Rockwell Automation LPM20 User Manual

LPM20 Liquid-Cooled Adjustable Frequency AC Drive

With High Performance Drive Control

Installation Manual

Important User Information

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 available from your local Rockwell Automation sales office or online at http:// www.rockwellautomation.com/literature) describes some 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.

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

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

DriveLogix5730 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.

ENo

Cat.

Code

Comm.

Embedded

Options

CONTROL CONFIGURATIONS

Ethernet/IP

700S Phase II Control

700S Phase II Control w/DriveLogix™

1B 1

C 1E

Cat. CodeType

FEEDBACK OPTIONS

None N

Resolver

Stegmann Encoder

Multi-Device Interface

Cat.

2nd Encoder

Requires Expanded Cassette.

Logix

CONTROL OPTIONS

Control

Code

No A

SyncLink

Expansion

Cassette

Expanded

Option

700S Phase II

2D 2

YesNoYes

Yes

Expanded

700S Phase II

Requires DriveLogix™5730 Controller.

42 43 44 45 46 4

Yes

Ship CartonDocument(s) Cat. Code

Cat.

Code

DOCUMENTS & SHIPPING CARTON

English Doc Set

No Doc Set

(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

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

None N

DeviceNet

RIO R

ControlNet (Coax)

COMM SLOTS

DriveLogix (NetLinx)

None

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

RS485 DF-1 S

Ethernet

N/A

ControlNet (Coax)

ControlNet Redundant (Coax)

N/A

ControlNet (Fiber)

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.

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

10 11 12

SECTION A-A

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

1-6 Installation/Wiring

Figure 1.3 Power Module Component Locations – Door Closed

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.

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

8.96

1.25

4.75

Ø.213 Thru For M6 TAPTITE Screw with Enclosure Mounting Bracket

Lifting Ø1.00 Both Sides

A1-P1

Input Filter Harness Connector

9.03

36.04

4.48

20.66

Output

Wiring

to Motor

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

A31

A32

A33

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".

2 1

A33

2.96

6.60

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)

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.

Installation/Wiring 1-17

Installing Input Power Wiring

Circuit Breaker Line Side Lugs

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

Installing Transformers and Reactors (Not Recommended)

The LPM20 AC drive may be used on distribution systems with 100,000 amps or less symmetrical fault current capacity. The Drive Input components consists of a 3% line reactor and a harmonic line filter. Additional input inductance is not recommended.

Figure 1.8 Drive Input Wiring

Ground Lug 2-600 MCM

Torque Label for

Line Side Lugs

L1 L2 L3

NOTE: Proper torque for Line Side Lugs is labeled on the circuit breaker.

1-18 Installation/Wiring

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 Installing

Transformers and Reactors (Not Recommended) on page 1-17 for

additional information.

Installing Power Wiring from the Input Filter Section to the Power Module

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

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.

1. Connect the three-phase AC input power leads (three-wire 380-480

VAC) to the appropriate terminals.

2. Tighten the AC input power terminals to the proper torque as shown in

Table 1.D

Table 1.D Terminal Tightening Torques

Terminals Hardware Type

L1 to L6 M10, CI. 9.8 43 N-m (31 lb.-ft.)

U, V, W M10, CI. 9.8 43 N-m (31 lb.-ft.)

GND, PE M8, CI. 9.8 22 N-m (16 lb.-ft.)

Maximum Tightening Torque (+

10%)

Installation/Wiring 1-19

Installing Output Power Wiring

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

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.

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

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:

1. Wire the three-phase AC output power motor leads by routing them as shown in Figure 1.5

ATTENTION: Do not route signal and control wiring with

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

terminals. Figure 1.5

3. Tighten the three-phase AC output power terminals to the proper torque as shown in Tab le 1. D

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

shows the locations of the output power terminals.

1-20 Installation/Wiring

Power Wiring

ATTENTION: National Codes and standards (NEC, VDE, BSI etc.) and local codes outline provisions for safely installing

electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.

Cable Types Acceptable for 200-600 Volt Installations

A variety of cable types are acceptable for drive installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, allow a spacing of 0.3 meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases, long parallel runs must be avoided. Do not use cable with an insulation thickness less than or equal to 15 mils (0.4mm/0.015 in.). Use Copper wire only. Wire gauge requirements and recommendations are based on 75°C. Do not reduce wire gauge when using higher temperature wire.

Unshielded

THHN, THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space and/or conduit fill rates limits are provided. Do not use THHN or similarly coated wire in wet areas. Any wire chosen must have a minimum insulation thickness of 15 mils and should not have large variations in insulation concentricity.

ATTENTION: To avoid a possible shock hazard caused by induced voltages, unused wires in the conduit must be grounded at

both ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled. This will help minimize the possible shock hazard from “cross coupled” motor leads.

Shielded/Armored Cable

Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC Drive. Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations or a high degree of communications/networking are also good candidates for shielded cable.

Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable may help extend the distance the motor can be located from the drive without the addition of motor protective devices such as terminator

Installation/Wiring 1-21

networks. Refer to Reflected Wave in Wiring and Grounding Guidelines for PWM AC Drives, publication DRIVES-IN001.

Consideration should be given to all of the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics and chemical resistance. In addition, a braided shield should be included and specified by the cable manufacturer as having coverage of at least 75%. An additional foil shield can be greatly improve noise containment.

A good example of recommended cable is Belden® 295xx (xx determines gauge). This cable has 4 XLPE insulated conductors with a 100% coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a PVC jacket.

Table 1.E Recommended Shielded Wire

Location Rating/Type Description

Standard (Option 1)

Standard (Option 2)

Class I & II; Division I & II

600V, 90°C (194°F) XHHW2/RHW-2 Anixter B209500-B209507, Belden 29501-29507, or equivalent

Tray rated 600V, 90°C (194°F) RHH/RHW-2 Anixter OLF-7xxxxx or equivalent

Tray rated 600V, 90°C (194°F) RHH/RHW-2 Anixter 7V-7xxxx-3G or equivalent

• Four tinned copper conductors with XLPE insulation.

• Copper braid/aluminum foil combination shield and

tinned copper drain wire.

• PVC jacket.

• Three tinned copper conductors with XLPE insulation.

• 5 mil single helical copper tape (25% overlap min.) with

three bare copper grounds in contact with shield.

• PVC jacket.

• Three bare copper conductors with XLPE insulation

and impervious corrugated continuously welded aluminum armor.

• Black sunlight resistant PVC jacket overall.

• Three copper grounds on #10 AWG and smaller.

Other types of shielded cable are available, but the selection of these types may limit the allowable cable length. Particularly, some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield. This construction can greatly increase the cable charging current required and reduce the overall drive performance. These cables are not recommended.

1-22 Installation/Wiring

Using Input/Output Contactors

Input Contactor Precautions

ATTENTION: A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop

the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor. If an input device is used, operation must not exceed one cycle per minute or drive damage will occur.

ATTENTION: The drive start/stop/enable control circuitry includes solid state components. If hazards due to accidental

contact with moving machinery or unintentional flow of liquid, gas or solids exist, an additional hardwired stop circuit may be required to remove the AC line to the drive. An auxiliary braking method may be required.

Output Contactor Precaution

ATTENTION: To guard against drive damage when using output contactors, the following information must be read and understood.

One or more output contactors may be installed between the drive and motor(s) for the purpose of disconnecting or isolating certain motors/loads. If a contactor is opened while the drive is operating, power will be removed from the respective motor, but the drive will continue to produce voltage at the output terminals. In addition, reconnecting a motor to an active drive (by closing the contactor) could produce excessive current that may cause the drive to fault. If any of these conditions are determined to be undesirable or unsafe, an auxiliary contact on the output contactor should be wired to a drive digital input that is programmed as “Enable.” This will cause the drive to execute a coast-to-stop (cease output) whenever an output contactor is opened.

Installation/Wiring 1-23

I/O Wiring

Important points to remember about I/O wiring:

• Use Copper wire only. Wire gauge requirements and recommendations are based on 75°C. Do not reduce wire gauge when using higher temperature wire.

• Wire with an insulation rating of 600V or greater is recommended.

• Control and signal wires should be separated from power wires by at

least 0.3 meters (1 foot).

• 4100CCF3 Flex I/O cable for use with DriveLogix is 0.9 meters (3 ft.) maximum length.

Important: I/O terminals labeled “(–)” or “Common” are

earth ground and are designed to greatly reduce common mode interference. Grounding these terminals can cause signal noise.

ATTENTION: Configuring an analog input for 0-20mA operation and driving it from a voltage source could cause

component damage. Verify proper configuration prior to applying input signals.

ATTENTION: Hazard of personal injury or equipment damage exists when using bipolar input sources. Noise and drift in

sensitive input circuits can cause unpredictable changes in motor speed and direction. Use speed command parameters to help reduce input source sensitivity.

not referenced to

Signal and Control Wire Types

Table 1.F Recommended Signal Wire

Signal Type/ Where Used Wire Type(s) Description

Standard Analog I/O Belden 8760/9460 (or equiv.) 0.750 mm

pair, 100% shield with drain

Remote Pot Belden 8770 (or equivalent) 0.750 mm

Encoder/Pulse I/O Less 30.5 m (100 ft.)

Encoder/Pulse I/O

30.5 m to 152.4 m (100 ft. - 500 ft.)

Encoder/Pulse I/O

152.4 m to 259.1 m (500 ft. - 850 ft.)

(1)

Belden 9730 is 3 individually shielded pairs (2 channel plus power). If 3 channel is required, use Belden 9728 (or equivalent).

(2)

Belden 8790 is 1 shielded pair.

(3)

Belden 9892 is 3 individually shielded pairs (3 channel), 0.33 mm2 (22 AWG) plus 1 shielded pair 0.5 mm2 (20 AWG) for power.

(4)

Belden 9773 is 3 individually shielded pairs (2 channel plus power). If 3 channel is required, use Belden 9774 (or equivalent).

(5)

If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessary, but is always recommended.

Combined: Belden 9730 (or

equivalent)

Signal: Belden 9730/9728

(or equivalent)

Power: Belden 8790

Combined: Belden 9892

Signal: Belden 9730/9728

(or equivalent)

Power: Belden 8790

Combined: Belden 9773/9774

(or equivalent)

(1)

shielded

0.196 mm2(24AWG), individually shielded

0.196 mm2(24AWG),

(1)

individually shielded

(2)

0.750 mm2(18AWG)

(3)

0.330 mm2 or 0.500 mm2

0.196 mm2(24AWG),

(1)

individually shielded

(2)

0.750 mm2(18AWG)

0.750 mm2(18AWG),

(4)

individually shielded pair

(18AWG), twisted

(18AWG), 3 cond.,

Minimum Insulation Rating

(5)

300V, 75-90°C (167-194°F)

(3)

1-24 Installation/Wiring

Table 1.G Recommended Control Wire for Digital I/O

Typ e Wire Type (s ) Desc rip ti on

Unshielded Per US NEC or applicable national

or local code

Shielded Multi-conductor shielded cable

such as Belden 8770 (or equivalent)

Wiring the Main Control Board I/O Terminals

Terminal blocks TB1 and TB2 contain connection points for all inputs, outputs, and standard encoder connections. Both terminal blocks reside on the Main Control Board of the PF700S Control Cassette.

Remove the terminal block plug from the socket, and make connections.

Important: For NEMA 1 applications, all wiring must be routed through

the conduit plate on the drive. Route any wires from the expanded cassette to the base cassette and out of the drive.

Reinstall the plug when wiring is complete. The terminal blocks have keys, which make it difficult to insert a terminal plug into the wrong socket.

Figure 1.9 Main Control Board I/O Terminal Locations

— 300V,

0.750 mm 3 conductor, shielded.

(18AWG),

Insulation Rating

60°C (140°F) minimum

TB1 Terminals

TB2 Terminals

Installation/Wiring 1-25

I/O Terminal Blocks

Table 1.H Main Control Board I/O Terminal Block Specifications

Name Description

I/O Blocks Signal and encoder

power connections

(1)

Maximum/minimum that the terminal block will accept - these are not recommendations.

