Rockwell Automation Reliance Electric LiquiFlo 41L4060 User manual

Instruction Manual
LiquiFlo AC Power Modules
Hardware Reference, Installation,
and Troubleshooting
Version 6.4
D2-3411-7

Copyright © 2005 Rockwell Automation. All rights reserved.
The information in this manual is subject to change without notice.
Throughout this manual, the following notes are used to alert you to safety considerations:
Important: Identifies information that is critical for successful application and understanding of the product.
The thick black bar shown on the outside margin of this page will be used throughout this instruction manual to
signify new or revised text or figures.
!
ATTENTION: Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.
DeviceNet is a trademark of Open DeviceNet Vendor Association.
INTERBUS is a trademark of Phoenix Contact.
Metasys is a trademark of Johnson Controls.
Modbus is a trademark of Schneider Automation.
P1 is a trademark of Landis & Staefa.
PROFIBUS is a trademark of PROFIBUS International.
LiquiFlo, AutoMax, and Reliance are trademarks of Rockwell Automation.
!
ATTENTION: Only qualified electrical personnel familiar with the construction and operation of
this equipment and the hazards involved should install, adjust, operate, or service this equipment.
Read and understand this manual and other applicable manuals in their entirety before
proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION: Do not install or remove modification kits with power applied to the drive. Disconnect
and lock out incoming power before attempting such installation or removal. Failure to observe
this precaution could result in severe bodily injury or loss of life.
ATTENTION: DC bus capacitors retain hazardous voltages after input power has been
disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors
to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are
discharged before touching any internal components. Failure to observe this precaution could
result in severe bodily injury or loss of life.
ATTENTION: The drive is capable of operating at and maintaining zero speed. The user is
responsible for assuring safe conditions for operating personnel by providing suitable guards,
audible or visual alarms, or other devices to indicate that the drive is operating or may operate
at or near zero speed. Failure to observe this precaution could result in severe bodily injury or
loss of life.
ATTENTION: The user must provide an external, hardwired emergency stop circuit outside of
the drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled
machine operation may result if this procedure is not followed. Failure to observe this precaution
could result in bodily injury.
ATTENTION: The user is responsible for conforming with all applicable local, national, and
international codes. Failure to observe this precaution could result in damage to, or destruction
of, the equipment.
ATTENTION: The drive contains ESD- (Electrostatic Discharge) sensitive parts and assemblies.
Static control precautions are required when installing, testing, servicing, or repairing the drive.
Erratic machine operation and damage to, or destruction of, equipment can result if this procedure
is not followed. Failure to observe this precaution can result in bodily injury.
Trademarks not belonging to Rockwell Automation are
property of their respective companies.

