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LPM20 Liquid-Cooled Adjustable Frequency AC Drive

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1. INPUT FILTER EXTERNALDPI CONNECTIONS r 180807 C01 7 Pos Plug 20 PIN Board to Board L1 poe m A11 n 4 VOLTAGE F B i L3 RESISTOR ASSY yg UT 180675 03 12 T ACTIVE CONVERTER DPI4 DPIS 0213 Factory Installed CONTROL ASSY 2 ee mL es CUSTOMER TEMP SENSOR PI 2 c ACE ASSY CONNECTIONS 180037 A01 A34 SEE DETAIL V J1 179828 Q01 5 1 180807 C02 15 Pos Plug J5 180777 01 lt Jumper 55 194706 001 ATP N eii IN J1 1 A13 M4 2 RECTIFIER POWER 80W POWER COMMUNICATIONS
2. amp CONTROL TB1 700S CONTROL amp FEEDBACK gt OPTIONS ADD L Sonik CUSTOMER CONNECTIONS A CONFIGURATIONS TB2 p A22 p MAIN From DC BUS 28 Pin Board To Board CONTROL 179828Q02 8242 6 Jt ASSY J P3 L A36 5 P6 HIGHVOLTAGE MOTOR VOLTAGE 179780 Q01 L INTERCONNECT ASSY 7 FEEDBACK ASSY Factory Installed Jumper P1 180812 A01 D 320390 A02 lt NC P2 B 16 Pin Board to Board A38 SWITCH SEEDETAILA _ 479749 79695 003 GATE J14 180822 C01 KILL OPTION Bh J9 JP1 4 D 1 _ 2 20 A23 Jumper TERMINAL BLOCK 80W POWER INVERTER POWER 179745 SUPPLY INTERFACE ASSY Jn 193087 02 179758 See Table Page 11 L Ji Je T 13 HUHH JZ J6 HNW 180427 Q02 Inverter Sid To To A36 J6 nverter Side 180799 01 m 180427 Q02 Inverter Side lt 180813 01 179111 18081901 C AM LAM BUS ul PORTET DC MEASUREMENT LEADS POINT BUSU W 179578 BUS V 179580 wp vp CURRENT FEEDBACK DEVICE 179701 INVERTER IGBT ASSY 1 INVERTER IGBT ASSY 2 See Table on Page C 11 See Table on Pag
3. w i 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 below provides communication between the LPM20 drive and another DPI device for example a HIM Figure 1 4 DPI Communication Interface Board DPI Port 4 5 DPI Port 5 For more information regarding operating LPM20 drives with a HIM refer to Appendix B 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
4. DPI Master ON A12 P1 Ze Terminals E Li g 12 13 5 7 6 5 4 3 2 B 1 P2 Voltage Feedback Terminals Resistor Assembly Terminal Blocks Table 1 N Active Converter Control Board I O Terminal Block Specifications Wire Size Range Maximum Minimum Maximum Signal and power 1 5 mm 0 14 mm 0 25 N m connections 16 AWG 28 AWG 2 2 Ib in 1 Maximum minimum that the terminal block will accept these are not recommendations Torque Recommended 0 22 N m 1 9 Ib in Name I O Blocks Description Table 1 0 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 Common 5 Comm In 13 Safety H
5. 4 0 213 Thru 21 97 For 6 TAPTITE a 1 19 Screw with Enclosure pues Mounting Bracket D 1 L a 1 92 2 0 80 _ T 0 88 iting e L 0100 1 Cy y Both Sides e W 2 i utput AS ji Wiring 4 0 472 4 to Motor 025 Hu LJ DETAIL A Input and Output Wiring Connection _ SCALE 1 2 n U i e 9 20 4 Coolant Connections IN See Notes 2 and 3 Et A m 448 Wiring 476 OUT J Input Filter Harness 9 9 1 Connector re 1 8 i ALIN 42 40 8 96 T7 9 03 L r e 4 6 66 1 9 T pov 4 E 9 9 2 65 From Back of 6 84 SEE DETAIL FRONT Chassis to ORFS of VIEW Sealing Surfaces Lifting 1 00 Both Sides LEFT SIDE VIEW 18 49 NOTES 050 1 Floor Mounting Flange Holes 2133 A Accept M8 Thread Rolling Screws per SAE J1237 i Tightening Torque 20 24 15 17 FT LBF 6 75 2 Inlet and Outlet Coolant Connection Hardware Provided With Unit A ORFS Braze Sleeve 9 25 m a Material Brass for 5 8 O D Copper Tube 3 88 b Reference Parker Hannifin P N 10 TL B or equivalent 1 ORFS Nut 1 56 a Material Brass for 5 8 O D Copper Tube 1 14 UN UNF 2B Thr
6. 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 2 1 17 Installing Output Power Wiring 1 19 Power eae mee eere h e Beet Me te 1 20 Using Input Output 1 1 22 TO WAT Esse Potes Pareto Pad 1 23 Main Control Board I O and Encoder 1 31 Connecting SynchEimk a eer PEU ERES 1 32 Active Converter 1 33 Auto Tune 1 33 Pre charge Operation eee Eee Yves 1 34 Wiring the Active Converter Control Board I O Terminals 1 34 CE s u VE Up rea DNE eee 1 36 C Tick Conformity lere ne Rl LR RR e RR eg ERE eee 1 37 Start Up Prepare For Drive 2 1 Status Indicators 1 0
7. h REGTIFIER LI4GOLLECTOR 42 tm 1 RECTIFERLGGATE S Pages 5 pe e 3 RECTIFIER LEGATE C 6 C 7 5 5 T co MEASUREMENT zz POINT 2 2 _ 4 Lr EM 7 8 L2BUS C 6 C 7 L1BUS 1 12 9 10 HRA is He CL E E E E E 1 3 5 1 3 5 To A36 J1 DC BUS See Pages C 8 C 9 DC BUS DC MEASUREMENT Wiring Diagrams C 11 15 INVERTER IGBT ASSY 1 126 INVERTER IGBT ASSY 2 See Table on this page See Table on this page J2 uu e INVERTER W COLLECTOR 3 INVERTER W GATE E EXT INESTERWCDLECIUR See ES 2E 3 INVERTER NTC2 See Pages C 8 C 9 J3 2 9 i INVERTER U COLLECTOR Pages INVERTER U GATE C 8 C 9 0 e RIERUEMITER WBUS See VBUS Pages C 8 C 9 U BUS 1 3 5 1 3 5 ___ BUS CAPACITOR 2700 pF 420 VDC See Table on this page A1 VFD POWER MODULE TABLE Bus Bus 15 A23 A25 Capacitor Capacitor A16 A26 Quantity Part Number 20ND6
8. Sourcing Digital Outputs using internal power supply ON 0 Sinking Digital Inputs using internal power supply Com 24V de N 9 10 11 12 13 14 4 16 H Hi Sourcing and Sinking Definitions Sinking Digital Outputs using internal power supply Com 24V dc z HHHHHHI Oc wr 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 cont
9. Shield Common O P Signal or Source Common Signal O Shield Common lt Signal or Source Common Signal O Shield Common H 9 HH H Figure 1 10 TB1 Terminals Analog Wiring Examples Continued Installation Wiring 1 27 Input Output Connection Example Analog Output 0 10V Analog Output Required Parameter Changes 10V dc Used to drive analog meters displaying speed and current Using Analog Output 1 10V to 10V to meter Motor RPM and direction e Send the data to the Analog Output Parameter 833 Anlg Out1 Real the destination linked to Parameter 71 Filtered SpdFdbk the source e 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 e Send the data to the Analog Output Parameter 840 Anlg Out2 Real the destination linked to Parameter 308 Output Current the source e Scale the Output to the source parameter Example
10. INTERFACE ASSY SUPPLY BOARD p m See Table on Page C 11 179753 193087 A02 See Pages C 6 C 7 INPUT FILTER CONNECTIONS D me PM OPTION m Y ig nm m 180427 Q01 RECTIFIER SIDE 179711 1 1 4 A36 J1 Fan Ieri 179196 AC POWER INPUT LEADS BUS L1 L3 179578 i BUS L2 179580 13 L2 L1 CURRENT FEEDBACK Li DEVICE 179701 GRD RECTIFIER IGBT ASSY 1 RECTIFIER IGBT ASSY 2 u See Table 11 A16 See Table on Page C 11 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 A1 R1 amp 1 82 DISCHARGE RESISTORS 2 6 KOHMS 24708 501 12 Wiring Diagrams C 5
11. Installation Wiring This chapter provides information on mounting and wiring the LPM20 Drive For information on See page 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 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 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 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 ATTENTION The following information is merely a guide for LPM20 Drives with Hi
12. Manually Clearing Drive Faults Drive Fault Descriptions Active Converter Fault Descriptions Clearing Drive Alarms 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 gt Faulted auto the following a e Faulted appears in the status line OverVoltage Fault number Time inco Eau t e Fault name iii e 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 gt Loss Auto the following Hz e Alarm name 2 alarms only Main Menu e Alarm bell graphic Diagnostics Parameter Device Select Step 5 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 of these methods 2 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 ple
13. 12V INV 12V INV DGND DGND COMM RXD INV COMM TXD INV COMM CS INV COMM CLK INV LED RED INV LED GRN INV 24V INV 24VCOM INV A31 J7 See Pages C 6 C 7 See Pages C 10 C 11 A36 HIGH VOLTAGE INTERCONNECT ASSY 180812 A01 J2 J3 P2 P3 A35 MOTOR VOLTAGE FEEDBACK ASSY 320390 A02 CURRENT FEEDBACK DEVICES 2 24NCOM ISO 1 24V ISO 4 5V PS 3 45V PS 6 5 5 5 45V PS 8 GND PS 7 GND PS 10 GND PS 9 GND PS 12 12 11 12V 14 GNDPS 13 16 15 GND PS 18 EE SK 17 EE IO 20 EE GND 19 22 GNDSHAT 21 JCHARGE 24 UNEG 23 UPOS 26 VNEG 25 VPOS 28 WNEGE 27 WPOS 30 29 KILL RESET 32 U AMPS 31 GND PS 34 VWV 5 33 VAMPS 36 JGATE KILL 35 GND PS 38 37 DCBUS 40 39 1 viso 2 3 4 viso DC BUS DC BUS PHASE V VOLTS 6 7 8 PHASE U VOLTS 9 0 1 12 PHASE W VOLTS 29 EN Wiring Diagrams To DC BUS See Pages C 10 C 11 AC y POWER OUTPUT CURRENT FEEDBACK PWR 228 leise MAIN GATE CONTROL DRIVER INTERFACE INTERFACE GATE DRIVER INTERFACE A23 INVERTER POWER INTERFACE ASSY See Table on Page C 11 GATE DRIVER INTERFACE IGBT TEMPERAT
