external bus resistor kit for liquiflo ac drives drive m/n

©2004 Rockwell Automation. All rights reserved.

What the Kit Contains

External Resistor Kit M/N 180788-A04 can be used only with D-frame (1200A) LiquiFlo AC drives, model numbers: 120L4060 and LF151200W4. Verify that you have the correct resistor assembly by verifying that the harness is labeled, “1200AMP EXT BUS RESIS KIT.”

This kit is for field upgrade only. You should not use it if you are replacing the drive. If you replace the drive in the future, you should remove the resistor kit from the drive system.

!ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

!ATTENTION: Do not install or remove modification kits with power applied to the drive. Disconnect and lock out incoming power before attempting such installation or removal. Failure to observe this precaution could result in severe bodily injury or loss of life.

!ATTENTION: DC Bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure that the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

!ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

!ATTENTION: The drive contains ESD- (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing the drive. Erratic machine operation and damage to, or destruction of, equipment can result if this procedure is not followed. Failure to observe this precaution could result in severe bodily injury or loss of life.

Quantity: Description1 Resistor Assembly6 M4 x 16 Mounting Screws with captive locking hardware1 Protective Cover1 Drilling Template / Cabinet Guard

External Bus Resistor Kitfor LiquiFlo AC Drives

Drive M/N’s 120L4060, LF151200W4

Instruction Manual D2-3537

2 Instruction Manual D2-3537

What You Need to Do To install the external bus resistor kit you need to:

❐ Step 1: Verify that the DC Bus Capacitors are discharged

❐ Step 2: Identify a mounting location for the resistor assemblies

❐ Step 3: Drill mounting holes for the resistor assemblies, using the template

❐ Step 4: Mount the resistor assemblies

❐ Step 5: Locate the connection points, and route harness

❐ Step 6: Connect the ground wires

❐ Step 7: Connect the J4, J4A and J4B

❐ Step 8: Connect the harness to the capacitor bank

❐ Step 9: Verify installation

❐ Step 10: Register installation

Step 1: Verifying the DC Bus Capacitors are Discharged

!ATTENTION: DC Bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure that 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.

Task DescriptionTurn off and lock out input power. Wait five minutes

Verify that there is no voltage at the drive’s input power terminals

Remove front cover

Measure the DC bus potential with a voltmeter while standing on a non-conductive surface and wearing insulated gloves (1000V)

A

B

C

D

DS2

U31 C47

D66C50

C49

FUSE1

D64 D65

U35C42 C43 C45C44

COM

TP3

IV

C46

TP5

IU

TP6

IW

J8

U37TP4

D33R36

T10

D60

C39

U36

1

R35

D50

Q5

Q6

T11

D49

R37

C31

C35

DS1

D51

C41

D52

D56

U21

C38

U29C40

FUSE2

C37

C33D43

C36

C32

U14

L2

D44

U30

D38

D36

D29

U1

D16Q4

T1

D11

D12

C22

L1D24

C20

R19

D10

C23

U6

D26

T2

C15R22

C8C7

D17 C14 D18

T9

T4T3

R29 R30

R23 D19

D27

T5

R38

R40

R41

U13

Made in USA

ASSY

BARCODE

Rockwell Automation

C29

C34

C27

D62D61

D57

U32

D35D34

U16

U22

D58

U33

U17

U23

R39

R42

R43

U9U8

U2

C16

D6

R24

RV5

C9

Q3

D7

R28

C24

R31

D28

D20

R20

D8

C25

D14D13

D5

R21

DIP16

U4

D31D30

TP2

-+

U3

D32

TP1

DANGERHIGH VOLTAGE

D25

D63

D41

D46

D47

U27

D40

U19

D54

C28

C30

D53

DS3D59

U34

C48

U18

DS4

D39

U24

D45

U26

U10 U11

D42

D37

D48

D55

U28

U20

U25

U12

C18 R26

C11

R25 D22

R33

C26

T7

C10

D15

C17D21

C21

R32

T6

U5

DIP8

U7

R27C19

C12

D23

R34

T8

C5

C4

C1

J6

J1

Q1

C3

RV1

Q2

C2

R1

R3

RV3

R2

J2

R4

RV4

D3D1 D2

R15

J3

R14 R16 R17

D4

R11

J9

R9

R8

J4

R10

D9

R18

R6

RV6

R13 R5

J5

R12

C6RV7

RV8

R7

RV2

TP2

-+TP1

D

Test Points for initial DC Bus Voltage Measurement

Pos(+)