Contents I
CONTENTS
Chapter 1
Introduction
1.1 Related Publications ........................................................................................ 1-1
1.2 Getting Assistance from Reliance Electric....................................................... 1-1
Chapter 2
About the Drive
2.1 Identifying the Drive by Model Number ........................................................... 2-1
2.2 Enclosure Ratings ........................................................................................... 2-2
2.3 B-Frame LiquiFlo Drive Component Locations................................................ 2-2
2.4 C-Frame LiquiFlo Drive Component Locations ............................................... 2-4
2.5 D-Frame LiquiFlo Drive Component Locations ............................................... 2-6
2.6 Regulator Board Description ........................................................................... 2-8
2.6.1 Jumper Locations and Settings ........................................................... 2-10
2.6.1.1 Setting the Analog Input Speed Reference Jumper (J4) ...... 2-10
2.6.1.2 Setting the Analog Output Jumper (J17)............................... 2-11
2.6.2 Wiring the Regulator Board Terminal Strip.......................................... 2-12
2.6.3 RS-232 Communication Port............................................................... 2-13
2.6.4 RMI Board Connector ......................................................................... 2-13
2.6.5 Operator Interface Module Connector................................................. 2-14
2.6.6 Keypad/Display ................................................................................... 2-14
2.7 RMI Board Description .................................................................................. 2-15
2.7.1 Digital Inputs ....................................................................................... 2-15
2.7.2 Digital Outputs..................................................................................... 2-15
2.7.3 Relay Outputs ..................................................................................... 2-15
2.7.4 Analog Input ........................................................................................ 2-15
2.7.5 Analog Outputs ................................................................................... 2-15
2.7.6 Frequency Input .................................................................................. 2-15
2.7.7 Wiring the RMI Board Terminal Strip................................................... 2-16
2.8 Optional Equipment ....................................................................................... 2-17
Chapter 3
Planning the Installation
3.1 General Requirements for the Installation Site................................................ 3-1
3.1.1 Making Sure Environmental Conditions are Met ................................... 3-1
3.1.2 Determining Total Area Required Based on Drive Dimensions ............ 3-2
3.1.3 Verifying the Site Provides for Recommended Air Flow Clearances .... 3-6
3.1.4 Verifying Power Module Input Ratings Match Supplied Power ............. 3-6
3.2 Wiring Requirements for the Drive .................................................................. 3-6
3.2.1 Meeting Terminal Strip Input and Output Specifications ....................... 3-6
3.2.2 Determining Wire Size Requirements ................................................... 3-6
3.2.2.1 Conduit Entry Opening Sizes.................................................. 3-6
3.2.2.2 Recommended Power Wire Sizes .......................................... 3-6
3.2.2.3 Recommended Control and Signal Wire Sizes ....................... 3-7
3.2.2.4 Recommended Motor Lead Lengths....................................... 3-8
3.2.2.5 Recommended Serial Communication Cable Lengths ........... 3-8
3.2.3 Selecting Input Line Branch Circuit Fuses ............................................ 3-8
3.2.4 Meeting Encoder Specifications (FVC Regulation Only)....................... 3-9
3.2.4.1 Encoder Wiring Guidelines ..................................................... 3-9
3.2.5 Verifying Power Module Output Current Rating Is
Greater Than Motor Full Load Amps..................................................... 3-9

II LiquiFlo AC Power Modules, Hardware Reference Version 6.4
Chapter 4
Mounting the Drive, Grounding, and Finding Wire Routing Locations
4.1 Lifting and Mounting the Drive .........................................................................4-1
4.1.1 Verifying the Drive’s Watts Loss Rating.................................................4-2
4.2 Determining Input, Motor Output, Ground, and Control Wire
Routing for the Drive ........................................................................................4-2
4.3 Installing the DC Bus Reactor Fan (C-Frame Drives Only)..............................4-6
4.4 Grounding the Drive .........................................................................................4-7
4.5 Connecting Coolant Lines ................................................................................4-7
4.5.1 B-Frame Coolant Connections ..............................................................4-7
4.5.2 C-Frame Coolant Connections ..............................................................4-7
4.5.3 D-Frame Coolant Connections ..............................................................4-8
Chapter 5
Installing Input Power Wiring
5.1 Installing Transformers and Reactors (Optional) .............................................5-1
5.2 Installing Fuses for Branch Circuit Protection ..................................................5-1
5.3 Installing a Required External/Separate Input Disconnect...............................5-4
5.4 Installing Power Wiring from the AC Input Line to the
Drive’s Power Terminals ..................................................................................5-4
Chapter 6
Installing Output Power Wiring
6.1 Installing Output Contactors (Optional) ............................................................6-1
6.2 Installing Mechanical Motor Overload Protection (Optional) ............................6-1
6.3 Installing Output Wiring from the Drive Output Terminals to the Motor............6-2
Chapter 7
Wiring the Regulator Board and RMI Board Terminal Strips
7.1 Stopping the Drive............................................................................................7-7
7.2 Wiring the Encoder Feedback Device
(FVC Regulation Only)8
7.3 Wiring the Signal and Control I/O...................................................................7-10
7.4 Wiring the RMI Board Terminal Strip .............................................................7-19
Chapter 8
Completing the Installation
8.1 Checking the Installation ..................................................................................8-1
8.2 Powering Up After Installation Is Complete......................................................8-2
Chapter 9
Troubleshooting the Drive
9.1 Test Equipment Needed To Troubleshoot .......................................................9-1
9.2 Drive Alarms and Faults...................................................................................9-1
9.3 Verifying That DC Bus Capacitors Are Discharged..........................................9-1
9.4 Checking the Power Modules with Input Power Off .........................................9-5
9.5 Replacement Parts...........................................................................................9-7
Appendix A
Technical Specifications........................................................................................... A-1
Appendix B
Cooling System Specifications................................................................................. B-1
Appendix C
B-Frame LiquiFlo Drive Wiring Diagrams................................................................. C-1