14. IEC 146 International Electrical Code impulses may be counted in addition to the standard pulse train causing erroneously high Pulse Freq Specification Drive 480V AC Input Overvoltage Trip 570Vac AC Input Undervoltage Trip 280Vac Bus Overvoltage Trip 810 Bus Undervoltage Shutoff Fault 305Vdc Nominal Bus Voltage 648Vdc All Drives Heat Sink Thermistor Monitored by microprocessor overtemp trip Drive Overcurrent Trip Software Overcurrent Trip 200 of rated current typical Hardware Overcurrent Trip 220 300 of rated current dependent on drive rating 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 Altitude 1000 m 3300 ft max without derating Maximum Surrounding Air Temperature without Derating 20 NEMA 1 0 to 40 C 32 to 104 F Storage Temperature all constructions 40 to 70 C 40 to 158 F A 2 Supplemental Drive Information Category Environment continued Electrical Control Specification Atmosphere Important Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive ga
15. 2 3 Assisted Start Up eee reo quet epe ete ihe Seto ont Poet e 2 4 Troubleshooting Faults and Alarms s ie Ren ecu wt ea 3 1 Drive Status cubito psc t etse Dy baa 3 2 Manually Clearing Drive Faults 3 3 Drive Fault Descriptions l yu uhuy 0 3 3 Active Converter Fault Descriptions 3 3 Cleanng Drive Alarms ouibus e heb eR et ia a bod aqa td 3 3 Common Symptoms and Corrective Actions 3 4 Test Equipment Needed Troubleshoot 3 6 Verifying That DC Bus Capacitors Are 1 3 6 Replacement s 3 7 Supplemental Drive Information SBecHICafIOnSr 9 uu PODER Ee DURS ee qaq 1 Communication Configurations A 3 ii Table of Contents Appendix B Appendix C Index HIM Overview Remote HIM B 1 LCD Display Elements s usa Arend ale Moo eral B 2 ALT Functions z uparaq bebe bee belie de Seen geese deg B 2 Menu Structure ten wb woe enc nek n e bah S Yu advo dO aioe Se B 3 Viewing and Editing Parameters 0 B 5
16. 23 UPOS 24 INTERFACE 5 RECTIFIER 26 NEG 25 H 1 8 RECTIFIER LI COLLECTOR 27 WPOS 28 A13 2 RIL RESET gemens TO RECTIFIER IGBT ASSY 1 J2 See U AMPS 12 RECTIHERLEEMITTER HE RECTIFIER POWER Pages 1 INTERFACE ASSY c 10 0 11 57 See Table Page 11 J8 Ed j RECTIRER woowector GATE satis TO RECTIFIER IGBT ASSY 2 J3 5 d J9 DRIVER INTERFACE 3 SOCIN asawa ani TO RECTIFIER IGBT ASSY 2 1 2 RECTIFIER LS EMITTER 4 p e _ 22 6 3 RECTIFIER NTC1 EN FEEDBACK INTERFACE See Pages IGBT TO RECTIFIER IGBT ASSY 1 J1 2 C 8 C 9 TEMPERATURE TO RECTIFIER IGBT ASSY 2 J1 J8 SENSE IN UPPER GATE SUPPLY OUPUT UPPER GATE DC BUS INTERFACE SUPPLY re VOLTAGE FEEDBACK RESISTOR ASSY CONNECTIONS AW 180675 A03 DC BUS 43 80W POWER SUPPLY DISTRIBUTION 193087 A02 0 EE J9 LOWER GATE ans LOWER GATE SUPPLY MO SUPPLY OUT lt JUMPER N 1 INPUT IND CTOR OVERIENE 3 IN FILTER Tee s NTERNAL I O CONNEC
17. 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 Eigure 1 6 AC Supply Source Considerations 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 Table 1 for input power rating specifications Be sure input power to the drive corresponds to the drive nameplate voltage and frequency 20 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 damage caused by improper circuit breaker selection use only the ATTENTION To guard against personal injury and or equipment recommended circuit breakers specified in Table 1 B Unbalanced or Ungrounded Distribution Systems 20 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 drive s printed circuit boards The MOVs are referenced to ground ATTENTION LPM20 drives contain protective MOVs on the The MOVs should not be disconnected Input Power Conditioning
18. Certain events on the power system supplying a drive can cause component damage or shortened product life They are e The power system has power factor correction capacitors switched in and out of the system either by the user or by the power company e 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 e 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 Mounting the Drive Determining Wire Routing and Grounding condition As a result of this fault the active converter 1s 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 be
19. Class Control 600VAC Time Delay S Transformer 25A 120V 25A 1 2 AC INPUT Class RK 5 m 12 1 2 T1 Input 50 60Hz H1 H4 380 415VAC CB1 H1 H5 440 480VAC Main Circuit Breaker Shunt Trip Class CC 1A 600V Time Delay 1 2 100 50W IND1 Input Inductor Filter Caps 46uF each x 1uF Potter amp Brumfield Part KUP 14D15 24 Socket 27E893 120V 4 Hold 20C318 Switched A 1 20A JFU10 600V Precharge Resistors E 100 600W Precharge Contactors DRIVE INPUT COMPONENTS in a Control 115V 60Hz 1PH 115V COM 4 1 1 1 24V FUSE TABLE DRIVE INPUT Ref Fuse Description Supplier A and P N Supplier B and P N FU1 Class RK 5 15A 600V Bussman FRS R 15 Gould Shawmut TRS R15 FU2 Class RK 5 15A 600V Bussman FRS R 15 Gould Shawmut TRS R15 FU3 Class CC 5A 600V Littelfuse KLDROO5 Gould Shawmut 5 FU4 150A 600V Bussman FWH 150B Gould Shawmut A50P150 4 FU5 150A 600V Bus
20. Parameter 822 Anlg Out2 Scale xx where Parameter 2 Motor NP FLA is divided by 10V output Primary Encoder Interface Supports 5V dc 12 V dc differential encoders with internal power supply Primary Encoder Internal Supply H The Z channel is not required in typical applications HH wF i The Z channel is not required in typical applications 23 Power V O Shield Using Encoder 0 as speed feedback e 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 e Set the value of Parameter 232 Encoder 0 PPR to match the installed encoder s resolution Pulses per Revolution 1 28 Installation Wiring 22 2 Y Table 1 J TB2 Terminals a Related Terminal Signal Description Parameter 1 24V dc Common Drive supplied 24V dc logic input power 2 24V Source Rating 300 mA maximum load 3 Digital Output 1 24V dc Open Collector sinking logic 816 847 Rating Internal Source 150 mA maximum External Source 750 mA 4 Digit
21. 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 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 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 these precautions 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 2 Connect the three phase AC power motor leads to the appropriate output terminals Figure 1 5 shows the locations of the output power terminals 3 Tighten the three phase AC output power terminals to the proper torque as shown in Table 1 D 1 20 Installation Wiring Power Wiring etc and local codes outline pro
22. 0 032 Male Faston Accessible SEE DETAIL COG DETAIL COG M by Removal of Top Cover SCALE 5 16 1 CENTER OF GRAVITY u X 17 5 Ysgd ___ SEE DETAIL 2 pon GATE KILL WEIGHT A22 TB1 amp TB2 1621B5 Main Control Assy Terminal Blocks 25 90 A33 Gate Kill 32 16 2 Pos Terminal Block A12 P1 Active NT d Ss Converter Control d e 9 2 96 With 6 32 Phillips Slotted Assy Terminal Screws Accepts 6 Stud Size Block 15 Pos E H Spade Tongue Terminal p pOUT Max Width is 0 37 i N 1347 LE 9 50 1 1 78 11 2 Voltage 154 IN H Feedback 4 H h 271 Resistor Ass y mar Terminal 10 32 Po 1 Block 7 Pos 1 296 14 6 60 p 44 9 T 1 11 2 2s DETAIL GATE KILL 5 RE RIGHT SIDE VIEW SCALE 5 8 ooling Fan Requires 1 13 Minimum AIRFLOW Unobstructed Space Below Fan 72 0 458 4 PL See Note 1 17 50 6 EE FIELD CONTROL WIRING N Ref Torque Wire Size Strip Length N M AWG Inch 9 56 A33 6 32 Screw 0 90 8 24 to 10 _ A12 P1 Screwdriver Blade aso 11 2 0 032 Thk x0 125 Wide 079 7 0121 03 A22 TB1 Screwdriver Blade A22 TB2 0 017 Thk 0 094 Wide 022 19 28016 0 25 156 I A1 P1 LINE SYNC ASS Y HARNESS CONNECTOR 04 A1 P1 Socket Housing AMP P N 172163 1 Socket AMP P N 770903 3 Pin Housing AM
23. 1 Bipolar differential input 10V 0 20 mA 11 bit sign 832 833 10 Analog Output 1 2K ohm minimum load 11 Analog Output 2 839 840 12 Analog Output 2 13 10V Reference Rating 20 mA maximum load recommend 5K ohm 14 Reference Common potentiometer 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 Rating 300 mA maximum 24 Encoder Shield Connection point for encoder shield 1 26 Installation Wiring Figure 1 10 1 Terminals Analog Wiring Examples Input Output Connection Example 0 10V Analog Input 0 10V Analog Input Internal Source Required Parameter Changes c ABA 6 0 10V Analog Input Bipolar HHHH 10 Analog Input External Source Signal or Source Common gt Signal
