Rockwell Automation Allen-Bradley LiquiFlo 2.0 User manual

LiquiFlo 2.0 AC Drive
User Manual
Original Instructions

Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are
required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may
be impaired.
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.
Labels may also be on or inside the equipment to provide specific precautions.
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.
ATTENTION: 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 a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death.Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication D2-3518-4 - January 2020 3
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 1
Introduction Firmware Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Getting Assistance from Rockwell Automation . . . . . . . . . . . . . . . . . . 11
Chapter 2
About the Drive Identifying the Drive by Cabinet Assembly ID Number . . . . . . . . . . 13
LiquiFlo 2.0 Drive Component Locations. . . . . . . . . . . . . . . . . . . . . . . 14
Identifying the Power Module by Model Number. . . . . . . . . . . . . . . . 24
AC Line I/O Board Description (Frame 3 Only) . . . . . . . . . . . . . . . . 25
Standard I/O Board Description (Frame 3 Only) . . . . . . . . . . . . . . . . 27
Combined I/O Board Description (Frame 4 Only) . . . . . . . . . . . . . . 29
DPI Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chapter 3
Planning the Installation General Requirements for the Installation Site. . . . . . . . . . . . . . . . . . . 35
Wiring Requirements for the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Stopping the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Chapter 4
Mounting The Power Module
and Grounding the Drive
Lifting and Mounting the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Grounding the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Lifting and Mounting the Power Module . . . . . . . . . . . . . . . . . . . . . . . 47
Chapter 5
Installing Input and Output
Power Wiring
Installing Power Wiring from the AC Input Line to the Main Input
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installing Wiring from the Power Module Output Terminals to
the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Chapter 6
Completing the Installation Checking the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Powering Up After Installation Is Complete. . . . . . . . . . . . . . . . . . . . . 52
Chapter 7
Using the Start-up Routines Preparing for Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Running the Start-up Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4Rockwell Automation Publication D2-3518-4 - January 2020
Table of Contents
Exiting Before Completing the Start-Up Routines . . . . . . . . . . . . . . . 54
Chapter 8
Programming Basics About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
How Parameters are Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Inverter Parameters View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Rectifier Parameters View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Accessing the Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Selecting the Parameter Access Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Security and Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Chapter 9
Parameter Descriptions What the Symbols Mean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Parameter Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Inverter Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Rectifier Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Chapter 10
Troubleshooting the Drive Verify that the DC Bus Capacitors are Discharged Before
Servicing the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Determining Drive Status Using the Status LEDs . . . . . . . . . . . . . . . 192
About Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
About Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Diagnostic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . 212
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Board Replacement, Firmware Setup Procedures. . . . . . . . . . . . . . . . 218
Troubleshooting the Drive Using the OIM. . . . . . . . . . . . . . . . . . . . . 222
Checking the Power Modules with Input Power Off . . . . . . . . . . . . 225
Appendix A
Technical Specifications Service Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Cooling System Specifications (Refrigerant) . . . . . . . . . . . . . . . . . . . . 230
Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Appendix B
Using the OIM Installing and Removing the OIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Display Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
OIM Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Powering Up and Adjusting the OIM. . . . . . . . . . . . . . . . . . . . . . . . . . 236
Selecting a Device in the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Using the OIM to Program the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Monitoring the Drive Using the Process Display Screen on
the OIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Rockwell Automation Publication D2-3518-4 - January 2020 5
Table of Contents
Displaying and Changing the OIM Reference . . . . . . . . . . . . . . . . . . 239
Customizing the Process Display Screen. . . . . . . . . . . . . . . . . . . . . . . . 239
Customizing the Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Controlling the Drive From the OIM. . . . . . . . . . . . . . . . . . . . . . . . . . 242
Appendix C
LiquiFlo 2.0 Drive Frame 3
Wiring Diagrams
Frame 3 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Appendix D
LiquiFlo 2.0 Drive Frame 4
Wiring Diagrams
Frame 4 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259