Table 1.I TB1 Terminals

Wire Size Range

Maximum Minimum Maximum Recommended

1.5 mm (16 AWG)

(1)

0.14 mm (28 AWG)

0.25 N-m (2.2 lb.-in.)

Torque

0.22 N-m (1.9 lb.-in.)

Terminal Signal Description

1 Analog Input 1 Common Bipolar, differential input, +/-10V, 0-20 mA, 13 bit + sign

2 Analog Input 1 (+/-) 800

3 Shield Analog Input Shield

4 Analog Input 2 Common Bipolar, differential input, +/-10V, 0-20 mA, 13 bit + sign

5 Analog Input 2 (+/-) 806

6 Analog Input 3 [NTC-] Common Differential input, 0-10V, 10 bit (for motor control mode FVC2,

7 Analog Input 3 [NTC+] 812

8 Shield Analog Output Shield

9 Analog Output 1 (-) Bipolar, differential input, +/-10V, 0-20 mA, 11 bit + sign

10 Analog Output 1 (+)

11 Analog Output 2 (-) 839, 840

12 Analog Output 2 (+)

13 +10V Reference Rating: 20 mA maximum load (recommend 5K ohm

14 Reference Common

15 -10V Reference

16 Encoder A Normal current draw per channel: 20 mA 230-233

17 Encoder A (Not)

18 Encoder B

19 Encoder B (Not)

20 Encoder Z

21 Encoder Z (Not)

22 Encoder Reference (+) 12 or 5 V dc power supply for primary encoder interface

23 Encoder Reference (-)

24 Encoder Shield Connection point for encoder shield

20K ohm impedance at Volt; 500 ohm impedance at mA

this is the temperature adaptation input).

2K ohm minimum load

potentiometer)

Rating: 300 mA maximum

Related Parameter

832, 833

1-26 Installation/Wiring

Figure 1.10 TB1 Terminals — Analog Wiring Examples

Input/Output Connection Example

0-10V Analog Input 0-10V Analog Input - Internal Source Required Parameter Changes

0-10V Analog Input - Bipolar

0-10V Analog Input - External Source

-Signal or Source Common

+Signal

Shield / Common

-Signal or Source Common

+Signal

Shield / Common

-Signal or Source Common

+Signal

Shield / Common

Figure 1.10 TB1 Terminals — Analog Wiring Examples (Continued)

Input/Output Connection Example

Installation/Wiring 1-27

Analog Output

+/- 10V dc

Used to drive analog meters displaying speed and current.

Primary Encoder Interface -

Supports 5V dc/12 V dc differential encoders with internal power supply.

0-10V Analog Output Required Parameter Changes

Using Analog Output 1 (-10V to +10V) to meter Motor RPM and direction:

• Send the data to the Analog Output Parameter

833 [Anlg Out1 Real], the destination, linked to Parameter 71 [Filtered SpdFdbk], the source.

• Scale the Output to the source parameter.

Example: Parameter 835 [Anlg Out1 Scale] = 175 (where Parameter 4 [Motor NP RPM] 1750 is divided by 10V output).

Using Analog Output 2 (-10V to +10V) to meter Motor current:

• Send the data to the Analog Output Parameter

840 [Anlg Out2 Real], the destination, linked to Parameter 308 [Output Current], the source.

• Scale the Output to the source parameter.

Example: Parameter 822 [Anlg Out2 Scale] = xx (where Parameter 2 [Motor NP FLA] is divided by 10V output).

Primary Encoder - Internal Supply Using Encoder 0 as speed feedback:

Encoder

A-

B-

The Z channel is not

required in typical

Z-

applications

• Set Parameter 222 [Motor Fdbk Sel Pri] to a

value of 0 (Encoder 0 = default), so the drive will use this encoder as the primary motor speed feedback device.

• Set the value of Parameter 232 [Encoder 0

PPR] to match the installed encoder’s resolution (Pulses per Revolution).

Primary Encoder - External Supply

Power +V

Common -V

Shield

Encoder

A A-

B B-

The Z channel is not

required in typical

Z-

applications

1-28 Installation/Wiring

Table 1.J TB2 Terminals

Terminal Signal Description

1 24V dc Common (-) Drive supplied 24V dc logic input power

2 24V dc Source (+)

3 Digital Output 1 24V dc Open Collector (sinking logic)

4 Digital Output 1/2 Common Common for Digital Outputs 1 and 2

5 Digital Output 2 24V dc Open Collector (sinking logic)

6 Relay Output 3 (NC) Relay contact output

7 Relay Output 3 Common

8 Relay Output 3 (NO)

9 Digital Input 1-3 Common Common for Digital Inputs 1, 2, and 3

10 Digital Input 1 High speed 12-24V dc sourcing Digital Input

11 Digital Input 2 826

12 Digital Input 3 Load: 15 mA at 24V dc sourcing 827

13 Digital Input 4-6 Common Common for Digital Inputs 4, 5, and 6

14 Digital Input 4 Load: 10 mA at 24V dc sinking/sourcing

15 Digital Input 5 829

16 Digital Input 6 (HW Enable) 830

Rating: 300 mA maximum load

Rating: Internal Source = 150 mA maximum External Source = 750 mA

Rating: 115V ac or 24V dc = 2 A maximum Inductive/Resistive

Load: 15 mA at 24V dc

Load: 7.5 mA at 115V ac

Related Parameter

816, 847

851, 852

856, 857

825

828

Figure 1.11 TB2 Terminals — Digital Wiring Examples

Input/Output Connection Example

Installation/Wiring 1-29

Digital Inputs used for enable and precharge control.

Note:

24V dc Supply - supports only on-board digital inputs. Do not use for circuits outside the drive.

Note:

The factory default for all Digital Inputs is 24V. This must be switched in order to use 115V.

Note:

Digital Inputs 1, 2, and 3 are always 24V dc.

Sourcing Digital Inputs - using internal power supply Sourcing and Sinking Definitions

Com

24V DC

Sourcing Digital Outputs - using internal power supply

Com

24V dc

Sinking Digital Inputs - using internal power supply

Com

24V dc

The digital inputs and digital outputs of the LPM20 with High Performance Drive Control support Sourcing or Sinking configuration. Typically, digital inputs are sourcing devices and digital outputs are sinking devices. The following definitions apply throughout this section:

Sourcing a Digital Input

A. Connect the digital input common (return) directly

to the power supply common.

B. Applying positive voltage to the digital input will

cause it to activate (pull up).

Sourcing a Digital Output

A. Connect the digital output common (return)

directly to the power supply common.

B. Connect the device to be controlled by the digital

output to the positive voltage, and the device common to the digital output.

Sinking a Digital Input

A. Connect the digital input common to the power

supply positive voltage.

B. Applying 0V or common to the digital input will

cause it to activate (pull down).

Sinking a Digital Output

A. Connect the digital output common (return) to the

power supply positive voltage.

B. Connect the digital output to the device to be

controlled, and the device common to the power supply common.

Note:

Digital Inputs 1, 2, and 3 can only be configured as sourcing inputs. Digital Inputs 4, 5, and 6 can be configured as sourcing or sinking inputs.

Sinking Digital Outputs - using internal power supply

Com

24V dc

1-30 Installation/Wiring

Figure 1.11 TB2 Terminals — Digital Wiring Examples (Continued)

Input/Output Connection Example

Digital Inputs - 24V dc Sourcing Digital Inputs - using internal power supply, 2-Wire

Control

Com

24V DC

Sourcing Digital Inputs - using internal power supply, 3-Wire Control

Com

24V DC

RUN

Enable

START

STOP

Enable

Required Parameter Changes

• Set Parameter 829 [DigIn 5 Sel] to a value of 7

(Run).

• Parameter 153 [Control Options] bit 8

(3WireControl) will automatically be OFF for 2-wire control.

• Set Parameter 168 [Normal Stop Mode] for the

desired stopping mode:

0 = Ramp Stop 1 = CurLim Stop 2 = Coast Stop

• Set Parameter 829 [DigIn 5 Sel] to a value of 14

(Normal Stop).

• Set Parameter 828 [DigIn 4 Sel] to a value of 5

(Start).

• Parameter 153 [Control Options] bit 8

(3WireControl) will automatically be ON for 3-wire control.

• Set Parameter 168 [Normal Stop Mode] for the

desired stopping mode:

0 = Ramp Stop 1 = CurLim Stop 2 = Coast Stop

Hard Enable Circuitry

A dedicated hardware enable input is provided on TB2 - Terminal 16 (Digital Input 6) for applications that require the drive to be disabled without software interpretation.

Main Control Board I/O and Encoder Settings

SWITCH S5

SIDE VIEW

Up = Open = Off

FRONT

TOP VIEW

Installation/Wiring 1-31

JUMPER P22

= HW Enable

= No HW Enable

Down = Closed = On

SWITCH S2

Up = Open = Off

Down = Closed = On

SIDE VIEW

SWITCH S3

Up = Open = Off

Down = Closed = On

Table 1.K Switch Settings

FRONT

TOP VIEW

SIDE VIEW

FRONT

TOP VIEW

SWITCH S4

Up = Open = Off

Down = Closed = On

SIDE VIEW

FRONT

TOP VIEW

Function Switch Open Closed Default Notes

Configuring Digital Input 6 for Hardware Enable (HW Enbl)

Analog Input 1 S5-1 Voltage Current Voltage Change with Power Off.

Analog Input 2 S5-2 Voltage Current Voltage Change with Power Off.

Digital Inputs 4-6 Voltage S4-1, S4-2 115V ac 24V dc 24V dc Change with Power Off.

Digital Input 1 Voltage S3-1 24V dc 12V dc 24V dc Change with Power Off.

Digital Input 2 Voltage S3-2 24V dc 12V dc 24V dc Change with Power Off.

Encoder Voltage Supply S2-1 12V dc 5V dc 24V dc Change with Power Off.

Encoder Signal A Voltage S2-2 12V dc 5V dc 12V dc

Encoder Signal B Voltage S2-3 12V dc 5V dc 12V dc

Encoder Signal Z Voltage S2-4 12V dc 5V dc 12V dc

Function Switch Open Closed Default Notes

DriveLogix Processor S1 RUN Remote Program Processor mode.

P22 Jumper

pin 2-4 HW enable

pin 1-3 No enable

pin 2-4 HW enable

No jumper = HW enable

Set all switches the same.

Please note there are two separate values for an encoder.

1-32 Installation/Wiring

Connecting SynchLink

SynchLink provides high-speed synchronization and communication between multiple LPM20 drives with High Performance Drive Control (or other products with SynchLink capability).

Class 1 LED Product

ATTENTION: Hazard of permanent eye damage exists when

When planning and connecting the SynchLink network, please refer to the SynchLink System Design Guide (Publication No. 1756-TD008).

Connect cables to J1 (transmit) and J2 (receive) connectors on the left side of the Main Control Board. Push the plug into the socket until it produces an audible click.

using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into module ports or fiber optic cable connectors.

J2 (Receive)

J1 (Transmit)

Important: Do not overtighten tie-wraps.

Table 1.L SynchLink Cables and Accessories

Description Cat. No.

2 x 1 M Fiber Optic Link 1403-CF001

2 x 3 M Fiber Optic Link 1403-CF003

2 x 5 M Fiber Optic Link 1403-CF005

10 M Fiber Optic Link 1403-CF010

20 M Fiber Optic Link 1403-CF020

50 M Fiber Optic Link 1403-CF050

100 M Fiber Optic Link 1403-CF100

250 M Fiber Optic Link 1403-CF250

500 M Fiber Optic Bulk 1403-CFBLK

Installation/Wiring 1-33

Table 1.L SynchLink Cables and Accessories (Continued)

Description Cat. No.

SynchLink Fiber-Hub, 1 input, Base 1751-SLBA

SynchLink Fiber-Hub, 4 output, “Star” Splitter 1751-SL4SP

SynchLink Bypass Switch 1751-SLBP/A

Table 1.M Fiber Optic Cable Assembly

Specification

Connecting Cables 200/230 micron HCS (Hard Clad Silica)

• Ve r s a link V- S y s tem

• Lucent Technologies,

• Specialty Fibers Technology Division

Maximum Cable Length 300 meters with no more than one splice or one adapter

Minimum Cable Length 1 meter

Minimum inside bend radius 25.4mm (1 in.) Any bends with a shorter inside radius can

permanently damage the fiber optic cable. Signal attention increases with decreased inside bend radius.