Contents III
Appendix D
C-Frame LiquiFlo Drive Wiring Diagrams .................................................................D-1
Appendix E
D-Frame LiquiFlo Drive Wiring Diagrams .................................................................E-1

IV LiquiFlo AC Power Modules, Hardware Reference Version 6.4

Contents V
List of Figures
Figure 2.1 – Identifying the Drive Model Number ..................................................... 2-1
Figure 2.2 – B-Frame LiquiFlo Drive Component Locations..................................... 2-3
Figure 2.3 – C-Frame LiquiFlo Drive Component Locations .................................... 2-5
Figure 2.4 – D-Frame LiquiFlo Drive Component Locations .................................... 2-7
Figure 2.5 – LiquiFlo Regulator Board Component Locations.................................. 2-9
Figure 2.6 – Jumper J4 Settings for Analog Input Speed Reference ..................... 2-11
Figure 2.7 – Jumper J17 Settings for Analog Outputs............................................ 2-12
Figure 2.8 – Typical Regulator Board Terminal Strip Connections......................... 2-13
Figure 2.9 – Keypad/Display................................................................................... 2-14
Figure 2.10 – Terminal Connections on the RMI Board ......................................... 2-16
Figure 3.1 – B-Frame Drive Dimensions .................................................................. 3-3
Figure 3.2 – C-Frame Drive Dimensions .................................................................. 3-4
Figure 3.3 – D-Frame Drive Dimensions .................................................................. 3-5
Figure 4.1 – Wire Routing Locations for B-Frame LiquiFlo Drives ........................... 4-3
Figure 4.2 – Wire Routing Locations for C-Frame LiquiFlo Drives ........................... 4-4
Figure 4.3 – Wire Routing Locations for D-Frame LiquiFlo Drives ........................... 4-5
Figure 4.4 – DC Bus Reactor Cooling Fan Mounting Location................................. 4-6
Figure 4.5 – Coolant Connector Locations for B-Frame LiquiFlo Drives .................. 4-8
Figure 4.6 – Coolant Connector Locations for C-Frame LiquiFlo Drives .................. 4-9
Figure 4.7 – Coolant Connector Locations for D-Frame LiquiFlo Drives .................. 4-9
Figure 5.1 – Typical AC Input/Output Electrical Connections
(6-Pulse Rectifier, All Frames)................................................................ 5-2
Figure 5.2 – Typical AC Input/Output Electrical Connections
(12-Pulse Rectifier, B- and C-Frames Only) ........................................... 5-3
Figure 7.1 – Two-Wire Start/Stop Sample Control Wiring ........................................ 7-5
Figure 7.2 – Three-Wire Start/Stop Sample Control Wiring...................................... 7-6
Figure 7.3 – Encoder Wiring Connections ................................................................ 7-9
Figure 7.4 – Terminal Connections on the RMI Board ........................................... 7-19
Figure 9.1 – DC Bus Voltage Terminals (B-Frame Drives)....................................... 9-2
Figure 9.2 – DC Bus Voltage Terminals (C-Frame Drives) ...................................... 9-3
Figure 9.3 – DC Bus Voltage Terminals (D-Frame Drives) ...................................... 9-4

