalent.
3. Coolant Connection Hardware Provided by User: A. ORFS Braze Adapter: a. Material: Brass; for 5/8" O.D. Copper Tube, 1-14 UN/UNF-2A Thread. b. Reference: Parker Hannifin P/N 10 LHB3-B, or equivalent. B. ORFS O-Ring: a. Material: Neoprene Rubber. b. Size: 0.614 I.D., 0.070 Width. c. Reference: Parker Hannifin P/N 2-016-C0873-70, or equivalent. C. O-Ring Lubricant: Parker Hannifin Super-O-Lube, or equivalent.
9.25
6.75
1.56
2.08
1.43
0.50
3.88
2.31
FRONT VIEW
3.64
6.05
18.49
4.81
Installation/Wiring 1-9
Neg (-)
4.12
DC
A31
A32
A33
DC
Pos (+)
2.92
DC Bus Measurement
1.15
Points on Laminated Bus Ass'y 0.25" x 0.032" Male Faston. Accessible
by Removal of Top Cover.
SEE DETAIL GATE KILL
A22-TB1 & TB2
Main Control Ass'y
Terminal Blocks
32.16 A12-P1 Active
Converter Control
Ass'y Terminal
Block 15-Pos.
A11-P2 Voltage
Feedback
Resistor Ass'y
Terminal
Block 7-Pos.
13.47
10.32
8.27 (A33)
6.17 (A22-TB1 & TB2)
5.54 (DC Bus Measurement Points)
SEE DETAIL COG
25.90
2.96
OUT
9.50
0.44
DETAIL COG
SCALE 5:16
CENTER OF GRAVITY: X = 17.5" Y = 3.1" Z = 7.4" (into Plane of Drawing) WEIGHT: 162 LBS.
A33 Gate Kill 2-Pos. Terminal Block With #6-32 Phillips/Slotted Screws. Accepts #6 Stud Size Spade Tongue Terminal. Max. Width is 0.37".
IN
2 1
A33
2.96
6.60
Y
X
1.78
AIRFLOW
17.50
BOTTOM VIEW
2.15
Cooling Fan Requires 1.13" Minimum Unobstructed Space Below Fan
Ø.453 (4)-PL. See Note 1
4.63
1.56
9.56
8.80
0.44
DETAIL GATE KILL
RIGHT SIDE VIEW
FIELD CONTROL WIRING
Name Reference
A33 #6-32 Screw 0.90 8 24 to 10 A12-P1
A11-P2 A22-TB1
A22-TB2
A1-P1 MATE
Screwdriver Blade:
0.032" Thk. x 0.125" Wide Screwdriver Blade:
0.017" Thk. x 0.094" Wide
A1-P1 LINE SYNC. ASS'Y HARNESS CONNECTOR Socket Housing, AMP P/N 172163-1 Socket, AMP P/N 770903-3 Pin Housing, AMP P/N 172171-1
Torque
[N-M] [IN-LBF] [AWG] [Inch]
0.79 7 26 to 12 0.31
0.22 1.9 28 to 16 0.25
SCALE 5:8
Wire Size Strip Length
Pin, AMP P/N 770904-3
−
1-10 Installation/Wiring
C/B
Disconnect
Handle
Figure 1.6 Drive Input Dimensions
6.076 Area for Input Power Wiring
[154,3]
20.157 [512]
Area for Input Power Wiring
23.80 Left Panel/Divider Panel
[605]
10.49 [266]
2.38 [60]
26.20 [665]
23.82 [605]
Field Install Roof Spacers Rittal p/n DK7967.000
Exhaust Air Space Required
Divider Panel Rittal p/n TS8609.060
Left View Shown
with Lifting Eye-Bolts
as Shipped
Rittal TS8 Enclosure
600mm x 600mm x 2000mm
81.11
[2060]
80.89
[2055]
78.99 [2006]
58.48
[1485]
Intake Louver
323mm x 323mm
Edge Guard
Power Cable
Opening Input
to Power Module
10.13 [257]
12.24 Ref
[311]
Control Cable Opening Input to Power Module
Verifying that 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.
For proper cabinet ventilation, roof spacers must be field installed as shown in Figure 1.6
.
Installation/Wiring 1-11
Verifying Power Module Input Ratings Match Supplied Power
It is important to verify that plant power will meet the input power requirements of the LPM20 drive’s Power Module circuitry. See Ta ble 1 . A for input power rating specifications. Be sure input power to the drive corresponds to the drive nameplate voltage and frequency.