Operating Wavelength 650 nm (Red)

Data Rate 5 Mbps Maximum Node Count • 10 - Daisy Chain

• 256 - Star Configuration

Active Converter Communication

Auto Tune Operation

The active converter communicates control and starts information with the 700S controller over DPI Data Link D.

• 700AC Parameter 71 - [Converter Status] is transferred to 700S Parameter 657 - [DPI Data In D1]. This may be used to monitor the operation of the active converter.

• 700S Parameter 666 - [DPI Data Out D1] is transferred to 700AC Parameter 70 - [Converter Control]. This may be used to start and stop the converter.

• 700S Parameter 667 - [DPI Data Out D2] is transferred to 700AC Parameter 72 - [Converter Min Vdc]. This may be used to set the minimum DC link voltage reference.

For more information, please refer to the PowerFlex 700 Active Converter Power Module User Manual (Publication No. PFLEX-UM002…).

The pre-charge bypass contactor must be closed and the converter must be enabled before Auto Tuning of the inverter can be performed. See the section below on Pre-charge Operation to accomplish this.

700S Parameter 431 sets the current level for the Auto Tune procedure. The default value of 50.0% is high for large horsepower drives. A typical value for a motor connected to an LPM20 drive is 20.0%.

After the converter is ready and parameters are set correctly, the Auto Tune operation can be initiated from the HIM as described in the PowerFlex 700S High Performance AC Drive — Phase II Control User Manual (Publication No. 20D-UM006…).

1-34 Installation/Wiring

Pre-charge Operation

The pre-charge bypass contactor is controlled by the active converter. On power up, the contactor is open so the pre-charge resistors limit the current charging the DC link. The contactor may operate in one of three ways as selected by 700AC-Parameter 50 - [Start Config]:

• If “Run On Start” is selected, then logic must be added to the application to turn on 700AC-Parameter 70 - [Converter Control] bit 0 to close the pre-charge and enable the converter to regulate the DC Link Voltage. The inverter may not be started until 700AC-Parameter 71 - [Converter Status] bits 2 and 3 have been turned on by the active converter.

• If “Run On PwrUp” is selected, then the pre-charge bypass contactor is automatically closed several seconds after power is turned on and the converter is automatically enabled.

• If “Manual Cntrl” is selected, then the pre-charge bypass contactor is manually controlled by 700AC-Parameter 52 - [Manual Control] bit 0, and enabling of the active converter is manually controlled by 700AC-Parameter 52 bit 1. This mode is primarily intended for troubleshooting or during startup.

WARNING: The user must verify that the pre-charge is closed

before enabling the inverter or the pre-charge resistors may be damaged. This can be done with a Logix application program or by wiring the auxiliary contacts on the pre-charge bypass contactor in series with the run permissive on the inverter.

Wiring the Active Converter Control Board I/O Terminals

Terminal blocks A11-P2 and A12-P1 contain connection points for all inputs, outputs, and power connections to the Active Converter Control Board.

Remove the terminal block plug from the socket, and make connections. For more information, please refer to the PowerFlex 700 Active Converter Power Module User Manual (Publication No. PFLEX-UM002…).

Reinstall the plug after wiring is complete. The terminal blocks have keys, which make it difficult to insert a terminal plug into the wrong socket.

Figure 1.12 Active Converter Control Board I/O Terminal Locations

A12 - Active Converter Control Assembly

A12 - P1

Terminals

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

7 6 5 4 3 2 1

SW1

Installation/Wiring 1-35

SW1

DPI Slave = OFF (Default)

DPI Master = ON

A11 - P2

Terminals

A11 - Voltage Feedback Resistor Assembly

I/O Terminal Blocks

Table 1.N Active Converter Control Board I/O Terminal Block Specifications

Name Description

I/O Blocks Signal and power

connections

(1)

Maximum/minimum that the terminal block will accept - these are not recommendations.

Table 1.O Active Converter Control Board A12-P1 Terminal Descriptions

Pin Description Pin Description

1 Comm Out + 9 Aux Out N.O.

2 Comm Out - 10 Aux Out Common

3 SOC Out + 11 Analog In Signal

4 SOC Out - 12 Analog In Common

5 Comm In + 13 Safety HW Enable

6 Comm In - 14 24 Vdc

7 SOC In + 15 Aux Input

8 SOC In -

Wire Size Range

Maximum Minimum Maximum Recommended

1.5 mm (16 AWG)

(1)

0.14 mm (28 AWG)

0.25 N-m (2.2 lb.-in.)

Torque

0.22 N-m (1.9 lb.-in.)

1-36 Installation/Wiring

Table 1.P Active Converter Voltage Feedback Board A11-P2 Terminal Descriptions

Pin Description

1L1

4L2

7L3

CE Conformity

EMC Instructions

CE Compliance

Compliance with the Low Voltage Directive 73/23/EEC and Electromagnetic Compatibility Directive 89/336/EEC has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. LPM20 drives comply with the EN standards listed below when installed according to instructions in this section.

Low Voltage Directive (73/23/EEC)

• EN50178 Electronic equipment for use in power installations

EMC Directive (89/336/EEC)

• EN61800-3 Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods

CE Declarations of Conformity are available online at: http://www.ab.com/certification/ce/docs

General Notes

• Without additional external filtering, LPM20 drives satisfy the 2nd Environment high-frequency emission limits of EN61800-3. Without external mitigation, LPM20 drives are not intended to be used on a low-voltage public network which supplies residential or office premises; radio frequency interference is expected if used in such an environment.

• The drive motor cable should be kept as short as possible in order to minimize electromagnetic emission and capacitive currents.

• Use of line filters in ungrounded systems is not recommended.

• Conformity of the drive with CE EMC requirements does not guarantee

an entire machine or installation complies with CE EMC requirements. Many factors influence overall machine/installation compliance.

Installation/Wiring 1-37

Essential Requirements for CE Compliance

Conditions 1-5 listed below must be satisfied for LPM20 drives to meet the requirements of EN61800-3:

1. Standard LPM20 CE compliant drive.

C-Tick Conformity

2. Grounding as described in Grounding the Drive

3. Output power wiring to the motor, and all control/signal wiring must use

braided shielded cable with a shield coverage of 75% or greater, or metal conduit.

4. The shields of all shielded cables must be terminated with the proper

connectors to chassis/earth.

5. Motor cables must not exceed 20 meters (65.6 feet) in length.

Compliance of LPM20 drives with the Australian Radiocommunications Act of 1992 has been demonstrated through compliance with EN61800-3. Both the General Notes and the Essential Requirements for CE Compliance provided above apply to C-Tick compliance for LPM20 drives.

C-Tick Declarations of Compliance are available online at: http://www.ab.com/certification/c-tick/index.html

on page 1-13.

1-38 Installation/Wiring

Notes:

Chapter 2

Start Up

This chapter describes how to start up the LPM20. Refer to Appendix B for a brief description of the LCD HIM (Human Interface Module).

For information on ... See page ...

Prepare For Drive Start-Up

Status Indicators 2-3

Assisted Start Up 2-4

ATTENTION: Power must be applied to the drive to perform the following start-up procedure. Some of the voltages present are at

incoming line potential. To avoid electric shock hazard or damage to equipment, only qualified service personnel should perform the following procedure. Thoroughly read and understand the procedure before beginning. If an event does not occur while performing this procedure, Do Not Proceed. Remove Power including user-supplied control voltages. User-supplied voltages may exist even when main AC power is not applied to the drive. Correct the malfunction before continuing.

2-1

Prepare For Drive Start-Up

Before Applying Power to the Drive

Important: If you have a DriveLogix application, you must first connect

the battery before starting this procedure.

❏ 1. Confirm that motor wires are connected to the correct terminals and are

secure.

❏ 2. Confirm that encoder wires are connected to the correct terminals and

are secure.

❏ 3. Confirm that all inputs are connected to the correct terminals and are

secure.

❏ 4. Verify that AC line power at the disconnect device is within the rated

value of the drive.

❏ 5. Verify that control power voltage is correct.

The remainder of this procedure requires that a HIM be installed. If an operator interface is not available, remote devices should be used to start up the drive.

2-2 Start Up

Applying Power to the Drive

❏ 6. Apply AC power and control voltages to the drive.

If any digital input is configured to “Stop – CF” (CF = Clear Fault) or “Enable,” verify that signals are present or the drive will not start. For a list of potential digital input conflicts or if a fault code appears, please refer to the PowerFlex 700S High Performance AC Drive — Phase II

…

Control User Manual (Publication No. 20D-UM006

❏ 7. Examine the Inverter Status and Rectifier Status LEDs located on the

DPI Communications Interface Board on the front of the power module (see Figure 2.1 refer to the descriptions in Figure 3.1 shown in Tab le 2.A

Table 2.A Common Causes of a Pre-Start Alarm

Examine Par 156 - [Run Inhibit Status]

bit Description Action

1 No power is present at the Enable Terminal (TB2 -Terminal 16). Apply the enable.

2, 3, 4 A stop command is being issued. Close all stop inputs.

5 Power loss event is in progress, indicating a loss of the AC input voltage. Restore AC power.

6 Data supplied by the power structure EEprom is invalid or corrupt. Cycle power. If problem persists, replace the power structure.

7 Flash update in progress. Complete Flash procedures.

8 Drive is expecting a Start Edge and is receiving a continuous signal. Open all start buttons and remove all start commands.

9 Drive is expecting a Jog Edge and is receiving a continuous signal. Open all jog buttons and remove all jog commands.

10 A conflict exists between the Encoder PPR programming (Par 232 or 242)

and the encoder configuration for edge counts (Par 233 or 243, bits 4 and 5).

11 The drive cannot precharge because a precharge input is programmed and

no signal is present.

Start input configured but stop not configured. Program Par 838-840 to include a stop button; rewire the drive.

Run input configured but control options do not match. Program Par 153, Bit 8 to “0” (2 wire control).

Start input configured but control options do not match. Program Par 153, Bit 8 to “1” (3 wire control).

14 Invalid Feedback Device for Permanent Magnet Motor Control Set Par 222 to a value of “5” (FB Opt Port0)

Multiple inputs configured as Start or Run. Reprogram Par 838-840 so multiple starts, multiple runs or any

Multiple inputs configured as Jog1. Program Par 838-840 so only (1) is set to Jog1.

Multiple inputs configured as Jog 2. Program Par 838-840 so only (1) is set to Jog2.

Digital Configuration

Multiple inputs configured as Fwd/Rev. Program Par 838-840 so only (1) is set to Fwd/Rev.

). Verify that they are flashing green. If not in this state,

. Also, check the possible causes

and take necessary corrective action.

Verify encoder data and reprogram.

Reprogram the input or close the precharge control contact.

combination do not exist.

), Chapter 4.

❏ 8. Proceed to Start-Up routine.

Start Up 2-3

Status Indicators

Figure 2.1 Drive Inverter and Rectifier Status LEDs

DPI Communications Interface Board (front surface of power module)

Inverter Status LED

Rectifier Status LED

2-4 Start Up

Figure 2.2 Drive RUN LED on PF700S Control Cassette

Drive RUN LED

RUN

I/O

DriveLogix Indicators

(only supplied when drive is equipped with



DriveLogix Controller)

Name Color State Description

Drive RUN LED (topmost indicator)

DriveLogix Indicators

If the DriveLogix option is not present, the associated indicators will not be present.

Important Information

5730

FORCE

COM

BAT

Green Off Drive inverter is not providing a modulated output.

Steady Drive inverter is providing a modulated output.

For status descriptions of the six DriveLogix indicators, please refer to the

DriveLogix



5730 Controller User Manual (Publication No. 20D-UM003…).

Assisted Start Up

Power must be applied to the drive when viewing or changing parameters. Previous programming may affect the drive status and operation when power is applied.