VI LiquiFlo 2.0 AC Drive User Manual

Contents VII
List of Tables
Table 2.1 – Power and Enclosure Ratings ............................................................... 2-2
Table 2.2 – Available Kits and Options................................................................... 2-17
Table 3.1 – Environmental Conditions...................................................................... 3-2
Table 3.2 – Drive Dimensions and Weights.............................................................. 3-2
Table 3.3 – Recommended Power Wire Sizes for B-Frame Drives.......................... 3-7
Table 3.4 – Recommended Power Wire Sizes for C-Frame Drives ......................... 3-7
Table 3.5 – Recommended Power Wire Sizes for D-Frame Drives ......................... 3-7
Table 3.6 – Recommended Terminal Strip Wire Sizes............................................. 3-8
Table 3.7 – AC Input Line Fuse and Circuit Breaker Selection Values .................... 3-9
Table 5.1 – Terminal Tightening Torques................................................................. 5-4
Table 7.1 – RS-232 Connections (Terminals 1-3) .................................................... 5-1
Table 7.2 – Encoder Connections (Terminals 4-9) ................................................... 7-1
Table 7.3 – Analog Output Connections (Terminals 10 and 11)............................... 7-2
Table 7.4 – Analog Speed/Torque Reference Connections (Terminals 12-15)........ 7-2
Table 7.5 – Digital Input Connections (Terminals 16-25) ......................................... 7-3
Table 7.6 – Reserved Connections (Terminals 26 and 27) ...................................... 7-3
Table 7.7 – Status Relay Connections (Terminals 28-31) ........................................ 7-4
Table 7.8 – Wiring Signal and Control I/O to the Regulator Board Terminal Strip.. 7-10
Table 7.9 – Wiring Signal and Control I/O to the RMI Board Terminal Strip........... 7-20
Table 9.1 – Resistance Checks ................................................................................ 9-6
Table 9.2 – B-Frame LiquiFlo Drive Replacement Parts .......................................... 9-7
Table 9.3 – C-Frame LiquiFlo Drive Replacement Parts .......................................... 9-8
Table 9.4 – D-Frame LiquiFlo Drive Replacement Parts .......................................... 9-9

VIII LiquiFlo 2.0 AC Drive User Manual

Introduction 1-1
CHAPTER 1
Introduction
This instruction manual describes the LiquiFlo ™ drive’s Power Module and regulator
hardware. It does not cover the LiquiFlo software. For software information, refer to the
LiquiFlo AC General Purpose (V/Hz) and Vector Duty Drive Software Start-Up and
Reference Manual (D2-3410).
This manual is intended for qualified electrical and plumbing personnel.
LiquiFlo drives will typically be referenced by frame size. If additional clarity is
required, drive model numbers wil also be included.
1.1 Related Publications
Refer to the following related publications as necessary for more information:
•D2-3410 - LiquiFlo AC General Purpose (V/Hz) and Vector Duty Drive Software
Start-Up and Reference Manual
•D2-3305 - Motor Encoder Cable Kit
•D2-3348 - Control and Configuration Software (CS3000)
•D2-3341 - Remote Meter Interface Board
• D2-3342 - Operator Interface Module
• D2-3449 - LiquiFlo AC Drive Panel Mount Kit
1.2 Getting Assistance from Reliance Electric
If you have any questions or problems with the products described in this instruction
manual, contact your local Reliance Electric sales office. For technical assistance, call
1-864-284-5444.