24. 10 ohm 300W Kit 3 per box SP 322542 A01 ao 400 480 608 Control Transformer Multi tap 3 KVA SP 180086 400 480 608 Wire Harness Assy P1 Connector to Input Filter SP 181251 A01 Control 400 480 608 Cap Bank Assy Input Filter 608A SP 342008 A01 1 400 480 608 Inductor Input Filter 608A 180824 01 1 400 480 608 Inverter Power Interface Assy 608 SP 180940 A04 1 400 480 608 Contactor AC Precharge 140A 600 VAC 100 D140D11 3 Replacement Fuses For replacement fuses refer to the drive wiring diagram on page C 2 3 8 Troubleshooting Notes Appendix A Supplemental Drive Information For information on Specifications A 1 Communication Configurations A 3 Specifications Category Specification Agency Certification 1 Applied noise readings Category Protection Environment Listed to UL508C and CAN CSA C2 2 No 14 91 0 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 The drive is also designed to meet the following specifications 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
25. 4 Position Precharge Resistors 3 115V Fans 2 po Um GPS gt N Installation Wiring 1 3 Figure 1 1 Drive Input Components Pa EENE 0 12 1 SECTION A A ET 5 9 4 See SECTION 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 Replacement parts are listed in Chapter 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 Gat
26. Drive Incremental Dual Channel Quadrature type Encoder Voltage Supply 5V dc or 12V dc 5V dc requires an external power supply 320 mA channel Maximum Input Frequency 400 kHz Stegmann Hi Resolution Option Encoder Voltage Supply 11 5V dc 130 mA Hi Resolution Feedback Sine Cosine 1V P P Offset 2 5 Maximum Cable Length 182 m 600 ft RS 485 Interface 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 Customer I O Plug P1 Hi Res Allen Bradley PN S94262912 Weidmuller PN BL3 50 90 12BK Resolver Option Excitation Frequency 2400 Hz Excitation Voltage 4 25 26 Vrms Operating Frequency Range 1 10 kHz Resolver Feedback Voltage 2V 300mV Maximum Cable Length 304 8 m 1000 ft DriveLogix User Available Memory Base 1 5 megabytes Battery 1756 BA1 Allen Bradley PN 94194801 0 599 lithium Serial Cable 1761 2 to 1761 NET AIC 1761 CBLPAOO to 1761 NET AIC 1756 CP3 directly to controller 1747 CP3 directly to controller Category 3 2 Compact I O Connection Up to 30 modules Cable 20D DL2 CL3 20D DL2 CR3 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
27. 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 e Versalink V System e Lucent Technologies e 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 e 10 Daisy Chain e 256 Star Configuration The active converter communicates control and starts information with the 7005 controller over DPI Data Link D 700 Parameter 71 Converter Status is transferred to 7005 Parameter 657 DPI Data In D1 This may be used to monitor the operation of the active converter 7005 Parameter 666 DPI Data Out D1 is transferred to 700AC Parameter 70 Converter Control This may be used to start and stop the converter 7005 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 Modu
28. 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 151413 1211109 8 7 6 5 413 2 1 0 Command Description x Normal 0 Not Normal Stop Stop 1 Normal Stop x Start Start 1 Start X Jog 1 0 Not Jog using Jog Speed 1 1 Jog using Jog Speed 1 X Clear 0 Not Clear Fault Fault 1 Clear Fault X X Unipolar 00 No Command Direction 101 Forward Command 10 Reverse Command 11 Hold Direction Control X Reserved X Jog 2 0 Not Jog using Jog Speed 2 1 Jog using Jog Speed 2 X Current 0 Not Current Limit Stop Limit Stop 1 Current Limit Stop X Coast Stop 0 Not Coast to Stop 1 Coast to Stop X Spd Ramp 000 Spd Ref A Hold 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 X Reserved X Spd Ref 0
29. 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 View Allows the selection of how parameters will be viewed or detailed information about a parameter or component Lang Displays the language selection screen Auto Man Switches between Auto and Manual Modes Remove Allows HIM removal without causing a fault if the HIM is not the last controlling device and does not have Manual control of the drive Exp Allows value to be entered as an exponent Param Allows entry of a parameter number for viewing editing Menu Structure HIM Overview B 3 Figure B 2 HIM Menu Structure User Display Faults gt Fault Info Status Info i n VY Drive Status 1 View Fault Queue Device Items Drive Status 2 Clear Faults 0962 Device Version gt PowerFlex 700 Drive Alarm 1 Clr Fault Queue HIM Version Product Data Drive Alarm 2 Reset Device Main Control Board Speed Ref Source Power Unit Board Start Inhibits Last Stop Source LCD HIM Product Data Dig In Status LCD HIM Standard Dig Out Status Control Board Drive Temp Keyboard Numeric Drive OL Count Motor OL Count View selected through Gp Y Param Access Ll gt v gt D Basic Qe FGP FGP
30. 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 HIM Copycat Device gt HIM Device lt HIM Description Save data to a HIM set load data from a HIM set to active drive memory or delete a HIM set Device User Sets Save data to a User set load data from a User set to active drive memory or name a User set Reset To Defaults Restore the drive to its factory default settings 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 Dis
31. 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 for power module mounting dimensions 7 Remove the s hooks and chain 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 Table 1 A This table lists the typical full load power loss watts value at 2 kHz rated carrier frequency Ensure that the enclosure is adequately ventilated with 0 to 40 C ambient air based on 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 and Figure 1 6 show the wire routing grounding terminal and power terminal strips of LPM20 drives with High Performance Drive Control 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
32. to Start Up routine Start Up 2 3 Status Indicators Figure 2 1 Drive Inverter and Rectifier Status LEDs n DPI Communications ao Interface Board front surface of oo power module Inverter Status LED T r3 oO O Rectifier Status LED 4 c E d 2 4 Start Up Assisted Start Up Figure 2 2 Drive RUN LED on PF700S Control Cassette Drive RUN LED RUN VO DriveLogix Indicators FORCE only supplied when drive is equipped with DriveLogix 5730 Controller COM BAT OK State Description 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 20D UM003 Drive RUN LED topmost indicator Green DriveLogix Indicators If the DriveLogix option is not present the associated indicators will not be present Important Information Power must be applied to the drive when viewing or changing parameters Previous programming may affect the driv
33. 00 Spd Ref Sel0 001 Spd Ref B 010 Preset 2 011 Ref 3 Preset 3 100 Ref 4 Preset 4 101 Ref 5 Preset 8 110 Ref 6 Preset 6 111 Ref 7 Preset 7 X Spd Ref 000 Spd Ref Sell 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 X Spd Ref 000 Spd Ref Sel2 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 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 Supplemental Drive Information A 5 Logic Status Word Logic Bits 15 14 13 12 11 10 Status Description Enabled 0 Not Enabled 1 Enabled Running 0 Not Running 1 Running Command 0 Reverse Direction 1 Forward Actual 0 Reverse Direction 1 Forward Accel 0 Not Accelerating 1 Accelerating Decel 0 Not Decelerating 1 Decelerating Jogging 0 Not Jogging 1 Jogging Fault 0 No Fault 1 Fault Alarm 0 Alarm 1 Alarm Flash Mode 0 Not in Flash Mode 1 Flash Mode x Run Ready 0 N
34. 08 179575 179527 A02 181023 A01 179527 A02 24 184698 C 12 Wiring Diagrams Notes A 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 C 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 Index biocide treatment 1 16 connections to drive 1 15 considerations 1 14 corrosion inhibitor 1 16 requirements 1 15 Copycat B 4 D 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 loca
35. 1 11 1 COMMUNICATIONS BOARD Refer to Communications Adapter Installation Manual for available options A34 CHILLPLATE TEMPERATURE SENSOR 180037 A01 AC POWER INPUT COMMUNICATIONS INTERFACE A12 ACTIVE CONVERTER CONTROL ASSY 180654 A01 EXTERNAL DPI VO A EE IFF ATN FACTORY INSTALLED JUMPER CURRENT FEEDBACK DEVICES L3 A18 A19 L1 uf L3 BUS 1 See L2 BUS Pages C 10 C 11 BUS Wiring Diagrams C 7 Ji J5 J6 4 2 2AVCOM ISO 1 RECTIFIER RECTIFIER POWER 3 TO RECTIFIER IGBT ASSY 1 J2 LAYER ij CONTROL GATE 5 GNDPS T INTERFACE DRIVER EE 2 ADDE H INTERFACE g RECTIFIER L2 COLLECTOR 12 SUV TI FO saras naye TO RECTIFIER IGBT ASSY 2 J3 12 RECTIFIER L2 EMITIER 13 12V 14 16 EE 5VDC 15 7 T EEO 18 J EN EECS G ATE 1 RECTIFIER L3 COLLECTOR Bl CHARGE 2 DRIVER E35 TO RECTIFIER IGBT ASSY 2 J1