For Assisted Start-Up information, please refer to the PowerFlex 700S High

Performance AC Drive — Phase II Control User Manual (Publication No. 20D-UM006

…

) in Chapter 2.

Chapter 3

Troubleshooting

Chapter 3 provides information to guide you in troubleshooting the LPM20 with High Performance Drive Control.

For information on ... See page ...

Faults and Alarms

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

3-1

Faults and Alarms

A fault is a condition that stops the drive. There are two fault types.

Type Fault Description

Non-Resettable This type of fault normally requires drive or motor repair. The cause of

➀

User Configurable These faults can be enabled/disabled to annunciate or ignore a fault

➁

An alarm is a condition that, if left untreated, may stop the drive. There are two alarm types.

Type Alarm Description

User Configurable These alarms can be enabled or disabled through [Alarm Config 1]

➀

Non-Configurable These alarms are always enabled.

➁

the fault must be corrected before the fault can be cleared. The fault will be reset on power up after repair.

condition.

parameter.

3-2 Troubleshooting

Drive Status

Power Module LED Indications

The Inverter Status LED and Rectifier Status LED are located on the DPI Communications Interface Board on the front of the power module. The LEDs indicate the status of the inverter and the rectifier as shown in the table in Figure 3.1 receiving power.

Figure 3.1 Inverter and Rectifier Status LEDs and Indications

DPI Communications Interface Board (front surface of power module)

. Note that if the LEDs are off, it indicates the drive is not

Inverter Status LED

Rectifier Status LED

Color State Description

Green Flashing Drive ready, but not running and no faults are present.

Steady Drive running, no faults are present.

Yellow Flashing A type 2 (non-configurable) alarm condition exists, but drive continues to run.

Steady A type 1 (user configurable) alarm condition exists, but drive continues to run.

Red Flashing A fault has occurred.

Steady A non-resettable fault has occurred.

Troubleshooting 3-3

HIM Indication

The LCD HIM also provides visual notification of a fault or alarm condition.

Condition Display

Drive is indicating a fault.

The LCD HIM immediately reports the fault condition by displaying the following:

• “Faulted” appears in the status line

• Fault number

• Fault name

• Time that has passed since fault occurred

Press Esc to regain HIM control.

Drive is indicating an alarm.

The LCD HIM immediately reports the alarm condition by displaying the following:

• Alarm name (Type 2 alarms only)

• Alarm bell graphic

F-> Faulted Auto

0.0

— Fault — F 5

Main Menu:

OverVoltage

Diagnostics

Time Since Fault

0000:23:52

Parameter

F-> Power Loss Auto

0.0

Main Menu: Diagnostics Parameter Device Select

Manually Clearing Drive Faults

Drive Fault Descriptions

Active Converter Fault Descriptions

Step Key(s)

1. Press Esc to acknowledge the fault. The fault information will be removed so that you can use the HIM.

2. Address the condition that caused the fault.

The cause must be corrected before the fault can be cleared.

3. After corrective action has been taken, clear the fault by one these methods:

• Press Stop

• Cycle drive power

• Set parameter 240 [Fault Clear] to “1.”

• “Clear Faults” on the HIM Diagnostic menu.

For a complete list and description of drive faults (with possible corrective actions, when applicable) and alarms, please refer to the PowerFlex 700S High Performance AC Drive — Phase II Control User Manual (Publication No. 20D-UM006…) in Chapter 4.

For a complete list and description of active converter faults (with possible corrective actions, when applicable) and alarms, please refer to the PowerFlex 700 Active Converter Power Module User Manual (Publication No. 20D-UM006…) in Chapter 4.

Esc

Clearing Drive Alarms

Drive alarms are automatically cleared when the condition that caused the alarm is no longer present.

3-4 Troubleshooting

Common Symptoms and Corrective Actions

Drive does not Start from Start or Run Inputs wired to the terminal block.

Cause(s) Indication Corrective Action

Drive is faulted. Flashing red

status light.

Incorrect input wiring. See

Figure 1.11

Incorrect digital input programming.

• Mutually exclusive choices have

• Exclusive functions (i.e, direction

• Stop is factory default and is not

Drive does not Start from HIM.

Cause(s) Indication Corrective Action

Drive is programmed for 2 wire control. HIM Start button is disabled for 2 wire control.

Active fault. Flashing or

Enable input is open. Flashing yellow

for wiring examples.

been made (i.e., Jog and Jog Forward).

control) may have multiple inputs configured.

wired or is open.

None Wire inputs correctly and/or install jumper.

None Program [Digital Inx Sel] parameter for correct

Flashing yellow status light and “DigIn CflctB” indication on LCD HIM.

[Drive Status 2] shows type 2 alarm(s).

None If 2 wire control is required, no action needed.

steady red LED.

LED.

Clear the fault:

• Press HIM Stop key if HIM is control

source.

• Cycle power.

• Set [Fault Clear] parameter to 1.

• “Clear Faults” on the HIM Diagnostic

menu.

inputs.

Start or Run programming may be missing.

Program [Digital Inx Sel] parameter to resolve conflicts.

Remove multiple selections for the same function.

Install stop button to apply a signal at stop terminal.

If 3 wire control is required, program [Digital Inx Sel] parameter for correct inputs.

Reset fault.

Close terminal block enable input.

Drive does not respond to changes in Speed Command.

Cause(s) Indication Corrective Action

No value is coming from the source of the command.

Incorrect reference source has been programmed.

Incorrect reference source is being selected via remote device or digital inputs.

LCD HIM Status Line indicates “At Speed” and output is 0 Hz.

None 3. Check [Speed Ref Source] parameter for

None 5. Check [Drive Status 1] parameter, bits 12

1. If the source is an analog input, check wiring and use a meter to check for presence of signal.

2. Check [Commanded Freq] parameter for correct source.

the source of the speed reference.

4. Reprogram [Speed Ref A Sel] parameter for correct source.

and 13 for unexpected source selections.

6. Check [Dig In Status] parameter to see if inputs are selecting an alternate source.

7. Reprogram digital inputs to correct “Speed Sel x” option.

Troubleshooting 3-5

Motor and/or drive will not accelerate to Commanded Speed.

Cause(s) Indication Corrective Action

Acceleration time is excessive. None Reprogram [Accel Time x] parameter.

Excess load or short acceleration times force the drive into current limit, slowing or stopping acceleration.

Speed command source or value is not as expected.

Programming is preventing the drive output from exceeding limiting values.

Motor operation is unstable.

Cause(s) Indication Corrective Action

Motor data was incorrectly entered. None Correctly enter motor nameplate data.

Drive will not reverse motor direction.

Cause(s) Indication Corrective Action

Digital input is not selected for reversing control.

Digital input is incorrectly wired. None Check input wiring. (See page 1-25)

Direction mode parameter is incorrectly programmed.

Motor wiring is improperly phased for reverse.

A bipolar analog speed command input is incorrectly wired or signal is absent.

None 1. Check [Drive Status 2] parameter, bit 10 to

see if the drive is in Current Limit.

2. Remove excess load or reprogram [Accel Time x] parameter.

None Check for the proper Speed Command using

Steps 1 through 7 previously described.

None Check [Maximum Speed] parameter and

[Maximum Freq] parameter to assure that speed is not limited by programming.

None Check [Digital Inx Sel] parameter. Choose

correct input and program for reversing mode.

None Reprogram [Direction Mode] parameter for

analog “Bipolar” or digital “Unipolar” control.

None Switch two motor leads.

None 1. Use meter to check that an analog input

voltage is present.

2. Check wiring. (See page 1-25)

Positive voltage commands forward direction. Negative voltage commands reverse direction.

3-6 Troubleshooting

Test Equipment Needed To Troubleshoot

Verifying That DC Bus Capacitors Are Discharged

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

ATTENTION: DC bus capacitors retain hazardous voltages

The LPM20 drive’s DC bus capacitors retain hazardous voltages after input power has been disconnected. Perform the following steps before touching any internal components:

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

2. Verify that there is no voltage at the power module’s input power

terminals (L1, L2, and L3) as shown in Figure 1.8

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.

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

non-conductive surface and wearing insulated gloves (1000 V). The DC bus measurement points are located on the Inverter (see Figure 3.2

4. After the drive has been serviced, reapply input power.

Figure 3.2 Location of DC Bus Voltage Measurement Points

Neg (-)

Pos (+)

DC Bus Measurement Points on Laminated Bus Ass'y 0.25" x 0.032" Male Faston. Accessible by Removal of Top Cover.

Front View of Inverter Right Side View of Inverter

Troubleshooting 3-7

Replacement Parts

Table 3.A lists the replacement parts that are available from Allen-Bradley.

For parts locations, refer to Figure 1.1

Table 3.A Drive Replacement Parts

Vol ta ge Class

400/480 608A 80W Power Supply Assembly SP-180944-A01 2

400/480 608A Inlet Hose & Outlet Hose Assys, w/spare O-ring SP-349811-A01 1

400/480 608A Resistor, Filter, 100K ohm, 50W, Kit - (3) per box SP-352489-A01 1

400/480 608A Resistor, Precharge, 10 ohm, 300W, Kit - (3) per box) SP- 322542-A01 1

400/480 608A Control Transformer, Multi-tap, 3 KVA SP-180086 1

400/480 608A Wire Harness Assy, P1 Connector-to-Input Filter

400/480 608A Cap Bank Assy, Input Filter, 608A SP-342008-A01 1

400/480 608A Inductor, Input Filter, 608A SP-180824-C01 1

400/480 608A Inverter Power Interface Assy, 608A SP-180940-A04 1

400/480 608A Contactor, AC Precharge, 140A, 600 VAC 100-D140D11 3

Replacement Fuses

For replacement fuses, refer to the drive wiring diagram on page C-2.

Drive Current Rating

Description Catalog Number

Control

, Figure 1.2, and Figure 1.3.

Qty. per Drive

SP-181251-A01 1

3-8 Troubleshooting

Notes:

Supplemental Drive Information

For information on ... See page ...

Specifications

Communication Configurations A-3

A-1

Appendix A

Specifications

Category Specification

Agency Certification

The drive is also designed to meet the following specifications:

(1)

Applied noise impulses may be counted in addition to the standard pulse train causing erroneously high [Pulse Freq] readings.

Category Specification

Protection Drive 480V

AC Input Overvoltage Trip: 570Vac

AC Input Undervoltage Trip: 280Vac

Bus Overvoltage Trip: 810Vdc

Bus Undervoltage Shutoff/Fault: 305Vdc

Nominal Bus Voltage: 648V dc

All Drives

Heat Sink Thermistor: Monitored by microprocessor overtemp trip

Environment Altitude: 1000 m (3300 ft) max. without derating

Drive Overcurrent Trip

Software Overcurrent Trip: Hardware Overcurrent Trip:

Line transients: Up to 6000 volts peak per IEEE C62.41-1991

Control Logic Noise Immunity: Showering arc transients up to 1500V peak

Power Ride-Thru: 15 milliseconds at full load

Logic Control Ride-Thru: 0.5 seconds minimum, 2 seconds typical

Ground Fault Trip: Phase-to-ground on drive output

Short Circuit Trip: Phase-to-phase on drive output

Maximum Surrounding Air Temperature without Derating:

IP20, NEMA Type 1: 0 to 40°C (32 to 104°F)

Storage Temperature (all constructions): –40 to 70°C (–40 to 158°F)

Listed to UL508C and CAN/CSA-C2.2 No. 14-M91.



Marked for all applicable European Directives

EMC Directive (89/336/EEC) EN 61800-3 Adjustable Speed electrical power drive systems Low Voltage Directive (73/23/EEC) EN 50178 Electronic Equipment for use in Power Installations

NFPA 70 - US National Electrical Code NEMA ICS 3.1 - Safety standards for Construction and Guide for Selection, Installation and Operation of Adjustable Speed Drive Systems. IEC 146 - International Electrical Code.