1-2 LiquiFlo AC Power Modules, Hardware Reference Version 6.4

About the Drive 2-1
CHAPTER 2
About the Drive
This chapter describes how to identify the drive using the model number matrix and
shows the major drive components.
The LiquiFlo AC drive is a PWM (pulse-width-modulated) liquid-cooled drive that
provides vector and general purpose regulation for a wide range of applications.
Using vector regulation, the drive can provide high dynamic response, maintain full
rated motor torque to zero speed, and precisely control motor speed in both
directions. The drive can provide this functionality either with encoder feedback (flux
vector control or FVC) or without (sensorless vector control or SVC).
Using general purpose (volts/hertz or V/Hz) regulation, the drive is suited for a broad
range of applications requiring adjustable speed control of motors.
2.1 Identifying the Drive by Model Number
Each LiquiFlo AC drive can be identified by its model number. See figure 2.1. This
number appears on the shipping label and on the drive’s nameplate. The drive’s model
number includes the Power Module and the regulator version. Drive power ratings are
provided in table 2.1.
Figure 2.1 – Identifying the Drive Model Number
NNN AA N N NN
Continuous Ampere Rating (x10)
41 = 414 amps
50 = 500 amps
64 = 643 amps
120 = 1200 amps
LW= water-cooled
LR = refrigerant-cooled
Voltage
2 = 200 to 230 VAC
3 = 270 to 310 VAC
4 = 380 to 480 VAC
Enclosure
0 = Open Chassis
1 = NEMA 1
2 = NEMA 12 Only
4 = NEMA 4x (Indoor Only) or NEMA 12
Regulator V ersion
60 = Version 6.x Firmware

2-2 LiquiFlo AC Power Modules, Hardware Reference Version 6.4
Table 2.1 – Power and Enclosure Ratings
* With V/Hz regulation, 110% continuous output current capability. With vector regulation, 150% output current capability for 5 sec.
**Note that LiquiFlo drives are rated for use with water at specified temperatures and pressures as the coolant. Some coolant fluids may
allow an increased output rating while others may require the output to be derated. The LiquiFlo drive is also capable of running at 4 kHz
or 8 kHz. Contact Reliance Electric for ratings.
2.2 Enclosure Ratings
LiquiFlo drives have the following enclosure rating:
•Open-Chassis Style: Intended to be installed in an enclosure.
LiquiFlo drives must be placed in an enclosure.
2.3 B-Frame LiquiFlo Drive Component Locations
The B-Frame LiquiFlo drives have the following main components. The numbered
items listed below provided correspond to the numbers used in figure 2.2.
Replacement parts are listed in chapter 9.
Model
Number
Frame Size and
Selected
Regulation*
Enclosure
Rating
Input
Power
(KVA)
Input
Current
(Amps)
Output Current
at 2 kHz**
(Amps)
Full Load
Power Loss Watts
Fluid / Air
41L4060
41LR4060
B-Frame
V/Hz or Vector
Open-Chassis
Style
344 414 414 4600 / 1100
50LW4060
50LR4060
C-Frame
V/Hz or Vector
Open-Chassis
Style
398 500 500 5500 / 1500
64LW4060
64LR4060
C-Frame
V/Hz or Vector
Open-Chassis
Style
512 643 643 7000 / 2000
120L4060 D-Frame
V/Hz or Vector
Open-Chassis
Style
956 1200 1200 11700/4000
1. Bus Bars (3) (AC Output)
2. Bus Bars (6) (AC Input)
3. IGBT Modules
4. Output Laminate
5. Capacitors
6. RMI Board
7. Casting
8. Membrane Switch Keypad
9. Coolant Lines - (a) Inlet, (b) Outlet
10. Regulator Board
11. Power Module Control (PCB)
12. Current Feedback Devices (3)

About the Drive 2-3
Figure 2.2 – B-Frame LiquiFlo Drive Component Locations
1
2
3
4
10
9a
8
7
6
5
12
9b
11