36. 196 of base speed across 120 1 speed range 120 1 operating range 50 rad sec bandwidth Speed Regulation with feedback 0 00196 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 Communication Configurations Supplemental Drive Information A 3 Category Specification Feedback Encoder Inputs 2 Dual Channel Plus Marker Isolated with differential transmitter output Line
37. 2 Email support drives ra rockwell com Online www ab com support abdrives www rockwellautomation com X Power Control and Information Solutions Headquarters Americas 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 Asia Pacific Rockwell Automation Level 14 Core E Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 20N INOO1D EN P November 2006 P N 180779 P04 Supersedes 20N INOO1C EN P July 2005 Copyright 2006 Rockwell Automation Inc All rights reserved Printed in USA
38. 60 00 Hz 250 00 lt gt 250 00 FGP Par 310 Output Freq 90 00 Hz 250 00 lt gt 250 00 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 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 Remove Intrfc 1 Press ALT and then Enter Remove The Remove HIM confirmation screen appears Press Enter to 2 Press Entert irm that u Disconnect Op Intrfc 4 UM er to confirm that you want to remove Port 1 Control 3 Disconnect the HIM from the drive To install HIM 1 Connectthe HIM cable to the drive DPI Port 4 See Figure B 1 Appendix C Wiring Diagrams Wiring diagrams on the following pages illustrate the drive and power module wiring For information on page Drive C 2 Power Module Overall C 4 Power Module Active Converter Control and Rectifier Power Interface 6 Power Module High Voltage Interconnect and Inverter Power Interface C 8 Power Module Rectifier IGBT and Inverter IGBT C 10 C 2 Wiring Diagrams Drive
39. B Allen Bradley LPM20 Liquid Cooled Adjustable Frequency AC Drive With High Performance Drive Control Installation Manual Automation 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 descr
40. Belden 8790 is 1 shielded pair 4 Belden 9773 is 3 individually shielded pairs 2 channel plus power If 3 channel is required use Belden 9774 or equivalent 8 Belden 9892 is 3 individually shielded pairs 3 channel 0 33 mm 22 AWG plus 1 shielded pair 0 5 mm 20 AWG for power 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 1 24 Installation Wiring Table 1 6 Recommended Control Wire for Digital I O Insulation Unshielded Per US NEC or applicable national 300V or local code 60 C Shielded Multi conductor shielded cable 0 750 mm 18AWG 140 F such as Belden 8770 equivalent conductor shielded minimum 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 Co
41. Drop From Drive Temperature Coolant Flowrate Inlet to Drive Outlet PSIG at Range C Minimum Coolant Flow Rate 608 5 to 40 7 10 Water 608 0 to 40 7 10 WEG25 2 550 0 to 40 7 10 WEG50 9 608 0 to 40 10 22 WEG50 9 608 0 to 30 7 10 WEG50 9 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 1096 by volume 2 Dow Chemical www dow com Dowtherm SR 1 inhibited ethylene glycol The recommended concentration of the inhibitor is 25 by volume Dowtherm is a registered trademark of the Dow Chemical Company free Use of common silicate containing automotive type ATTENTION Ethylene glycol must be inhibited and silicate ethylene glycol solutions is prohibited as they may damage the drive and cooling module equipment 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 Installing Input Power Wiring Circuit Breaker Line Side Lugs Torque Label for Line Side Lugs Installation Wiring 1 17 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 f
42. EDBACK PWR CURRENT FEEDBACK SIGW CURRENT FEEDBACK PWR J11 INTERNAL I O INTERFACE CURRENT FEEDBACK See Pages C 10 C 11 3 4 INVERTER DC BUS INVERTER DC BUS To DC BUS 2 TO INVERTER IGBT ASSY 1 J2 See Pages C 10 C 11 UPPER GATE SUPPLY OUPUT 1 46 4 80W POWER SUPPLY 193087 02 BLOCK FACTORY NSTALLED JUMPERS SWITCH 1 24V I ey Hee lt p I 5 424V A33 5 GATE KILL EXTERNAL TERMINAL OPTION OPTION C 9 C 10 Wiring Diagrams Power Module Rectifier IGBT and Inverter IGBT RECTIFIER IGBT ASSY 1 RECTIFIER IGBT ASSY 2 See Table on Page C 11 See Table on Page 11 Al a a u RECTIFIER L3 COLLECTOR e4 RECTIFIER L3 GATE RECTIFIER L3 EMITTER See RECTIFIER L3 COLLECTOR Pages RECTIFIER L3 GATE 6 7 12 13 14 RECTIFIER NIC2 RECTIFIER L2zCOLLECTOR RECTIFIER L2sGATE _____ RECTIFIER L2 EMITTER ____ RECTIFIER L2 COLLECTOR See Pages eo Rennes C 6 C 7 RECTIFIER NTC1 See Pages See Pages C 6 C 7 C 8 C 9 m PEET
43. ENTION 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 Signal and Control Wire Types Table 1 F Recommended Signal Wire Signal Type Where Used Wire Type s Description Minimum Insulation Rating Standard Analog I O Belden 8760 9460 equiv 0 750 mm 18AWG twisted pair 100 shield with drain 9 Remote Pot Belden 8770 or equivalent 0 750 18AWG 3 cond shielded Encoder Pulse I O Combined Belden 9730 or 0 196 mm 24 AWG Less 30 5 m 100 ft equivalent 4 individually shielded Encoder Pulse I O Signal Belden 9730 9728 0 196 mm 24 AWG 30 5 m to 152 4 m or equivalent individually shielded 100 ft 500 ft Power Belden8790 10 750 mm2 18AWG Combined Belden 9892 3 0 330 mm or 0 500 mm 9 Encoder Pulse I O Signal Belden 9730 9728 0 196 24 AWG 152 4 m to 259 1 or equivalent 2 individually shielded 500 ft 850 ft Power Belden 8790 0 750 mm2 18AWG Combined Belden 9773 9774 0 750 mm 18 or equivalent 4 individually shielded pair 300V 75 90 C 167 194 F 1 Belden 9730 is 3 individually shielded pairs 2 channel plus power If 3 channel is required use Belden 9728 or equivalent 2
44. File Advanced Numbered List File 1 Name FGP Group Changed File2Name Group 1 Name gt FGP Parameter File 3 Name Group 2 Name Parameter Name Group 3 Name Parameter Name Parameter Name LPM20 Y Connected DPI Devices gt Value Screen Him CopyCat K R Device gt Memory Storage 22 Device User Sets gt Drive User Set Device lt Reset To Defaults Save To User Set Delete HIM Set Load Frm Usr Set Active Set Start Up gt Introduction gt Complete Steps __ 1 Input Voltage 0 Motor Dat Ramp 3 Motor Tests 4 Speed Limits Make a selection 5 Speed Control Abort Drive Identit Preferences 6 Strt Stop l O Backup User Dspy Lines 7 Done Exit Resume 0362 User Time Start Up Menu User Dspy Video Reset User Dspy Contrast Press to move between menu items Press to select a menu item Press to move 1 level back in the menu structure Press to select how to view parameters 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
45. IEW Up Open O reg 2 amp Down Closed On ratiath SWITCH S2 SIDE VIEW FRONT g TOP VIEW up Open orf P 81 Down Cosed On 12134 xf SWITCH S4 SIDE VIEW FRONT TOP VIEW Up Open Off Down Closed On SWITCH S3 SIDE VIEW TOP VIEW Up Open Off Down Closed 7 FRONT Table 1 K Switch Settings Function Switch Open Closed Default Notes Configuring Digital Input 6 for P22 pin 2 4 pin 1 3 pin 2 4 No jumper HW enable Hardware Enable HW Enbl Jumper HW enable Noenable HW enable Analog Input 1 55 1 Voltage Current Voltage Change with Power Off Analog Input 2 5 2 Voltage Current Voltage Change with Power Off Digital Inputs 4 6 Voltage 54 1 54 2 115 ac 24V de 24V de Change with Power Off Digital Input 1 Voltage S3 1 24V dc 12V dc 24V dc Change with Power Off Digital Input 2 Voltage 53 2 24V dc 12V dc 24V dc Change with Power Off Encoder Voltage Supply 52 1 12V dc 5V dc 24V dc Change with Power Off Encoder Signal A Voltage 52 2 12V dc 5V dc 12V dc Encoder Signal Voltage 52 3 12V de 5V dc 12V dc Set all switches the same Encoder Signal Z Voltage 52 4 12V dc 5V dc 12V dc Function Switch Open Closed Default Notes DriveLogix Processor S1 RUN Remote Program Processor mode Please note there are two separate values for an encoder 1 32 Installation W
46. O 195 90d ON 355 204 oos 09 086 z a heen Bea 22 gadur 9NIddlHS 3 SLNIWNDOQA ONILVY LIN3xdadno LNdLNO 8 3SV1TOA LNdNI 1 joquog II 5002 5002 3 ON 105002 seud 5002 p pp quiq 10HINOO N ww vedo 3209 2 leuuoluoD aeJnsolou3 9po9 WI SNILVOO TVIW44O34NOO 3dAL ae Ln ESE i ee m ES STI m SE Es ES s WE r 02 6L 8l ZL 9 SL vL L 47 OL 6 8 2 9 6 v L The LPM20 with High Performance Drive Control catalog numbering scheme Is shown below suondo 901V1V9 1 eAug e ueuuojied 021091 Catalog Number Explanation P 6 Overview Notes Power Ratings Catalog Number positions 1 7 only 20ND608 Input Input Input Output Current Power Voltage V Current Amps at 4 kHz Amps HP Ratings 505 608 608 500 Chapter 1
47. O D an Copper Tube 0 4 N 5 8 inch O D Copper Tube ORFS Nut Parker p n 10 BL B Backup Wrench O Ring Neoprene Use to prevent twisting Parker pm 2 016 CO873 70 during nut tightening O Ring Lubricant Parker p n 884 2GRAMS LUBE 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 Perfo