AC Supply Source Considerations

LPM20 drives are suitable for use on a circuit capable of delivering up to a maximum of 100,000 rms symmetrical amperes, and a maximum of 480 volts. A circuit breaker with shunt trip as supplied with input drive components with the appropriate kAIC rating must always be used upstream of the power module.
ATTENTION: To guard against personal injury and/or equipment damage caused by improper circuit breaker selection, use only the
!
recommended circuit breakers specified in Tab le 1 . B
Unbalanced or Ungrounded Distribution Systems
LPM20 drives should not be used with a supply system that is ungrounded and when the phase-to-phase voltage exceeds 125% of normal line-to-line voltage.
ATTENTION: LPM20 drives contain protective MOVs on the drive’s printed circuit boards. The MOVs are referenced to ground.
!
The MOVs should not be disconnected.
Input Power Conditioning
Certain events on the power system supplying a drive can cause component damage or shortened product life. They are:
.
• The power system has power factor correction capacitors switched in and out of the system, either by the user or by the power company.
• The power source has intermittent voltage spikes in excess of 6000 volts. These spikes could be caused by other equipment on the line or by events such as lightning strikes.
• The power source has frequent interruptions.
Wiring Requirements for the Drive
Certain drive requirements should be checked before continuing with the drive installation. Wire sizes, branch circuit protection, encoder feedback (for FVC regulation), and wiring to disable the drive are all areas that need to be evaluated.
Operation of the drive can be disabled in two locations. Gate Kill terminal block (A33) on the front of the power structure can be used to disable the firing of inverter IGBTs. When the connection between terminals 1 and 2 is opened, inverter IGBTs are disabled independent of any software control. This action also generates fault 207 in the inverter to enunciate this
1-12 Installation/Wiring
condition. As a result of this fault, the active converter is also turned off, but this is done via software operation. The firing of IGBTs in the active converter can be disabled independently of any software control by opening the connection between terminals 13 and 14 on the active converter control assembly terminal block A12-P1. This action also genrates a fault in the inverter to enunciate this condition. Wiring diagrams are shown in
Figure 1.5
Input Line Branch Circuit Protection
!
Table 1.B AC Input Circuit Breaker Values
and on page C-3.
ATTENTION: Most codes require that upstream branch circuit protection be provided to protect input power wiring. The circuit breaker values provided in the Drive Input Components are listed in Tabl e 1.B
.

Mounting the Drive, Determining Wire Routing, and Grounding

LPM20 Drive Catalog Number (positions 1-7 only)
20ND608 380-480 VAC 800 A
Note: One 120 VAC shunt trip to be installed as shown in the drive wiring diagram on page C-2
This section shows how to mount the drive and properly ground it. Also described is the wiring to be routed in and out of the drive.
Lifting and Mounting the Power Module
Use the following procedure to lift the LPM20 power module and mount it in the required enclosure:
1. Install two s-hooks into the power module to serve as lifting points. Two
1-inch through holes are provided in the sheet metal chassis.
2. Connect 18 inches (nominal) of chain between the s-hooks and secure
them with a clevis clamp.
3. Using an overhead or portable hoist (minimum 1/2-ton rated capacity),
attach a free-fall chain to the chain secured to the drive. Take up any vertical slack in the chain.
Input Voltage
.
Circuit Breaker Provided
4. Using the hoist, lift the power module from the horizontal shipping pallet.
5. Position the power module in the enclosure.
6. 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 Figure 1.5
7. Remove the s-hooks and chain.
for power module mounting dimensions.
Installation/Wiring 1-13
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 Tabl e 1.A load power loss watts value at 2 kHz (rated carrier frequency). Ensure that the enclosure is adequately ventilated with 0 the drive’s watts loss rating.
Determining Input, Motor Output, Ground, and Control Wire Routing for the Drive
All wiring should be installed in conformance with the applicable local, national, and international codes (e.g., NEC/CEC). Signal wiring, control wiring, and power wiring must be routed in separate conduits to prevent interference with drive operation. Use grommets, when hubs are not provided, to guard against wire chafing. Figure 1.5 wire routing, grounding terminal, and power terminal strips of LPM20 drives with High Performance Drive Control.
. This table lists the typical full
° to 40° C ambient air based on
and Figure 1.6 show the
ATTENTION: Do not route signal and control wiring with
!
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.
!
Grounding the Drive
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.
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.
ATTENTION: The user is responsible for conforming with
!
Use the following steps to ground the drive:
1. Open the door of the enclosure.
all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
1-14 Installation/Wiring
2. Run a suitable equipment grounding conductor unbroken from the drive
to the motor’s ground terminal and then to earth ground. Use one of the bolts that pass through the drive baseplate and are used to fasten the drive to the wall or cabinet. See Figure 1.6 connections to the proper torque as shown in Table 1 . D
3. Connect a suitable grounding conductor to the motor frame and the
remote control station (if used). Run each conductor unbroken to earth ground. When adding more than one grounding conductor wire to a single chassis ground, twist the conductors together. Tighten these grounding connections to the proper torque as shown in Table 1.D
4. Close the door of the enclosure.
. Tighten these grounding
.
.