2-4 LiquiFlo AC Power Modules, Hardware Reference Version 6.4
2.4 C-Frame LiquiFlo Drive Component Locations
The C-Frame LiquiFlo drives have the following main components. The numbered
items listed below provided correspond to the numbers used in figure 2.3.
Replacement parts are listed in chapter 9.
1. Bus Bars (AC Input)
2. SCR Bridge (AC to DC Converter)
3. Power Module Adapter Printed Circuit Board (PCB)
4. Power Interface Harness
5. Bus Bars (AC Output)
6. LEM InterfaceHarness
7. DC Bus Control PCB
8. Gate Driver PCB -Low Side
9. DC Bus Laminate Assembly
10. Output Current Feedback Devices
11. IGBT Modules
12. Chillplate (Heatsink)
13. Capacitors
14. Drive Baseplate
15. Reactor (Not Shown)
16. Discharge Resistors (Not Shown)
17. Control Panel Assembly
18. Bus Control - PMA Harness
19. Bus Control - Gate Drive Harness
20. Gate Driver PCB- High Side (Not Shown)
21. Membrane Switch Keyboard/Bracket
22. Regulator PCB
23. Option Board (Optional)
24. Coolant Lines - (Not Shown)

About the Drive 2-5
Figure 2.3 – C-Frame LiquiFlo Drive Component Locations
1
3
5
7
8
21
22
23
9
15
11
13
20
17
12
10
2
4
6
14
18
19
16
24

2-6 LiquiFlo AC Power Modules, Hardware Reference Version 6.4
2.5 D-Frame LiquiFlo Drive Component Locations
The D-Frame LiquiFlo drives have the following main components. The numbered
items listed below provided correspond to the numbers used in figure 2.4.
Replacement parts are listed in chapter 9.
1. Chillplate Harness
2. Bus Bars (AC Input)
3. Bus Bars (AC Output)
4. Power Module Control PCB
5. Membrane Switch Keypad
6. Regulator PCB
7. RMI Option PCB
8. Current Feedback Devices
9. Gate Driver PCB
10. Coolant Connection (Outlet)
11. IGBT Module
12. Capacitors
13. Coolant Connection (Inlet)
14. Output Laminate

About the Drive 2-7
Figure 2.4 – D-Frame LiquiFlo Drive Component Locations
8
9
7
6
5
4
3
2
1
1310 11 12
14

2-8 LiquiFlo AC Power Modules, Hardware Reference Version 6.4
2.6 Regulator Board Description
LiquiFlo drive regulation is performed by a microprocessor on the Regulator board.
See figure 2.5. Drive operation is adjusted by the parameters entered through the
keypad. The Regulator board accepts power circuit feedback signals and an external
speed reference signal, as well as data from an encoder that is attached to the motor
when set up for FVC regulation. The Regulator board provides:
•PWM gating signals to the IGBT power devices
Based on the output of the control loop, the regulator sends PWM gating signals to
isolated drivers on the Gate Driver board. These drivers switch the Insulated Gate
Bi-polar Transistors (IGBTs), producing a waveform that corresponds to the voltage
and frequency outputs of the inner V/Hz, FVC, or SVC regulators. The IGBTs can be
switched at either a 2, 4, or 8 kHz carrier frequency.
•Form A and B contacts for drive status indicators
The Form A and B contacts are under control of the user via programmable
parameters. A Form A or B transition can indicate drive status. The contacts are
rated for 5 amps resistive load at 250 VAC/30 VDC and are made available through
the terminal strip.
•Display data for a four-character display and fourteen indicator LEDs
For a description of the keypad/display refer to section 2.6.6. For operational
instructions, see the LiquiFlo Software Reference manual (D2-3410).
•An analog output
The analog output is a scaled voltage (0-10 VDC) or current (4-20 mA) signal
proportional to either motor speed (RPM), motor torque, or current (%TORQUE).
The current signal selection (via jumper J17) requires a power supply for operation.
The power can be sourced from the encoder terminals (4 and 9) or from an external
15 V power supply. See table 7.1, terminals 10 and 11, for more information. The
analog output signal is available through the terminal strip.