Neg(-)

Instruction Manual D2-3537 3

Step 2: Identifying the Mounting Location

Consider the following factors when choosing the location for the resistor assemblies:

• both resistor assemblies must be mounted inside the drive cabinet• both resistor assemblies must be mounted vertically, with the closed part

of the protective cover pointing towards the front of the enclosure• the wiring harness must be able to reach the connection points inside the

drive• the wiring harness must not pass over unprotected sharp edges or hot

surfaces• the resistor assemblies must not be mounted on the enclosure door

ProtectiveCover

Towards

Enclosure

Door

Resistor assembly shown without harness for clarity


Step 3: Drilling the Mounting Holes

!ATTENTION: Metal debris or other foreign matter must be kept from falling into the drive. Metal debris or other foreign matter may become lodged in the drive circuitry resulting in component damage. Failure to observe this precaution could result in severe bodily injury or loss of life and/or damage to, or destruction of, equipment.

Task DescriptionProtect internal components from drilling debris

Using the template, mark locations for six mounting holes for the assembly

Drill 5mm (3/16 inch) mounting holes

A

B

C

Drilling Template /Cabinet Guard

A

B

B

B

B

B

B

TIP: The template is symmetrical, so you have the options of drilling from the outside or inside of the enclosure. Drilling outside reduces the risk of debris falling into the drive.


Step 4: Mounting the Resistor Assemblies

!ATTENTION: The cabinet can be very hot where the resistor assembly is mounted. HOT surfaces can cause severe burns. You must install the cabinet guard to protect personnel from accidental contact with the hot cabinet surface.

Task DescriptionUsing a Phillips screw driver, install and tighten the six M4 x 16 mounting screws (torque 12 in-lb)

A

Resistor assembly shown without harness for clarity

Enclosure Wall

Mounting Screwsinserted from outside

of enclosure

AA

AA

AA

Resistor assembly mounted on inside of enclosure

Cabinet Guard


Step 5: Locating the Connection Points and Routing the Harness

Important: The harness connections are considered power level wiring. Run them separately from I/O and signal wiring.

Task DescriptionLocate J4 on the PIC board on a LiquiFlo 1.0 drive or the PMC board on a LiquiFlo 1.5 drive

Locate CAP (-), CAP MID and CAP (+) connection points near the top of the capacitor bank

Route harness through opening on right side of drive, to the resistor assemblies

A

B

C

J4/J4A/J4BCAP (-) and

CAP MID CAP (+)

A

B

C


Step 6: Connecting the Ground Wires

Star Washer

BoltPaint Free Area

Welded StudGround Lug

Ground Lug

Star Washer

Star Washer

Component Ground Conductor

NutStar Washer

Nut Component Ground Conductor

Typical installations can use the existing ground stud originally intended for grounding the enclosure door.

This figure illustrates recommended practices for connecting grounds to an enclosure.


Step 7: Connecting J4, J4A and J4B Task Description

Disconnect the J4 plug from its header on the PIC board on a LiquiFlo 1.0 drive or the PMC board on a LiquiFlo 1.5 drivePlug J4 into J4B

Plug J4A into the J4 header on the PMC Board

A

B

C

J4 Header onPMC Board

Pin 1

Pin 1

J4

J3B

J4A

Harness toResistor Assembly

Harnessto Drive

J4B

Important: You must align J4 Pin 1 with J4B Pin 1. J4 has eleven pins and J4B has twelve pins. If you fail to align the connectors, the 120L4060 drive will not run because motor voltage feedback circuits will remain open. The LF151200W4 drive does not use motor voltage feedback, so there is no electrical connection between J4 and J4B.


Step 8: Connecting the New Harness to the Capacitor Bank

Task DescriptionRemove M5 screw to disconnect CAP(-) ring lug from capacitor bank. Wrap the ring in electrical tape to electrically insulate it and securely mount it.

Connect the new CAP(-) ring lug to the capacitor bank. Install and tighten the M5 screw (torque 24-28 in-lb).Remove M5 screw to disconnect CAP MID ring lug from capacitor bank. Wrap the ring in electrical tape to electrically insulate it and securely mount it.

Connect the new CAP MID ring lug to the capacitor bank. Install and tighten the M5 screw (torque 24-28 in-lb).Remove M5 screw to disconnect CAP (+) ring lug from capacitor bank. Wrap the ring in electrical tape to electrically insulate it and securely mount it.