48. P 172171 1 770904 3 BOTTOM VIEW 1 10 Installation Wiring Figure 1 6 Drive Input Dimensions 10 49 20 157 512 Area for Input Power Wiring 2380 Panel Divider Pane 605 266 Disconnect Handle I 81 11 2060 A Seed L Left View Shown 58 48 with Lifting Eye Bolts 1485 as Shipped Rittal TS8 Enclosure 600mm x 600mm x 2000mm 1 6 076 T 154 3 Area for Input Power Wiring 26 20 Field Install 238 665 2382 Roof Spacers 60 7 605 Rittal p n 1 0 7967 000 I Exhaust Air Space Required Divider Panel Rittal p n TS8609 060 80 89 2055 78 99 2006 Edge Guard Power Cable Opening Input to Power Module gt x 2 10 13 1 lt 1224 257 311 Ref Intake Lo Ver 323mm x 323mm 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
49. Removing Installing the 2 1 B 6 Wiring Diagrams BES SERS OSS ES BEE EES C 2 Power Module 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 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 1 What Is Not in this Manual 1 Reference Materials P 2 Manual Conventions P 3 General Precautions P 4 Catalog Number Explanation P 5 Who Should Use this This manual is intended for qualified personnel You must be able to mount Manual and wire Adjustable Frequency AC Drive devices What Is Not in this Manual 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 infor
50. TIONS s INTERFACE GOW 1 1 LOGIC SUPPLY 1 LOGIC SUPPLY VF IN oH OUT CURRENT FEEDBACK PWR 9 CURRENT FEEDBACK SIGU CURRENT FEEDBACK SIEV CURRENT amer FEEDBACK 1 semeenocus To DC BUS 1 DC BUS An Ln J11 C 8 Wiring Diagrams Power Module High Voltage Interconnect and Inverter Power Interface See Installation Manual for I O Wiring soc ADCON EN A12 J9 el See Pages C 6 C 7 T UJ 1 18 20 22 28 24 1 2 2 4 POWER CUSTOMER LAYER INTERFACE A22 MAIN CONTROL ASSY CUSTOMER 1 0 COMMUNICATIONS INTERFACE 700S CONTROL OPTIONS AND ADD L CONFIGURATIONS 24VCOM ISO 24V ISO 45V PS 35V PS 45V PS 45V PS GND PS GND PS GND PS GND PS 12V Vv GND PS AN EE 5VDC GND PS EESK EEIO EE GND EECS GNDSHAT ICHARGE UNEG UPOS VNEG VPOS WNEG WPOS NTC KILL RESET 30 UAMPS GND PS AMPS VAMPS KILL GND PS DC BUS 5V INV 35VINV 35VINV 35VINV 35V INV 5V INV 12V INV
51. URE SENSE IN UPPER GATE SUPPLY I F IN DC BUS DISTRIBUTION LOGIC SUPPLY VF IN LOWER GATE SUPPLY I F IN INVERTER U COLLECTOR INVERTER U GATE INVERTER U EMITTER INVERTER V COLLECTOR 1 INVERTER V GATE 12 INVERTER V EMITTER INVERTER W COLLECTOR INVERTER W GATE INVERTER W EMITTER INVERTER U COLLECTOR Lm 11 INVERTER U GATE 12 INVERTER U EMITTER 1 INVERTER V COLLECTOR INVERTER V EMITTER INVERTER W COLLECTOR 32 INVERTER W EMITTER INVERTER NTC1 1 2 3 INVERTER NTC2 4 10 P_UUP 16 P UUP 6 P_VUP 5 P_VUP 1 4 DC BUS INTERFACE 1 0 3 8 2 WUP 8 1 P WUP 7 6 TO INVERTER IGBT ASSY 1 J2 TO INVERTER IGBT ASSY 2 3 TO INVERTER IGBT ASSY 2 J1 INVERTER V GATE O INVERTER IGBT ASSY 2 J3 11 INVERTER W GATE O INVERTER IGB ASSY 2 1 ASSY 1 1 ASSY 2 1 2 INVERTERNTCI O INVERTER IGB 4 INVERTER NTC O INVERTER IGB A24 LOGIC SUPPLY OUT m a gt gt gt e m e e LOWER GATE SUPPLY OUT ec roles CURRENT FEEDBACK SIGU CURRENT FEEDBACK CURRENT FEEDBACK PWR CURRENT FEEDBACK SIGV CURRENT FEEDBACK CURRENT FE
52. W Enable 6 Comm In 14 24 7 SOC In 15 Input 8 SOCIn 1 36 Installation Wiring CE Conformity Table 1 P Active Converter Voltage Feedback Board A11 P2 Terminal Descriptions Pin Description 1 L1 4 L2 7 L3 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 e EN50178 Electronic equipment for use in power installations EMC Directive 89 336 EEC e 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 e 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 e The drive motor cable should be kept as short as possible in order to minimize electromagnetic emission and capacitive cur
53. 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 600V 90 C 194 F e Four tinned copper conductors with XLPE insulation tion 1 XHHW2 RHW 2 Anixt Option a e Copper braid aluminum foil combination shield and Belden 29501 29507 or tinned copper drain wire equivalent e PVC jacket Standard Tray rated 600V 90 C e Three tinned copper conductors with XLPE insulation Option 2 194 F RHH RHW 2 Anixter OLF 7xxxxx or 9 5 mil single helical copper tape 25 overlap min with three bare copper grounds in contact with shield equivalent e PVC jacket Class amp Il rated 600V 90 e Three bare copper conductors with XLPE insulation Division amp II 194 F RHH RHW 2 and impervious corrugated continuously welded Anixter 7V 7xxxx 3G or aluminum armor equivalent e Black sunlight resistant PVC jacket overall e Three copper grounds on 10 AWG and smaller Other types of shielded cable are available but the selection of these type
54. al Output 1 2 Common Common for Digital Outputs 1 and 2 5 Digital Output 2 24V dc Open Collector sinking logic 851 852 Rating Internal Source 150 mA maximum External Source 750 mA 6 Relay Output 3 NC Relay contact output 856 857 7 Relay Output 3 Common Rating 115V ac or 24V dc 2 A maximum Inductive Resistive 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 825 11 Digital Input 2 Load 15 mA at 24V dc 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 828 15 Digital Input 5 Load 7 5 mA at 115V ac 829 16 Digital Input 6 HW Enable 830 Installation Wiring 1 29 Figure 1 11 TB2 Terminals Digital Wiring Examples Input Output 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 Connection Example Sourcing Digital Inputs using internal power supply Com 24V DC HHEH 1
55. ase 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 200 0 006 in Chapter 4 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 Clear the fault e Press HIM Stop key if HIM is control source e Cycle power Set Fault Clear parameter to 1 e Clear Faults on the HIM Diagnostic menu Incorrect input wiring See None Wire inputs correctly and or install jumper Figure 1 11 for wiring examples Incorrect digital input programming None Program Digital Inx Sel parameter for correct Mutually exclusive choices have been made i e Jog and Jog Forward e Exclusive functions i e direction control may have multiple inputs configured Stop is factory default and is not wired or is open Drive does not Start from HIM inputs Start or Run programming may be missing Flashing yellow status light and Digln CflctB indication o
56. ault 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 Li 12 L3 14 k ON 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 power wiring in the same conduit This can cause interference with d
57. e P 5 Overview Xi6o1 IonuoO SOOL JepJo uondo WWOD xumleN pue S IA p 104 suono l s sloN pelswL 4 JON OUOD 19013 19llonuoO 08LSnaxI6o1eAud Seres sex o VN E 20 ON Se pepuedx3 5002 09 Too Se ON pepuedx3 5002 ol VIN uolsuedx3 uondo eras aion Ioue SNOILdO N uoN uoN 1991 HOLSIS3H 9 1991 JAVY OINVNAG ayjasseg p puedx3 ia Jepoou3 Ajayesedas SI WIH eloN 209 soehalul N uoN uueuibejs SWALI 5 1 Jenlosey WIH N uoN LEXIC en resoan SNOILd
58. e 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 1 5 Installation Wiring Figure 1 2 Power Module Component Locations Door Open
59. e C11 gt o DC MEASUREMENT POINT TSS Oe BUS CAPACITOR 2700 uF 420 VDC I See Table on Page C 11 A1 LAM LAMINATED BUS 179577 E 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 35V INV 30 30 45V 5 29 A31 29 RECT 5 28 28 RECT COMMUNICATION 3 25 25 5V RECT 5 12 24 24 12V RECT INTERFACE ASSY RET 12V INV 22 22 121 RECT DGND 21 179571 DGND DGND DGND DGND 17 7 DGND DGND f DGND 5 14 14 CAN HI CANLO 13 13 CANLO DGND 12 12 DGND DGND 1i 11 COMM RXD INV 0 10 COMM RXD COMM TXD INV RECTIFIER CORE 7 CONTROL CONTROL 7 CONMCIK REC 51 INTERFACE INTERFACE 5 24 INV 4 4 24V RECT 24VCOM INV 3 3 24VCOM RECT 2 2 gt lt 1 J7 J6 1 DPI PORT5 lt HEN GND 4 V 5 6 CANLO 7 12V 8 SELECT2 CHASSIS GND CAN HI J5 DPI PORT 3 DPI PORT 4 NTERNAL COMM I F 1 2 12 11 SCANPORT COM SELECT2 CARD CAN RXD CARD EXT SEL DGND DGND DGND 1 2 3 18 9 20
60. e 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 A voltage on the bus capacitors has discharged before performing ATTENTION This drive contains ESD Electrostatic Discharge 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 The voltage must be 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 damag
61. e status and operation when power is applied For Assisted Start Up information please refer to the PowerFlex 7008 High Performance AC Drive Phase II Control User Manual Publication No 20D UMO06 in Chapter 2 Faults and Alarms 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 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 9 7 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 the fault must be corrected before the fault can be cleared The fault will be reset on power up after repair UserConfigurable These faults be enabled disabled to annunciate or ignore a fault condition 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 parameter 2 Non Configurable These alarm
