Cautions | J. T. Eaton LCX9000 instruction

Cautions

LCX9000 Liquid-Cooled Drives User Manual

January 2007

WARNING

The motor terminals U, V, W and the DC-link/brake resistor terminals are live when the Liquid-Cooled drive is connected to mains, even if the motor is not running.

WARNING

After disconnecting the drive from the mains, wait until the indicators on the keypad go out (if no keypad is attached see the indicators on the cover). Wait 5 more minutes before doing any work on the Liquid-Cooled drive connections. Do not touch the enclosure before this time has expired.

WARNING

The control I/O-terminals are isolated from the mains potential. However, the relay outputs and other I/O-terminals may have a dangerous control voltage present even when the Liquid-Cooled drive is disconnected from mains.

Cautions

CAUTION

Always remove all cooling agent from the cooling element(s) before shipping to avoid damage caused by freezing.

CAUTION

Do not perform any voltage withstand tests on any part of the Liquid-Cooled drive. There is a certain procedure according to which the tests shall be performed. Ignoring this procedure may result in damaged product.

CAUTION

Do not touch the components on the circuit boards. Electrostatic voltage discharge may damage the components.

CAUTION

Before connecting the Liquid-Cooled drive to mains, ensure the functionality of the coolant circulation and check the circulation for possible leaks.

CAUTION

Before connecting the drive to mains make sure that the enclosure door is closed.

MN04005001E

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J. T. Eaton LCX9000 user manual Cautions