Connect the new CAP (+) ring lug to the capacitor bank. Install and tighten the M5 screw (torque 24-28 in-lb).

A

B

C

CAP (-)

CAP MID

CAP (+)

AB

C


Step 9: Verifying the Installation

Follow the normal steps for verifying drive installation and operation. Refer to the drive Hardware Reference and Software Start-up manuals.

Performing Continuity Tests

In these tests you are verifying continuity, a short circuit, between the two test points. The continuity mode on a digital multi-meter provides the easiest method for performing this test. Place one meter lead on the first test point and the meter should beep when you place the other lead on the second test point.

If your meter does not have a continuity mode, you can use a resistance mode. Place one meter lead on the first test point and the meter should indicate a short circuit (read approximately zero ohms) when you place the other lead on the second test point.

Task DescriptionDisconnect J4A from the PIC board on a LiquiFlo 1.0 drive or the PMC board on a LiquiFlo 1.5 driveConfirm continuity between the points specified in Table A

Reconnect J4A

Confirm continuity between the points specified in Table B

A

B

C

C

J4/J4A/J4BCAP (-) and

CAP MID CAP (+)

Pin 1

Table A J4 Continuity Tests

Table B Capacitor Bank Continuity Tests

Test Points(1)

Meter ReadingJ4 End of Cable

Resistor Assembly End of Cable(2)

J4:Pin 1 BUS (+) Continuity or approximately zero ohms

J4:Pin 3 BUS MID J4:Pin 5 BUS (-)

Test Points(1)

(1) If you are unfamiliar with continuity tests, refer to Performing Continuity Tests on page 10.

Meter ReadingCapacitor Bank End of Cable

Resistor Assembly End of Cable(2)

(2) See Wiring Diagram for Reference on page 12.

CAP (+) BUS (+) Continuity or approximately zero ohms

CAP MID BUS MID CAP (-) BUS (-)

If you have a... ... refer to these publications:LiquiFlo 1.0 drive • D2-3410, LiquiFlo AC General Purpose (Volts/Hertz) and Vector Duty Drive

Software Start-up • D2-3411, LiquiFlo AC Power Modules Hardware Reference, Installation and

Troubleshooting LiquiFlo 1.5 drive • D2-3494, LiquiFlo 1.5 AC Power Modules Hardware Reference, Installation,

and Troubleshooting • D2-3495, LiquiFlo 1.5 AC General Purpose (Volts/Hertz) and Vector Duty

Drive Software Start-Up and Reference Manual


Step 10: Registering the Installation

Register the installation of the External Bus Resistor kit on the Rockwell Automation Warranty And Returns Processing (WARP) website (http://www.automation.rockwell.com/warp/).

Click on “Field Retrofits”A

BSelect “External Bus Resistor Upgrade” from the drop-downC Click on “Continue”

D

Enter all the required andpertinent information.

E

Click on “Create Registration”F

Click on “Register Retrofit”


Wiring Diagram for Reference

11M

V W

MV

U

MV

V

DC

+ BU

S

DC

MID

PT

DC

- BU

S 4

J4

3 1 2 510 6 8 7 9

MO

TOR

WR

1EXIS

TIN

G B

US

DIS

CH

ARG

E R

ESIS

TOR

S

R4

10K

Ohm

3 2 1123

J4 4D

C M

IDPT

DC

+ BU

S 1 2 3

10

DC

- BU

SMV

V

MV

U 7 6 5 9 8

MV

W11

MO

TOR

V

MO

TOR

U

J4A 4

DC

MID

PT

DC

+ BU

S 1 2 310

DC

- BU

S

MV

V

MV

U 7 6 5 9 8

MV

W11

CAP

(+)

CAP

MID

CAP

(-)

RES

ISTO

R 2

4708

-501

-12

2600

Ohm

J4B 4 1 2 310

MV

V

MV

U 7 6 5 9 8

MV

W1112

CAP

(-)

CAP

MID

CAP

(+)

6348

1-10

5SFY

BUS

(+)

BUS

MID

BUS

(-)

EXTE

RN

AL B

US

RES

ISTO

R A

SSEM

BLY

120L

4060

ON

LY12

0L40

60 O

NLY

2600

Ohm

Not

e:Th

e ol

d re

sist

ors

and

thei

r co

nnec

ting

wire

s re

mai

n in

the

drive

.


Notes:

U.S. Drives Technical Support Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives

Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication D2-3537-July 2004 Copyright © 2004 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

external bus resistor kit for liquiflo ac drives drive m/n

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