200% of rated current (typical) 220-300% of rated current (dependent on drive rating)

(1)

A-2 Supplemental Drive Information

Category Specification

Environment

(continued)

Electrical Voltage Tolerance: For full power and operating range, see the Powe rFlex

Control Method: Sine coded PWM with programmable carrier

Atmosphere: Important: Drive must not be installed in an area

where the ambient atmosphere contains volatile or corrosive gas, vapors or dust. If the drive is not going to be installed for a period of time, it must be stored in an area where it will not be exposed to a corrosive atmosphere.

Relative Humidity: 5 to 95% non-condensing Shock: 15G peak for 11 milliseconds duration (± 1.0 ms)

Vibration: 0.152 mm (0.006 in.) displacement, 1G peak

700S High Performance AC Drive — Phase II Control User Manual (Publication No. 20D-UM006…),

Appendix E.

Frequency Tolerance: 47-63 Hz.

Input Phases: Three-phase input provides full rating for all drives.

Single-phase operation provides 50% of rated current.

Displacement Power Factor: 0.98 across entire speed range.

Efficiency: 97.5% at rated amps, nominal line volts.

Max. Short Circuit Rating: 100,000 Amps symmetrical.

Actual Short Circuit Rating: Determined by AIC rating of installed circuit breaker.

Motor Lead Lengths: 76 meters (250 feet) total

frequency. Ratings apply to all drives (refer to the

Derating Guidelines in the PowerFlex Reference Manual). The drive can be supplied as 6 pulse or 12

pulse in a configured package.

Carrier Frequency: 2, 3 or 4 kHz. Drive rating based on 4 kHz.

Output Voltage Range: 0 to rated motor voltage

Output Frequency Range: 0 to 400 Hz.

Speed Control: Speed Regulation - without feedback

0.1% of base speed across 120:1 speed range 120:1 operating range 50 rad/sec bandwidth

Speed Regulation - with feedback

0.001% of base speed across 120:1 speed range 1000:1 operating range 300 rad/sec bandwidth

Torque Regulation: Torque regulation - without Feedback

± 10%, 600 rad/sec bandwidth

Torque regulation - with Feedback

± 5%, 4400 rad/sec bandwidth

Selectable Motor Control: Field Oriented Control with and without a feedback

device and permanent magnet motor control.

Stop Modes: Multiple programmable stop modes including - Ramp,

Coast, and Current Limit.

Accel/Decel: Independently programmable accel and decel times,

adjustable from 0 - 6553.5 seconds in 0.01 second increments.

S-Curve Time Adjustable from 0.5 to 4.0 seconds

Intermittent Overload: 110% Overload capability for up to 1 minute

150% Overload capability for up to 3 seconds

Current Limit Capability: Proactive Current Limit programmable from 20 to

160% of rated output current. Independently programmable proportional and integral gain.

Electronic Motor Overload Protection: Class 10 protection with speed sensitive response.

Investigated by U.L. to comply with N.E.C. Article 430. U.L. File E59272, volume 12.

Category Specification

Feedback Encoder Inputs (2):

Encoder Voltage Supply:

Maximum Input Frequency:

Stegmann Hi-Resolution Option:

Encoder Voltage Supply:

Hi-Resolution Feedback:

Maximum Cable Length:

RS-485 Interface:

Customer-I/O Plug (P1) - Hi Res:

Resolver Option:

Excitation Frequency:

Excitation Voltage:

Operating Frequency Range:

Resolver Feedback Voltage:

DriveLogix User Available Memory Base: 1.5 megabytes

Maximum Cable Length:

Battery: 1756-BA1 (Allen-Bradley PN 94194801) 0.59g lithium

Serial Cable: 1761-CBLPM02 to 1761-NET-AIC

Compact I/O Connection: Up to (30) modules

Cable: 20D-DL2-CL3

Supplemental Drive Information A-3

Dual Channel Plus Marker, Isolated with differential transmitter output (Line Drive), Incremental, Dual Channel Quadrature type

5V dc or 12V dc (5V dc requires an external power supply), 320 mA/channel

400 kHz

11.5V dc @ 130 mA

Sine/Cosine 1V P-P Offset 2.5

182 m (600 ft.)

Hi-Resolution Feedback Option card obtains the following information via the Hiperface RS-485 interface shortly after power-up: Address, Command Number, Mode, Number of Turns, Number of Sine/Cos cycles, Checksum

Allen-Bradley PN: S94262912

Weidmuller PN: BL3.50/90/12BK

2400 Hz

4.25 - 26 Vrms

1 - 10 kHz

2V ± 300mV

304.8 m (1000 ft.)

1761-CBLPA00 to 1761-NET-AIC

1756-CP3 directly to controller

1747-CP3 directly to controller

Category 3 (2)

20D-DL2-CR3

Communication Configurations

Typical Programmable Controller Configurations

Important: If programs are written that continuously write information to

the drive, care must be taken to properly format the block transfer. If attribute 10 is selected for the block transfer, values will be written only to RAM and will not be saved by the drive. This is the preferred attribute for continuous transfers. If attribute 9 is selected, each program scan will complete a write to the drive’s non-volatile memory (EEprom). Since the EEprom has a fixed number of allowed writes, continuous block transfers will quickly damage the EEprom. Do Not assign attribute 9 to continuous block transfers. Refer to the individual communications adapter User Manual for additional details.

A-4 Supplemental Drive Information

Logic Command Word

Logic Bits

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Command Description

xNormal

Stop

xStart

x Jog 1 0 = Not Jog using [Jog Speed 1]

xClear

x x Unipolar

x Reserved

x Jog 2 0 = Not Jog using [Jog Speed 2]

x Current

x Coast Stop 0 = Not Coast to Stop

xSpd Ramp

x Reserved

x Spd Ref

x Reserved

(1)

A Not Stop condition (logic bit 0 = 0, logic bit 8 = 0, and logic bit 9 = 0) must first be present before a 1 = Start condition will start the drive.

(2)

To perform this command, the value must switch from “0” to “1.”

Fault

Direction

Limit Stop

Hold

Sel0

Sel1

Sel2

0 = Not Normal Stop 1 = Normal Stop

(1)

0 = Not Start 1 = Start

1 = Jog using [Jog Speed 1]

0 = Not Clear Fault

(2)

1 = Clear Fault

00 = No Command 01 = Forward Command 10 = Reverse Command 11 = Hold Direction Control

1 = Jog using [Jog Speed 2]

0 = Not Current Limit Stop 1 = Current Limit Stop

1 = Coast to Stop

000 = Spd Ref A 001 = Spd Ref B 010 = Preset 2 011 = Ref. 3 (Preset 3) 100 = Ref. 4 (Preset 4) 101 = Ref. 5 (Preset 5) 110 = Ref. 6 (Preset 6) 111 = Ref. 7 (Preset 7)

Supplemental Drive Information A-5

Logic Status Word

Logic Bits

1514131211109876543210Status Description

x Enabled 0 = Not Enabled

x Running 0 = Not Running

xCommand

x Actual

x Accel 0 = Not Accelerating

x Decel 0 = Not Decelerating

x Jogging 0 = Not Jogging

x Fault 0 = No Fault

xAlarm0 = No Alarm

x Flash Mode 0 = Not in Flash Mode

x Run Ready 0 = Not Ready to Run

x At Limit

x Tach Loss Sw0 = Not Tach Loss Sw

x At Zero Spd 0 = Not At Zero Speed

x At Setpt

x Reserved

(1)

See Par 304 - [Limit Status] in the PowerFlex 700S High Performance AC Drive — Phase II Control User Manual

(Publication No. 20D-UM006

…

) for a description of the limit status conditions.

Direction

Spd

1 = Enabled

1 = Running

0 = Reverse 1 = Forward

1 = Accelerating

1 = Decelerating

1 = Jogging

1 = Fault

1 = Alarm

1 = In Flash Mode

1 = Ready to Run

(1)

0 = Not At Limit 1 = At Limit

1 = Tach Loss Sw

1 = At Zero Speed

0 = Not At Setpoint Speed 1= At Setpoint Speed

A-6 Supplemental Drive Information

Notes:

HIM Overview

For information on … See page

Remote HIM Connection

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

B-1

Appendix B

Remote HIM Connection

The LPM20 provides a cable connection point (DPI Port 4) for a remote LCD HIM. This port is located on the Communications Interface Assembly (item 29 shown in Figure 1.3

Figure B.1 DPI Port 4 Location for Remote HIM Connection

DPI Port 3

DPI Port 4

DPI Port 5

B-2 HIM Overview

LCD Display Elements

ALT Functions

Display Description

F-> Power Loss Auto

0.0

Main Menu: Diagnostics Parameter Device Select

To use an ALT function, press the ALT key, release it, then press the programming key associated with one of the following functions:

Table B.A ALT Key Functions

ALT Key and then … Performs this function …

S.M.A.R.T. Displays the S.M.A.R.T. screen.

Esc

View Allows the selection of how parameters will be viewed or detailed

Sel

Lang Displays the language selection screen.

ALT

Auto / Man Switches between Auto and Manual Modes.

Remove Allows HIM removal without causing a fault if the HIM is not the

Exp Allows value to be entered as an exponent.

Param # Allows entry of a parameter number for viewing/editing.

+/–

Direction | Drive Status | Alarm | Auto/Man | Information

Commanded or Output Frequency

Programming / Monitoring / Troubleshooting

information about a parameter or component.

last controlling device and does not have Manual control of the drive.

HIM Overview B-3

Menu Structure

Figure B.2 HIM Menu Structure

Esc Sel

Diagnostics

Parameter

Device Select

Faults Status Info Device Items Device Version HIM Version

View selected through

Param Access Lvl FGP Numbered List Changed

LPM20 Connected DPI Devices

User

Display

PowerFlex 700

Product Data Main Control Board Power Unit Board

LCD HIM Product Data LCD HIM Standard

Control Board

Keyboard – Numeric

Sel

ALT

FGP: File File 1 Name File 2 Name File 3 Name

Drive Status 1 Drive Status 2 Drive Alarm 1 Drive Alarm 2 Speed Ref Source Start Inhibits Last Stop Source Dig In Status Dig Out Status Drive Temp Drive OL Count Motor OL Count

FGP: Group Group 1 Name Group 2 Name Group 3 Name

Fault Info View Fault Queue Clear Faults Clr Fault Queue Reset Device

Basic Advanced

FGP: Parameter Parameter Name Parameter Name Parameter Name

Value Screen

Memory Storage

Start-Up

Preferences

Him CopyCat Device User Sets Reset To Defaults

Continue Start Over

Drive Identity Change Password User Dspy Lines User Dspy Time User Dspy Video Reset User Dspy Contrast

Introduction

Drive User Set: Save To User Set Load Frm Usr Set Active Name Set

Complete Steps:

1. Input Voltage

2. Motor Dat/Ramp

3. Motor Tests

4. Speed Limits

5. Speed Control

6. Strt/Stop/I/O

7. Done/Exit

Press

Esc

Press

Press to select how to view parameters

ALT

Sel

Device -> HIM Device <- HIM Delete HIM Set

Make a selection: Abort

Esc

Backup Resume Start-Up Menu

to move between menu items

to select a menu item

to move 1 level back in the menu structure

Diagnostics Menu

When a fault trips the drive, use this menu to access detailed data about the drive.

Option Description

Faults View fault queue or fault information, clear faults or reset drive.

Status Info View parameters that display status information about the drive.

Device Version View the firmware version and hardware series of components.

HIM Version View the firmware version and hardware series of the HIM.

B-4 HIM Overview

Parameter Menu

Refer to Viewing and Editing Parameters on page B-5.

Device Select Menu

Use this menu to access parameters in connected peripheral devices.

Memory Storage Menu

Drive data can be saved to, or recalled from, User and HIM sets.

User sets are files stored in permanent non-volatile drive memory. HIM sets are files stored in permanent non-volatile HIM memory.

Option Description

HIM Copycat Device -->HIM Device <-- HIM

Device User Sets Save data to a User set, load data from a User set to active drive memory or

Reset To Defaults Restore the drive to its factory-default settings.

Save data to a HIM set, load data from a HIM set to active drive memory or delete a HIM set.

name a User set.

Start Up Menu

See Chapter 2.

Preferences Menu

The HIM and drive have features that you can customize.

Option Description

Drive Identity Add text to identify the drive.