Contents

MN04005001E LCX9000 Liquid-Cooled DrivesUser Manual January Supersedes September Page Important Notice - Please Read Contents CHAPTER 4 - CONTROL WIRING AND INTERNAL CONNECTIONSTable of List of Figures List of Figures Continued List of Tables Table 5-11 System Menu Functions List of Tables ContinuedTable 5-13 Resettable Counters Table A-1 Fault Codes Hazardous High Voltage SafetyDeﬁnitions and Symbols Warnings Warnings, Cautions and Notices Cautions Motor and Equipment Safety Grounding and Ground Fault Protection Receiving and Inspection Chapter 1 - Overview L C X 0 1 6 A 0 - 4 A 2 B Storage and Shipping MaintenanceTechnical Data LCX9000 Liquid-Cooled Drives User Manual Figure 1-1 Liquid-Cooled Drive Principal Block Diagram Drives Power RatingsPage Page Table 1-4 Technical Information Speciﬁcations 1-10 Table 1-4 Technical Information Continued Lifting the Drive Chapter 2 - InstallationMounting Figure 2-2 LCX9000 Liquid-Cooled Drive, CH3 Liquid-Cooled DimensionsTable 2-1 One-Module Drive Dimensions Mounting Base Included Drives Consisting of One Module Top View Figure 2-3 LCX9000 Liquid-Cooled Drive, CH4Figure 2-4 LCX9000 Liquid-Cooled Drive, CH5 Bottom View Figure 2-6 LCX9000 Liquid-Cooled Drive, CH72 Figure 2-5 LCX9000 Liquid-Cooled Drive, CH61 Figure 2-7 Drive Mounted Inside Mounting Bracket Table 2-2 Several Module Drive Dimensions Mounting Bracket IncludedDrives Consisting of Several Modules Figure 2-8 LCX9000 Liquid-Cooled Drive with Mounting Bracket, CH63 12-Pulse Supply Figure 2-9 LCX9000 Liquid-Cooled Drive, CH74, IP00Bottom 6-Pulse Supply Table 2-4 Drinking Water Quality Recommendations - Maximum Values CoolingDrinking Water Speciﬁcation Table 2-3 Drinking Water Chemical Speciﬁcation Table 2-6 Process Water Speciﬁcation Table 2-5 Drinking Water Quality Recommendations - Desired Values Heat Figure 2-10 Example of Cooling SystemExchanger Table 2-7 Information About Cooling Agent and Its Circulation Figure 2-11 Example PI-Diagram of Cooling System and Connections Table 2-9 Coolant Volumes and Temperatures Figure 2-12 Safe Operating Conditions in Relation to Condensation Condensation Figure 2-14 External Thread of Hose Table 2-10 Liquid Connector Types All Pressure Values at Nominal FlowCooling System Connections Figure 2-13 Aluminum Hose Adapters Outﬂow Hoses and Pressure Losses Table 2-11 Pressure Losses - CH6xFigure 2-15 Pressure Loss - CH6x rubber EPDM only aluminium other stainless and acid-proof materials Table 2-12 Pressure Losses - CH7xFigure 2-16 Pressure Loss - CH7x The following main line hose materials are acceptable plastic PVC Fast Connector Lock Screw, Cable Seal and Clamp Installation of Flow SwitchAbout Flow Switch Installation Figure 2-17 Flow Switch Hose Connection, Fast Connector Electrical External Cooling Fan for CH4 Figure 2-18 Direction of Coolant Circulation Drive Derating Input Chokes Table 2-16 Input Choke Dimensioning, 6-Pulse Supply Sizes 87 - 145A and 590A Installation of Input ChokeFigure 2-19 Example of Input Chokes for Liquid-Cooled Sizes Up to 62A Figure 2-20 Example of Input Chokes for Liquid-Cooled January Table 2-17 Choke Dimensions Sizes 23 - 145A and 590A Table 2-18 Choke Dimensions Sizes 261 - 1150A LCX9000 Liquid-Cooled Drives User Manual Motor Cable Chapter 3 - Power WiringPower Connections Mains Cable Table 3-2 Cable Sizes 400 Table 3-1 Cable Types Required to Meet StandardsCable Data Three grounding terminals per mounting plate, see Page Table 3-2 Cable Sizes 400 - 500V ContinuedUnits with 6-pulse supply Units with 12-pulse supply See the tightening torques of bolts in Table Table 3-3 Cable Sizes 525Table 3-4 Tightening Torques of Bolts Table 3-5 Fuse Sizes for LCX9000 Liquid-Cooled 500V Drives Fuse Sizes, Drives Fuse information Table 3-6 Fuse Sizes for LCX9000 Liquid-Cooled 690V Drives 4. If cable insulation checks are needed, see Page Cable Installation InstructionsThe maximum length of the motor cables is 984 feet 300m Figure 3-1 Maximum Terminal Stresses Figure 3-2 Installation Space Installation Space Figure 3-3 Grounding Terminal on Mounting Plate Grounding of Power UnitCable Installation and the UL Standards Cable and Motor Insulation Checks 3-12 Figure 4-1 Control Board Chapter 4 - Control Wiring and Internal Connections Figure 4-3 Drives Connected in Parallel Figure 4-2 Basic and Option Board Connections of the Control Board WRONG Terminal J1 Upper Control Board Power-UpFigure 4-4 Connection of Control Board Cable from the Power Board See Figures 4-4 and Figure 4-6 I/O Terminals of the Two Basic Boards Figure 4-5 Connection of Control Board Cable from the Power BoardControl Connections CORRECT Terminal J2 Lower Figure 4-8 General Wiring Diagram of the Basic Relay Board OPT-A2 Figure 4-7 General Wiring Diagram of the Basic I/O Board OPT-A9 Figure 4-9 Galvanic Isolation Barriers Control CablesGalvanic Isolation Barriers Table 4-1 Control I/O Terminal Signals Control Terminal Signals Figure 4-11 Jumper Blocks on OPT-A9 Digital Input Signal InversionsFigure 4-10 