6Rockwell Automation Publication D2-3518-4 - January 2020
Table of Contents
Notes:

Rockwell Automation Publication D2-3518-4 - January 2020 7
Preface
Summary of Changes
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at rok.auto/literature.
Topic Page
Updated the short circuit rating specifiction 229
Resource Description
VS Utilities Getting Results Manual, publication D2-3488 Provides information explaining the uses and
interface ofVS Utilities, and information to help you
complete basic tasks such as installing the software
and starting the application, and finding instructions
to complete more sophisticated tasks using the online
help.
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Provides general guidelines for installing a Rockwell
Automation industrial system.
Product Certifications website: rok.auto/certifications Provides declarations of conformity, certificates, and
other certification details.

8Rockwell Automation Publication D2-3518-4 - January 2020
Preface
Notes:

Rockwell Automation Publication D2-3518-4 - January 2020 9
Chapter 1
Introduction
This manual is intended for qualified electrical and plumbing personnel familiar
with installing, programming, and maintaining AC drives.
This manual contains information on:
• Installing and wiring the LiquiFlo 2.0 AC drive
•Programmingthedrive
• Troubleshooting the drive
ATTENTION: Only qualified electrical personnel familiar with the construction
and operation of this equipment and the hazards involved can 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: DC bus capacitors retain hazardous voltages after input power has
been disconnected. After disconnecting input power, wait 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 can operate at and maintain zero speed. You are
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 can operate at or near zero speed. Failure to observe this
precaution can result in severe bodily injury or loss of life.
ATTENTION: Do not install 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 can result in severe bodily injury or
loss of life.
ATTENTION: You 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 can result if this
procedure is not followed. Failure to observe this precaution can result in bodily
injury.

10 Rockwell Automation Publication D2-3518-4 - January 2020
Chapter 1 Introduction
Firmware Versions There are two frame types for LiquiFlo 2.0 drives: Frame 3 and Frame 4. See
Chapter 2 for a description of the physical layout, components, and ratings for
each frame type.
Each drive contains two sections: the inverter section and the rectifier section.
Each section contains its own firmware.
• Firmware for Frame 3 drives are version 1.xx series
• Firmware for Frame 4 drives are version 2.xx series
The current drive firmware versions are listed in Tab le 1.
Table 1 - Firmware Versions
See Determining the Product Version on page 223 for instructions on
determining the firmware version currently installed in a drive.
ATTENTION: The drive contains ESD- (Electrostatic Discharge) sensitive parts
and assemblies. Static control precautions are required when you install, test,
service, or repair this assembly. Component damage can result if ESD control
procedures are not followed. If you are not familiar with static control
procedures, see Guarding Against Electrostatic Damage, publication 8000-4.5.2,
or any other applicable ESD Protection handbook.
ATTENTION: You are 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.
Release Date Firmware Type Current Version
May 2011 Frame 3 inverter application firmware 1.12
May 2011 Frame 3 rectifier application firmware 1.14
June 2011 Frame 4 inverter application firmware 2.12
June 2011 Frame 4 rectifier application firmware 2.12

Rockwell Automation Publication D2-3518-4 - January 2020 11
Introduction Chapter 1
Manual Conventions Parameter names: In most instances, parameter names are shown as the
parameter name followed by the parameter number. The parameter name is
preceded by inverter or rectifier for reference.
For example: inverter PI Control (125).
Getting Assistance from
Rockwell Automation
If you have any questions or problems with the products described in this
instruction manual, contact your local Rockwell Automation sales office. For
technical assistance, call 1-888-926-6786, Option 1.
Also, see Rockwell Automation Support on the back cover of this user manual for
technical support contact information.