62. ead i b Tightening Torque 37 45 27 1 33 3 FT LBF Reference Parker Hannifin P N 10 BL B or equivalent 3 Coolant Connection Hardware Provided User 2 08 3 64 4 81 A ORFS Adapter 2 31 6 05 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 Installation Wiring 1 9 2 02 m 8 27 A33 6 17 A22 TB1 amp TB2 DC Bus Measurement 5 54 DC Bus Measurement Points Points on Laminated Y Bus Assy 0 25 x
63. er 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 Acceleration time is excessive None Corrective Action Reprogram Accel Time x parameter Excess load or short acceleration None times force the drive into current limit slowing or stopping acceleration 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 Speed command source or value is not as expected Check for the proper Speed Command using Steps 1 through 7 previously described Programming is preventing the drive None output from exceeding limiting values Motor operation is unstable Cause s Indication Motor data was incorrectly entered None Drive will not reverse motor direction Check Maximum Speed parameter and Maximum Freq parameter to assure that speed is not limited by programming Corrective Action Correctly enter motor nameplate data Cause s Indication Corrective Action Digital input is not selected for None Check Digital Inx Sel parameter Choose reversing control correct input and program for reversing mode Digital input is incorrectly wired None Check input wiring See page 1 25 Direction mode parameter is None Reprogram Direc
64. es 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 conflict exists between the Encoder PPR programming Par 232 or 242 Verify encoder data and reprogram 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 Reprogram the input or close the precharge control contact no signal is present Start input configured but stop not configured Program Par 838 840 to include a stop button rewire the drive 5 Run input configured but control options do not match Program Par 153 Bit 8 to 0 2 wire control 8 Start input configured but control options do not match Program Par 153 Bit 8 to 1 3 wire control 12 2 Multiple inputs configured as Start Reprogram Par 838 840 so multiple starts multiple runs or any combination not exist Multiple inputs configured as Jog1 Program Par 838 840 so only 1 is set to Jog1 amp Multiple inputs configured as Jog 2 Program Par 838 840 so only 1 is set to Jog2 Multiple inputs configured as Fwd Rev Program Par 838 840 so only 1 is set to Fwd Rev 14 Invalid Feedback Device for Permanent Magnet Motor Control Set Par 222 to a value of 5 FB Opt 0 8 Proceed
65. es 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 20D UMO006 Chapter 4 Examine Inverter Status and Rectifier Status LEDs located DPI Communications Interface Board on the front of the power module see Figure 2 1 Verify that they are flashing green If not in this state refer to the descriptions in Figure 3 1 Also check the possible causes shown in Table 2 A and take necessary corrective action Table 2 Common Causes of a Pre Start Alarm Examine Par 156 Run Inhibit Status bit Description Action 1 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 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 procedur
66. from Output Current at 2 kHz Amps to Output 1 1 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 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 gt The information below summarizes the changes to this manual since the last release January 2005 Description of Changes 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 e In Digits 4 through 7 Input Voltage amp 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 e In Digit 12 Input Filter Items deleted Cat Code Added a reference to the PowerFlex 700 Active Converter Power Module User Manual Publication No PFLEX UM002 for more information abo
67. gh Performance Drive Control have power ratings as described in Table 1 A below Table 1 4 Power Ratings 1 Full Load Power Loss Watts Fluid Air 9000 3000 380 to 480 1 110 output current capability for one minute 150 output current capability for 5 seconds 2 Note that 20 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 1 2 Installation Wiring Enclosure Ratings Drive Component Locations LPM20 drives have the following enclosure rating e 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 Replacement parts are listed in Chapter 3 Main Circuit Breaker Circuit Breaker Operating Mechanism Capacitor Bank Filter Fan Tray Precharge AC Contactors 3 Fuses 15A Primary Control Transformer 2 Control Transformer 120 VAC 1 Phase 3 KVA Ground Lug 2 600 MCM Inductor Fuses Precharge Resistors 20A 600V 3 Terminal Block
68. ibed 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 gt Important Identifies information that is critical for successful application and understanding of the product 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 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 gt P P 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 In Table 1 changed column heading
69. ief description of the LCD HIM Human Interface Module For information on See page Prepare For Drive Start Up 2 1 Status Indicators 2 3 Assisted Start Up 2 4 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 ATTENTION Power must be applied to the drive to perform the 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 devic
70. iring 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 using optical transmission equipment This product emits intense light and invisible radiation Do not look into module ports or fiber optic cable connectors 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 TD006 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 F 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 Active Converter Communication Auto Tune Operation Installation Wiring 1 33 Table 1 L SynchLink Cables and Accessories Continued Description Cat No
71. l Resolver Feedback Option Card Installation Instructions for 200 002 PowerFlex 7005 Drives also LPM20 with High Performance Drive Control Multi Device Interface Option Card Installation Instructions for 200 004 PowerFlex 7005 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 Title DriveLogix 5730 Controller User Manual Publication 200 0 003 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 INO01 SynchLink Design Guide 1756 0008 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 Manual Conventions Overview P 3 In this manual we refer to the LPM20 Liquid Cooled AC Drive as drive To help differentiate parameter names and LCD display text from other LPM20 or LPM20 Drive text following conventions will used Parameter Names will appear in brackets For example DC Bus Voltage Display Text will appear i
72. le User Manual Publication No PFLEX UMO002 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 UMO06 1 34 Installation Wiring Pre charge Operation Wiring the Active Converter Control Board I O Terminals 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 e f 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 e f Run On is selec
73. ll drives using this conduit should be disabled This will help minimize the possible shock hazard from cross coupled motor leads ATTENTION To avoid a possible shock hazard caused by 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
74. mation 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 PowerFlex 7005 High Performance AC Drive Phase II Control User Manual Publication No 20D UM006 in the locations shown in parenthesis below for information on e Start up Chapter 2 e Drive programming and parameters Chapter 3 e 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 Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives Publication DRIVES IN001 Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES TD001 Safety Guidelines for the Application Installation and Maintenance of Solid SGI 1 1 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 20D INOO1 PowerFlex 7005 Drives also LPM20 with High Performance Drive Contro
