external bus resistor kit for liquiflo ac drives drive m/n’s … · c drilling template / cabinet...

©2004 Rockwell Automation. All rights reserved.

What the Kit Contains

External Resistor Kit M/N 180788-A03 can be used only with C-frame (500/643A) LiquiFlo AC drives, model numbers: 50L4060, 50LW4060, 50LR4060, 64L4060, 64LW4060, 64LR4060, LF150500W4 and LF150643W4. Verify that you have the correct resistor assembly by verifying that the harness is labeled, “500/643AMP EXT BUS RESIS KIT.”

!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 Kit for LiquiFlo AC DrivesDrive M/N’s 50L4060, 50LW4060, 50LR4060, 64L4060, 64LW4060,

64LR4060, LF150500W4, LF150643W4

Instruction Manual D2-3536

2 Instruction Manual D2-3536

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.

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 assembly

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

❐ Step 4: Mount the resistor assembly

❐ Step 5: Unplug connectors P1 and P2, and route harness

❐ Step 6: Connect the ground wire

❐ Step 7: Connect the harness

❐ Step 8: Verify installation

❐ Step 9: Register installation

Instruction Manual D2-3536 3

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

D

Test Points for initial DC Bus Voltage Measurement

Pos(+)

Neg(-)

Checking DC Bus Voltage on LiquiFlo 1.0 Drives (M/N’s 50LXXX, 64LXXXX)

Checking DC Bus Voltage on LiquiFlo 1.5 Drives (M/N’s LF150XXXX)

DPos(+)

Neg(-)

Test Points for initial DC Bus Voltage Measurement


Step 2: Identifying the Mounting Location

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

• the resistor assembly must be mounted inside the drive cabinet• the resistor assembly 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 connectors P1 and P2 inside the

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

surfaces• the resistor assembly 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

Drill six 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 Assembly

!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: Unplugging Connectors P1 and P2 and Routing the Wiring Harness

Locate the P1 and P2 Connectors near the upper part of the power structure and unplug them.

Route the harness from the resistor assembly to P1 and P2.

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

P1 and P2

Push Here

to Release

Connector


Step 6: Connecting the Ground Wire

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 the Harness Task Description

Plug P1A into P1

Plug P2A into P2A

B

P1

P2

Wires

to

DriveP2A

P1A

Harness to Resistor Assembly

Wires

from

Drive

B

A


Step 8: Verifying the Installation Task Description

Disconnect connector (J3 on PMA board for LiquiFlo 1.0 drives or J4 on PMC board for LiquiFlo 1.5 drives)Confirm continuity between the points specified in either Table A or Table B

Reconnect connector (J3 on PMA board for LiquiFlo 1.0 drives or J4 on PMC board for LiquiFlo 1.5 drives)

A

B

C

J3

Pin 1

Continuity Checks on LiquiFlo 1.0 Drives (M/N’s 50LXXX, 64LXXXX)

Table A J3 Continuity Tests

Test Points(1)

(1) If you are unfamiliar with continuity tests, refer to Performing Continuity Tests on page 11.

Meter ReadingJ3 End of CableResistor Assembly End of Cable(2)

(2) See Wiring Diagram for Reference on page 13.

J3:Pin 1 BUS (+) Continuity or approximately zero ohmsJ3:Pin 3 BUS MID

J3:Pin 5 BUS (-)

AB

C

Pin 1

J4

Continuity Checks on LiquiFlo 1.5 Drives (M/N’s LF150XXXX)

Table B J4 Continuity Tests

Test Points(1)

(1) If you are unfamiliar with continuity tests, refer to Performing Continuity Tests on page 11.

Meter ReadingJ4 End of CableResistor Assembly End of Cable(2)

(2) See Wiring Diagram for Reference on page 13.

J4:Pin 1 BUS (+) Continuity or approximately zero ohmsJ4:Pin 3 BUS MID

J4:Pin 5 BUS (-)

AB

C


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.

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 9: 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

TEM

PSW

1TE

MPS

W2

BLEE

DER

(-)

BLEE

DER

(+)

P2 1 7 4 5 6 3 2P1

1 7 6 5 4 2 3

CH

ILLP

LATE

TEM

PSW

ITC

H

REA

CTO

R

1 2 3

1 2 3

DIS

CH

ARG

E R

ESIS

TOR

10K

Ohm

sR1

R3

DIS

CH

ARG

E R

ESIS

TOR

10K

Ohm

s

1 7 6 5 4 2 3P1A

7 6

P2A

DC

+ BU

S

DC

MID

PT

DC

- BU

S

1 2 3

R2

4 5

6348

1-10

5SFY

OR

2470

8-50

1-13

2470

8-50

1-13

6348

1-10

5SFY

OR

TEM

PSW

ITC

H

EXTE

RN

AL B

US

RES

ISTO

R A

SSEM

BLY

RES

ISTO

R 2

4708

-501

-12BU

S M

ID

2600

Ohm

BUS

(-)

2600

Ohm

BUS

(+)

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. PublicationD2- 3536- July 2004 Copyright © 2004 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

external bus resistor kit for liquiflo ac drives drive m/n’s … · c drilling template / cabinet...

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