12 Rockwell Automation Publication D2-3518-4 - January 2020
Chapter 1 Introduction
Notes:

Rockwell Automation Publication D2-3518-4 - January 2020 13
Chapter 2
About the Drive
This chapter describes how to identify the drive assembly, the power module, and
shows the major drive components.
The LiquiFlo 2.0 AC drive is a pulse-width-modulated (PWM) liquid-cooled
drive that provides vector and general purpose regulation for a wide range of
applications.
Identifying the Drive by
Cabinet Assembly ID
Number
Each LiquiFlo 2.0 AC drive is identified by its assembly number or order number
(see Figure 1). These numbers appear on the shipping label and on the nameplate
of the drive.
Figure 1 - Identifying the Drive by Cabinet Assembly ID Number
Made in USA by Rockwell Automation
Input: 440-480VAC 60HZ 3PH
Output: 480VAC 405A 0-250 Hz
Type Enclosure: TYPE 1
Short Circuit Rating: 65kAIC
ID NO. Cab. Assy: 180264-A03-600
Cabinet Assy S/N: XXXXXXXXXX
PWR Mod. S/N: XXXXXXXXXXX
PWR Mod. M/N: LF200460AAR
Mfg On: XX-XX-XX
Design Pressure: 185 psig
Coolant Type: R134a OR Treated Water
Max. Ambient: 40˚C
Frame Code
Frame 3 180264
3 = 2AA
6 = 2CC
Frame 4 180580
7 = 4AA
9 = 4CC
Voltage (3-PH input)
3 = 380 - 415V, 50 Hz
6 = 440 - 480V, 60 Hz
8 = 346V, 50 Hz
Options
180264-A 03 - 3 00
180580-A 09 - 6 AA
Cabinet Assembly ID Number
Cabinet Assembly Serial Number
AA = 3PH Meter Kit
BA = 100 kAIC Circuit Breaker
CA = CE Touch Kit
KA = Meter Kit + 100 kAIC Circuit Breaker
LA = Meter Kit + CE Kit
TA = 100 kAIC Circuit Breaker + CE Kit
ZB = Meter Kit + 100 kAIC Circuit Breaker + CE Kit
00 = No Options

14 Rockwell Automation Publication D2-3518-4 - January 2020
Chapter 2 About the Drive
LiquiFlo 2.0 Drive
Component Locations
LiquiFlo 2.0 AC drives include a drive section and a power module section. The
components are listed and illustrated below.
Drive Components Locations (Frame 3)
Frame 3 Units 180264-A0x
The drive section contains the following main components. The numbered items
listed below correspond to the numbers used in Figure 2. Replacement parts are
listed in Chapter 10.
1. AC Contactor (3) with Surge Suppressor
2. Terminal Block, 6-position
3. Precharge Resistors (3)
4. Power Module Assembly
5. Power Module Nameplate
6. Fuse Block, 30 A, 600V, Class CC, 3-Line
7. Fuse, Class CC, 600V, 1 A
8. Fuse, Class CC, 600V, 20 A
9. Line Sync. PC Board Assembly
10. Line Sync. Board Cover
11. 115V Fan, 6 in. diameter (2)
12. Capacitor Guard Panel (not shown)
13. Capacitor Bank Assembly
14. Fuse Block, 30 A, 600V, Class CC
15. Fuse, Class CC, 600V, 5 A
16. Fuse, Class CC, 600V, 25 A
17. Fuse Holder, 600V, 30 A
18. Fuse, Class RK5, 600V, 15 A
19. Tra n s f o rm e r, 5 kVA
20. Resistor, 100 kOhm, 50 W
21. Operating Mechanism, Complete Kit
22. Main Input Circuit Breaker
23. Ground Lug, 2-600 MCM
24. 115V Fan, 5 in., sq.
25. Air Filter
26. Floor Mounting Kit (3)
27. Surge Suppressor

Rockwell Automation Publication D2-3518-4 - January 2020 15
About the Drive Chapter 2
Figure 2 - Drive Components (Frame 3)
L2
L1 L3
L2
L1
L3
U
V
W
1
2
8
6
3
4
5
67
9
10
11
25
12
13
26
16
15
14
18
17
19
27
20
21
22
23
24