75. n quotes For example Enabled e The following words are used throughout the manual to describe an action Word Meaning 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 _ recommended P 4 Overview General Precautions Class 1 LED Product optical transmission equipment This product emits intense light and invisible radiation Do not look into module ports or fiber optic cable connectors ATTENTION Risk of permanent eye damage exists when using 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 th
76. n LCD HIM Drive Status 2 shows type 2 alarm s 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 Cause s Indication Corrective Action Drive is programmed for 2 wire None If 2 wire control is required no action needed control HIM Start button is disabled T If 3 wire control is required program Digital for 2 wire control Inx Sel parameter for correct inputs Active fault Flashing or Reset fault steady red LED Enable input is open Flashing yellow LED Close terminal block enable input Drive does not respond to changes in Speed Command Cause s No value is coming from the source of the command Indication LCD HIM Status Line indicates At Speed and output is 0 Hz Corrective Action 1 If the source is an analog input check wiring and use a meter to check for presence of signal Check Commanded Freq parameter for correct source Incorrect reference source has been None 3 Check Speed Ref Source parameter for programmed the source of the speed reference 4 Reprogram Speed Ref A Sel parameter for correct source Incorrect reference source is being None 5 Check Drive Status 1 parameter bits 12 selected via remote device or digital inputs and 13 for unexpected source selections 6 Check Dig In Status paramet
77. nputs using internal power supply 3 Wire e Set Parameter 829 Digln 5 Sel to a value of 14 Control Normal Stop Set Parameter 828 DigIn 4 Sel to a value of 5 Com E 1 Start 24V DC 2 e Parameter 153 Control Options bit 8 3 3WireControl will automatically be ON for 3 wire 9 71 control gt 10 gt e Set Parameter 168 Normal Stop Mode for the T6 L1 1 desired stopping mode T 12 0 Ramp Stop gt 8 13 1 CurLim Stop ET t4 sum 2 Coast Stop 15 o o 8 16 Enable dedicated hardware enable input is provided 2 Terminal 16 Digital Input 6 for applications that require the drive to be disabled without software interpretation Installation Wiring 1 31 Main Control Board I O and Encoder Settings JUMPER P22 HW Enable 4 2 914 SWITCH 55 HW Enable SIDE VIEW FRONT T TOP V
78. nstalling 1 18 powering up the drive 2 1 precautions general P 4 programmable controller configurations A 3 R 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 5 saving data 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 T TB1 Terminals 1 25 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 U unbalanced ungrounded supply 1 11 unshielded power cables 1 20 user configurable alarm 3 1 V viewing and changing parameters B 5 W 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 1 23 power 1 20 requirements for drive 1 11 Index 3 Index 4 U S Allen Bradley Drives Technical Support Tel 1 262 512 8176 Fax 1 262 512 222
79. ntrol Board I O Terminal Locations Jis TB1 Terminals 2 Terminals WHEE OO 99 GS 69 OO VVJ Installation Wiring Terminal Blocks Table 1 H Main Control Board I O Terminal Block Specifications Name I O Blocks Description Signal and encoder 1 5 mm 0 14 mm 0 25 N m power connections 16 AWG 28 AWG 2 2 Ib in Wire Size Range Torque 1 25 Maximum Minimum Maximum 1 Maximum minimum that the terminal block will accept these are not recommendations Table 1 1 TB1 Terminals Recommended 0 22 N m 1 9 Ib in er Related Terminal Signal Description Parameter 1 Analog Input 1 Common Bipolar differential input 10V 0 20 mA 13 bit sign 2 Analog Input 1 20K ohm impedance at Volt 500 ohm impedance at mA 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 20K ohm impedance at Volt 500 ohm impedance at mA 806 6 Analog Input 3 NTC Common Differential input 0 10V 10 bit for motor control mode FVC2 7 Analog Input 3 NTC this is the temperature adaptation input 812 8 Shield Analog Output Shield 9 Analog Output
80. of the equipment 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 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 Unused wires in conduit must be grounded at Grounding the Drive all applicable local national and international codes Failure to Observe this precaution could result in damage to or destruction of the equipment ATTENTION The user is responsible for conforming with Use the following steps to ground the drive 1 Open the door of the enclosure 1 14 Installation Wiring Coolant Considerations 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 Tighten these grounding connecti
81. ons 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 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 mating process includes 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 Ib 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 USER SIDE CONNECTION ORFS Braze Adapter bie gd Parker pin 10 LOHB3 B 5 8 inch
82. ot Ready to Run 1 Ready to Run x At Limit 0 Not At Limit 1 At Limit X Tach Loss 0 Not Tach Loss Sw Sw 1 Tach Loss Sw X At Zero Spd 0 Not At Zero Speed 1 At Zero Speed X At Setpt 0 Not At Setpoint Speed Spd 1 At Setpoint Speed X Reserved See Par 304 Limit Status in the PowerFlex 7005 High Performance AC Drive Phase Control User Manual Publication No 20D UM006 for a description of the limit status conditions A 6 Supplemental Drive Information Notes Remote HIM Connection HIM Overview For information on See page 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 B 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 B 2 HIM Overview LCD Display Elements ALT Functions Display Description gt Power Loss amp Auto Hz Main Menu Diagnostics Parameter Device Select Direction Drive Status Alarm Auto Man Information Commanded or Output Frequency Programming Monitoring Troubleshooting To use an ALT function press the ALT
83. play 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 LCD HIM Parameters Step Key s Example Displays 1 In the Main Menu press the Up Arrow or Down Arrow to scroll to Parameter or erm P File 2 Press Enter FGP File appears on the top line and the first three files appear below it Motor Control 3 Press the Up Arrow or Down Arrow to scroll Dynamic Control through the files or 62 4 Press Enter to select file The groups in the FEP Grou are displayed under it Metering 5 Repeat steps 3 and 4 to select a group and then Control Status a parameter The parameter value screen will Drive Data appear 6 Press Enter to edit the parameter 7 Press the Up Arrow or Down Arrow to change the O value If desired press Sel to move from digit to Parameter Motor Flux 62 Output Freq Output Power 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 FGP Par 310 Output Freq
84. rents e Use of line filters in ungrounded systems is not recommended e 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 C Tick Conformity 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 2 Standard LPM20 CE compliant drive Grounding as described in Grounding the Drive on page 1 13 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 The shields of all shielded cables must be terminated with the proper connectors to chassis earth 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 1 38 Installation Wiring Notes Prepare For Drive Start Up Chapter 2 Start Up This chapter describes how to start up the LPM20 Refer to Appendix B for a br
85. rive operation Failure to observe this precaution could result in damage to or destruction of the equipment ATTENTION Do not route signal and control wiring with 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 Maximum Tightening Torque 10 L1 to L6 M10 CI 9 8 43 N m 81 lb ft U V W M10 CI 9 8 43 N m 31 lb ft GND PE 8 1 98 22 N m 16 lb ft Installing Output Power Wiring Installation Wiring 1 19 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 e amotor thermostat be installed internal to the motor e amechanical 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
86. rmance Drive Control have inlet and outlet connections as shown in Figure 1 5 Tube assemblies with O ring fittings 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 Table 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 e Less than 50 ppm of sulfate and chloride e 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 The coolant must be compatible with the following materials Copper brass aluminum and neoprene 1 16 Installation Wiring LPM20 Drive Catalog Number positions 1 7 only 20ND608 Table 1 C Coolant Requirements for LPM20 Drives 1 Water equals good quality or distilled water with Chemtool Inc corrosion inhibitor 2 inhibitor by volume 2 WEG25 equals good qual 8 WEG50 equals good qual Corrosion Inhibitor ity or distilled water with approved ethylene glycol 25 glycol by volume ity or distilled water with approved ethylene glycol 50 glycol by volume Coolant Minimum Pressure