Coolant Considerations

LPM20 drives use o-ring face seal fittings for connection to the coolant supply. The coolant is typically clean water with a corrosion inhibitor as described in this section.
LPM20 drive coolant connections are made with o-ring face seal fittings. The copper tube running from the heatsink to the o-ring fittings is covered with closed cell foam insulation.
The mating connection is shown in Figure 1.7 the following steps:
1. Coat the o-ring with the o-ring lubricant. The goal is a thin film covering
the entire o-ring surface. Avoid excess globs of lubricant.
2. Insert the o-ring into the o-ring groove in the external thread-side fitting
on the user side. Avoid any twisting of the o-ring.
3. Assemble the fittings and tighten to a torque of 37 to 45 N-m (or 27 to 33
lb.-ft.). Use a backup wrench on the user side fitting to avoid twisting the drive side tubing.
Figure 1.7 Mating Connection
DRIVE SIDE CONNECTION
ORFS Braze Sleeve
5/8-inch O.D. Copper Tube
(Parker p/n 10-TL-B)
. The mating process includes
USER SIDE CONNECTION
ORFS Braze Adapter (Parker p/n 10-LOHB3-B)
ORFS Nut
(Parker p/n 10-BL-B)
O-Ring, Neoprene
(Parker p/n 2-016-CO873-70)
(Parker p/n 884-2GRAMS-LUBE)
O-Ring Lubricant
5/8-inch O.D. Copper Tube
Backup Wrench (Use to prevent twisting during nut tightening.)
Installation/Wiring 1-15
Other recommendations include:
1. The allowable coolant temperature range is 0°C to 40°C (32°F to 105°F). When using coolant at a temperature below the dew point of the surrounding air, condensation could accumulate on the drive heatsink and/or circuit boards and damage the drive. In this situation, install a coolant flow regulating device and tube/hose insulation. A flow regulating device modulates the coolant flow rate to a level that permits the drive heatsink temperature to rise above the dew point. Insulation for customer side tube or hose may be closed-cell foam insulation with minimum 1/2-inch wall thickness.
2. Install a flow switch after the coolant outlet connection to shutoff the drive if coolant flow drops below 4 gpm.
3. Circulate water through the drive only when the drive is also powered. Failure to do this may result in condensation accumulating on the drive heatsink and/or circuit boards, which could damage the drive.
4. For applications requiring a closed loop coolant system, ensure the system is vented to remove air that would otherwise degrade the performance of the drive heatsink.
Coolant Connections
LPM20 drives with High Performance Drive Control have inlet and outlet connections as shown in Figure 1.5 are bolted to the heatsink.
The rated working pressure of the drive is 185 psig. Coolant supply and return lines should be sized for 10 gpm/185 psig service with a maximum operating temperature of 40°C (105°F). The required operating flow rate and pressure drop is specified in Tabl e 1.C
Coolant Requirements
LPM20 drives are rated for use with coolant consisting of clean water with a corrosion inhibitor. Deionized water is prohibited. Use distilled water or water with the following concentrations:
• Less than 50 ppm of sulfate and chloride.
• Less than 50 ppm of hard water ions such as Mg++ and Ca++.
Coolant must be properly strained and/or filtered to ensure it is free of contamination.
. Tube assemblies with O-ring fittings
.
The coolant must be compatible with the following materials: Copper, brass, aluminum, and neoprene.
1-16 Installation/Wiring
Table 1.C Coolant Requirements for LPM20 Drives
LPM20 Drive Catalog Number (positions 1-7 only)
20ND608
(1)
Water equals good quality or distilled water with Chemtool, Inc. corrosion inhibitor, 2% inhibitor by volume.
(2)
WEG25 equals good quality or distilled water with approved ethylene glycol, 25% glycol by volume.
(3)
WEG50 equals good quality or distilled water with approved ethylene glycol, 50% glycol by volume.
Max. Output Current (Amps)
608 5 to 40 7 10 Water
608 0 to 40 7 10 WEG25
550 0 to 40 7 10 WEG50
608 0 to 40 10 22 WEG50
608 0 to 30 7 10 WEG50
Corrosion Inhibitor
A corrosion inhibitor is required. The following two options are approved sources:
1. Chemtool, Inc. (www.chemtool.com) part number Watertool 4435-C.
The recommended concentration of the inhibitor is 8 to 10% by volume.
2. Dow Chemical (www.dow.com) Dowtherm
glycol. The recommended concentration of the inhibitor is 25% by volume.
Coolant Temperature Range (°C)
Minimum Coolant Flowrate (GPM)
Pressure Drop From Drive Inlet to Drive Outlet (PSIG) at Minimum Coolant Flow Rate
®
SR-1 inhibited ethylene
Coolant Typ e
(1)
(2)
(3)
(3)
(3)
Dowtherm is a registered trademark of the Dow Chemical Company.
ATTENTION: Ethylene glycol must be inhibited and silicate
!
Biocide
A biocide may be needed to control biological growth. Use of a biocide is permitted. For specific recommendations, consult a reputable water treatment company.
free. Use of common silicate-containing, automotive-type ethylene glycol solutions is prohibited as they may damage the drive and cooling module equipment.
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