16 Rockwell Automation Publication D2-3518-4 - January 2020
Chapter 2 About the Drive
Power Module Components Locations (Frame 3)
Frame 3 Units LF200460AAR and LF200608CCR
The power module section contains the following main components. The
numbered items listed below correspond to the numbers used in Figure 3 and
Figure 4. Replacement parts are listed in Chapter 10.
1. Wire Harness Assembly, Power Supply, Logic (2)
2. Current Feedback Device, 1000 A (6)
3. Terminal Block, 2-Position
4. 80 W Power Supply Assembly (2)
5. Cable Assembly, 40-pin, 0.050 in Pitch, Flex Film (2)
6. Cable Assembly, 30-pin, 0.050 in Pitch, Flex Film (2)
7. Wire Harness Assembly, Power Supply, Upper Gate (2)
8. Inverter Power Interface Assembly
9. Wire Harness Assembly, Power Supply, Lower Gate (2)
10. Insulation Sheet (2)
11. Communications Interface Assembly
12. Rectifier Power Interface Assembly
13. Wire Harness Assembly, Gate Driver
14. Wire Harness Assembly, Current Feedback Device
15. Wire Harness Assembly, Line Sync.
16. Wire Harness Assembly, DC Bus Bleeder Resistors
17. Cable Assembly, 20-pin, 0.050 in Pitch, Flex Film (optional)
18. Communications Assembly (optional)
19. Internal Fan
20. Connector, Terminal Block, 32-pin
21. AC Line I/O Assembly
22. Rectifier Control Assembly
23. Inverter Control Assembly
24. Standard I/O Assembly
25. Wire Harness Assembly, Control Sync.

Rockwell Automation Publication D2-3518-4 - January 2020 17
About the Drive Chapter 2
Figure 3 - Power Module Component Locations - Door Open (Frame 3)
15
16
13
2
14
12
8
10
4
4
10
3
7
7
1
1
9
9
11
6
5
6
5
7
25

18 Rockwell Automation Publication D2-3518-4 - January 2020
Chapter 2 About the Drive
Figure 4 - Power Module Component Locations - Door Closed (Frame 3)
22
21
23
20
11
19
17
18
24
20
Optional
Optional

Rockwell Automation Publication D2-3518-4 - January 2020 19
About the Drive Chapter 2
Drive Components Locations (Frame 4)
Frame 4 Units 180580-A07 and 180580-A09
The drive section contains the following main components. The numbered items
listed below correspond to the numbers used in Figure 5. Replacement parts are
listed in Chapter 10.
1. Circuit Breaker, 600V
2. Inductor
3. AC Contactor
4. Power Module Assembly
5. Input Filter Capacitor Assembly
6. OIM
7. Fans, 115V AC, Inductor (4)
8. Tra n s f o rm e r, 5 kVA
9. Fan, 115V AC, Contactor
10. Resistors, 100 kOhms, 50 W
11. Precharge Resistors
12. Relay, Oil Pump & Control Power Terminals
13. Fuse, Class RK-5, 600V, 10 A (2)
14. Fuse, Class CC, 600V, 25 A (1)
15. Fuse, Class CC, 600V, 10 A (1)
16. Fuse, Class T, 600V, 300 A (3)
17. Fuse, Class CC, 600V, 20 A (3)
18. Fuse, Class CC, 600V, 1 A (3)
19. Ground Lug, 2-600 MCM
20. Nameplate, Power Module
21. Door Inter-lock (2)
22. Surge Suppressor
23. Circuit Breaker Operating Mechanism

20 Rockwell Automation Publication D2-3518-4 - January 2020
Chapter 2 About the Drive
Figure 5 - Drive Components (Frame 4)
L1 L3L2
4
12
20
211821151413 675
8
1
2
10
16
19
3
911 17
22
L1
L2
L3
U
V
W
23