Positive/Negative Logic Jumper Selections on the OPT-A9 Basic Board AO1 Mode Figure 4-12 Jumper Selection for OPT-A9AI1 Mode AI2 Mode Figure 4-13 Control Unit Mounting Box Installing the Control Unit Mounting BoxFigure 4-14 Control Unit Installed into the Mounting Box Control Unit Mounting Box Table 4-2 Installing the Control Unit Mounting Box January MN04005001E Table 4-2 Installing the Control Unit Mounting Box Continued Internal Connections Connections between Power Unit ASIC and Driver Boards X29 Flow supervision input Figure 4-15 Terminals and Connections between ASIC and Driver BoardCH61, CH62 and CH72 Table 4-3 Terminals CH61, CH62 and CH72 X9 OEVA feedback X15 Charging relay output X6 DC terminal Connect to WL on Phase V/W driver board Table 4-4 Terminals CH63 Table 4-5 Terminals between Driver Boards CH64 and CH74 Connections with Optical Cable Connections between Power Unit ASIC and the Control UnitFigure 4-18 Remove Cover to Access Power Unit Connections with Round Cable Control board connection Figure 4-19 Optical Cable Adapter BoardTable 4-6 Terminals on Adapter Board Supply voltage 24Vin from power unit Figure 5-1 Control Keypad and Drive Status Indications Indicators on the Keypad DisplayChapter 5 - Menu Information Keypad Operation Table 5-2 Control Place Indicators Drive Status IndicatorsTable 5-1 Drive Status Indicators Control Place Indicators Text Lines Keypad PushbuttonsStatus LEDs Green - Green - Red Table 5-3 Status LEDs Green - Green - Red Table 5-5 Button Descriptions Monitor Menu NavigationFigure 5-3 Keypad Display Data Figure 5-4 Keypad Navigation Chart Figure 5-5 Monitoring Menu Monitoring Menu M1 Parameter Menu M2 Table 5-6 Monitored Signals Table 5-7 Keypad Control Parameters, M3 Figure 5-6 Parameter Value Change ProcedureKeypad Control Menu M3 Keypad Direction Selection of Control PlaceFigure 5-7 Selection of Control Place Keypad Reference STOP Button Activated Active Faults Menu M4Figure 5-8 Normal State, No Faults Fault Type Symbol Fault TypesFigure 5-9 Fault Display Table 5-8 Fault Types Fault Time Data Record Table 5-10 Real Time Record Table 5-9 Fault Time Recorded DataFault History Menu M5 Real Time Record System Menu M6 Figure 5-10 Fault History Menu Table 5-11 System Menu Functions 5-16 Table 5-11 System Menu Functions Continued Figure 5-12 Change of Application Selection of LanguageFigure 5-11 Selection of Language Application Selection Upload parameters to keypad To keypad, S6.3.2 Copy ParametersParameter Sets S6.3.1 Figure 5-13 Storing and Loading of Parameter Sets Download parameters to drive From keypad, S6.3.3 Automatic Parameter Backup P6.3.4Figure 5-14 Parameter Copy to Keypad P2.1.2= 20.0 Hz Parameter ComparisonFigure 5-15 Parameter Comparison Security Password S6.5.1Figure 5-16 Password Setting Figure 5-18 Activation of Start-Up Wizard Parameter Lock P6.5.2Figure 5-17 Parameter Locking Start-Up Wizard P6.5.3 Figure 5-21 Default Page Function Keypad SettingsFigure 5-20 Keypad Settings Submenu Default Page P6.6.1 Contrast Adjustment P6.6.4 Default page in the operating menu P6.6.2Timeout Time P6.6.3 Figure 5-22 Timeout Time Setting Figure 5-23 HMI Acknowledge Timeout Hardware SettingsHMI Acknowledge Timeout P6.7.3 Table 5-12 Counter Pages Number of retries to receive HMI acknowledgement P6.7.4System info Total Counters Software S6.8.3 Table 5-13 Resettable CountersFigure 5-24 Counter Reset Trip Counters Hardware S6.8.5 Applications S6.8.4Table 5-15 Applications Information Pages Figure 5-25 Applications Info Submenu Expander Board Menu M7 Expander Boards S6.8.6Figure 5-26 Expander Board Information Menus Debug Menu S6.8.7 Figure 5-27 Expander Board Information Menu Further Keypad FunctionsExpander Board Parameters Table 5-17 Expander Board Parameters Board OPTA1 Chapter 6 - Start-Up Safety Precautions Sequence of Operation Page MN04005001E Table A-1 Fault Codes Appendix A - Fault Codes Table A-1 Fault Codes Continued Table A-1 Fault Codes Continued Load Test with Motor DC Link Test without Motor MN04005001E Appendix B - Technical Reference Main Circuit and Control DiagramsFigure B-1 Main Circuit and Control Diagram, CH3 ATerm Figure B-2 Main Circuit and Control Diagram, CH4Figure B-3 Main Circuit and Control Diagram, CH5 Term H8...H13 Figure B-4 Main Circuit and Control Diagram, CH61Figure B-5 Main Circuit and Control Diagram, CH61, Control SPF1 VB00491 Figure B-6 Main Circuit and Control Diagram, CH63, ModuleFigure B-7 Main Circuit and Control Diagram, CH63, Module Figure B-9 Main Circuit and Control Diagram, CH72 Figure B-8 Main Circuit and Control Diagram, CH63, Control Figure B-11 Main Circuit and Control Diagram, CH74, Phase U Figure B-10 Main Circuit and Control Diagram, CH72, Control Figure B-12 Main Circuit and Control Diagram, CH74, Control Figure B-14 Fan Support Fan DimensionsFigure B-13 Fan Mounting Pallet - Hot Dip Zinc Coated MN04005001E B-10 Page Publication No. MN04005001E/CPG January Company InformationEaton Electrical Inc 2007 Eaton Corporation All Rights Reserved Printed in USA