Change Password Enable/disable or modify the password.

User Dspy Lines Select the display, parameter, scale and text for the User Display. The User

Display is two lines of user-defined data that appears when the HIM is not being used for programming.

User Dspy Time Set the wait time for the User Display or enable/disable it.

User Dspy Video Select Reverse or Normal video for the Frequency and User Display lines.

Reset User Dspy Return all the options for the User Display to factory default values.

The LPM20 drive is initially set to Basic Parameter View. To view all parameters, set [ParamAccessLevel] parameter to option 1 “Advanced”. The [ParamAccessLevel] parameter is not affected by the Reset to Defaults function.

HIM Overview B-5

Viewing and Editing Parameters

LCD HIM

Step Key(s) Example Displays

1. In the Main Menu, press the Up Arrow or Down Arrow to scroll to “Parameter.”

2. Press Enter. “FGP File” appears on the top line and the first three files appear below it.

3. Press the Up Arrow or Down Arrow to scroll through the files.

4. Press Enter to select a file. The groups in the file are displayed under it.

5. Repeat steps 3 and 4 to select a group and then a parameter. The parameter value screen will appear.

6. Press Enter to edit the parameter.

7. Press the Up Arrow or Down Arrow to change the value. If desired, press Sel to move from digit to digit, letter to letter, or bit to bit. The digit or bit that you can change will be highlighted.

8. Press Enter to save the value. If you want to cancel a change, press Esc.

9. Press the Up Arrow or Down Arrow to scroll through the parameters in the group, or press Esc to return to the group list.

Sel

FGP: File

Monitor

Motor Control

Dynamic Control

FGP: Group

Metering

Control Status

Drive Data

FGP: Parameter

% Motor Flux

Output Freq

Output Power

FGP: Par 310

Output Freq

60.00 Hz

-250.00 <> 250.00

Esc

Numeric Keypad Shortcut

If using a HIM with a numeric keypad, press the ALT key and the +/– key to access the parameter by typing its number.

FGP: Par 310

Output Freq

90.00 Hz

-250.00 <> 250.00

B-6 HIM Overview

Removing/Installing the HIM

The HIM can be removed or installed while the drive is powered.

Important: HIM removal is only permissible in Auto mode. If the HIM is

removed while in Manual mode or the HIM is the only remaining control device, a fault will occur.

Step Key(s) Example Displays

To remove the HIM …

1. Press ALT and then Enter (Remove). The Remove HIM confirmation screen appears.

2. Press Enter to confirm that you want to remove the HIM.

3. Disconnect the HIM from the drive.

To install HIM …

1. Connect the HIM cable to the drive (DPI Port 4). See Figure B.1

ALT

Remove Op Intrfc:

Press Enter to

Disconnect Op Intrfc?

(Port 1 Control)

Appendix C

Wiring Diagrams

Wiring diagrams on the following pages illustrate the drive and power module wiring.

For information on ... See page ...

Drive

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

C-2

C-2 Wiring Diagrams

Drive

CB1

Main

Circuit Breaker

IND1 Input

Inductor

TS1

20A

FU10

600V

Precharge Resistors

10Ω, 600W

AC INPUT

L3L1 L2

RST

1263

789

FU11

Shunt Trip

Fan

150A 500V

FU6

FU5

FU4

4x, MOV

140J

Fan

FU12

15A/600V

Class 'RK-5'

100k

(3kVA, 120V, 25A)

FU1

FU2

*T1 Input (50/60Hz) H1-H4: 380-415VAC

H1-H5: 440-480VAC

Class 'CC'

1A/600V Time Delay

Ω

, 50W

Filter Caps

Control

Transformer

2 FU7 FU8 FU9

F each

Class 'CC'

600VAC Time Delay

25A

FU13

FU3

120V_N

Potter & Brumfield Part # KUP-14D15-24 Socket # 27E893 Hold Down # 20C318

120V

Switched

4 A

Precharge Pilot

7 B

Relay

13 14 13 141413

T1L1

T2L2

T3L3

A2A1 A1 A2

K1A K1B K1C

T1L1

L2 T2

L3 T3

A1 A2

L1 T1

T2L2

T3L3

Precharge Contactors

DRIVE INPUT COMPONENTS

Wiring Diagrams C-3

Control 115V, 60Hz 1PH

115V COM

Inductor Overtemp

Inductor Overtemp Return

Coil Return

A1-P1

+24V Coil

11 12

13 14

Ref.

FU1 FU2 FU3 FU4 FU5 FU6

FU8 FU9 FU10 FU11 FU12 FU13

Voltage Feedback

Resistor Assembly

Active Converter

Control Assembly

A12-P1

AUX_OUT_COM IFF_IN IFF_RTN SAFETY_HW_EN AUX_IN _24V AUX_IN

Fuse Description

Class RK-5, 15A/600V Class RK-5, 15A/600V Class CC, 5A/600V 150A/600V 150A/600V 150A/600V Class CC, 1A/600VFU7 Class CC, 1A/600V Class CC, 1A/600V Class CC, 20A/600V Class CC, 20A/600V Class CC, 20A/600V Class CC, 25A/600V

A22

Main Control

Assembly

A11

180675-A03

A12

180654-A01

9AUX_OUT_NO 10 11 12 13 14 15

Bussman FRS-R-15 Bussman FRS-R-15 Littelfuse KLDR005 Bussman FWH-150B Bussman FWH-150B Bussman FWH-150B Littelfuse KLDR001 Littelfuse KLDR001 Littelfuse KLDR001 Littelfuse CCMR020 Littelfuse CCMR020 Littelfuse CCMR020 Littelfuse KLDR025

Comm.

Interface Assy.

179571

A32

DPI Comm.

Board

A33

Temp. Sensor

180037-A01

Factory-Installed Jumper

A31

194706-Q01

Terminal

Block

179745

1 2

Factory-Installed

A34

Chillplate

DRIVE POWER MODULE

FUSE TABLE - DRIVE INPUT

Supplier "B" and P/NSupplier "A" and P/N

Gould/Shawmut TRS-R15 Gould/Shawmut TRS-R15 Gould/Shawmut ATQR5 Gould/Shawmut A50P150-4 Gould/Shawmut A50P150-4 Gould/Shawmut A50P150-4 Gould/Shawmut ATQR1 Gould/Shawmut ATQR1 Gould/Shawmut ATQR1 Gould/Shawmut ATDR20 Gould/Shawmut ATDR20 Gould/Shawmut ATDR20 Gould/Shawmut ATQR25

Jumper

HIM

Door-Mounted

Option

E-Stop Connection

External

T3/T5

T2/T4

T1/T6

Motor

GRD

NOTES:

1.) Dashed lines indicate wiring by others.

C-4 Wiring Diagrams

Power Module – Overall

INPUT FILTER CONNECTIONS

CUSTOMER CONNECTIONS

INPUT FILTER CONNECTIONS

AC POWER INPUT LEADS

POWER & CONTROL

180777-C01

A1-P1

A1-M1

Fan

179196

180807-C01 - 7 Pos. Plug

TEMP. SENSOR

Jumper

A11

VOLTAGE F/B

RESISTOR ASSY.

180675-A03

179780-Q01

Factory Installed

Jumper P1-13 & P1-14

CHILLPLATE

180037-A01

180807-C02 - 15 Pos. Plug

J11

179711

20-PIN Board-to-Board

CONVERTER

CONTROL ASSY.

180654-A01

A34

J13

A13

RECTIFIER POWER

INTERFACE ASSY.

See Table on Page C-11

A12

ACTIVE

179828-Q01

EXTERNAL DPI

180808-C01

DPI 4

179694-Q01

SEE DETAIL A

179710

J14

179753

179754

COMMUNICATION INTERFACE ASSY.

JP1

A14

80W POWER

SUPPLY

193087-A02

180427-Q01 - RECTIFIER SIDE

DPI 5 DP1 3

A31

179571

COMMUNICATIONS

See Pages C-6/C-7

194706-Q01

A32

BOARD

OPTION

A36-J1

BUS L1, L3

179578

BUS L2

179580

GRD

NOTES:

1.) See Table on Page C-11 for A1 VFD Power Module Model and component numbers.

2.) See Pages C-6/C-7, C-8/C-9, and C-10/C-11 for PC board pin designators and signal names.

A19

A18

A17

CURRENT

FEEDBACK

DEVICE

179701

E E

A15

RECTIFIER IGBT ASSY. #1

See Table on Page C-11 See Table on Page C-11

E E E

RTD

A1-R1 & A1-R2 DISCHARGE

RESISTORS, 2.6 kOHMS

24708-501-12

G G

E E

A16

RECTIFIER IGBT ASSY. #2

RTD

1 2

I/O & CONTROL

180814-C01

SEE DETAIL A

JP1

A24

80W POWER

SUPPLY

193087-A02

179753

179710 J14

TB1

TB2

A22

MAIN

CONTROL

ASSY.

179828-Q02

A23

INVERTER POWER INTERFACE ASSY.

See Table on Page C11

700S CONTROL & FEEDBACK

OPTIONS; AND ADD'L

CONFIGURATIONS

From

A24-J2

INTERCONNECT ASSY.

DC BUS,

U, V, & W

A36

HIGH VOLTAGE

180812-A01

179695-Q03

J11

28-Pin Board-To-Board

MOTOR VOLTAGE FEEDBACK ASSY.

16-Pin Board-to-Board

180822-C01

Jumper

A35

320390-A02

I/O &

CONTROL

A33

GATE

KILL

TERMINAL BLOCK

179745

Wiring Diagrams C-5

CUSTOMER CONNECTIONS

179780-Q01 Factory-Installed Jumper

SWITCH

OPTION

To A36-J6

180427-Q02 - Inverter Side

180813-C01

DC +

MEASUREMENT

POINT

180799-C01

A1-LAM

LAM. BUS

179577

+ +

...

M M

...

- -

DC -

MEASUREMENT

POINT

179743-Q02

J13

RTD

E E

A1-LAM LAMINATED BUS

BUS CAPACITOR, 2700 uF, 420 VDC See Table on Page C-11

INVERTER IGBT ASSY. #1

A25

See Table on Page C-11

179577

180427-Q02 - Inverter Side

180813-C01

A36-J1

179111

AC POWER

OUTPUT

LEADS

BUS U, W

179701

179578

BUS V

179580

E E

A26

RTD

INVERTER IGBT ASSY. #2

See Table on Page C11

A29

A28

A27

CURRENT

FEEDBACK

DEVICE

JP1

Jumper, 2 Pos. on Pins JP1-1

and JP1-2

DETAIL A

C-6 Wiring Diagrams

Power Module – Active Converter Control and Rectifier Power Interface

To A22-P2 See Pages C-8/C-9

CUSTOMER CONNECTIONS

COMM RXD INV

COMM TXD INV

COMM CS INV

COMM CLK INV97

+5V INV 29 +5V INV +5V INV

+5V INV +12V INV +12V INV

DGND DGND DGND

CAN LO 13

DGND DGND

LED GRN INV

+24V INV

24VCOM INV43

CAN HI 1 SELECT0 GND +12V SELECT1 CAN LO +12V SELECT2

CAN HI SELECT0 GND +12V SELECT1 CAN LO +12V 7 SELECT2 8

30+5V INV

28 27 26+5V INV 25 24 23 22+12V INV 21 20 19 18DGND 17 16 15 14CAN HI

12 11 10

6LED RED INV 5

2 1

COMMUNICATION

INTERFACE ASSY.

MAIN CONTROL INTERFACE

DPI PORT 3

2 3 4 5 6 7 8

DPI PORT 4

2 3 4 5 6

INTERNAL COMM. I/F

SCANPORT +5VDC

SELECT0

CAN LO

SELECT1

SCANPORT COM

SELECT2

CAN HI

COMMUNICATIONS

BOARD

Refer to Communications

Adapter Installation

Manual for available options.