87. rolled 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 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 1 30 Installation Wiring Figure 1 11 TB2 Terminals Digital Wiring Examples Continued Input Output Digital Inputs 24V dc Connection Example Sourcing Digital Inputs using internal power supply 2 Wire Control Com 24V DC H Q C FUERTE 9 0 1 2 13 4 5 6 j RUN Enable Required Parameter Changes e Set Parameter 829 Digln 5 Sel to a value of 7 Run e 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 Sourcing Digital I
88. s 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 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 A contactor or other device that routinely 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 ATTENTION The drive start stop enable control circuitry Output Contactor Precaution 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 contin
89. s 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 Voltage Tolerance For full power and operating range see the PowerFlex 7005 High Performance AC Drive Phase II Control User Manual Publication No 200 0 006 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 Method 76 meters 250 feet total Sine coded PWM with programmable carrier 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
90. s are always enabled 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 Note that if the LEDs are off it indicates the drive is not receiving power Figure 3 1 Inverter and Rectifier Status LEDs and Indications DPI Communications TE Interface Board front surface of power module Inverter Status LED 95 O O Rectifier Status LED A co L E L1 Ij e x O I 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
91. s input power terminals L1 L2 and L3 as shown in Figure 1 8 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 DC Bus Measurement Points on Laminated 22277 BusAssy0 25 x0 002 cn P a Male Faston Accessible d E by Removal of Top Cover 4 O pe w 3 2 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 Figure 1 2 and Figure 1 3 Table 3 A Drive Replacement Parts Drive Qty Current Description Catalog Number per Rating Drive 400 480 608A 80 Power Supply Assembly 5 180944 01 2 400 480 608 Inlet Hose amp Outlet Hose Assys w spare O ring SP 349811 A01 400 480 608 Resistor Filter 100K ohm 50W Kit 3 per box SP 352489 A01 400 480 608 Resistor Precharge
92. sman FWH 150B Gould Shawmut A50P150 4 FU6 150A 600V Bussman FWH 150B Gould Shawmut A50P150 4 FU7 Class CC 1A 600V Littelfuse KLDR001 Gould Shawmut ATQR1 FU8 Class CC 1A 600V Littelfuse KLDR001 Gould Shawmut ATQR1 FU9 Class CC 1A 600V Littelfuse KLDR001 Gould Shawmut ATQR1 FU10 Class CC 20A 600V Littelfuse CCMR020 Gould Shawmut ATDR20 FU11 Class CC 20A 600V Littelfuse CCMRO20 Gould Shawmut ATDR20 FU12 Class CC 20A 600V Littelfuse CCMR020 Gould Shawmut ATDR20 FU13 Class CC 25A 600V Littelfuse KLDR025 Gould Shawmut ATQR25 Main Control Assembly Interface Assy 179571 ary 1 4 Voltage Feedback Resistor Assembly 180675 A03 7 Active Converter Control Assembly 180654 A01 AUX OUT NO AUX OUT COM IFF LETEN SUN 112 194706 001 v DPI Comm Terminal Block 179745 Chillplate Temp Sensor 180037 A01 IFF SAFETY HW EN AUX IN 24V DRIVE POWER MODULE Factory Installed Jumper NOTES 1 Dashed lines indicate wiring by others m HM Door Mounted l Option Wiring Diagrams yT5 External T2 T4 Tm GRD C 3 C4 Wiring Diagrams Power Module Overall
93. ted then the pre charge bypass contactor is automatically closed several seconds after power is turned on and the converter is automatically enabled If Manual 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 7OOAC Parameter 52 bit 1 This mode is primarily intended for troubleshooting or during startup 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 WARNING The user must verify that the pre charge is closed 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 UMO02 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 Installation Wiring 1 35 Figure 1 12 Active Converter Control Board I O Terminal Locations A12 Active Converter Control Assembly ite DPI Slave OFF Default
94. tion Mode parameter for incorrectly programmed analog Bipolar or digital Unipolar control Motor wiring is improperly phased None for reverse Switch two motor leads A bipolar analog speed command input is incorrectly wired or signal is absent 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 An isolated multimeter will be needed to measure the DC bus voltage and to Troubleshoot make resistance checks Note that dedicated troubleshooting test points are not provided Verifying That DC Bus Capacitors Are Discharged 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 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
95. tions 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 E earthing see grounding Electrostatic Discharge ESD P 4 enclosure ratings 1 2 F fault clearing 3 3 descriptions for active converter 3 3 descriptions for drive 3 3 queue B 3 types 3 1 G general precautions P 4 grounding the drive 1 13 H 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 wiring 1 23 1 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 L LCD HIM menus B 3 LEDs drive status 2 3 3 2 Logic Command Word A 4 Logic Status Word A 5 M manual conventions P 3 menu structure HIM B 3 motor lead lengths A 2 overload protection installing 1 19 mounting the drive 1 12 N non resettable fault 3 1 0 operator interface 5 output contactors start stop 1 22 current rating 1 1 wiring installing 1 19 P 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 i
96. tween 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 Eigure 1 5 and on page C 3 Input Line Branch Circuit Protection circuit protection be provided to protect input power wiring The circuit breaker values provided in the Drive Input Components are listed in Table 1 B ATTENTION Most codes require that upstream branch Table 1 B AC Input Circuit Breaker Values LPM20 Drive Catalog Number Circuit Breaker positions 1 7 only Input Voltage Provided 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 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 4 Using the hoist lift the power module from
97. ue 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 ATTENTION To guard against drive damage when using output Wiring Installation Wiring 1 23 Important points to remember about I O wiring e Use Copper wire only Wire gauge requirements and recommendations are based on 75 C Do not reduce wire gauge when using higher temperature wire e Wire with an insulation rating of 600V or greater is recommended e Control and signal wires should be separated from power wires by at least 0 3 meters 1 foot 4100 Flex I O cable for use with DriveLogix is 0 9 meters 3 ft maximum length Important I O terminals labeled or Common are not referenced to 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 A operation and driving it from a voltage source could cause component damage Verify proper configuration prior to applying input signals ATT
98. ut active converter communication Added a reference to the PowerFlex 700 Active Converter Power Module User Manual Publication No PFLEX UMO002 for more information about wiring the active converter control board 1 0 terminals HR 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 69 co In Table 3 B changed replacement Voltage Feedback Resistor Assembly 460 V kit number from 180924 03 to 180923 A03 soc ii Summary of Changes Preface Chapter 1 Chapter 2 Chapter 3 Appendix A Table of Contents Overview Who Should Use this Manual P 1 What Is Not in this P 1 Ret rence Materials Ga Ge e as been Rt URN P 2 Gonventlofls 43 Seb SEE EE dd P 3 General Precautions renta tn Mt e nA SIDE ERE P 4 Catalog Number Explanation P 5 Installation Wiring Power Ratings i EU ie bi aed a Ged gs 1 1 Enclosure Ratings neon paqa ped eee este bee Ged Ha ee ee 1 2 Drive Component Locations
99. visions 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 ATTENTION National Codes and standards NEC VDE BSI 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 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 a

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