OPTION

A31

179571

86534

9(CARD SER RXD)

(CARD CAN RXD)

(CARD CAN TXD)

(CARD EXT SEL)

+5V INV

(CARD SER TXD)

86534

A32

RECTIFIER

CONTROL

INTERFACE

DPI PORT 5

1514131112

2019171618

+5V INV

DGND

1514131112

2019171618

+5V RECT

+12V RECT

DGND

CAN HI

CAN LO

DGND

COMM RXD INV

COMM TXD RECT

COMM CS RECT

LED RED RECT

LED GRN RECT

+24V RECT

24VCOM RECT

3 2 1

CAN HI

SELECT0

GND

3 4 +12V

SELECT1 CAN LO

+12V 5 7

8 SELECT2

CHASSIS GND-

CHILLPLATE

TEMPERATURE

AC POWER

INPUT

A34

SENSOR

180037-A01

A17

2 1 4

COMMUNICATIONS

3 6

INTERFACE

5 8 723 +12V RECT 10 9 12 11 14 13 16 15 18 17

CAN HI SELECT0 GND +12V SELECT1 CAN LO +12V SELECT2

CHASSIS GND CAN HI SELECT0 GND +12V SELECT1 CAN LO +12V SELECT2

CHASSIS GND

20 19 22 21 24 23COMM CLK RECT 26 25 28 27 30 29

1 3 5 7

9 11 13 15 17

8 10 12 14 16 18

ACTIVE CONVERTER

CONTROL ASSY.

EXTERNAL DPI

I/O

421376598

SOC_OUT-

SOC_OUT+

COM_OUT+

COM_OUT-

COM_IN-

COM_IN+

CURRENT FEEDBACK DEVICES

A19

+ M -

A18

+ M -

180654-A01

SOC_IN+

AUX_OUT_NO

SOC_IN-

AUX_OUT_COMMON

IFF_IN

L3 BUS

L2 BUS

L1 BUS

A12

1312111514

SAFETY_HW_EN

IFF_RTN

AUX_IN_24V

AUX_IN

FACTORY INSTALLED JUMPER

See Pages C-10/C-11

Wiring Diagrams C-7

POWER

LAYER

INTERFACE

FEEDBACK INTERFACE

431

768

1617121314

LB1

---

LB1-LALALB1

LB2

LB2LCLC

LB1

5J1431

768

1617121314

A11

VOLTAGE FEEDBACK

RESISTOR ASSY.

180675-A03

AI-P1

INPUT

FILTER

CONNECTIONS

11 12 13 14

LB2

181920

LB2

JUMPER

A1-M1

24VCOM ISO

+24V ISO

+5V PS

4 3

+5V PS

GND PS

+12V

GND PS

-12V

EE+5VDC GND PS

EE SK

EE IO

EE GND

EE CS

GNDSHRT

/CHARGE

U NEG+

V NEG+

V POS+

W NEG+

W POS+

NTC+

/GATE KILL RESET

U AMPS+

VV AMPS+

V AMPS+

/GATE KILL

GND PS

35 38

DC BUS

37 40

SOC_IN+

SOC_IN-

To A22-P6 See Pages C-8/C-9

L1 2 3 4 5 6 7

INDUCTOR OVERTEMP RETURN

PRECHARGE RELAY +24V COIL

CURRENT FEEDBACK PWRCURRENT FEEDBACK SIGU CURRENT FEEDBACK PWR+ CURRENT FEEDBACK PWRCURRENT FEEDBACK SIGV CURRENT FEEDBACK PWR+ CURRENT FEEDBACK PWRCURRENT FEEDBACK SIGW CURRENT FEEDBACK PWR+

INPUT

FILTER

CONNECTIONS

GATE KILL

INDUCTOR OVERTEMP

COIL_RETURN

24V_COM

+24V

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24U POS+23 25 26 27 28 29 30 31 32GND PS31 33 34 35 36 37 38 39 4039

J11

RECTIFIER CONTROL INTERFACE

1 2 3 4

INTERNAL I/O

INTERFACE

6 7 8

9 8 7 6

CURRENT

5 4

FEEDBACK

3 2 1

GATE

DRIVER

INTERFACE

GATE

DRIVER

INTERFACE

A13

RECTIFIER POWER

INTERFACE ASSY.

See Table on Page C-11

GATE

DRIVER

INTERFACE

IGBT

TEMPERATURE

SENSE IN

UPPER GATE

SUPPLY I/F

DC BUS

DISTRIBUTION

LOWER GATE

SUPPLY I/F

LOGIC SUPPLY

DC BUS

I/F IN

RECTIFIER L1+COLLECTOR

1 2 3

RECTIFIER L1+GATE

RECTIFIER L1+EMITTER

5 6 7

RECTIFIER L2+COLLECTOR

8 9

RECTIFIER L2+GATE

RECTIFIER L2+EMITTER

RECTIFIER L3+COLLECTOR 1 2 3

RECTIFIER L3+GATE

RECTIFIER L3+EMITTER 5 6 7

RECTIFIER L1-COLLECTOR

8 9

RECTIFIER L1-GATE

RECTIFIER L1-EMITTER

12 13 14

RECTIFIER L2-COLLECTOR 1 2 3 4

RECTIFIER L2-GATE

RECTIFIER L2-EMITTER 5 6 7

RECTIFIER L3-COLLECTOR

8 9

RECTIFIER L3-GATE

RECTIFIER L3-EMITTER

12 13

J13

RECTIFIER NTC1+

1 2

RECTIFIER NTC1-

RECTIFIER NTC2+ 4

RECTIFIER NTC2-

J14

2 3 4

1 2 3 4 5 6 7

10 9 8

6 5 4 3 2 1

P_UUP-

P_UUP+

137 P_VUPP_VUP+

P_WUPP_WUP+

-DC 1

+DC

P_ULO+ P_ULOP_VLO+ P_VLOP_WLO+ P_WLOISO_15V ISO_15V_COM 81

UPPER GATE SUPPLY OUPUT/

DC BUS INTERFACE

9 8 7 6 5 4 3 2 1

8 7 6 5

LOWER GATE

4 3

SUPPLY OUT

1 2 3 4

6 7

9 10 11

BUS_FB AD_COM AD_COM 5V 5V

-12V AD_COM +12V 5 8 24V_COM

+24V

RECTIFIER -DC BUS

RECTIFIER +DC BUS

1 2 3 4 5

LOGIC SUPPLY

6 7 8

OUT

To DC BUS See Pages C-10/C-11

TO RECTIFIER IGBT ASSY. #1-J2

TO RECTIFIER IGBT ASSY. #2-J3

TO RECTIFIER IGBT ASSY. #2-J1

TO RECTIFIER IGBT ASSY. #1-J2

TO RECTIFIER IGBT ASSY. #2-J3

TO RECTIFIER IGBT ASSY. #2-J1

TO RECTIFIER IGBT ASSY. #1-J1

TO RECTIFIER IGBT ASSY. #2-J1

A14

80W POWER SUPPLY

193087-A02

JP1

See Pages C-10/C-11

C-8 Wiring Diagrams

Power Module – High Voltage Interconnect and Inverter Power Interface

To A12-J9 See Pages C-6/C-7

See Installation Manual for I/O Wiring

ADCON

SOC_IN+

HIHP_GATE_EN GND

SOC_IN-

GND VBUS_RX_NEG VBUS_TX_NEG VBUS_RX_POS VBUS_TX_POS VBUS2_RX VBUS2_TX

TB1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

TB2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

9 8 7 6 5 4 3 2 1

CUSTOMER I/O

A22

MAIN CONTROL

ASSY.

CUSTOMER I/O

COMMUNICATIONS

POWER

LAYER

INTERFACE

2 24VCOM ISO 1

+24V ISO +5V PS4

+5V PS

GND PS

GND PS +12V12

+12V

GND PS

-12V

EE+5VDC

GND PS

EE SK

EE IO

EE GND

EE CS

GNDSHRT

/CHARGE

U NEG+

U POS+

V NEG+

V POS+

W NEG+ W POS+27

NTC+

/GATE KILL RESET

U AMPS+

GND PS

VV AMPS+

V AMPS+

/GATE KILL

GND PS 38 37

DC BUS 40 39

+5V INV

+12V INV

DGND

CAN HI

CAN LO

DGND

COMM RXD INV

COMM TXD INV

COMM CS INV

COMM CLK INV

LED RED INV

LED GRN INV

+24V INV

24VCOM INV

27 30 29

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

To A31- J7 See Pages C-6/C-7

A36

HIGH VOLTAGE

INTERCONNECT

ASSY.

180812-A01

P2 P3

J2 J3

A35

MOTOR VOLTAGE FEEDBACK ASSY.

320390-A02

2 1 4 +5V PS 3 6 5 8 GND PS

10 9 12 +12V 11

13 16 15 18 EE SK

20 1922EE CS

23 U POS+ 26 25 28

30 29 32 31 GND PS 34 3338V AMPS+ 36 35

40 39

1 2 3 4

1 2 3 4 5 6 7 8 9 10 11 12

24VCOM ISO +24V ISO

+5V PS +5V PS +5V PS

GND PS7 GND PS GND PS

+12V GND PS14

-12V EE+5VDC GND PS

EE IO17 EE GND

GNDSHRT /CHARGE U NEG+24

V NEG+ V POS+ W NEG+ W POS+27 NTC+ /GATE KILL RESET U AMPS+

VV AMPS+

/GATE KILL GND PS

DC BUS37

V_ISO+

V_ISO-

+ DC BUS

- DC BUS

PHASE U VOLTS

PHASE V VOLTS

PHASE W VOLTS

700S CONTROL

OPTIONS AND ADD'L

CONFIGURATIONS

See Pages C-10/C-11

W BUS

V BUS

U BUS

A27

CURRENT FEEDBACK DEVICES

A29

A28

+ M -

Wiring Diagrams C-9

To DC BUS See Pages C-10/C-11

POWER

OUTPUT

CURRENT FEEDBACK PWRCURRENT FEEDBACK SIGU CURRENT FEEDBACK PWR+ CURRENT FEEDBACK PWRCURRENT FEEDBACK SIGV CURRENT FEEDBACK PWR+ CURRENT FEEDBACK PWRCURRENT FEEDBACK SIGW CURRENT FEEDBACK PWR+

1 2 3

MAIN

4 5

CONTROL DRIVER

6 7

INTERFACE

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

A23

INVERTER POWER INTERFACE ASSY.

See Table on Page C-11

9 8 7 6

CURRENT

5 4

FEEDBACK

3 2 1

J11

GATE

INTERFACE

GATE

DRIVER

INTERFACE

GATE

DRIVER

INTERFACE

TEMPERATURE

IGBT

SENSE IN

UPPER GATE

SUPPLY I/F

DC BUS

DISTRIBUTION

LOGIC SUPPLY

I/F IN

LOWER GATE

SUPPLY I/F

DC BUS

INTERNAL I/O

INTERFACE

INVERTER U+COLLECTOR

1 2 3

INVERTER U+GATE

INVERTER U+EMITTER

5 6 7

INVERTER V+COLLECTOR

9 10 11

INVERTER V+GATE

INVERTER V+EMITTER

INVERTER W+COLLECTOR

INVERTER W+GATE

INVERTER W+EMITTER

INVERTER U-COLLECTOR

9 10 11

INVERTER U-GATE

INVERTER U-EMITTER 13 14

INVERTER V-COLLECTOR

1 2 3

INVERTER V-GATE

INVERTER V-EMITTER

5 6 7

INVERTER W-COLLECTOR 8

INVERTER W-GATE

11 12

INVERTER W-EMITTER

J13

INVERTER NTC1+

1 2

INVERTER NTC1-

INVERTER NTC2+

INVERTER NTC2-

9 8

6 5 4 3 2 1

J14

2 3 4

1 2 3 4 5 6 7 8 9 10 11 +24V 11

1 2 3 4 5 6

1 2 3 4

5 6

7 8

P_UUP-

P_UUP+

137 P_VUPP_VUP+

P_WUPP_WUP+

-DC 1

+DC

BUS_FB AD_COM AD_COM 5V 5V

-12V AD_COM +12V 24V_COM +24V

P_ULO+ P_ULOP_VLO+ P_VLOP_WLO+ P_WLO-

V_ISO+ V_ISO-

INVERTER -DC BUS

INVERTER +DC BUS

UPPER GATE SUPPLY OUPUT/

DC BUS INTERFACE

9 8 7 6 5 4 3 2 1

1 2 3 4 5

LOGIC SUPPLY

6 7

OUT

8 9

8 7 6

LOWER GATE

5 4

SUPPLY OUT

3 2 7 1

To DC BUS See Pages C-10/C-11

FACTORY-INSTALLED JUMPERS

+24V GATE KILL OVER_TEMP_1 OVER_TEMP_2

+24V COIL_RETURN

+24V 24V_COM

GATE KILL TERMINAL

BLOCK

TO INVERTER IGBT ASSY. #1-J2

TO INVERTER IGBT ASSY. #2-J3

TO INVERTER IGBT ASSY. #2-J1

TO INVERTER IGBT ASSY. #1-J2

TO INVERTER IGBT ASSY. #2-J3

TO INVERTER IGBT ASSY. #2-J1

TO INVERTER IGBT ASSY. #1-J1

TO INVERTER IGBT ASSY. #2-J1

A24

80W POWER SUPPLY

193087-A02

JP1

SWITCH

1 2

A33

EXTERNAL-

OPTION

See Pages C-10/C-11

C-10 Wiring Diagrams

Power Module – Rectifier IGBT and Inverter IGBT

See Pages C-6/C-7

RECTIFIER IGBT ASSY #1

A15 A16

2 3 4 5 6 7 8 9 10

L3 BUS

L2 BUS

L1 BUS

See Table on Page C-11 See Table on Page C-11

1 2 3 4 5 6 7 8 9 10 11 12 13 14

NTC

RECTIFIER L1+COLLECTOR

1 2 3

RECTIFIER L1+GATE

RECTIFIER L1+EMITTER

RECTIFIER L1-COLLECTOR

6 7 8

RECTIFIER L1-GATE

RECTIFIER L1-EMITTER

2 4

7,8

11,12

E E

9,10

GGG

1 2 3 4 5 6 7 8 9 10

See Pages C-6/C-7

To A36-J1

See Pages C-8/C-9

A1-R1

RECTIFIER IGBT ASSY #2

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2 3 4 5 6 7 8 9 10

2 4 6

135

DC BUS(+)

DC BUS(-)

11,12

C C

E E

NTC

9,10

7,8

GG G

RECTIFIER L3+COLLECTOR

RECTIFIER L3+GATE RECTIFIER L3+EMITTER RECTIFIER L3-COLLECTOR

RECTIFIER L3-GATE RECTIFIER L3-EMITTER

RECTIFIER NTC2+ RECTIFIER NTC2-

RECTIFIER L2+COLLECTOR

RECTIFIER L2+GATE RECTIFIER L2+EMITTER RECTIFIER L2-COLLECTOR

RECTIFIER L2-GATE RECTIFIER L2-EMITTER

RECTIFIER NTC1+ RECTIFIER NTC1-

See Pages C-6/C-7

See Pages C-8/C-9

RECTIFIER -DC BUS

RECTIFIER +DC BUS

See Pages C-6/C-7

DC +

MEASUREMENT

POINT

INVERTER -DC BUS

INVERTER +DC BUS

...

DC -

MEASUREMENT

POINT

A1-R2

1 2

INVERTER IGBT ASSY #1 INVERTER IGBT ASSY #2

A25 A26

3 4 5 6 7 8 9 10

See Table on this page

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2 2 3 4 5 6 7 8 9

INVERTER U+COLLECTOR

INVERTER U+GATE INVERTER U+EMITTER

INVERTER U-COLLECTOR

INVERTER U-GATE INVERTER U-EMITTER

See Pages C-8/C-9

See Table on this page

1 2 3 4 5 6 7 8 9 10

INVERTER W+COLLECTOR

2 3 4

INVERTER W+GATE

INVERTER W+EMITTER

INVERTER W-COLLECTOR

7 8 9

INVERTER W-GATE

INVERTER W-EMITTER

11 12 13

INVERTER NTC2+

INVERTER NTC2-

INVERTER V+COLLECTOR

1 2 3

INVERTER V+GATE

INVERTER V+EMITTER

INVERTER V-COLLECTOR

6 7 8

INVERTER V-GATE

INVERTER V-EMITTER

INVERTER NTC1+ INVERTER NTC1-

Wiring Diagrams C-11

See Pages C-8/C-9

11,12

4 6

NTC

9,10

E E

7,8

BUS CAPACITOR, 2700 µF, 420 VDC See Table on this page

Model

Number

20ND608...

A13

179575

NTC

A25

A26

9,10

GGGGGG

Bus

Capacitor

Quantity

7,8

W BUS

V BUS

U BUS

Bus

Capacitor

Part Number

11,12

C C

E E

VFD POWER MODULE TABLE

A15

A16

179527-A02 179527-A02 24 184698

A23

181023-A01

See Pages C-8/C-9

C-12 Wiring Diagrams

Notes:

Index

AC input

ground, 1-13

wiring, 1-17

AC supply, unbalanced or ungrounded, 1-11

active converter assembly

fault descriptions, 3-3

agency certification, A-1

air flow clearance requirements, 1-10

alarm

clearing, 3-3

types, 3-1

ALT key functions, B-2

armored cable, 1-20

biocide use in coolant, 1-16

bipolar inputs, 1-23

bus capacitors, discharging, P-4

cables, power

armored, 1-20

insulation, 1-20

separation, 1-20

shielded, 1-20

unshielded, 1-20

capacitors - bus, discharging, P-4

catalog number explanation, P-5

checklist for drive start-up, 2-1

clearance for air flow, 1-10

clearing

alarms, 3-3

faults, 3-3

common mode interference, 1-23

common symptoms/corrective actions, 3-4

communication port, DPI, 1-7

communications - programmable controller

configurations, A-3

component locations for drive, 1-2

contactors, input/output, 1-22

control wire for I/O, 1-24

conventions used in this manual, P-3

coolant

biocide treatment, 1-16

connections to drive, 1-15

considerations, 1-14

corrosion inhibitor, 1-16

requirements, 1-15

Copycat, B-4

data saving, B-4

diagnostic data, viewing, B-3

distribution systems, unbalanced or

ungrounded, 1-11

Dowtherm, 1-16

DPI communication port, 1-7, B-1

DPI port location, 1-7, B-1

drive

alarms and faults, 3-1

applying power, 2-1

component locations, 1-2

grounding, 1-13

lifting and mounting, 1-12

power loss watts rating, 1-13

power ratings, 1-1

start-up checklist, 2-1

status indicators, 2-3, 3-2

earthing, see grounding

Electrostatic Discharge (ESD), P-4

enclosure ratings, 1-2

fault

clearing, 3-3

descriptions for active converter, 3-3

descriptions for drive, 3-3

queue, B-3

types, 3-1

general precautions, P-4

grounding the drive, 1-13

Index-2

HIM

Device User Sets, B-4

diagnostics, B-3

memory storage, B-4

menu structure, B-3

preferences, setting, B-4

removing/installing, B-6

Reset to Defaults, B-4

I/O wiring, 1-23

TB1 Terminal examples, 1-26

TB2 Terminal examples, 1-29

input

contactors - start/stop, 1-22

current rating, 1-1

line branch circuit protection, 1-12

power conditioning, 1-11

power rating, 1-1

installation - drive, total area required, 1-7

LCD HIM menus, B-3

LEDs, drive status, 2-3, 3-2

Logic Command Word, A-4

Logic Status Word, A-5

manual conventions, P-3

menu structure, HIM, B-3

motor

lead lengths, A-2

overload protection, installing, 1-19

mounting the drive, 1-12

non-resettable fault, 3-1

operator interface, B-5

output

contactors - start/stop, 1-22

current rating, 1-1

wiring, installing, 1-19

parameter

changing/editing, B-5

viewing, B-5

port, DPI type, B-1

power

before applying, 2-1

cables/wiring, 1-20

conditioning, input, 1-11

loss watts rating, 1-13

ratings for drive, 1-1

wiring, installing, 1-18

powering up the drive, 2-1

precautions, general, P-4

programmable controller configurations, A-3

ratings, drive, 1-1

reflected wave, 1-21

repeated start/stop, 1-22

replacement parts, 3-7

required external/separate input disconnect,

installing, 1-18

Reset to Defaults using the HIM, B-4

saving data, B-4

setting HIM preferences, B-4

shielded cables, power, 1-20

signal wire, 1-23

specifications

agency certification, A-1

control, A-2

electrical, A-2

environment, A-1

protection, A-1

start/stop, repeated, 1-22

start-up checklist, 2-1

static discharge (ESD), P-4

status indicators, 2-3, 3-2

SynchLink, 1-32

system grounding, 1-13

TB1 Terminals, 1-25

Index-3

TB2 Terminals, 1-28

terminal block wire size

encoder - Main Control Board, 1-25

I/O - Active Converter Control Board, 1-35

I/O - Main Control Board, 1-25

transformers and reactors, installing, 1-17

troubleshooting, 3-1

unbalanced/ungrounded supply, 1-11

unshielded power cables, 1-20

user configurable alarm, 3-1

viewing and changing parameters, B-5

web site

ControlNet installation references, P-2

drive reference materials, P-2

DriveLogix5730 Controller, P-2

feedback devices, P-2

SynchLink Design Guide, P-2

wire

control, 1-24

routing, 1-13

signal, 1-23

wiring

I/O, 1-23

power, 1-20

requirements for drive, 1-11

Index-4

U.S. Allen-Bradley Drives Technical Suppor t - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives

www.rockwellautomation.com

Power, Control and Information Solutions Headquarters

mericas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444

Europe/Middle East/Africa: Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640

sia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846

Publication 20N-IN001D-EN-P – November, 2006 P/N 180779-P04

Rockwell Automation LPM20 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Summary of Changes

Table of Contents

Preface

Overview

Who Should Use this Manual?

What Is Not in this Manual

PowerFlex 700 Active Converter Power Module Information

PowerFlex 700S Phase II Control Information

Reference Materials

For Allen-Bradley Drives Technical Support:

Manual Conventions

General Precautions

Class 1 LED Product

Catalog Number Explanation

Chapter 1

Installation/Wiring

Powe r R at in gs

Enclosure Ratings

Drive Component Locations

Drive Input Component Locations

Power Module Component Locations

DPI Communication Port

Determining Total Area Required Based on Drive Dimensions

Verifying that Site Provides for Recommended Air Flow Clearances

Verifying Power Module Input Ratings Match Supplied Power

AC Supply Source Considerations

Unbalanced or Ungrounded Distribution Systems

Input Power Conditioning

Wiring Requirements for the Drive

Input Line Branch Circuit Protection

Mounting the Drive, Determining Wire Routing, and Grounding

Lifting and Mounting the Power Module

Verifying the Drive’s Watts Loss Rating

Determining Input, Motor Output, Ground, and Control Wire Routing for the Drive

Grounding the Drive

Coolant Considerations

Coolant Connections

Coolant Requirements

Corrosion Inhibitor

Biocide

Installing Input Power Wiring

Installing Transformers and Reactors (Not Recommended)

Installing a Required External/Separate Input Disconnect

Installing Power Wiring from the Input Filter Section to the Power Module

Installing Output Power Wiring

Installing Mechanical Motor Overload Protection (Optional)

Installing Output Wiring from the Drive Output Terminals to the Motor

Power Wiring

Cable Types Acceptable for 200-600 Volt Installations

Using Input/Output Contactors

Input Contactor Precautions

Output Contactor Precaution

I/O Wiring

Signal and Control Wire Types

Wiring the Main Control Board I/O Terminals

I/O Terminal Blocks

Hard Enable Circuitry

Main Control Board I/O and Encoder Settings

Connecting SynchLink

Class 1 LED Product

Active Converter Communication

Auto Tune Operation

Pre-charge Operation

Wiring the Active Converter Control Board I/O Terminals

I/O Terminal Blocks

CE Conformity

EMC Instructions

C-Tick Conformity

Chapter 2

Start Up

Prepare For Drive Start-Up

Before Applying Power to the Drive

Applying Power to the Drive

Status Indicators

Assisted Start Up

Chapter 3